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A6474X375 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X375 (Introduction - Operation)

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 Safety Instructions............................................................................. 4 Red Zones ......................................................................................... 6 General Description........................................................................... 10 Installation ......................................................................................... 11 Storage .............................................................................................. 16 Machine Mounted Controls ............................................................... 18 Remote Operation ............................................................................. 22 Operation........................................................................................... 23 Pre-Operational Checks............................................................ 23 Daily Checks ............................................................................. 23 Machine Shutdown Functions ........................................................... 24 Machine (Emergency) Stop Bypass.................................................. 24 Start-Up Procedure ........................................................................... 27 Shutdown Procedure......................................................................... 28 Sump Tramming................................................................................ 29 Hydraulic System .............................................................................. 35 Electrical System............................................................................... 37 Water System.................................................................................... 38

________________________________________________________________ A6474X375

REV 2

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, as well as all Federal, State, and Mine safety regulations must be followed at all times.

!

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

!

WARNING Do not attempt to operate the continuous miner until you have been sufficiently trained on the machine and have read and understand this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

!

WARNING Follow all applicable laws and regulations regarding the use of temporary roof supports before approaching the machine to connect the umbilical cord. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

!

WARNING Only use the Emergency Stop Bypass function to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Bypass when a Machine Stop switch has been activated intentionally. Failure to comply with this warning may lead to severe injury or death of personnel.

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

________________________________________________________________ 4 CM235 Continuous Miner

______________________________________________________ Red Zones Introduction

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

Most significantly, the operator’s greatest danger is from his Continuous Miner, especially when he is maneuvering it during mining operations. The miner is capable of slewing when turning, especially when the crawlers are split. The discharge conveyor can also swing. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

Red Zones (Danger Areas)

Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 1) is indicated by alternating red and white diagonal stripes.

This information is for general reference only. All mining methods are dictated by the mine regulations and ventilation and roof control procedures.

Fig. 1: Red zone designation

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Red Zones ______________________________________________________ Tramming the miner (Fig. 2) from one place to another, especially maneuvering around intersections. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump (Fig. 2) in a new cut. The miner is against the left rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car. The operator must stay clear of the discharge conveyor and the rear of the miner.

Fig. 2: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

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______________________________________________________ Red Zones Sumping in the left hand side of the cut (Fig. 3). As the miner penetrates the face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Repositioning the miner for the right hand cut (Fig. 3). Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the right hand cut (Fig. 3). Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

Fig. 3: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

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Red Zones ______________________________________________________ Crosscut red zones (Fig. 4). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newly-exposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

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

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

Fig. 4: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

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______________________________________________________ Red Zones Pillaring red zones (Fig. 5) Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

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

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

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

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

Fig. 5: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

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General description_______________________________________________ Introduction

The CM235 is designed for harder cutting applications. The cutter head is powered by two 275 HP (one hour rating) cutting head motors mounted in the cutter head assembly. The motors tie together at a common drive shaft, allowing for the combined power of both motors at the cutter head. Additionally, there are two 60 HP conveyor/gathering head motors, two 110HP AC traction motors controlled by Variable Frequency Drives (VFDs), and a 50 HP pump motor.

Fig. 6: General Arrangement 10

9

1

6

7

5 8 4

2 3

1.

2.

3.

4.

5.

Cutter head assembly Cutter motor location Gathering head assembly Gather head motor location Hydraulic pump and motor location

6. Traction motor location 7. Traction controller 8. Gathering head cylinder 9. Conveyor swing cylinder 10. Conveyor assembly

________________________________________________________________ 10 CM235 Continuous Miner

______________________________________________________ Installation Introduction

Machine and Component Weights

The CM235 Continuous Miner can be shipped either as a complete machine or in component sections, depending on customer preference or transportation weight restrictions. The machine should only be unloaded by experienced personnel. Always refer to the Pre-Operational Checks and Start Up procedure before attempting to unload an assembled machine. If shipped in components, it is recommended that a representative assist in the reassembly.

When lifting the machine, also verify machine or component weights and use appropriate lifting mechanisms. Note that the weights listed below may vary depending on options and custom design.

Table 1: Component Weights

Description

Approximate Weight

Complete machine

140,000 lbs (63,503 kg)

Tractor frame assembly

65,000 lbs (29,484 kg)

Gathering head assembly

23,000 lbs (10,433 kg)

Conveyor assembly

17,000 lbs (7,711 kg)

Cutter head support frame with drum drives and drums

35,000 lbs (15,846 kg)

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Installation ______________________________________________________ Fig. 7: Assembly lifting points and transport dimensions Frame transport dimensions and lifting eye locations

Lifting eye location

Lifting eye location

Lifting eye location (both sides)

________________________________________________________________ 12 CM235 Continuous Miner

______________________________________________________ Installation Fig. 7, continued: Assembly lifting points and transport dimensions Conveyor transport dimensions and lifting eye locations Lifting eye

Lifting eye

Lifting eye Lifting eye

Lifting eye (both sides)

Lifting eye (both sides)

______________________________________________________________ A6474X375 REV 2 13

Installation ______________________________________________________ Fig. 7, continued: Assembly lifting points and transport dimensions Cutter head transport dimensions and lifting eye locations

Lifting points

________________________________________________________________ 14 CM235 Continuous Miner

______________________________________________________ Installation Fig. 7, continued: Assembly lifting points and transport dimensions Gathering head transport dimensions and lifting eye locations

Lifting point Lifting point

Lifting point

Lifting point

Lifting point (both sides)

______________________________________________________________ A6474X375 REV 2 15

Storage _________________________________________________________ Storage

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

Corrosion Protection

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

Exposure to Sunlight

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

Dirt and Moisture

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

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

Short-term Storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed.

Such components must be particularly protected against excessive temperatures, dirt, and moisture.

Long-term Storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: 1. If the cylinder rods are exposed, the rods must be coated with a corrosion inhibiting fluid.

2. Completely fill the hydraulic oil tank with oil.

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

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

5. Completely drain the water system and refill with a 50/50 antifreeze/water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND NO WATER OR AIR POCKETS EXIST. 6. The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

Machine Electrical Components

Electronic components must be stored at -10° C to 55° C (14° F to 131° F).

________________________________________________________________ 16 CM235 Continuous Miner

_________________________________________________________Storage Traction Drives

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

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

Random Sample Inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. Upon request, the inspection can be carried out by a service representative.

Natural Aging

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

Long-term storage of spare components Hydraulic Components

Miscellaneous Components

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

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

Motors

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

Fan Assembly

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

Plastic Deformation

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

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Machine Mounted Controls ________________________________________ Circuit Breakers

Power is supplied to the machine via a trailing cable. Once the trailing cable is connected and energized, power is isolated from the machine by the main circuit breaker, the cutter circuit breaker, and the tram circuit breaker.

As soon as the main circuit breaker is closed, power is supplied to the pump motor, left and right conveyor/gathering head circuits, and the lighting and control circuits.

Fig. 8: Circuit Breaker

2 1

1. Main circuit breaker Breaker Operation

2. Auxiliary circuit breaker Breaker 1. Main circuit

Function

Operation

Isolates the entire machine from power supplied via the trailing cable.

Push to the left to turn ON (close the breaker).

Push to the right to turn OFF (open the breaker).

2. Aux. circuit

Isolates the gathering head, fan and pump motor circuits.

Push to the right to turn ON (close the breaker).

Push to the left to turn OFF (open the breaker).

!

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

________________________________________________________________ 18 CM235 Continuous Miner

________________________________________ Machine Mounted Controls There are control switches located on the front of the controller case that will function after the main circuit breaker is on (closed). The continuous miner is normally operated by radio remote. Manual operation via controls on the controller case is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only. Not all switches depicted below are active. The following are the active switches on this machine:

Control Switches

!

WARNING Do not attempt to operate the continuous miner until you have been sufficiently trained on the machine and have read and understand this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

Fig. 9: Control switches 4 - 13

1

1.

2.

3.

4.

5.

6.

Panic Bar/Pump Stop Radio/E-Tram Switch Machine Lighting MCB4 MCB5 MCB6

14

2

15

16

3

7. MCB7 8. MCB8 9. MCB9 10. MCB10 11. MCB11 12. MCB12

13. MCB13 14. Pump Hour Meter 15. Cutter Hour Meter 16. Conveyor Hour Meter

______________________________________________________________ A6474X375 REV 2 19

Machine Mounted Controls ________________________________________ Control Switch Operation Switch

Function

Operation

Panic Bar/Machine Stop Removes power from the control circuit, PUSH the bar to stop all motors. shutting down the machine.

Radio/E-Tram

Determines mode of operation.

MANUAL puts the machine under manual control.

RADIO puts the machine under radio control.

Machine Lighting

Controls the lights.

MANUAL turns on the headlights and area lights.

OFF turns off all lights.

RADIO turns on area lights. Headlights can be controlled by the radio remote.

MCB4

15A beaker for the 120VAC+ side of the PUSH in to set/reset. control power circuit.

PULL to open.

MCB5

15A breaker for the 120VAC- side of the control power circuit.

PUSH in to set/reset.

PULL to open.

MCB6

10A breaker for the 120VAC+ side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB7

10A breaker for the 120VAC- side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB8

20A breaker for the 12VAC+ side of the PUSH in to set/reset. headlight circuit.

PULL to open.

MCB9

20A breaker for the 12VAC- side of the headlight circuit.

PUSH in to set/reset.

PULL to open.

MCB10

Spare 5A breaker.

N/A

MCB11

Spare 5A breaker.

N/A

MCB12

5A breaker on the 110VDC+ side of the PUSH in to set/reset. solenoid circuit.

PULL to open.

MCB13

5A breaker on the 0VDC- side of the solenoid circuit.

PUSH in to set/reset.

PULL to open.

________________________________________________________________ 20 CM235 Continuous Miner

________________________________________ Machine Mounted Controls Control Switch Operation, continued Switch

Function

Operation

Pump Hour Meter

Displays hours of running time for the pump motor.

N/A

Cutter Hour Meter

Displays hours of running time for the cutter head motors.

N/A

Conveyor Hour Meter

Displays hours of running time for the conveyor motors.

N/A

Left Side Machine Stop

There is a machine stop button located on the left rear corner of the machine.

Like the machine stop button on the control case, pressing the left side machine stop button will shutdown the pump, thereby shutting down the machine.

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Remote Operation ________________________________________________ Radio Remote

The continuous miner is normally radio remote controlled during production operations. Remote operation is allowed when the machine is energized and the miner switch is in the remote position. See the Remote Operation section of this manual for further information on the radio remote control of the machine.

Pendant Control

Limited machine functions can be operated from a pendant control connected to the machine by an umbilical cable. This control is used in the event that the operator loses radio link with the miner and the miner needs to be moved.

The pendant controller can turn the pump motor on and off, can tram the machine, and can raise and lower the cutting head.

In order to use the pendant, it must be connected to the machine via a pigtail.

After plugging in the umbilical cord, the miner switch must be placed in the ETram position.

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

!

WARNING Follow all applicable laws and regulations regarding the use of temporary roof supports before approaching the machine to connect the umbilical cord. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

________________________________________________________________ 22 CM235 Continuous Miner

_______________________________________________________ Operation Pre-Operational Checks

The following checks should be completed before the machine is put into service for the first time. Corrections or adjustments should be made by a qualified maintenance person.

1. Verify that all circuit breakers are in their OFF positions.

2. Check all hydraulic and lubricant fluid levels.

3. Verify that the cooling water is connected. Operating the machine without cooling water will seriously reduce the life of the motors.

4. Check and operate all control handles and remote switches to ensure all machine functions are operating correctly. Return all handles/switches to the neutral position.

5. Check, and adjust as necessary, the tension of the conveyor and crawler chains.

Daily Checks

The following checks should be completed at the beginning of every shift. Repairs and adjustments should be made immediately by a qualified maintenance person.

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

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

3. Check the full length of the trailing cable for damage. Ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the machine is secure.

4. Clean any foreign material from the conveyor and gathering pan.

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

6. Perform daily maintenance.

7. Check the conveyor and crawler chain tensions.

8. Be certain that all other machines and personnel are clear of the area and start the machine. Check for correct operation of all stop and emergency stop buttons (both on the machine and on the radio remote).

9. After starting the machine, allow the hydraulic system to warm up for five to ten minutes and then verify that the hydraulic system pressure is correct (see the hydraulic schematic in the parts book for your machine).

______________________________________________________________ A6474X375 REV 2 23

Emergency Shutdown_____________________________________________ Emergency Shutdown Controls

The are controls located on the machine, the radio remote, and the tram pendant that give the operator the ability to quickly shutdown the miner. All personnel should be aware of the location of shutdown controls and how to use them.

