DOWNLOAD PDF : Cat CM235 Continuous Miner Operation and Maintenance Manual A6474X377

A6474X377 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X377 (Mechanical - Traction)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© CATERPILLAR 2012 ALL RIGHTS RESERVED

_________________________________________________Table of contents Table of Contents

Safety Instructions............................................................................. 4 Tram motor........................................................................................ 6 Tram primary planetary gear ............................................................. 12 Tram secondary planetary gear ........................................................ 15 Tram case ......................................................................................... 20 Tram reach gear set .......................................................................... 26 Tram sprocket ................................................................................... 35 Tram track front idler ......................................................................... 43 Stabilizer cylinder .............................................................................. 50

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REV 0

Safety instructions _______________________________________________

Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.

!

WARNING The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom.

!

WARNING The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

!

WARNING Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.

!

WARNING The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

!

WARNING Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.

!

WARNING Stand clear of the miner when using the motor to pull the tram track through the tram case.

!

WARNING Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

IMPORTANT The re-installation procedure for the tram case includes re-installation of the primary

and secondary planetary gears and the tram motor, and reconnection of the tram track.

!

WARNING Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.

!

WARNING The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.

________________________________________________________________ 4 CM235 Mechanical - Traction

_______________________________________________ Safety instructions IMPORTANT When the bearing sleeve is inserted into position, the o-ring forms a seal between the

sleeve and the piece that holds it.

!

WARNING Stand clear of the miner when using the motor to pull the tram track through the tram case.

!

WARNING Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

!

WARNING Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.

!

WARNING Verify that the conveyor tail section is adequately secured before crawling under the block supports.

!

WARNING Each stabilizer cylinder is extremely heavy. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

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Tram Motor______________________________________________________ Introduction

Tool Set Safety

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

Basic Tool Set Blocking

When removing or installing a tram motor, observe the following safety precautions:

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING Do not reconnect the trailing cable to the miner while the power cable is disconnected from the motor. Serious injury or death may occur.

________________________________________________________________ 6 CM235 Mechanical - Traction

_____________________________________________________ Tram Motor Tram Motor Removal

To remove the tram motor: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the rub rail pins that secure the tram rub rail to the rub rail section adjacent to it.

5. Swing the tram rub rail out to expose the tram gear case and locate the tram drive motor inside the gear case (Fig. 1).

6. Remove the seven (7) 1/2 X 1 1/4” hex head capscrews and hi-collar lock washers that secure the input shaft access cover to the motor housing.

7. Remove the input shaft access cover and its o-ring.

8. Remove the retaining ring that secures the shaft plug in position.

9. Remove the shaft plug with o-ring that secures the input shaft in the motor.

10. Pull the input shaft from the motor and store in a safe place.

11. Replace the input shaft access cover on the motor housing and secure the cover with the two (2) 5/8 X 1 3/4” hex head capscrews and hi-collar lock washers.

12. Tag, disconnect, and cap the cooling water hoses from the cooling water fittings located on the top left and right corners of the tram motor.

13. Remove the cooling water fittings from the top left and right corners of the tram motor and store in a safe place.

14. Remove the two (2) 1/2 X 1 1/4” hex head capscrews and disc lock washers that secure the tram motor bracket to the tram case.

15. Remove the two (2) 6 X 3/8” socket head set screws that secure the tram motor bracket to the tram motor.

16. Remove the tram motor bracket from the tram motor.

17. Carefully slide the tram motor out from the tram case until the motor’s electrical connection and junction box cover are accessible.

18. Remove the three (3) 3/4 X 2/1/4” socket head capscrews and hi-collar lock washers that secure the junction box cover to the motor housing.

19. Remove the junction box cover and its o-ring from the motor housing.

______________________________________________________________ A6474X377 REV 0 7

Tram Motor______________________________________________________ 20. Remove the three (3) 3/4 X 2 1/4” socket head capscrews and lock washers that secure the stuffing box's half moon clamp to the junction box.

21. Tag and disconnect the power cable lugs and the communication connections.

22. Remove the clamps and slide the stuffing box out of the junction box. The power cable and communication cable should be completely disconnected from the motor.

23. To prevent damage to the power cable lugs and gland assembly, cover the power cable and communication cable, and secure them to the miner in a safe location.

24. To protect the motor’s electrical connections, replace the motor junction box cover and o-ring and secure using the socket head capscrews and hi-collar lock washers.

25. Carefully remove the tram motor from the tram case and slide onto blocking.

________________________________________________________________ 8 CM235 Mechanical - Traction

_____________________________________________________ Tram Motor Tram Motor Installation

To install the tram motor: 1. Slide the tram motor (Fig. 1) into the tram case, leaving the motor’s junction box cover and stuffing box accessible outside the tram case.

2. Remove the three 3/4 X 2 1/4” socket head capscrews and hi-collar lock washers that secure the junction box cover to the motor housing.

3. Remove the junction box cover and its o-ring.

4. Insert the three lugs of the power cable (with gland and stuffing box already installed) and communication cable into the tram motor’s junction box.

5. Replace the stuffing box’s half-moon clamp in its channel to secure the stuffing box in the junction box.

6. Tighten the three (3) 3/4 X 2 1/4” socket head capscrews to secure the clamp to the junction box, and torque to 210 - 230 lb-ft.