The following controls can be used to shutdown the machine: Control

Location

Action

Result

Main Circuit Breaker

Main Disconnect Box

Push to the right to Isolates the entire maturn OFF (open the chine from power supbreaker). plied via the trailing cable.

Machine Stop

Control Case

Push to activate.

Shuts down all motors on the machine.

E- STOP

Radio Remote Push to activate.

Shuts down all motors on the machine.

Pump Off

Radio Remote Push toggle switch up to activate.

Shuts down all motors on the machine.

Machine Stop

Tram Pendant Push to activate.

Shuts down all motors on the machine.

Machine Left Side Tram Pendant

Emergency Stop (Machine Stop) Bypass (optional)

!

A typical continuous miner is fitted with a mushroom style emergency stop button on the left side of the machine. The button is used to shutdown the machine in the event of an emergency. It is possible for the button to be stuck in the “ON” position if the left side of the machine becomes jammed against the rib. In this event, there is an optional Emergency Stop Bypass function available that allows the pump motor to be started and the machine to be trammed away from the wall. The override feature is only active in thirty second intervals.

WARNING Only use the Emergency Stop Bypass function to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Bypass when a Machine Stop switch has been activated intentionally. Failure to comply with this warning may lead to severe injury or death of personnel.

Emergency Stop (Machine Stop) Bypass Procedure

To activate the Emergency Stop Bypass function: 1. Press and hold the “SHIFT” and “BYPASS” keys (Fig. 10) together for a continuous five seconds.

________________________________________________________________ 24 CM235 Continuous Miner

____________________________________________ Emergency Shutdown Fig. 10: Bypass key Press key down

Press key up

2. While the keys are held together, the text display on the miner will show a countdown timer (Fig. 11), indicating bypass mode is active. The timer counts the five second delay period.

Fig. 11: Bypass enable delay period timer

Five second timer

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Emergency Shutdown_____________________________________________ 3. Once the five second delay has passed, the system enters bypass mode.

The “SHIFT” and “BYPASS” keys can then be released. The text display will now show a timer that will count down the thirty second active period (Fig. 12). Once the thirty seconds has expired, the bypass will again be disabled and the procedure must be repeated.

Fig. 12: Bypass active countdown timer

Thirty second timer

________________________________________________________________ 26 CM235 Continuous Miner

_______________________________________________ Start-Up Procedure Introduction

!

The following procedures are recommended for starting up the continuous miner. These procedures are for starting the machine during normal operations and assume that the operator has been fully trained and that machine is correctly connected to the trailing cable and that all pre-operational checks, including daily maintenance, have been performed.

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

Start-Up (Radio Remote)

To start the continuous miner using the radio remote: 1. Turn the main circuit breaker to the “ON” position.

2. Select “RADIO” on the “RADIO/E-TRAM” switch on the operator’s case.

3. Press and hold the “ON” key for 1 second. The console display should read “HOLD”. Release the key and the display should read “ON”.

4. Press “SHIFT” and wait 1/4 second.

5. While pressing “SHIFT”, press “PUMP ON”. Hold both keys in until the pump starts.

6. Release the “PUMP ON” key.

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

7. Release the “SHIFT” key.

Start-Up (Tram Pendant)

To start the continuous miner using the tram pendant: 1. Press and hold the “PUMP START/ENABLE” button.

2. Press the “PUMP ON” button. Hold both buttons until the pump starts (approximately one second).

3. Release both buttons.

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Shutdown Procedure _____________________________________________ Shutdown Procedure (Radio Remote)

The following procedures are recommended for shutting the machine down during normal operations: 1. Back the miner about one foot from the face providing sufficient clearance.

2. Turn off the cutter motors by pressing the “CUTTER OFF” key. The cutter motors should shutdown immediately.

3. Empty the conveyor and shut it off by pressing the “CONV OFF” key. The conveyor motors should shutdown immediately.

4. Lower the cutter head to the floor.

5. Lower the conveyor and gathering head.

6. Park the machine in its designated parking area, out of traffic and on flat, solid ground. If it is not possible to park the machine on flat ground, park at a right angle to the slope.

7. Press and hold the “PUMP OFF” key. The pump motor should shutdown immediately.

8. Release the “PUMP OFF” key.

9. Position all levers and controls to Neutral or Off. 10. Turn off the water sprays.

11. Turn off the radio remote.

12. Shut off the main power supply.

13. Shut off the mine water supply.

________________________________________________________________ 28 CM235 Continuous Miner

_________________________________________________ Sump Tramming Sump Tramming (Tramming Forward While Cutting)

Tramming is limited by the control system as shown in Table 5.

Table 5: Tramming limitations Cutters not Running Tramming Operation

Speed Limitation

Both remote control levers forward or reverse

Tram speed selected (1, 2 or 3)

One lever forward, one reverse (split track tramming)

Both motors limited to 1st speed

One lever engaged (forward or reverse), on lever home (single track tramming)

Speed of engaged motor limited to 1st or 2nd speed

Cutter Running and Cutter Amps < cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

FWD CLEANUP speed regardless of speed selected

Both remote control levers reverse

Tram speed selected (1, 2 or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited to FWD CLEANUP speed regardless of speed selected Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

FWD CLEANUP speed regardless of speed selected

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

Cutters Running and Cutter Amps > Cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

Speed limited by control system

Both remote control levers reverse

Tram speed selected (1, 2 or 3)

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited by control system Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

Speed is limited by control system

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

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Sump Tramming _________________________________________________ The controller settings can be adjusted through the graphics display AC traction parameters page, “SUMP SETUP MENU” (Fig. 40) which is accessed with a password. This screen allows the operator to tune the machine for individual min conditions. A description of the parameters are given in Table 6.

Fig. 40: “SUMP SETUP MENU”, AC traction parameters page

________________________________________________________________ 30 CM235 Continuous Miner

_________________________________________________ Sump Tramming Table 6: AC traction adjustable parameters Menu LH Tram Config

RH Tram Config

Sump Settings

Parameter

Description

Value

LEFT FWD SPEED 1 (%)

Traction drive target speed forward - 1st speed

0 - 45%

1%

20

LEFT FWD SPEED 2 (%)

Traction drive target speed forward - 2nd speed

35 - 80%

1%

40

LEFT FWD SPEED 3 (%)

Traction drive target speed forward - 3rd speed

50 - 100%

1%

72

LEFT REV SPEED 1 (%)

Traction drive target speed reverse - 1st speed

0 - 45%

1%

20

LEFT REV SPEED 2 (%)

Traction drive target speed reverse - 2nd speed

35 - 80%

1%

40

LEFT REV SPEED 3 (%)

Traction drive target speed reverse - 3rd speed

50 - 100%

1%

72

RIGHT FWD SPEED 1 (%)

Traction drive target speed forward - 1st speed

0 - 45%

1%

20

RIGHT FWD SPEED 2 (%)

Traction drive target speed forward - 2nd speed

35 - 80%

1%

40

RIGHT FWD SPEED 3 (%)

Traction drive target speed forward - 3rd speed

50 - 100%

1%

72

RIGHT REV SPEED 1 (%)

Traction drive target speed reverse - 1st speed

0 - 45%

1%

20

RIGHT REV SPEED 2 (%)

Traction drive target speed reverse - 2nd speed

35 - 80%

1%

40

RIGHT REV SPEED 3 (%)

Traction drive target speed reverse - 3rd speed

50 - 100%

1%

72

MAX LH SUMP SPEED (%)

Determines maximum forward speed available when system has determined that the machine is cutting in the face

16 - 45%

1%

20

16 - 45%

1%

20

Determines minimum forward speed available when system has determined that the machine is cutting in the face

0 - 27%

1%

2

0 - 27%

1%

2

Determines the rate of change in forward sump direction from minimum to maximum speeds when system has determined that the machine is cutting in the face

0 - 100%

1.00%

1

MAX RH SUMP SPEED (%) MIN LH SUMP SPEED (%) MIN RH SUMP SPEED (%) SUMP SPEED DELTA (%)

Change Default

______________________________________________________________ A6474X375 REV 2 31

Sump Tramming _________________________________________________ Table 6, continued: AC traction adjustable parameters Menu

Parameter

Description

Value

Sump Settings, continued

MAX SUMP CUTTER CURRENT (A)

Determines maximum threshold for cutter current that determines if the machine is increasing or decreasing speed output

110 250A

1A

170

MIN SUMP CUTTER CURRENT (A)

Determines minimum threshold for cutter current that determines if the machine is increasing or decreasing speed output

20 - 200A

1A

120

STOP CURRENT (A)

Determines the threshold for cutter current at which the machine will halt until the current level drops below the Stop current value

250 400A

1A

350

SHEAR UP STOP CURRENT (A)

Sets the threshold for cutter current that determines when to stop shear up control. When the current falls below this, shear up will restart

0 - 500A

1A

250

SHEAR DOWN STOP CURRENT (A)

Sets the threshold for cutter current that determines when to stop shear down control. When the current falls below this, shear down will restart

0 - 500A

1A

250

CUTTER IN COAL CURRENT (A)

Determines the point at which the machine will engage automatic sumping/ traction control. Above this point, algorithm will activate

60 - 250A

1A

120

FWD CLEAN UP Determines the forward speed that will be SPEED (%) available when the cutters are running before the cutter in face current threshold has been reached

0 - 50%

1%

35

HIGH SPEED When set to YES, inhibits the maximum PREVENT (YES/ reverse speed to 2nd speed when cutters NO) are running

YES/NO

N/A

NO

REVERSE ANTI SLEW SPEED (%)

20 - 70%

1%

35

Determines the speed in the reverse direction when tramming in single track or pirouette when the system has determined that the machine is cutting in the face

Change Default

________________________________________________________________ 32 CM235 Continuous Miner

_________________________________________________ Sump Tramming Table 6, continued: AC traction adjustable parameters Menu VFD Setup

Traction Setup

Machine Setup

Parameter

Description

Value

Change Default

CURRENT LIMIT AC traction drive current limit as a per(A) AC ONLY centage of full load. Determines the value at which the traction drives protect against overload

100 200%

1%

180

RECTIFIER DC AC traction rectifier DC bus braking limit.

BUS REF (V) AC Braking will activate when the DC bus ONLY exceeds this value during regeneration.

Rectifier IGBT will dump energy into bus resistors to keep the bus voltage below this level

1600 2000V

1V

1800

LH TRAM TRIM (%) DC ONLY

Left tram reference adjustment for DC traction drives. Due to inherent mismatch of drive components, firing angle is trimmed with this value to assure that the machine trams straight in all speeds

-10 +10%

1%

0

RH TRAM TRIM (%) DC ONLY

Right tram reference adjustment for DC traction drives. Due to inherent mismatch of drive components, firing angle is trimmed with this value to assure that the machine trams straight in all speeds

-10 +10%

1%

0

CUTTER SOL CURRENT (mA)

Digital output current to shear solenoid when cutter head running. Ignored when in proportional mode or auto shear active

0 - 800mA

1mA

450

PAN SOL CURRENT (mA)

Digital output to pan solenoid at all times.

Ignored in proportional mode

0 - 800mA

1mA

450

Using these parameter, the machine will automatically control the machine cut sequence to provide optimal traction/motor control.

To set the traction parameters: 1. Enter the sump configuration menu in the engineering menu and record all existing parameter values.

2. Start the cutter head and observe and record the running current in free air for the cutter motors.

3. Set the “CUTTER IN FACE CURRENT” approximately 30 amps above the free air current observation (step 2).

4. Operate the miner in the face and, using the graphics screen for cutting operations, observe the peak current reached during sumping operation. Set this value as the “SUMP TRAM MAX CUTTER CURRENT” value.

5. Set the “SUMP TRAM MIN CUTTER CURRENT” approximately 30 amps below the max value (step 4).

______________________________________________________________ A6474X375 REV 2 33

Sump Tramming _________________________________________________ 6. At this time, set the left and right hand max sump speeds at 20% and set the left and right had min sump speeds at 5% below max.

7. Start raising the max sump tram cutter current in small increments until the cutter current levels out or peaks in sumping operations. This value now becomes the “SUMP TRAM MAX CUTTER CURRENT”.

8. Set the “SUMP TRAM MIN CUTTER CURRENT” value 30 amps below the value obtained in step 7.

9. Start raising the sump speeds (left and right hand) until the crawlers appear to start breaking traction. This is the max sump speed.

10. Set the min sump speed (left and right hand) 5% below the max sump speed (step 9).

The miner may start with a lurching motion when sumping at this time. If this occurs, start raising the “SUMP DELTA” value in small increments until this action subsides.

Clean up speed allows faster tram when approaching the face with cutters running and pulling only free air current.

Once the “in face” current is met, the algorithm for the sump configuration is activated.

These parameter values should be the optimum values for this machine in your cutting conditions. The following example illustrates the parameter setting procedure.

IMPORTANT

This example is for illustration only. Parameters must be determined for each individual application.

Parameter settings: Left and right max sump speed: 15% Left and right min sump speed: 10% Sump Delta: 4 Max Cutter Current: 140 amps Min Cutter Current: 110 amps Forward clean up %: 20% Forward and Reverse speeds: 20, 40, and 72% Cutter in Coal: 80 amps

________________________________________________________________ 34 CM235 Continuous Miner

________________________________________________ Hydraulic System Introduction

Hydraulic power for all hydraulically actuated functions originates with the pump assembly. This includes power for the conveyor swing and raise/lower cylinders, the conveyor chain take-up cylinders, the stabilizer shoe cylinders, the cutting head raise/lower cylinders, and the hydraulically actuated dust suppression system.

A 50 HP pump motor drives a two-stage gear pump that delivers hydraulic oil to the hydraulic system. The 72 gallon (273 L) hydraulic oil tank is an integral part of the main frame. Only anti-wear hydraulic oil meeting Specification 100-1 should be used in the hydraulic system.

Load Holding (Load Lock) Valves

The purpose of a load holding (load locking) valve is to prevent the accidental lowering of a hydraulic cylinder, whether suddenly or by gradual bleed off. Both the conveyor raise/lower cylinders and the cutter head raise/lower cylinders incorporate load holding valves.

There is a pilot operated check valve in the load holding valve of each conveyor raise/lower cylinder and a pilot load holding valve attached to each cutter head raised/lower cylinder. Each of these valves prevents its respective cylinder from lowering its load in the absence of a specific pilot pressure. (This pressure is induced only when the lower control of that particular function is engaged.) The load holding valves fro the conveyor and cutter head incorporate a relief function which by-passes the pilot operation whenever the pressure setting is exceeded.

Shear Down (anti-chatter)/ Maintenance valve

The shear down (anti-chatter)/maintenance valve provides back pressure against the cutter head (shear) cylinders in the cutter head lower (shear down) cycle. This back pressure must be overcome before the cutter head will lower, preventing cutter head bounce (chatter).

System Pressure

The machine operator should be familiar with the operating (system) pressure of the machine during normal operations. If the operating pressure is outside of the normal range, it should be reported immediately.

Power Fill Function

The machine is equipped with a power fill function that assists in adding hydraulic oil to the machine’s hydraulic oil tank. The power fill operates from the conveyor lower circuit. The conveyor lower line tees off to a 2-position, 4-way valve that is normally closed. With the conveyor in the down position, the valve is manually opened. When the conveyor lower function is activated, oil enters the circuit and runs the power fill function. Oil passes through the valve to a jet pump, which creates a venturi (vacuum) effect, pulling oil from the clean oil reservoir through a 10 micron filter, a check valve, a Y strainer and then to tank.

______________________________________________________________ A6474X375 REV 2 35

Hydraulic System ________________________________________________ Power Fill Operation

To operate the power fill function: 1. Start the pump motor and fully lower the conveyor.

2. Wipe the suction hose clean and place it in a clean container of hydraulic fluid.

3. Open the 2-position, 4-way valve.

4. Engage the conveyor down function.

5. After filling the tank, release the conveyor down function.

6. Close the 2-position, 4-way valve.

7. Clean and plug the suction hose to prevent contamination and secure the hose on the machine.

8. Stop the pump motor.

Filters

There are three hydraulic filters on the machine: 1. Pressure filter, bypassing 2. Pilot filter, non-bypassing 3. Power fill filter

________________________________________________________________ 36 CM235 Continuous Miner

_________________________________________________Electrical System Introduction

The main input power supply for this machine is three-phase 995VAC power which directly supplies the motor circuits. A control transformer steps the voltage down to 120VAC for the control circuit and 12VAC for the lighting circuit and thermistor module.

Motors

This machine is powered by seven 995VAC electric motors: 1. One 50 hp pump motor 2. Two 275 hp cutter motors 3. Two 60 hp gathering head/conveyor motors 4. Two 110 hp AC traction motors

______________________________________________________________ A6474X375 REV 2 37

Water System____________________________________________________ Introduction

The miner is equipped with a water system used for dust control and to cool the electrical machine components. The mine water is normally connected on the right rear of the machine.

Water supply requirements are: Flow: 30 gpm for cooling Pressure: 250 psi (dynamic) minimum 500 psi maximum The water supply is connected to a ball valve, which must be manually opened before the cooling/dust suppression system can be activated. From the ball valve, water flows through a non-bypassing water filter and a flow meter.

Activation

After the ball valve is manually opened, the dust-cooling circuit is operated by remote solenoid control. When the dust-cooling solenoid is energized, the normally closed water valve is opened. Water passes through the solenoid water valve to a pressure manifold and is distributed to the left and right dust cooling circuits.

Maintenance

The following maintenance items should be observed to properly maintain the dust/cooling system: 1. Insure that the water supply meets the requirements listed above. Insufficient water flow and/or pressure will affect cooling capabilities and dust spray operation.

2. Only use water that is clean and as free as possible of corrosive elements.

3. Do not operate the miner without the water supply being connected and activated. Operating the electric motors without proper cooling will seriously reduce motor life.

4. Monitor the water filter and remove and clean as needed to eliminate clogging. This is a by-passing filter; if the filter is clogged, the water will pass unfiltered to the dust/cooling system.

5. Inspect the water spray nozzles on a regular basis. Water should flow from all nozzles when the sprays are operating. Clean as necessary.

________________________________________________________________ 38 CM235 Continuous Miner

___________________________________________________ Water System Fig. 10: Water system layout

1

1

10

10

2

3 1

1

4

5 9 8

7

13

11

1. Dust Sprays 2. Cutter Motor, LH 3. Cutter Motor, RH 4. Gathering Head Motor, LH 5. Gathering Head Motor, RH 6. Pump Motor 7. Tram Motor, LH 8. Tram Motor, RH 9. Control Case 10. Relief Valves 11. Pump Control Manifold 12. Fire Spray Valves 13. Pressure Manifold 14. Flow Meter 15. Filter, Non-bypassing 16. Pressure Gauges 17. Ball Valve 18. Flow Control Valve 19. Sump Pump

6 16

19

15 18

14

17 12

______________________________________________________________ A6474X375 REV 2 39

Water System____________________________________________________

________________________________________________________________ 40 CM235 Continuous Miner

A6474X376 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X376 (Introduction - Maintenance)

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 Safety Precautions ............................................................................ 4 General Maintenance Instructions .................................................... 6 Lock Wiring Fasteners....................................................................... 8 Self-locking Screws ........................................................................... 8 Locknuts ............................................................................................ 8 Torque Values ................................................................................... 9 Lubrication and Maintenance Schedule ............................................ 12 Specific Lubrication and Maintenance Procedures ........................... 17 Every Shift................................................................................. 17 Daily .......................................................................................... 20 Weekly....................................................................................... 27 Crawler Chain Adjustment Procedure.................................. 29 Conveyor Chain Tension Adjustment Procedure................. 33 Monthly...................................................................................... 36 Every Three Months.................................................................. 42 Every Six Months ...................................................................... 47 Tail Shim Adjustment Procedure....................................................... 50 Lubricant Specifications .................................................................... 58

________________________________________________________________ A6474X376

REV 1

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 If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

!

CAUTION

Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT

Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

! WARNING

Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks by feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin.

! NOTICE

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to drain into the bottle.

IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), a special “button” style lubrication fitting is available to prevent the accidental use of multi-purpose lithium complex grease at these locations.

! NOTICE

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

IMPORTANT

For motor bearings that require high temperature lithium complex grease, a special “button” style lubrication fitting is available to prevent the accidental use of multipurpose lithium complex grease at these locations.

IMPORTANT

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

________________________________________________________________ 4 CM235 Maintenance

_______________________________________________ Safety Instructions !

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

!

WARNING The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.

IMPORTANT

This example is for illustration only. Parameters must be determined for each individual application.

______________________________________________________________ A6474X376 REV 1 5

General Maintenance Instructions___________________________________ Introduction

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. This manual contains recommendations on machine and component inspections, machine lubrication, lubricant (oil) change procedures, filter maintenance, and adjustment procedures to properly maintain the machine.

Tools

General tools are required for maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations and Procedures The maintenance intervals and procedures given in this manual are based on typical machines and typical mine conditions. Mine conditions and machine configuration may require the recommended intervals or maintenance procedure be modified from those given.

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts book supplied with your machine.

Maintenance Notes

Before performing maintenance on this machine, observe the following: 1. In order to avoid individual components not being serviced or being inadequately serviced, a general maintenance plan should be developed.

2. Use only suitable and approved tools for maintenance work.

3. Use only original spare parts when replacing components.

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

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

6. Shutdown the machine on level ground.

7. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all Mine, State, and Federal lockout/tagout procedures.

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

9. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.

10. Relieve all hydraulic pressures and position the levers and controls, if applicable, in Neutral or Off. 11. After ensuring that all personnel are clear of the machine, test all controls to ensure that the unit will not move.

________________________________________________________________ 6 CM235 Maintenance

__________________________________ General Maintenance Instructions 12. Test the air for methane (if applicable) before and during any maintenance or repair work.

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

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

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

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

______________________________________________________________ A6474X376 REV 1 7

Special Fasteners ________________________________________________ Introduction

Various types of specialty fasteners, self-locking bolts and nuts, lock wiring, Super Bolts, etc., may be in use on the machine. It is important that these fasteners be used in the correct manner to provide the locking qualities required.

Locking Wire Fasteners

When using a single locking wire, insert the wire through the fastener from the inside to the outside of the bolt circle, advancing in a clockwise direction (Fig. 1).

When using wired pairs, insert the wire in the left hand fastener (as viewed from the center of the bolt circle) from the inside to the outside of the bolt circle. Insert the right end of the wire through the right hand fastener (Fig. 1).

Fig. 1: Lock wire fasteners

Self-Locking Screws

1. Self-locking screws are generally used where measured torque is required.

2. Use a hand wrench, not a power wrench, to tighten to get an accurate reading.

3. Performance is reduced with each use. Limit reuse to twice.

4. If assembly requires shimming, establish the shimming requirements using standard fasteners. After shimming requirements are established, replace standard fastener with self-locking and torque as required.

Lock Nuts

1. Lock nuts with nylon or fiber inserts should not be reused.

2. Lock nuts with a spring steel lock ring in the head can be reused.

3. Hand thread the nut to engage the threads before using a power wrench.

4. Bolt or stud threads should extend beyond the nut.

________________________________________________________________ 8 CM235 Maintenance

___________________________________________________ Torque Values Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Imperial Bolts

Table 1: Grade 8 bolt torque specifications (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16

12 25

6 12

3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8

212

106

3/4

376

188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4

17794

8897

3

23507

11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X376 REV 1 9

Torque Values ___________________________________________________

Table 2: Metric bolt torque specifications (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

________________________________________________________________ 10 CM235 Maintenance

____________________________________________Maintenance Schedule Introduction

This section outlines the frequency at which maintenance tasks should be carried out. Depending on operating conditions, more frequent intervals may be required.

Lubricant and Fluid Capacities

The following lubricant specifications and fluid capacities should be observed when adding or changing a lubricant or greasing a component.

Table 3: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank

Spec. 100-1

72 gal (273 L)

GH Assembly CLA Primary GH Assembly CLA POT

Spec. 100-15 Spec. 100-15

1 gal (3.79 L) 2.5 gal (9.46 L)

Tram Drive Assembly Input Cutter Head Gear Case Reach Cutter Head Gear Case Final Cutter Head Gear Case Motor Lube Hoses

Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-15 Spec. 100-14

3 gal (11.36 L) 3.7 gal (14.01 L) 6 gal (22.71 L) 3.5 gal (13.25 L) Variable

Notes

1

Spec, sheets, listing both the physical characteristics and vendors and lubricants that are known to meet each specification, are given at the end of this section.