7. Connect the motor so that it is phased correctly. Traction motor have to be phased such that one motor rotates clockwise and the other counterclockwise. At all times, the left and right motor connections should be made as below: Motor 1 - Left

2 - Right

Inverter Terminal

Color

Motor Terminal

Color

T1

Red

U/T1

Red

T2

White

V/T2

White

T3

Black

W/T3

Black

T1

Red

U/T1

Red

T2

White

V/T2

Black

T3

Black

W/T3

White

Note: The motor leads are phased at the MOTOR END. The electrician should only change the motor end connections to phase the motor correctly.

A new motor should come equipped with an encoder. The encoder connections should be made inside the traction enclosure and the traction case.

See the Encoder removal and installation procedure in this section for more information.

8. Replace the motor junction box cover and o-ring, and secure it with socket head capscrews and hi-collar lock washers.

9. Assemble the bracket to the motor.

10. Carefully slide the tram motor into position in the tram case. The end of the motor must be completely flush against the primary planetary adapter plate.

11. Insert and tighten the two (2) 1/2 X 1 1/4” hex head capscrews and disc lock washers to secure the tram motor bracket to the tram case, and torque to 35 - 40 lb-ft. ______________________________________________________________ A6474X377

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9

Tram Motor______________________________________________________ 12. Insert the two cooling water fittings into the cooling water ports located on the top left and right corners of the tram motor.

13. Attach the cooling water hoses to the two cooling water fittings located on the top left and right corners of the tram motor.

14. Remove the input shaft access cover and its o-ring.

15. Slide the input shaft through the tram motor and into the tram planetary primary gear (the input shaft end without the threaded hole should be inserted first). The shaft may require some adjusting so that its splined end fits into the gear.

16. When the drive shaft is correctly positioned in the motor, install the o-ring onto the input shaft plug and then insert the plug into the motor.

17. Insert the retaining ring to secure the input shaft plug inside the tram motor.

18. Replace the input shaft access cover and its o-ring on the motor housing.

Secure the cover with hex head capscrews and hi-collar lock washers.

19. Swing in the tram rub rail between the two adjacent rub rails and secure it with the rub rail pins.

________________________________________________________________ 10 CM235 Mechanical - Traction

_____________________________________________________ Tram Motor Fig. 1: Tram motor removal and installation

Tram motor

Tram case

______________________________________________________________ A6474X377 REV 0 11

Tram Primary Planetary Gear _______________________________________ Introduction

The following procedure is for the removal and installation of the tram primary planetary gear case.

Tool Set

Basic Tool Set Blocking

Safety When removing or installing a tram primary planetary gear case, observe the following safety precautions: !

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

________________________________________________________________ 12 CM235 Mechanical - Traction

_______________________________________Tram Primary Planetary Gear

Primary Planetary Gear Removal

To remove the primary planetary gear: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram gear case.

5. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).

6. Remove the sixteen (16) 3/4 X 7 1/2” socket head capscrews that secure the motor adapter plate to the primary gear ring (and also secure the primary planetary carrier assembly to the tram case).

7. Remove the motor adapter plate from the tram case.

8. Carefully slide the primary planetary carrier assembly out of the primary gear ring and remove the assembly from the tram case.

9. Carefully slide the primary gear ring out of the tram case.

______________________________________________________________ A6474X377 REV 0 13

Tram Primary Planetary Gear _______________________________________ Primary Planetary Gear Installation

To install the tram primary planetary gear: 1. Insert alignment dowels into four of the sixteen capscrew holes in the tram case.

2. To facilitate gear ring insertion, mark the mounting holes of the primary planetary gear ring that corresponds to the holes in which dowels were placed.

3. Slide the primary planetary gear ring onto the alignment dowels so the dowels appear through the marked holes.

4. Carefully insert the primary planetary gear assembly into the gear ring, ensuring that the extension of the sun gear faces out from the centerline of the miner and that the internal gear teeth of the primary carrier are seated securely onto the tram drive pinion gear.

5. Place the two adapter plate dowels into two (2) 1 inch holes on the bottom left and right corners of the adapter plate.

6. Orient the adapter plate with the adapter dowels along the bottom edge.

7. Slide the adapter plate onto the four alignment dowels.

8. Insert and tighten twelve (12) 3/4 X 7 1/2” socket head capscrews into the holes in the adapter plate not blocked by the alignment dowels.

9. Remove the four alignment dowels and insert and tighten the final four socket head capscrews to secure the adapter plate and gear ring to the tram case.

10. Torque the sixteen (16) 3/4 X 7 1/2” socket head capscrews to 210 - 230 lbft.

11. Install the tram motor in the tram case (see Tram motor removal and installation procedure in this chapter).

12. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

13. Refill the tram gear case with oil.

________________________________________________________________ 14 CM235 Mechanical - Traction

____________________________________ Tram Secondary Planetary Gear Introduction

The following procedure is for the removal and installation of the tram secondary planetary gear case.

Tool Set

Basic Tool Set Blocking

Safety When removing or installing a tram secondary planetary gear case, observe the following safety precautions: !

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING The secondary planetary gear ring is extremely heavy. Be prepared to support its weight before removing it from the secondary planetary assembly.