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

______________________________________________________________ A6474X376 REV 1 11

Maintenance Schedule ____________________________________________ Table 4: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pins, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pins, lower

2

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

4

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

5

Cutter head frame pivot pin, right

1

Lithium based grease

Spec. 100-3

6

Cutter head frame pivot pin, left

1

Lithium based grease

Spec. 100-3

7

Cutter head bits

Inspect

8

Scrubber screen

Clean

9

Daily Conveyor roller

1

Lithium based grease

Spec. 100-3

10

Gathering head pivot pin, left

1

Lithium based grease

Spec. 100-3

11

Gathering head pivot pin, right

1

Lithium based grease

Spec. 100-3

12

Crawler idler roller

2

Lithium based grease

Spec. 100-3

13

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

14

Conveyor swing pivot pins

Lithium based grease

Spec. 100-3

15

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

16

Gathering head cylinder pin, lower

2

Lithium based grease

Spec. 100-3

17

Stabilizer shoe pin

2

Lithium based grease

Spec. 100-3

18

Conveyor chain take-up pin

2

Lithium based grease

Spec. 100-3

19

CLA head pot assembly (Check)

2

High demulsibility EP gear oil

Spec. 100-15

20

CLA head transfer case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

21

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Reach cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Final cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

25

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

26

Weekly Return filter element (Change)

1

27

Pilot pressure filter element (Change)

1

28

Pressure filter element (Change)

1

29

Crawler chain (Inspect)

2

30

Conveyor chain (Inspect)

31

Fasteners (nuts, bolts, screws)

Inspect

32

Electrical cables, conduits, and glands

Inspect

33

Hydraulic/water hoses and connections

Inspect

34

Lighting

Inspect

35

Reflectors and warning tags

Inspect

36

Machine stop switch (Inspect)

37

Scrubber

1

2 Clean

________________________________________________________________ 12 CM235 Maintenance

____________________________________________Maintenance Schedule Table 4 (continued): Lubrication and maintenance Item

Description

Places

Lubricant

Specification

38 39

Monthly CLA head pot assembly (Change) CLA head transfer case (Change)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

40 41

Input cutter head gear case (Change) Reach cutter head gear case (Change)

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

42 43

Final cutter head gear case (Check) CLAs

2 Inspect

High demulsibility EP gear oil

Spec. 100-15

44 45

Input cutter head gear case Reach cutter head gear case

2 2

Sample Sample

See Note 1 See Note 1

46 47

Final cutter head gear case (Check) CLA head pot assembly

2 2

High demulsibility EP gear oil Sample

Spec. 100-15 See Note 1

48 49 50

CLA head transfer case Tram gear case Crawler idler roller

2 2 2

Sample Sample Sample

See Note 1 See Note 1 See Note 1

51

Main hydraulic tank

1

Sample

See Note 1

52

Every three months Cutter motor bearings

4

Spec. 100-14

53

Gathering head motor bearings

4

54

Pump motor bearings

2

55

Scrubber motor bearings

2

High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease High temperature lithium complex grease

56

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

57 58 59

Hydraulic oil (Change) Water filter (strainer) (Change) Breathers (Change)

1 1 All

AW hydraulic oil

Spec. 100-1

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

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

______________________________________________________________ A6474X376 REV 1 13

Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart 22, 41, 44 3 - Conveyor swing cylinder rear pin 4 - Conveyor swing cylinder front pin 22, 41, 44 - Main cutter head gear case 23, 48, 53, 54, 55 - Hydraulic oil tank 37 - Machine stop switch 47, 52 - Tram gear case

23, 48, 53, 54, 55

47, 52 47, 52

37

4

3

________________________________________________________________ 14 CM235 Maintenance

____________________________________________Maintenance Schedule Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 13 - Conveyor raise cylinder upper pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head input case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 25, 26, 27 - Hydraulic filters 30 - Crawler chain 37 - Pump stop switch 49 - Cutter motor 50 - Gathering head motor 51 - Pump motor

21, 40, 43 49

50 18, 38, 45 19, 39, 46

9

16

30

51

20

12 37 25, 26, 27 13

15

15

______________________________________________________________ A6474X376 REV 1 15

Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart, continued 9 - Crawler idler roller 12 - Stabilizer shoe cylinder lower pin 15 - Conveyor swing pivots 16 - Gathering head cylinder upper pin 18, 38, 45 - CLA head pot assembly 19, 39, 46 - CLA head input case 20 - Tram gear case 21, 40, 43 - Input cutter head gear case 49 - Cutter motor 50 - Gathering head motor 15

15

12

20

16

18, 38, 45

9

19, 39, 46 50

49 21, 40, 43

________________________________________________________________ 16 CM235 Maintenance

__________________________________________Maintenance Instructions Specific lubrication and maintenance procedures Every shift The purpose of this section is to describe the following maintenance procedures, to be performed every shift: 1. Cutter head lift cylinder pins (upper and lower, left and right) lubrication 2. Conveyor swing cylinder pins (front and rear) lubrication 3. Cutter head pivot pin lubrication 4. Cutter head bit inspection 5. Scrubber cleanout Cutter Head Cylinder Pins (upper and lower)

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

Fig. 3: Cutter head cylinder pins (typical both sides)

Upper cutter head cylinder pin

Lower cutter head cylinder pin grease fitting

______________________________________________________________ A6474X376 REV 1 17

Maintenance Instructions __________________________________________ Conveyor Swing Cylinder Pin (front and rear)

Lubricate the front and rear conveyor swing cylinder pins through the grease fittings located on each end of the cylinder (Fig. 4). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 4: Conveyor swing cylinder pin lubrication Conveyor swing cylinder pin, rear

Cutter Head Pivot Pin (left and right)

Conveyor swing cylinder pin, front

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 5). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 5: Cutter head pivot pins (typical both sides) Cutter head pivot pin lubrication

________________________________________________________________ 18 CM235 Maintenance

__________________________________________Maintenance Instructions Cutter Head Bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 6). Replace bits immediately if any are missing or damaged.

Fig. 6: Cutter head bits Bit holder

Scrubber Cleanout

Bit

Cleanout the scrubber every shift.

1. Open the scrubber screen access cover (Fig. 7).

2. Remove the scrubber screen and wash.

3. Remove the demistor cell and wash.

4. Using the washdown hose, spray out the scrubber. Spray forward and out the front of the scrubber.

5. Wash out the demistor sump.

Fig. 7: Scrubber screen access cover Scrubber screen access cover

______________________________________________________________ A6474X376 REV 1 19

Maintenance Instructions __________________________________________ Daily The purpose of this section is to describe the following maintenance procedures, to be performed daily: 1. Conveyor roller lubrication 2. Gathering head pivot pin (right and left) lubrication 3. Crawler idler roller (right and left) lubrication 4. Conveyor raise pivot pin (right and left) lubrication 5. Stabilizer shoe cylinder pin (upper and lower, left and right) lubrication 6. Conveyor raise cylinder in (upper and lower, left and right) lubrication 7. Conveyor swing pivot pin (top and bottom) lubrication 8. Gathering head cylinder pin (upper and lower, left and right) lubrication 9. CLA head pot (right and left) and transfer gear cases (right and left), oil level check 10. Tram gear cases (right and left), oil level check 11. Input cutter head and reach cutter gear cases, oil level check 12. Hydraulic oil level check 13. Final cutter gear case, oil level check Conveyor Roller Lubrication

Lubricate the conveyor roller through the grease fittings located on the shaft (Fig. 8). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 8: Conveyor roller lubrication Grease fittings (2)

________________________________________________________________ 20 CM235 Maintenance

__________________________________________Maintenance Instructions Gathering Head Pivot Pin (right and left)

Lubricate the left and right upper and lower gathering head cylinder pins through the grease fittings located on the left and right front lubrication blocks (Fig. 9). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Crawler Idler Roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 9) through the grease fittings located on the outside face of the crawler idler roller.

Conveyor Raise Cylinder Pin (left and right)

Lubricate the upper conveyor raise cylinder pins through the grease fittings located on the right side of the conveyor (Fig. 10). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 9: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides)

Gathering head pivot pin lubrication

Crawler idler roller

Fig. 10: Conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fittings (2)

______________________________________________________________ A6474X376 REV 1 21

Maintenance Instructions __________________________________________ Conveyor Swing Pivot Pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 11). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting Fig. 11: Conveyor swing pivot pins (typical top and bottom) .

Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

Gathering Head Raise Cylinder Pins

Lubricate the upper gathering head raise cylinder pins (Fig. 12) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 12: Gathering head raise cylinder pins (typical both sides)

Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

________________________________________________________________ 22 CM235 Maintenance

__________________________________________Maintenance Instructions Stabilizer Shoe Pin (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the rod end of each cylinder (Fig. 13). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 13: Lower stabilizer shoe cylinder pin (typical both sides)

Stabilizer cylinder pivot (right) Stabilizer cylinder pin (right) Stabilizer cylinder pin (left) Stabilizer cylinder pivot (left) Stabilizer shoe pivot

Conveyor Chain Take-up Pin (right and left)

Lubricate the conveyor chain take-up pin (Fig. 14) through the grease fitting located on the pin. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 14: Conveyor chain take-up pin (right and left) Conveyor chain take-up pin

______________________________________________________________ A6474X376 REV 1 23

Maintenance Instructions __________________________________________ CLA Head Pot Assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 15). If oil is needed, add oil through the fill hole until oil comes out of the breather.

CLA Head Transfer Case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 15). If oil is needed, add oil through the fill hole until oil comes out of the breather.

Fig. 15: CLA head pot assembly and transfer case lubrication Input case Check plug

Pot check plug

Oil fill, Input case

Tram Gear Case (right and left)

Pot fill plug

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 16). Oil should be visible in each sight glass. If oil level is low, add oil through the fill plug hole.

Fig. 16: Tram gear case oil level (typical both sides)

Oil fill plug

Oil check

________________________________________________________________ 24 CM235 Maintenance

__________________________________________Maintenance Instructions Input Cutter Gear Case Reach Cutter Gear Case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both input and reach cutter gear cases through the sight glasses located on each side of the cutter head assembly (Fig. 17). If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 17: Input and reach cutter head gear case oil levels Input sight glass (typical both sides) Input fill plug (one per side)

Reach fill plug (one per side)

Final Cutter Gear Case

Reach sight glass (typical both sides)

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 18). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 18: Final cutter head gear case oil levels Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X376 REV 1 25

Maintenance Instructions __________________________________________ Hydraulic Oil Level

Check the hydraulic oil level using the read out on the main page of the graphics display on the operator’s case on the right hand side of the machine (Fig. 19).

If the oil level is low, add oil as follows: Hydraulic oil power fill procedure 1. Open the diversion valve.

2. Check that the hydraulic tank overflow is obstruction free (Fig. 19).

!

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

3. Activate the “CONVEYOR DOWN” function on the remote control to begin power fill.

4. Add oil until oil flow from the overflow.

5. Verify that the oil level is OK on t he main page of the graphics display.

6. Closes the diversion valve.

Fig. 19: Hydraulic oil level

Hydraulic oil level

Hydraulic oil overflow

Hydraulic oil fill hose

________________________________________________________________ 26 CM235 Maintenance

__________________________________________Maintenance Instructions Weekly The purpose of this section is to describe the following maintenance procedures, to be performed weekly: 1. Pressure filters (bypassing and non-bypassing), check and change as required 2. Return filter, check and change as required 3. Crawler chain, inspect 4. Conveyor chain, inspect 5. Inspect/check tightness/condition of all fasteners (nuts, bolts, screws, etc.)

6. Inspect electrical cables, conduits, and glands 7. Inspect hydraulic and water hoses and connections 8. Inspect lighting 9. Inspect reflectors and warning tags 10. Inspect/check the function of each machine stop switch 11. Scrubber cleaning Pressure Filter

Change the pressure filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Pilot Pressure Filter

Change the pilot pressure filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Return Filter

Change the return filter element (Fig. 20). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 20: Hydraulic filter location

Pilot pressure filter

Pressure filter

Return filter

______________________________________________________________ A6474X376 REV 1 27

Maintenance Instructions __________________________________________ Crawler Chain Tension

Check the crawler chains for proper tension.

To check for proper tension: 1. Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.

2. Chain sag should be 2-1/2 inches (64 mm) to 3-1/2 inches (89 mm) at the center of the crawler (Fig. 21).

Fig. 21: Crawler track tension measurement

Bottom of tractor wear shoe

Conveyor Chain Tension

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

Check the conveyor chain tension with the machine running. The conveyor chain should rise about 51 mm (2 inches) or less above the gathering head foot shaft sprocket as the chain emerges from under the conveyor pan (Fig. 22). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 22: Conveyor chain tension measurement

Chain measurement area

________________________________________________________________ 28 CM235 Maintenance

__________________________________________Maintenance Instructions Crawler Chain Adjustment Introduction

It is critical to maintain proper crawler chain tension. Loose chains can damage the sprocket and tight chains can cause excessive wear on the tram track assembly, including motors and drives. Both conditions reduce crawler chain life.

The crawler chain tension is adjusted using the front idler take-up jacks.

Grease is added to tighten or bled off to loosen the track .

Tool List

Standard tool set Grease gun

Procedure

To adjust the crawler chain tension: 1. Lower the conveyor tail section until it is level with the floor.

2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

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

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

5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

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

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

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

9. Evaluate the tram track for proper tension (Fig. 21). The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. Using this evaluation, determine whether step 11, 12, or 13 provides the appropriate sub-procedure to correct improper track tension.

10. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.

11. If the tram track tension is too tight, readjust the idler position using the following steps: a. Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims. b. Remove one or more idler adjustment shims from the idler slide channel.

______________________________________________________________ A6474X376 REV 1 29

Maintenance Instructions __________________________________________ c.

Open the pressure release valve for the front idler take-up jack and allow the jack to contract. The pusher plate will slide backwards until it is stopped by the remaining idler shims.

d. Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

12. If the tram track is too loose, readjust the idler position using the following steps: a. Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. b. Insert shims (Fig. 23) into the idler slide channel until the space between the tractor frame and the pusher plate is filled. c.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

d. Evaluate the resulting track tension and repeat these steps until the track reaches proper tension.

CAUTION

Shims must be inserted completely into the idler slide channel. A shim that is not correctly seated on the idler slide channel’s inside surface provides uneven support that can cause idler slant. A slanted idler can cause uneven wear and stress on the tram track and can cause improper operation of or damage to the tram system.

IMPORTANT

Check that the shims are correctly seated on the idler slide channel’s inside surface by looking at the channel’s inside surface from the opposite side of the miner through the space between the gathering head and the idler assembly.

!

13. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps: a. Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims. b. Remove all of the idler adjustment shims from the idler slide channel. c.

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

________________________________________________________________ 30 CM235 Maintenance

__________________________________________Maintenance Instructions d. The tram track tension should now be reduced and separation of the tram track will be easier. e. Locate a tram track link near the tram idler. f.

Remove the four Conelok nuts and flat head screws that secure the crawler pins (Fig. 23).

g. Using the hammer and punch, remove the crawler pins to disconnect the link from the track. Remove the disconnected link. h.

Connect the two ends of the tram track and secure the two end links together with the crawler track pin.

i.

Secure the crawler track pin between the two links with the 3/8-16X11/4 flat head socket head screws and 3/8-16 Conelok nuts.

j.

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

k.

Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

l.

Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

m. The idler adjustment shims will keep the idler stationary and the track tensioned. n. Evaluate the resulting track tension and repeat until the track reaches proper tension.

14. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.

15. Open pressure release to take pressure off of take-up cylinder.

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

17. Connect the trailing cable to energize the miner.

18. Raise the tractor frame off the blocking by lowering the stabilizer and gathering head and cutter head assemblies.

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

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

21. Carefully remove the blocking from underneath the raised stabilizer, gathering head, and cutter head assemblies.

______________________________________________________________ A6474X376 REV 1 31

Maintenance Instructions __________________________________________ Fig. 23: Tram track adjustment

Take-up cylinder

Shims Idler assembly

Pad

Track retention pin

Lock pin

________________________________________________________________ 32 CM235 Maintenance

__________________________________________Maintenance Instructions Conveyor Chain Tension

To check the chain tension: 1. Make sure the conveyor chain area is clean and free of any loose material.

2. Position the rear conveyor section in a straight line with the cutting head to maximum possible height.

3. Position yourself to the side of the gathering pan, under protected roof, and start the conveyor. a. There should be a smooth transition or flow of the chain as it comes through and over the foot shaft sprocket. If the arch of the chain is trailing above the sprocket, the chain needs to be tensioned. b. If, when the conveyor is rapidly started and stopped, the chain tends to fold back on itself, the chain needs tensioned. c.

If, when the conveyor is swung to the extreme left to right, there is too much excess chain, the chain may need to be adjusted in that position.

If adjusted in this position, swing the conveyor back straight and recheck adjustment to verify that the chain has not been over-tensioned.

5. With correct tension, there should be no deflection of the flight tips near the tail roller.

Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. If the valve adjustment is correct, then 2. The cylinder may be fully extended and, therefore, unable to take up any more chain slack. Remove a link from the chain or replace chain as necessary.

______________________________________________________________ A6474X376 REV 1 33

Maintenance Instructions __________________________________________ Fasteners

The miner is subjected to continual shock loading and vibration and close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure of bearings, couplings, etc. Inspect the following fasteners and tighten as required: 1. Cutter head gear case bolts 2. Cutter head motors bolts 3. Center drums bolts 4. End drums bolts 5. Tram cases bolts 6. Tram motors bolts 7. Gathering head CLAs bolts 8. Gathering head pots bolts 9. Gathering head motors bolts

Electrical Cables, Conduits, and Glands

Visually inspect all electrical cables and glands for signs of wear or damage.

Hoses and Fittings

Visually inspect hydraulic and water hoses and fittings for signs of wear, damage, or leakage. This inspection should be performed with the machine running. Observe the following precautions/procedures while checking for leaks or making repairs: 1. Relieve pressure before disconnecting hoses.

2. Check for leaks with a piece of cardboard. Do not use hands.

3. Do not exceed the working pressure of hydraulic hoses.

! WARNING

Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

Escaping fluids under pressure can penetrate skin and cause serious injury. Do not attempt to locate hydraulic leaks by feeling hoses and fittings with bare hands. Pin hole leaks can penetrate the skin.

Lighting

Turn on the lights and visually inspect for bulbs that need to be replaced.

Reflectors and Warning Tags

Visually inspect the condition and readability of all warning tags, labels, and reflectors for signs of wear or damage. Replace any reflector or tag that is missing or damaged.

Machine Stop Switches

Check the machine stop switches located on each side of the machine for proper operation. Start the machine and strike the switch; the machine pump motor will shutdown, in turn shutting down all other motors. Repeat for the other switch.

________________________________________________________________ 34 CM235 Maintenance

__________________________________________Maintenance Instructions Scrubber Cleaning

Clean the scrubber (Fig. 24) as follows: 1. Lower the gathering head and cutter head assemblies until they touch the floor.

2. Lower the conveyor assembly until it is level with the floor.

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

4. Insert a hose in the scrubber air intake at the front of the miner. Thoroughly flush the scrubber inlet duct.

5. Remove any accumulated debris from inside the duct. Insert the hose into the duct and thoroughly flush it with water.

Fig. 24: Scrubber cleaning

Scrubber intake

______________________________________________________________ A6474X376 REV 1 35

Maintenance Instructions __________________________________________ Monthly The purpose of this section is to describe the following maintenance procedures, to be performed monthly: 1. CLA head pot and transfer gear cases, change the oil 2. Input and reach cutter head gear cases, change the oil 3. Inspect the CLAs 4. Sample the oil in the input and reach cutter head gear cases, the CLA head pot and transfer gear cases, the tram gear cases, and the main hydraulic oil tank CLA Head Pot Assembly

Change the oil in both CLA head pot assemblies (Fig. 25).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

7. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.

8. Clean and reinstall the check and fill plugs.

CLA Input Case

Change the oil in both CLA head input cases (Fig. 25).

1. Level the miner, raise the gathering head pan, and secure in place.

2. Clean dirt and debris from around the drain plug located under the gear case.

3. Remove the drain plug and allow oil to completely drain from the gear case.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check plug and remove the plug.

6. Clean dirt and debris from around the fill plug and remove the plug.

________________________________________________________________ 36 CM235 Maintenance

__________________________________________Maintenance Instructions 7. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.

8. Clean and reinstall the check and fill plugs. ! NOTICE

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to run out into the bottle.

If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Fig. 25: CLA pot assembly and input case Input case Check plug

Pot check plug

Oil fill, Input case

Pot fill plug

______________________________________________________________ A6474X376 REV 1 37

Maintenance Instructions __________________________________________ Input Cutter Head Gear Case Reach Cutter Head Gear Case

Change the oil in both input and reach cutter head gear cases (Fig. 26).

1.

Position the cutter head horizontally (flat back in a vertical position). Clean dirt and debris from around the drain plug located under the gear case.

2.

Remove the drain plug and allow oil to completely drain from the gear case.

3.

Clean and reinstall the drain plug.

4.

Clean dirt and debris from around the check plug and remove the plug.

5.

Clean dirt and debris from around the fill plug and remove the plug.

6. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling.

7. Clean and reinstall the check and fill plugs.

Fig. 26: Input and reach cutter head gear case Input sight glass (typical both sides) Input fill plug (one per side)

Reach fill plug (one per side)

Reach sight glass (typical both sides)

________________________________________________________________ 38 CM235 Maintenance

__________________________________________Maintenance Instructions Final Cutter Head Gear Case Change the oil in both final cutter head gear cases (Fig. 27).

1. Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.

2. Remove the drain plug and allow oil to completely drain from the gear case.

3. Clean and reinstall the drain plug.

4. Clean dirt and debris from around the check plug and remove the plug.

5. Clean dirt and debris from around the fill plug and remove the plug.

6. Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.

7. Clean and reinstall the check and fill plugs.

Fig. 27: Final cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X376 REV 1 39

Maintenance Instructions __________________________________________ CLAs

Inspect the CLAs (Fig. 28) for damage. If a CLA needs replaced, see CLA removal and installation procedure in the Mechanical section of this manual.

Fig. 28: CLAs

CLA

Oil sampling plan This plan contains specific instructions to be followed in order to correctly collect gear case lubricant samples, and preparation of the samples for laboratory analysis. Adherence to these instructions will insure that all oil sample analysis reports give an accurate picture of the oils condition as well as wear trends of gears, bearings, etc. Accurate reporting and analysis of oil samples will prove extremely beneficial providing a tool to allow planning of scheduled down-time and prevention of costly equipment breakdown.

Preparation prior to sample collection For each machine to be sampled, you will need a supply of sample collection bottles and identification labels (Fig.29) sufficient to sample each identified gear case (every sixty shifts).

One sample bottle and collection hose is required for each gear case to be sampled. Label each container with the identifying name of the gear case (crawler gear case, left or cutter head gear case, right front, etc.).

Collection of oil samples If the gear case is scheduled for oil drain and refill, obtain the oil sample prior to the oil change.

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature.

Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

IMPORTANT

Always collect oil samples using a siphon pump. Do not remove the drain plug and collect oil by allowing it to drain into the bottle.

________________________________________________________________ 40 CM235 Maintenance

__________________________________________Maintenance Instructions Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample.

To do so will contaminate the next sample with oil from the previous sample.

After taking sample, check and refill gear case back to proper fill level.

Following collection of all oil samples, record the specific brand and product name of the lubricant that has been installed in each gear case.

Recommended gear cases to be sampled: 1. Input cutter head gear case (left and right) 2. Main cutter head gear case (left and right) 3. Input gathering head gear case (left and right) 4. Main gathering head gear case (left and right) 5. Main hydraulic oil tank

Fig. 29: Oil sampling procedure Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

______________________________________________________________ A6474X376 REV 1 41

Maintenance Instructions __________________________________________ Every three months The purpose of this section is to describe the following maintenance procedures, to be performed every three months: 1. Lubricate the cutter motors 2. Lubricate the gathering head motors 3. Lubricate the pump motor 4. Lubricate the scrubber motor bearings IMPORTANT

For motor bearings that require high temperature lithium complex grease (Spec. 10015), a special “button” style lubrication fitting is available to prevent the accidental use of multi-purpose lithium complex grease at these locations.

Cutter Motor Bearings

Lubricate the left and right cutter head motor bearings with high temperature lithium complex grease through the two grease fittings located on each side of the cutter head (Fig. 30) using the following procedure: 1. Open the cover (Fig. 30) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

! NOTICE

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined above.

________________________________________________________________ 42 CM235 Maintenance

__________________________________________Maintenance Instructions Fig. 30: Cutter motor bearing lubrication (typical each side)

Entry plug

Exit plug

______________________________________________________________ A6474X376 REV 1 43

Maintenance Instructions __________________________________________ Gathering Head Motor Bearings

Lubricate the left and right gathering head motor bearings with high temperature lithium complex grease through the two grease fittings located on each motor (Fig. 29).

To lubricate the motors: 1. Open the cover (Fig. 31) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

Fig. 31: Gathering head motor bearing lubrication (typical each side)

Bearing grease fittings located behind cover

________________________________________________________________ 44 CM235 Maintenance

__________________________________________Maintenance Instructions Pump Motor Bearings

Lubricate the pump motor (Fig. 32) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the right side of the machine using the following procedure: 1. Open the cover (Fig. 32) to access the motor.

2. Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring loaded relief fittings, then a. Lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

If the exit side motor bearing ports are equipped with plugs, then: a. Remove the plug and lubricate both motor bearings until new grease appears out of the relief ports on the exit side of the bearing. b. Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.

3. Replace the plugs in the ports.

Fig. 32: Pump motor bearings

Pump motor location Operator’s case (swing open to expose pump motor)

Rub rail (Swing open to allow operator’s case to swing out)

______________________________________________________________ A6474X376 REV 1 45

Maintenance Instructions __________________________________________ IMPORTANT

For motor bearings that require high temperature lithium complex grease, a special “button” style lubrication fitting is available to prevent the accidental use of multipurpose lithium complex grease at these locations.

Scrubber Motor Bearings

Lubricate the scrubber motor bearings (Fig. 33) with high temperature lithium complex grease through the grease fittings located on the scrubber side of the machine. To lubricate the motors: 1. Remove the cover to access the motor.