______________________________________________________________ A6474X377 REV 0 15

Tram Secondary Planetary Gear ____________________________________ Secondary Planetary Gear Removal

To remove the tram secondary planetary gear: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head assemblies until they touch the floor.

3. Disconnect the trailing cable to de-energize the miner.

4. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail.

5. Remove the plug from the bottom of the tram secondary planetary gear cover and drain the lubricant from the gear case.

6. Replace the oil drain plug in the gear cover (Fig. 2).

7. Remove the sixteen (16) 3/4 X 7 1/2” socket head capscrews that secure the secondary planetary gear cover to the tram case and carefully remove the secondary planetary gear cover.

Fig. 2: Tram secondary planetary gear cover and drain plug

Tram secondary Planetary gear cover

Socket head capscrews

Drain plug

________________________________________________________________ 16 CM235 Mechanical - Traction

____________________________________ Tram Secondary Planetary Gear 8. Remove the secondary planetary gear thrust washer (Fig. 3).

9. Carefully slide the secondary planetary gear ring off the secondary planetary gear assembly.

10. Insert eight hex head capscrews into the sprocket bearing carrier to secure it to the tram case.

11. Carefully pull the secondary tram drive shaft from the gear and sprocket and store in a safe place.

12. Carefully slide the secondary planetary assembly out of the sprocket bearing carrier.

Fig. 3: Secondary planetary assembly removal

Ring gear

Thrust washer

Secondary planetary gear assembly

Hex head capscrew

Secondary planetary gear assembly

Secondary tram drive shaft

Sprocket bearing carrier Secondary planetary gear assembly

______________________________________________________________ A6474X377 REV 0 17

Tram Secondary Planetary Gear ____________________________________ Secondary Planetary Gear Installation

To install the tram secondary planetary gear: 1. Carefully insert the secondary planetary gear assembly into the sprocket bearing carrier (Fig. 4), ensuring that the splined extension of the planetary carrier seats securely in the interior teeth of the sprocket.

Fig. 4: Planetary carrier installation Sprocket teeth

Sprocket bearing carrier

Splined extension

Secondary planetary gear assembly

2. Slide the secondary tram drive shaft through the secondary planetary gear assembly and into the tram drive sprocket and reach gear set (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that the end fits into the reach gears.

3. Insert four alignment dowels into the holes in the sprocket bearing carrier not blocked by the eight hex head capscrews (Fig. 5).

4. To facilitate gear ring insertion, mark the mounting holes of the secondary planetary gear ring that corresponds to the holes in which the dowels were placed.

5. Remove the eight hex head capscrews that secure the sprocket bearing carrier to the tram.

Fig. 5: Gear ring installation Secondary planetary gear assembly

Sprocket bearing carrier

Gear ring Thrust washer

Alignment marks

Hex head capscrews

Alignment dowels

________________________________________________________________ 18 CM235 Mechanical - Traction

____________________________________ Tram Secondary Planetary Gear 6. Apply silicon sealant to the ring gear.

7. Carefully slide the secondary planetary gear ring onto the four alignment dowels so that the dowels appear through the marked holes. The planetary gear teeth should slide smoothly and securely into the gear teeth should slide smoothly and securely into the gear ring teeth.

8. Place the thrust water into the secondary planetary carrier directly behind the secondary tram drive shaft. The side of the thrust washer with the inscribed circles should face away from the drive shaft.

9. Apply silicon sealant to the cover.

10. To facilitate gear cover replacement, mark the mounting holes of the secondary planetary gear cover that corresponds to the holes in which alignment dowels are placed.

11. Slide the secondary planetary gear case cover onto the alignment dowels so that the dowels appear through the marked holes.

WARNING The flat edge of the cover located adjacent to the lubrication fitting is the top of the cover. Orient the cover so that the lubricant level check plug is on the motor side of the cover and the drain plug is on the bottom. !

12. Insert and tighten the twelve socket head capscrews into the holes in the gear case cover not blocked by the alignment dowels.

13. Remove the four alignment dowels.

14. Insert and tighten the remaining four socket head capscrews to secure the cover, the gear ring, and the sprocket bearing carrier to the tram case.

15. Using a torque wrench, torque all sixteen (16) 3/4 X 7 1/2” to 210 - 230 lb-ft.

16. Using the lubrication fitting at the top of the gear cover, fill the secondary planetary gear case to the proper level with lubricant.

17. Examine the secondary planetary gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

18. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

______________________________________________________________ A6474X377 REV 0 19

Tram Case ______________________________________________________ Introduction

Tool Set Safety

The following procedure is for the removal and installation of the tram case.

Basic Tool Set Blocking

When removing or installing a tram case, observe the following safety precautions:

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING The tram case (with sprocket and reach gears) is extremely heavy. Be prepared to support the tram case before removing it from the tractor frame.

!

WARNING Ensure that the electrical cables and cooling water hoses for the tram motor are free from the tram cases before attempting to remove the tram case from the tractor frame.

!

WARNING Stand clear of the miner when using the motor to pull the tram track through the tram case.

________________________________________________________________ 20 CM235 Mechanical - Traction

______________________________________________________ Tram Case Tram Case Removal

To remove the tram case: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off of the floor.