2. Remove grease plug (s) on exit side of bearing (s).

3. Lubricate bearing using “button” fitting until new grease appears out of open port on exit side of bearing (s).

4. Operate motor (s) for five (5) minutes.

5. Replace grease plug (s) in all port (s).

IMPORTANT

Incorrect grease or over greasing of the electric motor may cause serious damage to the motor. Follow the greasing procedure outlined in previous instructions.

Fig. 33: Scrubber motor bearings

Scrubber motor

________________________________________________________________ 46 CM235 Maintenance

__________________________________________Maintenance Instructions Every six months The purpose of this section is to describe the following maintenance procedures, to be performed every six months: 1. Change the oil in the tram gear cases 2. Change the hydraulic oil 3. Change the water filter 4. Inspect and clean/change all breathers Tram Gear Case

Change the oil in both tram gear cases (Fig. 34).

1. Remove the drain plug and allow oil to completely drain from the gear case.

2. Clean and reinstall the drain plug.

3. Replace the breather, located in the fill tube.

4. Remove the fill plug located on top of the gear case or on the fill tube.

5. Add oil through the fill plug hole until oil is visible in the sight glass. When filling, allow sufficient time for the oil to travel throughout the gear case.

6. Clean and reinstall the fill plug.

Fig. 34: Tram gear case

Oil fill plug

Oil check

______________________________________________________________ A6474X376 REV 1 47

Maintenance Instructions __________________________________________ Hydraulic Oil

Change the oil in the hydraulic oil tank (Fig. 35).

1. Clean all dirt and debris from around the fill cap and the drain plug.

2. Remove the drain plug and allow the oil tank to completely drain.

3. Clean and reinstall the drain plug.

4. Inspect and clean oil overflow, making sure there are no obstructions to overflow.

!

WARNING If the hydraulic overflow is blocked during power fill operations, the hydraulic tank will become pressurized during the power fill procedure and damage to the air reservoirs may result.

5. Fill the tank with oil using the power fill pump until the oil level reaches the full level as indicated on the dipstick. The hydraulic tank capacity is 73 gal (273 L), hydraulic system capacity is 82 gal (310 L). To activate the power fill: a. Open the diversion valve. b. Engage the conveyor down function.

6. After filling, start the machine and engage all cylinders for the full length of travel (full extend and retract) in order to purge the hydraulic system of air.

7. Check the oil level on the graphics display on the operator’s case on the right hand side of the machine. Add additional oil as required until oil level is “OK”.

Fig. 35: Hydraulic oil change

Hydraulic oil level

Hydraulic oil overflow

Hydraulic oil fill hose

________________________________________________________________ 48 CM235 Maintenance

__________________________________________Maintenance Instructions Water Filter (Strainer)

Change the water circuit filter (Fig. 36).

Fig. 36: Water filter Water filter

Gear Case Breathers

Change the breathers on the input and main cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases (Fig. 37).

Fig. 37: Gear case breather locations Breather

CLA input case breather plug

CLA pot breather

Breather

______________________________________________________________ A6474X376 REV 1 49

Maintenance Instructions __________________________________________ Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.

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

2. Position the conveyor tail section directly behind the miner and raise it to its highest position.

3. Insert blocking under the tail section and lower the tail onto the blocking.

The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 51 mm (2 inches) of space between the blocking and the conveyor bottom.

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

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 38).

Fig. 38: Shim removal Socket head capscrews

Shim retainer

Lower pivot plate

Shims

7. Connect the trailing cable to energize the miner.

________________________________________________________________ 50 CM235 Maintenance

__________________________________________Maintenance Instructions !

WARNING The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.

8. Slowly lower the conveyor slightly so that the front section rests on the frame support blocking. The slotted shims will now fall free.

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

10. Replace the removed shims (Fig. 38) and add the number of shims required to level the conveyor front and tail sections.

11. Tighten the socket head capscrews.

12. Connect the trailing cable to energize the miner.

13. Raise the conveyor tail from the blocking.

14. Remove both sets of blocking and lower the conveyor tail until it is level with the floor.

15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment (Fig. 39). If the sections are not horizontally aligned, then add or subtract shims as required.

16. Re-insert the blocking between the top of the tractor frame and the bottom of the conveyor following mine standard blocking procedures.

17. Securely retighten the socket head capscrews.

Fig. 39: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

______________________________________________________________ A6474X376 REV 1 51

Lubricant Specifications___________________________________________ Introduction

The following lubricants specifications are referenced throughout this manual.

Any lubricant used must meet these standards listed. For your convenience, a list of manufacturers and lubricants that have been identified as meeting these standards is given for each specification.

Failure to use lubricants that meet the standard listed may reduce component life and may void any associated warranty.

Table 7: Spec. 100-1: Anti-wear hydraulic oil specification Limit

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-29° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

Rust Prevention Test (ASTM D-665, A & B

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

Four Ball Wear Test (ASTM D-2266) (40 KG, 1800 RPM, 130° F, one hour)

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

Sludge & Metal Corrosion (ASTM D-943) (conducted at conclusion of 1000 hour oxidation test) Insoluble sludge in oil and water layers plut that adhering to the catalyst coils or the test tub.

Metals in combined oil, water, and sludge (ASTM D-810-59)

Pump Wear Test (ASTM D-2882) (Total Ring and Vane Weight Loss) Hydrolytic Stability Test (ASTM D-2619)

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

________________________________________________________________ 52 CM235 Maintenance

___________________________________________Lubricant Specifications

Table 8: Spec. 100-1: Anti-wear hydraulic oil approved 1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil

13

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

14 15 16 17 18

Brand name Amoco AW Oil No. 68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

______________________________________________________________ A6474X376 REV 1 53

Lubricant Specifications___________________________________________ Table 9: Spec. 100-3: Extreme pressure motor bearing grease and hand grease specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour) Table 10: Spec. 100-3: Extreme pressure motor bearing and hand grease approved suppliers

1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease, or Replex 2, or Uniwrl 2, or Uniwrl EMB, or Hullith GP 2, or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2, or Super Sta Grease No. 2 LC-65 Hyplex

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

________________________________________________________________ 54 CM235 Maintenance

___________________________________________Lubricant Specifications Table 11: Spec. 100-14: Synthetic lithium complex grease for electric motor bearings Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

Worked Penetration (60 strokes) (ASTM D-217)

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

Water Washout Resistance Weight 10% or less Loss @ 175° F (79° C) (ASTM D-1264)

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

Table 12: Spec. 100-14: Synthetic lithium complex grease for electric motor bearings approved suppliers 1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

______________________________________________________________ A6474X376 REV 1 55

Lubricant Specifications___________________________________________ Table13: Spec. 100-15: High demulsibility extreme pressure gear oils specification Limit

Type

ISO VG

220

220

A.G.M.A. Grade

5EP

5EP

Viscosity Index (ASTM D-2270)

Min. 95

98

Flash Point (ASTM D-92)

Min. 450° F (232° C)

480° F (250° C)

Pour Point (ASTM D-97)

Max. 15° F (-9° C)

-27° F (-17° C)

Timken Test (ASTM D-2782)

Min. 65 lbs.

70 lbs.

FKOUR Ball EP Test (ASTM D-2783)

Weld load kg. Min. 260 load wear index not less than 51.0

270 57

Oxidation Stability (ASTM D-2893) Viscosity Increase @ 100° C

Not more than 6%

4.6%

FZG Scuffing Test (ASTM D-5182) Failure Load Stage

Not less than 12th stage.

>12

SUS @ 100° F

950-1200

1119

SUS @ 210° F

85-110

95.5

CST @ 40° C

198-242

212

CST @ 100° C

15.24

18.7

DEMULSIBILITY (ASTM D-1401) Min. 30 @ 180° F ml Oil, Water, Emulsion

0 ml. Emulsion Max.

42 ml. Oil 38 ml. Water 0 ml. Emulsion

Copper Corrosion (ASTM D-130)

1 or 1b

1b

Foam Test (ASTM D-892)

Pass

Pass

Rust Test (ASTM D-665)

Pass

Pass

Viscosity (ASTM D-445)

Table 14: Spec. 100-15: High demulsibility extreme pressure gear oils approved suppliers

1

Supplier Conoco Inc.

Brand name GLW Gear Oil 220

________________________________________________________________ 56 CM235 Maintenance

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

________________________________________________________________ A6474X377

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.

______________________________________________________________ A6474X377 REV 0 5

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

REV 0

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.

______________________________________________________________ A6474X377 REV 0 25

_____________________________________________ 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

A6474X378 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X (Mechanical - Gathering Head/Conveyor)

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 Safety Instructions............................................................................. 4 Preliminary Instructions ..................................................................... 6 Torque Values ................................................................................... 7 Component Weights.......................................................................... 9 Gathering Head Assembly ................................................................ 10 Gathering Head Drive Motor ............................................................. 16 Gathering Head Gear Case .............................................................. 23 Foot Shaft.......................................................................................... 30 Gathering Head Cylinder................................................................... 33 Centrifugal Loading Arm (CLA) ......................................................... 37 Swivel Pin Assembly ......................................................................... 42 Tail Roller .......................................................................................... 46 Conveyor Chain................................................................................. 49

________________________________________________________________ A6474X378

REV 1

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 lifting and blocking devices and keep a safe distance from suspended loads.

!

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

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

!

WARNING When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

!

WARNING When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

!

WARNING Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.

!

WARNING Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

!

WARNING The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.

!

WARNING While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

!

WARNING

The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

!

WARNING

The bottom ports on the high speed input cases are the fill lines. The top ports on the high speed input cases are the check lines.

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

IMPORTANT

Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

________________________________________________________________ 4 CM235 Mechanical - Gathering Head and Conveyor

_______________________________________________ Safety Instructions !

WARNING Stand clear of the blocked cutter head and gathering head assemblies during gathering head lift cylinder contraction.

!

WARNING When aligning the cylinder end bearings within their clevises to allow for insertion of the retaining pins, do not test alignment with your fingers. Shifting parts could cause serious injury.

IMPORTANT

Insert the pin so that its retaining channel remains outside of the bushing.

IMPORTANT

Hog rings should be installed so that their sharp points are directed clockwise.

______________________________________________________________ A6474X378 REV 1 5

Preliminary Instructions ___________________________________________ Introduction

The following general guidelines, in addition to specific procedural instructions, should be followed whenever performing maintenance on this machine.

The procedures for the removal and installation of components are for a typical machine and conditions. Tools available, work conditions, or other factors may require procedures to vary from those given.

Tools

It is the responsibility of the mine operator or the employee to provide the necessary tools required for routine maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts book supplied with your machine.

Before Maintenance

Before performing maintenance on this machine, observe the following: 1. Shutdown the machine on level ground.

2. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all applicable lockout/tagout procedures.

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

4. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.

Important Notes

1. Use only suitable and approved tools for maintenance work.

2. Use only original spare parts when replacing components.

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

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

5. Always refer to the appropriate engineering drawing when replacing components.

________________________________________________________________ 6 CM235 Mechanical - Gathering Head and Conveyor

___________________________________________________ Torque Values Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Table 1: Imperial Bolts

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X378 REV 1 7

Torque Values ___________________________________________________ Table 2: Metric Bolts

Metric Bolts Torque Recommendations (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

________________________________________________________________ 8 CM235 Mechanical - Gathering Head and Conveyor

______________________________________________ Component Weights Component Weights

Following are the approximate weights of the major components of the gathering head and conveyor systems. Be certain that adequate lifting and blocking is available whenever a component is being removed or installed as serious injury or death can result from falling loads. Never work under a component that is not adequately and correctly supported.

Table3: Component Weights Component

Approximate Weight

Foot Shaft Gathering Head Cylinder Gathering Head Assembly Gathering Head Motor Centrifugal Loading Arm Gathering Head Gear Case Conveyor Swing Cylinder Conveyor Lift Cylinder Conveyor Discharge Assembly Conveyor Assembly (without chain or cylinders)

66 lbs (30 kg) 163 lbs (74 kg) 23,515 lbs (10,666 kg) 900 lbs (408 kg) 472 lbs (214 kg) 985 lbs (447 kg) 217 lbs (98 kg) 166 lbs (75 kg) 4,700 lbs (2,132 kg) 14,000 lbs (6,350 kg)

______________________________________________________________ A6474X378 REV 1 9

Gathering Head Assembly _________________________________________ Introduction

The following procedure is for the removal and installation of the gathering head assembly. The foot shaft is coupled to the gathering head gear cases and drives the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the gathering head assembly, observe the following safety precautions:

Slide Hammer Blocking

!

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

!

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

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during the contraction of the gathering head lift cylinders.

!

WARNING When separating the gathering head from the tractor frame, ensure that the disconnected ends of the conveyor chain smoothly slide out of the gathering head.

!

WARNING When tramming the miner toward the gathering head, be careful that the conveyor chain and gathering head lift cylinders do not become pinched between the tractor frame and the gathering head.

!

WARNING Use caution when using the lift cylinders and stabilizer to adjust the alignment of the clevis and pivot pins.

________________________________________________________________ 10 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly Gathering Head Assembly

To remove the gathering head assembly: 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head (Fig. 1) until it rests on the floor. Place blocking under the rear of the gathering head to stabilize its position during and after removal of the pivot pins and disconnection of the lift cylinders.

2. Raise the cutter head to its highest point and place blocking underneath it.

Lower the cutter head onto the blocking.

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

Fig. 1: Gathering head assembly Foot shaft

CLA Gear case (under CLA)

CLA key

______________________________________________________________ A6474X378 REV 1 11

Gathering Head Assembly _________________________________________

4. Double check that the cutter head is securely blocked.

5. Separate the conveyor chain and remove the foot shaft (see Foot shaft removal procedure in this chapter).

6. Remove the retaining pin that secures each of the front rub rails to the tractor frame and open both front rub rails.

7. Remove the electrical power cables from the gathering head.

8. Disconnect, tag, and cap the motor cooling water and scrubber spray water hoses from the gathering head.

9. Remove the 2 (two) 1” hex head capscrews and lockwashers that secure the right gathering head pivot pin retaining plate to the tractor frame (Fig. 2).

10. Remove the 2 (two) 1” hex head capscrews and lock washers that secure the pin retaining plate to the gathering head pivot pin and remove the retaining plate.

Fig. 2: Gathering head pivot pin

Gathering head pivot pin Lockwashers Pivot pin retaining plate Hex head capscrews

11. Using a slide hammer, pull the pivot pin.

12. Repeat the previous three (3) steps for the left gathering head pivot pin.

13. Remove the 2 (two) 1/2” hex head capscrews and lock washers that secure the piston pin retaining bar on the right gathering head lift cylinder to the gathering head side panel and remove the retaining bar (Fig. 3).

14. Repeat the previous step for the left gathering head lift cylinder.

________________________________________________________________ 12 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly Fig. 3: Gathering head lift cylinder piston pin retaining bar

Retaining bar Lockwashers pin cylinder

Hex head capscrews

Piston end pin 15. Connect the trailing cable to energizer the miner.

16. Slowly retract the lift cylinders until the piston ends come free from their gathering head clevises.

17. Lift the cutter head off the blocking and slowly tram the miner in reverse until the cutter head clears the backboard of the gathering head.

______________________________________________________________ A6474X378 REV 1 13

Gathering Head Assembly _________________________________________ Gathering Head Assembly Installation

To install the gathering head assembly: 1. Position the gathering head assembly at the front of the tractor frame. Block up the rear of the gathering head so that it’s pivot points are at the level of the tractor frame clevises.

2. Raise the cutter head assembly to its highest point.

3. Slowly tram the miner forward until the gathering head pivot points are inserted into the tractor frame clevises.

4. Place blocking underneath the cutter head and lower the cutter head onto the blocking.

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

6. Thread the lower end of the conveyor chain into the gathering head assembly return pan so that the end appears on the foot shaft return plate. Place the upper end of the conveyor chain down the front of the gathering head entrance pan.

7. Connect the trailing cable to energize the miner.

8. Extend the gathering head lift cylinders so that the piston end bearings can be inserted into the gathering head lift cylinder clevises.

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

10. Insert the piston end clevis of the right gathering head lift cylinder into the gathering head clevis.

11. Using the hammer, insert the piston end pin through the aligned clevis bushings and the rod end bearing.

!

WARNING Insert the pin far enough to avoid obstructing the placement of the pin retaining bar.

12. Place the pin retaining bar over the end of the pin and insert and tighten the two (2) 1/2 X 1 1/2” hex head capscrews and lock washers that secure the piston pin retaining bar to the gathering head side panel and torque to 114 ft-lbs (156 Nm).

13. Repeat the previous three steps for the left gathering head lift cylinder.

________________________________________________________________ 14 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________Gathering Head Assembly

14. Use the gathering head lift cylinders and tractor frame stabilizer to align the tractor frame clevis and the gathering head pivot points to make inserting pivot pins easier.

15. Gently tap the right gathering head pivot pin through the aligned tractor frame clevis and gathering head pivot bushings. !

WARNING The pin must be inserted far enough so that it does not obstruct positioning of the retaining plate flat against the tractor frame.

16. Place the pivot pin retaining bar (Fig. 3) so that edge with two cutouts located in the corners is positioned against the backup strip. The edge of the plate with two cutouts and a hole for the pin’s grease fitting must be positioned over the pivot pin.

17. Insert and tighten the two (2) 1 X 2 1/4” hex head capscrews and lock washers to secure the pivot pin retaining plate to the gathering head pivot pin, and torque to 970 ft-lbs.

18. Insert and tighten the two (2) 1 X 2 1/4” hex head capscrews and lock washers to secure the pivot pin retaining plate to the tractor frame, and torque to 970 ft-lbs.

19. Repeat the previous three steps for the left gathering head pivot pin.

20. Replace the motor cooling water and scrubber spray water hoses onto the gathering head assembly.

21. Replace the electrical power cables onto the gathering head assembly.

22. Close the front rub rails and insert and tighten a hex head capscrew and lock washer to secure the front rub rail closed against the tractor frame.

23. Replace the foot shaft into the gathering head (see foot shaft removal and installation procedure in this chapter) and reconnect the conveyor chain.

______________________________________________________________ A6474X378 REV 1 15

Gathering Head Drive Motor________________________________________ Introduction

The following procedure is for the removal and installation of the gathering head drive motor.

Tool Set

Basic Tool Set Pry Bar

Safety

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

Blocking Retaining Ring Pliers

Slide Hammer

!

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

!

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

!

WARNING While the power cable is detached from the motor, the trailing cable should not be reconnected to the miner. Damage to the machine or injury or death to personnel could result.

!

WARNING

The gathering head drive motor is extremely heavy. Be prepared to support this weight before performing the following steps.

________________________________________________________________ 16 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor Gathering Head Drive Motor Removal

To remove the gathering head drive motor: 1. Lower the gathering head completely until it touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

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

4. If necessary, remove the CLA to allow access to the motor (See CLA removal and installation procedure in this chapter).

5. Remove the three (3) M12 hex head capscrews and lock washers that secure the upper deck cover (Fig. 4) to the gathering head assembly.

6. Remove the upper deck cover. The gear case and drive shaft end of the motor should be exposed.

7. Locate the side cover of the gathering head motor and remove the six (6) M20 X 50 hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

8. Remove the cover to expose the end of the motor.

9. Remove the square-head pipe plug on the end of the gathering head motor.

10. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 4).

11. Using a slide hammer, pull the drive shaft end plug out.

12. Pull the drive shaft from the motor and store in safe place.

13. Use the adjustable wrench to replace the pipe plug into the end of the motor.

14. Remove the four (4) 1/2” hex head capscrews and lock washers that secure the motor junction box cover 15. Remove the cover and its o-ring (Fig. 5).

16. Locate the three tapped power connections inside the junction box and strip the tap covering each lug connection.

17. Tag each connection and remove the 3/8 X 7/8” hex head capscrew, flat washer, lock washer, and hex head nut that secures each of the power cable lugs. .

______________________________________________________________ A6474X378 REV 1 17

Gathering Head Drive Motor________________________________________ 18. Remove the socket head capscrews and lock washers that secure the stuffing box’s half-moon clamp to the junction box.

19. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

20. To prevent damage to the power cable lugs, stuffing box, and gland assembly, cover and secure the power cable to the miner in a safe location.

21. Replace the junction box o-ring and cover and secure with the eight (8) 1/4 X 5/8” hex head capscrews and lock washers to protect the motor’s electrical connections.

22. Tag, disconnect, and cap the two cooling water hoses (with elbow and adapter) from the two motor cooling water fittings on the gear case end of the motor.

23. Remove the two motor cooling water fittings from the motor and store in a clean place.

24. Plug the two motor cooling water ports to keep them clean.

25. Remove the four (4) M20 X 50 socket head capscrews that secure the motor to the gear case adapter plate.

26. The gathering head drive motor should now be detached from the gear case and able to be removed from the gathering head assembly through the motor side cover opening.

________________________________________________________________ 18 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor Fig. 4: Upper deck cover

Upper deck cover Lower deck cover

Fig. 5: Drive shaft and end plug removal

Drive shaft O-ring Drive shaft End plug

Retainer ring

______________________________________________________________ A6474X378 REV 1 19

Gathering Head Drive Motor________________________________________ Gathering Head Drive Motor Installation

To install the gathering head drive motor: 1. Insert the gathering head motor through the slide cover opening, attachment bolt holes first. The junction box of the motor should be positioned toward the front of the gathering head.

Fig. 6: Gear case to motor seal installation

Gear case adapter plate

Motor

2. Position the motor against the gear case adapter plate and align the four attachment bolt holes on the gear case side of the motor with the four holes on the corners of the adapter plate.

3. Insert and tighten the socket head capscrews to secure the motor to the gear case adapter plate.

4. Using an adjustable wrench, insert the two motor cooling water fittings into the gathering head drive motor’s cooling water ports, which are located on the gear case end of the motor.

5. Attach the two motor cooling water hoses (with elbow and adapter) to the fitting.

6. Remove the four (4) 1/2” hex head capscrews and lock washers that secure the junction box cover.

7. Remove the cover and its o-ring.

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

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

________________________________________________________________ 20 CM235 Mechanical - Gathering Head and Conveyor

________________________________________Gathering Head Drive Motor

10. Insert and tighten the two (2) 3/8” socket head capscrews and lock washers to secure clamp to the junction box.

11. Locate the motor’s lug connections inside the junction box and match the motor lug connections to the corresponding power cable lugs.

12. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the power cable lug, through the motor lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.

13. Repeat this step with the other two power cable and motor lugged connections.

14. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of electrical (black) tape, and finally a layer of glass tape.

15. Replace the junction box o-ring and junction box cover and secure the cover with four (4) 1/2” hex head capscrews and lock washers to secure the junction box cover.

16. Remove the pipe plug from the end of the motor (Fig. 7).

17. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first). The shaft may require some adjustment so that its end fits into the gear case.

18. Install the o-ring into the channel on the shaft end plug.

19. Insert the drive shaft end plug into position in the center of the motor.

20. Insert the retaining ring to secure the shaft end plug inside the motor housing.

21. Replace the pipe plug into the end of the motor.

______________________________________________________________ A6474X378 REV 1 21

Gathering Head Drive Motor________________________________________ Fig. 7: Drive shaft installation

Drive shaft O-ring Retainer ring Pipe plug

24. Replace the gathering head motor side access cover. Secure the cover to the gathering head by inserting and tightening the hex head capscrews.

25. Replace the upper deck cover and secure to the gathering head by inserting and tightening the three (3) M12 hex head capscrews.

26. If removed, install the CLA over the motor (see CLA removal and installation procedure in this chapter).

________________________________________________________________ 22 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Introduction

The following procedure is for the removal and installation of the gathering head gear case. The gathering head gear case turns the CLAs and drives the foot shaft which powers the conveyor chain.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing a gathering head gear case, observe the following safety precautions:

Blocking Slide Hammer

!

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

!

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

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems, and miner downtime. Always keep the conveyor chain at proper tension.

______________________________________________________________ A6474X378 REV 1 23

Gathering Head Gear Case _________________________________________ Gathering Head Gear Case Removal

To remove the gathering head gear case: 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly. Lower the cutter head assembly onto the blocking.

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

4. Remove the gathering head motor’s side cover by removing the hex head capscrews and lock washers that secure the side cover to the gathering head assembly.

5. Remove the cover to expose the end of the motor.

6. Remove the square-head pipe plug on the end of the gathering head motor.

7. Remove the retaining ring that secures the shaft end plug inside the motor housing (Fig. 7).

8. Using a slide hammer, pull out the drive shaft end plug.

9. Pull the drive shaft from the motor and store in a safe place.

10. Replace the pipe plug into the end of the motor.

11. Remove the CLA to expose the gathering head gear case (see CLA removal and installation procedure in this chapter).

12. Remove the three (3) M12 X 30 hex head capscrews and lock washers that secure the upper deck cover (Fig. 8) to the gathering head assembly. Remove the upper deck cover to expose the gear case and the drive shaft end of the motor.

13. Remove the five (5) M12 X 30 hex head capscrews and lock washers that secure the lower deck cover (Fig. 8) to the gathering head assembly and remove the lower deck.

14. Loosen tension on the conveyor chain as much as possible.

15. Separate the conveyor chain and remove the gathering head foot shaft (see the Foot shaft removal and installation procedure in this chapter).

16. Connect the trailing cable to energize the miner.

17. Raise the gathering head to its highest position. Place blocking underneath the gathering head and lower the gathering head onto the blocking.