5. Place blocking in multiple locations under the miner tram track. When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

9. Remove the hex head capscrew and lock washer that secure the front rub rail to the tractor frame and open the front rub rail cover.

10. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 6) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

______________________________________________________________ A6474X377 REV 0 21

Tram Case ______________________________________________________ 11. Remove all the idler adjustment shims and store the shims in a safe place.

12. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 6: Idler take-up cylinder Pressure release valve

Idler take-up cylinder

Grease fitting location

Idler adjustment shims 13. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 7) and, using a hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

14. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 7: Tram track removal

Roll pins

Separate track here

Tram track pin

________________________________________________________________ 22 CM235 Mechanical - Traction

______________________________________________________ Tram Case 15. Attach guide wires to the end of the tram track that passes through the tram case.

16. Connect the trailing cable to energize the miner.

17. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.

18. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

19. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

20. Remove the tram motor (see Tram motor removal and installation procedure in this chapter).

21. Remove the bolts and washers from the sprocket and motor sides of the tram case.

22. Place a stack of blocking in front of the tram case onto which the case can be removed.

23. Carefully slide the tram case out from the tractor frame and onto the blocking.

24. Pull the tram track guide wires out of the tram case exit opening and secure the wires to the tractor frame.

______________________________________________________________ A6474X377 REV 0 23

Tram Case ______________________________________________________ Tram Case Installation

To install the tram case: 1. Block up the tram case adjacent to its tractor frame position at a level that makes it easy to slide the case into the tractor frame.

2. Thread the guide wires through the tram case exit opening, between the sprocket gears, and out the tram case entry opening.

3. Slide the tram case into position in the tractor frame.

!

WARNING The guide wires will be used to pull the tram track links onto the tram case sprocket after the tram case is installed.

!

WARNING Before attempting to slide the tram case into the tractor frame, ensure that the tram motor electrical and water connections are out of the way. Failure to do so may result in damage to the electrical and water connections.

4. Slide the tram case into position in the tractor frame.

5. Install the bolts that secure the motor side of the tram case to the tractor frame.

6. Install the bolts that secure the sprocket side of the tram case to the tractor frame.

7. Replace the tram motor (see Tram motor removal and installation procedure in this chapter).

8. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.

9. Connect the trailing cable to energize the miner.

10. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom.

!

WARNING Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

11. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

12. Remove the guide wires from the tram track.

13. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.

14. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

________________________________________________________________ 24 CM235 Mechanical - Traction

______________________________________________________ Tram Case 15. Adjust the tram track tension.

16. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

17. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

18. Connect the trailing cable to energize the miner.

19. Remove blocking.

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_____________________________________________ Tram Reach Gear Set Introduction

The following procedure is for the removal and installation of the tram reach gear set.

Tool Set

Basic Tool Set Blocking

Safety When removing or installing a tram reach gear set, observe the following safety precautions: !

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

IMPORTANT The re-installation procedure for the tram case includes re-installation of the primary

and secondary planetary gears and the tram motor, and reconnection of the tram track.

______________________________________________________________ A6474X377 REV 0 26

_____________________________________________ Tram Reach Gear Set Tram Case Removal

To remove the tram reach gear set: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head assemblies and place a small stack of blocking under each.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

5. Place blocking in multiple locations under the miner tram track to securely support the tractor frame off the floor.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking. When the tractor frame is lowered, the tram track should be secured between the blocking and the tractor frame.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Double-check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.

9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

10. Remove the tram case (see Tram case removal and installation procedure in this chapter).

11. Remove the plug from the motor end of the reach gear case bottom and drain the lubricant from the gear case.

12. When the lubricant has been completely drained, replace the plug.

13. Remove the fourteen (14) 1/2 X 1 1/4” hex head capscrews and lock washers (Fig. 8) that secure the reach gear case cover to the gear case and remove the cover.

Fig. 8: Reach gear case cover removal Hex head capscrews Lock washers Reach gear case cover

Rear side of tram case

Reach gear case Drain plug

______________________________________________________________ A6474X377 REV 0 27

Tram Reach Gear Set _____________________________________________ 14. Locate the cap bearing carrier that secures the tram drive pinion inside the reach gear case.

15. Using retaining ring pliers, remove the retaining ring located outside the cap bearing carrier on the tram drive pinion (Fig. 9).

16. Using the wire cutters, cut and remove the wire securing the cap bearing carrier capscrews in position.

17. Remove the six (6) 5/8 X 1 3/4” drilled head capscrews and lock washers that secure the cap bearing carrier to the tram case and remove the cap bearing carrier.

Fig. 9: Cap bearing carrier removal

Drilled head capscrews

Cap bearing carrier

Tram drive pinion

Retaining ring

________________________________________________________________ 28 CM235 Mechanical - Traction

_____________________________________________ Tram Reach Gear Set 18. Remove the three steel shims and the bearing found under the shims (Fig. 10).

19. Carefully pull the tram drive pinion out of the reach gear case through the cap bearing carrier opening.

Fig. 10: Tram drive pinion removal Bearing carrier opening

Shims Cap bearing carrier

Tram drive pinion

Bearing cup and cone set

20. Cut and remove the wire securing the idler shaft capscrews in position.

21. Remove the ten (10) 1/2 X 1 1/4” drilled hex head capscrews that secure the idler shaft cap to the tram case and remove the idler shaft and three steel shims located under the cap.

22. Carefully slide the idler shaft out of the reach gear case through the idler shaft cap opening.

23. Remove the idler reach gear through the top opening of the reach gear case (Fig. 11).

24. Remove the bearing cup and cone sets from the center indentions of the idler reach gear.

Fig. 11: Idler reach gear and idler shaft removal Idler reach gear Bearing cup and cone set

Reach gear case

Shims Idler shaft cup

Rear side of tram case

Hex head capscrews

______________________________________________________________ A6474X377 REV 0 29

Tram Reach Gear Set _____________________________________________ 25. Remove the six (6) 5/8 X 1 3/4” hex head capscrews and lock washers that secure the sprocket reach gear bearing cap to the reach gear case (Fig. 12).

26. Remove the bearing cap and the three steel shims under the cap.

27. Remove the bearing cone and cup set from the end of the splined sleeve.

28. Carefully slide the splined sleeve out of the sprocket reach gear.

29. Remove the sprocket reach gear through the top opening of the reach gear case.

30. Remove the second splined sleeve bearing cone and cup set from the rear of the reach gear case, located behind the sprocket reach gear.

Fig. 12: Sprocket reach gear removal Sprocket reach gear Bearing cup and cone set

Shims

Splined sleeve

Sprocket reach Gear bearing cup

Reach gear case

Hex head capscrews

________________________________________________________________ 30 CM235 Mechanical - Traction

_____________________________________________ Tram Reach Gear Set Tram Reach Gear Set Installation

To install the tram reach gear set: 1. Insert one of the bearing cup and cone sets (cone side facing out) into the cut-out inside the reach gear case adjacent to the tram case sprocket (Fig. 13).

Fig. 13: Bearing cup and cone set installation Bearing cup And cone set

2. Insert the sprocket reach gear into the top of the reach gear case and position it against the bearing cup and cone set adjacent to the tram case sprocket (Fig. 14).

Fig. 14: Sprocket reach gear installation Sprocket reach gear set

3. Insert the splined sleeve into the reach gear case (Fig. 15), through the sprocket reach gear and through the bearing cup and cone set until it is positioned against the tram sprocket.

4. Slide the second bearing cup and cone set (cup side facing out) onto the end of the splined sleeve.

5. Replace the three steel shims over the bearing set.

6. Replace the sprocket reach bearing cap.

7. Insert and tighten the six (6) 5/8 X 1 3/4” hex head capscrews and lock washers to secure the sprocket reach gear bearing cap to the reach gear case, and torque to 120 - 130 lb-ft. ______________________________________________________________ A6474X377

REV 0

31

Tram Reach Gear Set _____________________________________________ Fig. 15: Splined sleeve and bearing cap installation Sprocket reach gear Splined sleeve

Shims Hex head capscrews

Bearing cup and cone set Reach gear case

Sprocket reach gear bearing cap

8. Insert two cup and cone bearing sets into the central cut-outs on either side of the idler reach gear (Fig. 16). The cone side of the bearing sets should face out of the gear on both sides.

9. Insert the idler reach gear through the top opening of the reach gear case and position it against the sprocket reach gear, ensuring that the gear teeth securely mesh.

10. Insert the idler shaft through the bearing sets in the idler reach gear until it is positioned against the tractor frame.

11. Replace the three steel shims over the idler shaft.

12. Replace the idler shaft cap.

Fig. 16: Idler reach gear and idler shaft installation Idler reach gear Bearing cup and cone set Reach gear case Shims Idler shaft cup

Rear side of tram case

Hex head capscrews

________________________________________________________________ 32 CM235 Mechanical - Traction

_____________________________________________ Tram Reach Gear Set 13. Insert and tighten the ten (10) 1/2 X 1 1/4” drilled hex head capscrews to secure the idler shaft cap.

14. Insert the tram drive pinion through the cap bearing carrier opening (located on the inside of the tram case tram motor bay) into the reach gear case.

Ensure that the teeth of the pinion securely mesh with the idler reach hear teeth.

15. Replace the pinion bearing.

16. Replace the three steel shims over the pinion bearing.

17. Replace the cap bearing carrier over the pinion end.

18. Insert and tighten the six (6) 5/8 X 1 3/4” drilled hex head capscrews and lock washers to secure the cap bearing carrier to the tram case, and torque to 120 - 130 lb-ft.

19. Install the retaining ring on the tram drive pinion.

20. Double check that the tram drive pinion, idler reach gear and sprocket reach gear teeth are properly meshed and the gears rotate smoothly.

21. Tighten the idler shaft cap capscrews, and torque to 35 - 40 lb-ft.

22. Lock wire the idler shaft cap capscrews to secure their positions.

23. Lock wire the tram drive pinion cap bearing carrier capscrews to secure their positions.

24. Replace the reach gear case cover onto the top of the reach gear case.

25. Insert and tighten fourteen (14) 1/2 X 1 1/4” hex head capscrews and lock washers to secure the reach gear case cover to the gear case, and torque to 35 - 40 lb-ft.

26. Remove the plug from the sprocket side of the reach gear case cover.

27. Fill the reach gear case to the proper level with lubricant (Spec. 100-14).

28. Replace the fill plug.

29. Replace the tram case into the tractor frame (see Tram case removal and installation procedure in this chapter).

30. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

31. Reconnect the trailing cable to energize the miner.

32. Raise the tractor frame by lowering the stabilizer and the gathering head and cutter head assemblies.

33. Carefully remove the support blocking from under the tractor frame.

34. Lower the tractor frame onto the floor by raising the stabilizer and the gathering head and cutter head assemblies.

______________________________________________________________ A6474X377 REV 0 33

Tram Sprocket ___________________________________________________ Introduction

The following procedure is for the removal and installation of the tram sprocket.

Tool Set

Basic Tool Set Blocking

Safety

When removing or installing a tram sprocket, observe the following safety precautions:

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING Ensure that the end of the tram track is out of the tram case exit opening before attempting to remove the tram case from the tractor frame.

!

WARNING The sprocket is extremely heavy. Be prepared to support its weight before removing it from the tram case.

!

WARNING Stand clear of the miner when using the motor to pull the tram track through the tram case.

________________________________________________________________ 34 CM235 Mechanical - Traction

___________________________________________________ Tram Sprocket Tram Sprocket Removal

To remove the tram sprocket: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and place a small stack of blocking under these two assemblies.

3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.

4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.

5. Place blocking in multiple locations under the miner tram track. When the miner is lowered, the tram track should be secured between the blocking and the tractor frame.

6. Raise the stabilizer and the gathering head and cutter head assemblies so the weight of the miner rests on the blocking.

7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.

9. Remove the two rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and remove the tram rub rail to expose the tram case.

10. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the cover.

11. Attach the grease gun to the fitting on the grease take-up cylinder (Fig. 17) and pump grease to extend the cylinder and remove pusher plate pressure on the idler shims.

Fig. 17: Idler adjustment shim removal

Pressure Release valve Idler take-up cylinder

Grease fitting

Idler adjustment shims

______________________________________________________________ A6474X377 REV 0 35

Tram Sprocket ___________________________________________________ 12. Remove all the idler adjustment shims and store the shims in a safe place.

13. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

14. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 18) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

15. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 18: Tram track removal Idler take-up cylinder

Tram track pin

Separate track here

________________________________________________________________ 36 CM235 Mechanical - Traction

___________________________________________________ Tram Sprocket 16. Attach guide wires to the end of the tram track that passes through the tram case.

17. Connect the trailing cable to energize the miner.

18. Use the tram motor to slowly rotate the sprocket so that the end of the tram track that passes through the case is pulled up through the case and rolls off the sprocket.

19. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

20. Pull on the tram track from the front of the miner (near the idler) so that the free end of the tram track is pulled clear of the tram case exit opening.

21. Remove the plug from the bottom of the cover and drain the lubricant from the gear case (Fig. 19).

22. Replace the oil drain plug in the gear cover.

23. Remove the Secondary planetary gear assembly (see Secondary planetary gear assembly removal and installation procedure in this chapter).

Fig. 19: Tram secondary planetary gear cover and drain plug

Tram secondary Planetary gear cover

Socket head capscrews

Drain plug

______________________________________________________________ A6474X377 REV 0 37

Tram Sprocket ___________________________________________________ 24. Remove the bearing carrier (Fig. 20).

25. Remove the bearing/seal sleeve assembly from the end of the sprocket.

Fig. 20: Sprocket bearing carrier removal

Sprocket Bearing/seal sleeve assembly

Sprocket bearing carrier 26. Remove the sprocket from the tram case (Fig. 21).

27. Remove the bearing/seal sleeve assembly from the rear of the sprocket bay of the tram case.

Fig. 21: Tram sprocket removal

Bearing/seal sleeve assembly Tram case

Sprocket

________________________________________________________________ 38 CM235 Mechanical - Traction

___________________________________________________ Tram Sprocket Tram Sprocket Installation

To install the tram sprocket: 1. Install a spherical bearing into one of the bearing sleeves (Fig. 22).

2. Install the o-ring into the outside channel of the bearing sleeve (Fig. 22).

IMPORTANT When the bearing sleeve is inserted into position, the o-ring forms a seal between the

sleeve and the piece that holds it.

3. Install a Duo-Cone seal into the seal sleeve (Fig. 22) (see Duo-cone seal installation notes in this chapter). The rubber side of the seal should face toward the sleeve; the metal ring of the seal should face outward.

4. Insert the seal sleeve into the bearing sleeve.

Fig. 22: Bearing/seal sleeve assembly

Duo-cone seal

Seal sleeve Metal ring

Spherical bearing

Bearing sleeve

O-ring

rubber seal

______________________________________________________________ A6474X377 REV 0 39

Tram Sprocket ___________________________________________________ 5. Insert and tighten the three set screw into the bearing sleeve to secure the seal sleeve in the bearing sleeve.

6. Insert the bearing/seal sleeve assembly into position at the rear of the sprocket bay of the tram case.

7. Install the two Duo-Cone seals into the channel in each end of the sprocket.

The rubber side of the seals should face into the sprocket channel; the metal rings of the Duo-Cone seals should face outward.

8. Insert the end of the sprocket into the seal sleeve so that it seats into the spherical bearing. Push the sprocket until the metal rings of the Duo-Cone seals are securely against each other.

9. Install the other spherical bearing into the remaining bearing sleeve.

10. Install the o-ring into the outside channel of the bearing sleeve.

11. Install a Duo-Cone seal into the remaining seal sleeve. The rubber side of the seal should face toward the sleeve; the metal ring of the seal should be facing outward.

12. Insert the seal sleeve into the bearing sleeve.

13. Insert and tighten the three set screws into the bearing sleeve to secure the seal sleeve in position.

14. Slide the bearing/seal sleeve assembly onto the end of the sprocket. Push the sleeve assembly until the end of the sprocket seats into the spherical bearing and the metal rings of the Duo-Cone seals are securely against each other.

15. Replace the bearing carrier over the bearing sleeve and end of the bearing sleeve and end of the sprocket.

16. Install the Secondary planetary gear assembly (see the Secondary planetary gear assembly removal and installation procedure in this chapter).

17. While feeding the tram track from the front of the miner (near the idler), pull on the tram track guide wires until a link of the tram track engages the sprocket.

18. Connect the trailing cable to energize the miner.

19. Use the tram motor to slowly rotate the sprocket and pull the tram track through the case until the end appears out the bottom. !

WARNING Double check that the links of the tram track are correctly seated onto the tram drive sprocket. Improper engagement of the tram track links onto the sprocket can cause serious mechanical damage.

________________________________________________________________ 40 CM235 Mechanical - Traction

___________________________________________________ Tram Sprocket 20. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

21. Remove the guide wires from the tram track.

22. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.

23. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

24. Adjust the tram track tension.

25. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

26. Replace the tram rub rail between the two adjacent rub rails and secure it with the two rub rail pins.

27. Connect the trailing cable to energize the miner.

28. Remove blocking.

______________________________________________________________ A6474X377 REV 0 41

Tram Track Front Idler_____________________________________________ Introduction

The following procedure is for the removal and installation of the tram track front idler.

Tool Set

Basic Tool Set Blocking

Safety

When removing or installing a tram track front idler, observe the following safety precautions:

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

________________________________________________________________ 42 CM235 Mechanical - Traction

____________________________________________ Tram Track Front Idler Tram Track Front Idler Removal

To remove the tram track front idler: 1. Raise the gathering head and cutter head assemblies to their highest points and place blocking underneath. Lower the assemblies onto the blocking.

The gathering head and cutter head must be blocked high enough to allow the idler assembly to be removed from the tractor frame’s idler slide channel.

2. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

3. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.

4. Attach the grease gun to the front idler take-up cylinder fitting (Fig. 23) and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims.

5. Remove all the idler adjustment shims and store the shims in a safe place.

6. Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract.

Fig. 23: Idler take-up cylinder Idler take-up cylinder

Pressure Release valve

Grease fitting

Idler adjustment shims

______________________________________________________________ A6474X377 REV 0 43

Tram Track Front Idler_____________________________________________ 7. Locate a tram track link near the track entry opening at the bottom of the tram case (Fig. 24) and, using the hammer and punch, remove the two roll pins that secure the tram track pin between the links. Store the roll pins in a safe place.

8. Using the hammer and punch, remove the tram track pin to disconnect the links and separate the track. Store the track pin in a safe place.

Fig. 24: Tram track removal

Roll pins

Separate track here

Tram track pin 9. Attach guide wires to the end of the tram track that passes through the tram case.

10. Slide the front idler assembly out of the idler slide channel (Fig. 25).

Fig. 25: Front idler assembly removal Idler take-up cylinder

Front idler assembly

Pressure relief valve

Idler slide channel

________________________________________________________________ 44 CM235 Mechanical - Traction

____________________________________________ Tram Track Front Idler 11. Slide the pusher plate and the spacer pusher out of the idler slide channel (Fig. 26).

Fig. 26: Pusher plate removal Take-up cylinder

Spacer pusher Pusher plate

Pressure relief valve Idler slide channel Tram Track Front Idler Installation

To install the tram track front idler: 1. Insert the pusher spacer (Fig. 27) into the tractor frame’s idler slide channel so that it rests on the slide block support and is positioned against the takeup jack.

2. Ensuring that the channel guides face away from the take-up jack, insert the pusher plate into the idler slide channel until it touches the pusher spacer.

Fig. 27: Pusher plate installation

Pusher spacer Pusher plate

______________________________________________________________ A6474X377 REV 0 45

Tram Track Front Idler_____________________________________________ 3. Insert the block slides of the front idler assembly (Fig. 28) into the idler slide channel. The relief valve of the slide blocks must be oriented toward the front of the miner.

4. Push the front idler assembly into the slide channel until the block slides are against the pusher plate channel guides.

Fig. 28: Front idler installation

Take-up cylinder

Front idler assembly

Block slide Pressure relief valve

Relief valve Idler slide channel

5. Connect the two ends of the tram track and using the hammer and punch, insert the track pin to secure the two track links together.

6. Using the hammer and punch, insert the two roll pins into the track pin to secure the pin in the links.

7. Adjust the tram track tension.

8. Close the front rub rail cover and replace the hex head capscrews and lock washers that secure the front rub rail to the tractor frame.

________________________________________________________________ 46 CM235 Mechanical - Traction

____________________________________________ Tram Track Front Idler Front Idler Cylinder Removal

To remove the front idler take-up cylinder: 1. Lower the conveyor tail section until it is level with the floor.

2. Lower the gathering head and cutter head until these two assemblies touch the floor.

3. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

4. Remove the hex head capscrew and lock washer that secures the front rub rail to the tractor frame and open the front rub rail cover.

5. Remove the eight (8) 5/8 X 2” hex head capscrews that secure the fill plate to the frame and remove the fill plate.

6. Locate the front idler take-up cylinder bracket assembly (Fig. 29) which is mounted to the rear of the idler shim channel.

7. Pull the flip pin (Fig. 30) from the half link to release the take-up cylinder bracket from the tractor frame.

8. Lower the end of the bracket until it clears the half link and pull the bracket straight out to remove it from the tractor frame.

Fig. 29: Front idler take-up cylinder bracket

Bracket assembly

Idler shim channel

______________________________________________________________ A6474X377 REV 0 47

Tram Track Front Idler_____________________________________________ Fig. 30: Front idler take-up cylinder removal

Bracket assembly

Flip pin

Idler take-up assembly Flip pin

front idler cylinder installation

To install the front idler take-up cylinder: 1. Replace the take-up cylinder bracket assembly into the tractor frame and secure it by inserting the flip pin through the half link.

2. Replace the fill plate and secure with capscrews.

3. Close the front rub rail cover and secure to the tractor frame with a hex head capscrew and lock washer to secure the front rub rail to the tractor frame.

________________________________________________________________ 48 CM235 Mechanical - Traction

________________________________________________Stabilizer Cylinder Introduction

The following procedure is for the removal of the stabilizer cylinder.

Tool Set

Basic Tool Set Blocking

Safety

When removing a stabilizer cylinder, observe the following safety precautions:

!

WARNING You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.

!

WARNING Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.

!

WARNING Stand clear of the blocked tractor frame during contraction of the stabilizer cylinder.

!

WARNING Verify that the conveyor tail section is adequately secured before crawling under the block supports.

!

WARNING Each stabilizer cylinder is extremely heavy. Be prepared to support the weight from its tractor frame mounting. Be prepared to support the weight of the cylinder when it becomes free from the mounting.

______________________________________________________________ A6474X377 REV 0 49

Stabilizer Cylinder ________________________________________________ Stabilizer Cylinder Removal

To remove a stabilizer cylinder: 1. Raise the conveyor tail assembly to its highest position.

2. Raise the cutter head and gathering head assemblies. Place appropriate blocking under the cutter head and gathering head assemblies.

3. Lower the cutter head and gathering head assemblies onto the blocking so that the front of the tractor frame lifts off the floor. Place blocking under the front of the tractor frame. Raise the cutter head and gathering head assemblies slightly so that the tractor frame lowers onto the blocking.

4. Completely extend the stabilizer so that the rear of the tractor frame lifts off the floor. Place blocking under the rear of the tractor frame. Raise the stabilizer slightly so that the tractor frame lowers onto the blocking.

5. Place blocking under the conveyor tail assembly and lower the tail assembly onto the blocking.

6. Extend the stabilizer so that it touches the floor. The stabilizer should not support any miner weight.

7. Double check that the tractor frame and the conveyor tail are securely blocked.

8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

9. Locate the rod end bearing pin of the stabilizer cylinder (Fig. 31). Remove the two (2) 1/2” pin retaining bolts and then pull the pins.

10. Connect the trailing cable to energize the miner.

11. Retract the stabilizer cylinder. The rod end bearing of the cylinder should remove itself from its stabilizer shoe clevis.

12. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

13. Raise and lower the stabilizer cylinder lever to release any pressure from the conveyor lift cylinder.

________________________________________________________________ 50 CM235 Mechanical - Traction

________________________________________________Stabilizer Cylinder Fig. 31: Stabilizer cylinder bearings

Piston end pin

Piston end pin Pin retaining bolts

Rod end pin

14. Tag, disconnect, and cap the hydraulic hoses from the stabilizer cylinder’s fittings.

15. Remove the hydraulic fittings from the stabilizer cylinder and store in a clean place.

16. Remove the two (2) 1/2” bolts that hold the bearing pin retainer in place and remove the retainer.

17. Remove the pin.

______________________________________________________________ A6474X377 REV 0 51

Stabilizer Cylinder ________________________________________________ Stabilizer Cylinder Installation

To install a stabilizer cylinder: 1. Install the bearing pin.

2. Install the bearing retainer and the two (2) 1/2” bolts that hold the bearing pin retainer in place, and torque the bolts to 114 lb-ft (154 Nm).

3. Install the hydraulic fittings to the stabilizer cylinder.

4. Connect and cap the hydraulic hoses to the stabilizer cylinder.

5. Lower and raise the stabilizer cylinder lever to release any pressure from the conveyor lift cylinder.

6. Connect the trailing cable to energize the miner.

7. Retract the stabilizer cylinder. Install the rod end bearing of the cylinder to the stabilizer shoe clevis.

8. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

9. Locate the rod end bearing pin of the stabilizer cylinder (Fig. 31). Install the two (2) 1/2” pin retaining bolts and the pins, and torque the bolts to 114 lb-ft (154 Nm).

________________________________________________________________ 52 CM235 Mechanical - Traction