________________________________________________________________ 24 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Fig. 8: Deck covers

Upper deck cover

Lower deck cover

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

19. Remove the drain plugs from the underside of the gathering head gear case and completely drain the gear case lubricant. Follow all local, state and Federal regulations for the catching and disposal of lubricant. In the event the miner will be serviced by a technician, leave the gear case lubricant intact.

20. Replace the drain plugs into the underside of the gear case.

21. Connect the trailing cable to energize the miner.

22. Raise the gathering head off the blocking, remove the blocking, and lower the gathering head until it touches the floor.

______________________________________________________________ A6474X378 REV 1 25

Gathering Head Gear Case _________________________________________ 23. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine regulations for lockout/tagout.

24. Disconnect, tag, and cap the four lubrication connections from the gathering head gear case.

25. Remove the four (4) 3/4 X 4” socket head capscrews (Fig. 9) that secure the motor to the gear case.

26. Remove the motor and clean out the cavity.

27. Remove the twelve (12) M24 X 80 hex head capscrews that secure the gathering head gear case pot to the mounting plate.

28. The gathering head gear case is now unattached and can be removed from its position in the gathering head.

Fig. 9: Gear case removal

Adapter plate Hex head capscrews

Socket head capscrews

Gear case to mounting plate

________________________________________________________________ 26 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case gathering head gear case installation

To install the gathering head gear case: 1. Insert a new gear case-to-motor seal between the adapter plate and the gear case (Fig. 10). When the gear case is inserted into the gathering head and the transfer case is positioned against the gathering head motor, the seal should be located between the surfaces of the motor and the gear case.

2. Carefully insert the gathering head gear case into position in the gathering head assembly.

3. Insert and tighten the twelve (12) M24 X 80 hex head capscrews and lock washers to secure the gear case pot to its mounting plate, and torque to 776 ft-lb.

Fig. 10: Gear case mounting Gear case adapter plate

Hex head capscrews

4. Install the motor and align the four holes on the corners of the adapter plate with the four attachment bolt holes on the gear case side of the motor.

Tighten outside wedge blocks until the gear case is snug against the inside wall. Tighten front wedge blocks until the case is snug against the front wall.

5. Insert and tighten the four (4) 3/4 X 4” socket head capscrews to secure the gear case adapter plate to the motor, and torque to 416 ft-lb.

6. Torque wedge blocks to 432 ft-lbs.

7. Attach the four lubrication connections to the gathering head gear case. ______________________________________________________________ A6474X378 REV 1 27

Gathering Head Gear Case _________________________________________ 8. Attach the rose gun to the lower ports located adjacent to the gathering head side cover and fill the gathering head gear case to the proper level with lubricant. Check the gear case lubricant level at the sight glass adja cent to the gathering head side cover. !

WARNING

The bottom ports on the high speed input cases are the fill lines. The top ports on the high speed input cases are the check lines.

9. Examine the gathering head gear case in various places for signs of leaking lubricant that identify improper installation or gear case damage.

10. Install the gathering head foot shaft and reconnect the conveyor chain (see Foot shaft installation procedure in this chapter).

11. Tighten the conveyor chain to the proper tension (see Conveyor chain ad justment procedure in the Maintenance section of this manual 12. Replace the lower deck cover (Fig. 8) onto the gathering head assembly and secure to the gathering head assembly by inserting and tightening the hex head capscrews and washers.

13. Replace the upper deck cover (Fig. 8) onto the gathering head assembly and secure by inserting and tightening the hex head capscrews and washers.

14. Install the CLA onto the gathering head gear case turntable (see CLA removal and installation procedure in this chapter).

15. Remove the pipe plug from the end of the motor.

16. Slide the drive shaft through the gathering head motor and into the gathering head gear case (the drive shaft end without the threaded hole should be inserted first.) The shaft may require some adjustment so that its end fits into the gear case.

17. Install the o-ring into the channel on the shaft end plug (Fig. 11).

18. Insert the drive shaft end plug into position in the center of the motor.

19. Insert the retaining ring to secure the shaft end plug inside the motor housing.

20. Replace the pipe plug into the end of the motor.

21. Replace the side cover onto the gathering head assembly.

22. Insert and tighten the hex head capscrews and lock washers to secure the side cover to the gathering head assembly.

________________________________________________________________ 28 CM235 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Fig. 11: Drive shaft installation

Drive shaft O-ring Retainer ring Pipe plug

______________________________________________________________ A6474X378 REV 1 29

Foot Shaft_______________________________________________________ Introduction

The following procedure is for the removal and installation of the conveyor foot shaft. The foot shaft is coupled to the gathering head gear cases and drives the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the foot shaft, observe the following safety precautions:

Blocking

!

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

!

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

IMPORTANT

Position the foot shaft so its sprocket will engage the conveyor chain links when the chain is reconnected.

________________________________________________________________ 30 CM235 Mechanical - Gathering Head and Conveyor

______________________________________________________ Foot Shaft Gathering Head Foot Shaft Removal

To remove the gathering head foot shaft (Fig. 12): 1. Lower the gathering head until it touches the floor.

2. Position the conveyor tail section directly behind the miner so that it is level with the floor.

3. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

4. Slowly advance the conveyor chain until a connecting link appears on the gathering head entrance pan.

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

6. Loosen tension on the conveyor chain as much as possible (see Conveyor chain adjustment procedure in the Maintenance section of this manual).

7. With conveyor chain tension removed, remove the connecting link pins and the connecting link.

8. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the gathering head foot shaft.

9. Remove the hex head capscrews and lock washers that secure the foot shaft cover to the gathering head and remove the foot shaft cover.

10. Locate the two collars on the foot shaft and remove the eight (8) M12 X 60 hex head capscrews that secure each of the collars to the foot shaft. When the capscrews are removed, the flex lock nuts will fall free from the other side of the collar. Hand tighten new nuts onto their capscrews. Remove both collars from the foot shaft.

11. Slide the foot shaft couplings from the ends of the foot shaft toward the sprocket in the center. Once the couplings have been moved, the foot shaft is disconnected from the gear case bevel pinions.

12. The foot shaft can now be removed from the gathering head.

______________________________________________________________ A6474X378 REV 0 31

Foot Shaft_______________________________________________________ Fig. 12: Foot shaft removal

Foot shaft collar Foot shaft coupling

Hex head capscrews Gathering Head Foot Shaft Installation

To install the gathering head foot shaft (Fig. 12): 1. Slide a coupling onto each end of the foot shaft.

2. Insert the gathering head foot shaft into position between the two gathering head gear case bevel pinions.

3. Align the foot shaft splines with the bevel pinions’ splines.

4. Slide the right coupling over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat with the left coupling.

5. Place a collar onto each end of the foot shaft so that the collars keep the couplings secure against the gear case seal carriers, bridged between the foot shaft and bevel pinion.

6. Insert and tighten the eight (8) M12 X 60 hex head capscrews through both halves of each collar and into new flex lock nuts to secure the collars to the foot shaft, and torque to 75 ft-lb.

7. Replace the foot shaft cover.

8. Insert and tighten the hex head capscrews and lock washers to secure the foot shaft cover to the gathering head.

9. Reattach the two ends of the conveyor chain by replacing the connecting link. Secure the link.

10. Tighten the conveyor chain to the proper tension.

________________________________________________________________ 32 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder Introduction

The following procedure is for the removal and installation of a gathering head cylinder.

Tool Set

Basic Tool Set Sling or Chain Slide Hammer

Safety

When removing or installing a gathering head cylinder, observe the following safety precautions:

Blocking Pry Bar Puller Bolts

!

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

!

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

!

WARNING Stand clear of the blocked cutter head and gathering head assemblies during gathering head lift cylinder contraction.

!

WARNING When aligning the cylinder end bearings within their clevises to allow for insertion of the retaining pins, do not test alignment with your fingers. Shifting parts could cause serious injury.

______________________________________________________________ A6474X378 REV 0 33

Gathering Head Cylinder __________________________________________ Gathering Head Lift Cylinder Removal

To remove a gathering head lift cylinder: 1. Lower the conveyor tail section so that it is level with the floor.

2. Completely raise the cutter head and gathering head assemblies.

3. Place blocking under the cutter head and gathering head assemblies and lower the assemblies onto the blocking.

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

5. Remove the two (2) M16 X 35 hex head capscrews and lock washers that secure the lift cylinder piston pin retaining bar to the gathering head side panel and then remove the retaining bar (Fig. 13).

Fig. 13: Gathering head lift cylinder piston pin retaining bar

Retaining bar Lockwashers Piston pin

Hex head capscrews

6. Use a slide hammer to pull the pin from the clevis bushings.

7. Connect the trailing cable to energize the miner.

8. Slowly retract the lift cylinder until the piston end comes free from its clevis.

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

10. Check the blocking that supports the cutter head and gathering head assemblies.

________________________________________________________________ 34 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder 11. Move the gathering head lift cylinder control lever up and down to release any pressure from the gathering head lift cylinders.

12. Disconnect and plug the hydraulic hose from the gathering head lift cylinder’s hydraulic fitting.

13. Remove the hydraulic fitting from the gathering head lift cylinder and store it in a clean place.

14. Attach a lifting device to the gathering head lift cylinder. Take up any slack in the lift device so that the weight of the cylinder rests on the left device.

15. Remove the two hex head capscrews and lock washers that secure the pin retaining plate (Fig. 14) on the gathering head lift cylinder to the tractor frame and remove the retaining plate.

16. Using a slide hammer, remove the rod end pin (Fig. 14) from the frame clevis bushing. The cylinder should now be able to be removed from the miner.

Fig. 14: Gathering head lift cylinder piston pin retaining bar Retaining plate

Hex head capscrews

Rod end pin

______________________________________________________________ A6474X378 REV 0 35

Gathering Head Cylinder __________________________________________ Gathering Head Lift Cylinder Installation

To install the lift cylinder: 1. Insert the piston end bearing of the gathering head lift cylinder into the gathering head assembly clevis.

2. Insert the piston end through the aligned clevis bushings and piston end bearing.

3. Place the pin retaining bar (Fig. 13) over the piston end pin and secure to the gathering head side panel with the two (2) M16 X 35 hex head capscrews and lock washers.

4. Insert the hydraulic fitting into the gathering head lift cylinder hydraulic port.

5. Attach the hydraulic hose to the gathering head cylinder hydraulic fitting.

6. Connect the trailing cable to energize the miner.

7. Slowly extend the cylinder so that its rod end bearing can be inserted into the gathering head cylinder frame clevis.

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

9. Position the gathering head cylinder rod and bearing into the gathering head cylinder frame clevis.

10. Insert the rod end pin into the aligned clevis bushings and rod end of the cylinder.

IMPORTANT

Insert the pin so that its retaining channel remains outside of the bushing.

11. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

12. Insert and tighten the two two (2) M16 X 35 hex head capscrews and lock washers (Fig. 13) that secure the pin retaining plate to the tractor frame.

________________________________________________________________ 36 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm Introduction

The following procedure is for the removal and installation of a centrifugal loading arm (CLA). The gathering head gear case turns the CLAs and drives the foot shaft which powers the conveyor chain.

Tool Set

Basic Tool Set Torque Wrench

Safety

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

Blocking Slide Hammer

!

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

!

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

IMPORTANT

Hog rings should be installed so that their sharp points are directed clockwise.

______________________________________________________________ A6474X378 REV 0 37

Centrifugal Loading Arm __________________________________________ To remove a CLA:

CLA Removal

1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly. Lower the cutter head assembly onto the blocking.

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

4. Use a screwdriver to pry out the hog rings (Fig. 14) from around each of the CLA’s socket head capscrews.

5. Remove the twelve (12) 1 X 2 3/4” socket head capscrews located where the arms meet the CLA hub.

6. Remove the capscrews located in the center of the CLA hub. The CLA should now be free and able to be removed.

Fig. 14: Centrifugal loading apparatus (CLAs)

Hog rings

CLA tip

CLA

Socket head capscrews

________________________________________________________________ 38 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm 7. Remove the four CLA alignment keys (Fig. 15) from the exposed gathering head gear case turntable and store the keys in a safe place.

Fig. 15: CLA alignment key removal

Alignment key

Inner hub

CLA installation

To install the CLA: 1. On the CLA exterior, mark the bolt hole (outer set of three holes) located directly adjacent to a key cut-out.

2. Place an alignment dowel (Fig. 16) in the gathering head gear case turntable bolt hole (outer set of three holes) that is directly adjacent to a key cutout.

3. Place the four keys into their cutouts on the gathering head gear case turntable.

4. Place the CLA onto the gear case turntable so that the dowel extends through the marked CLA hole. Adjust the CLA as necessary to fit the turntable keys into the CLA cut-outs.

5. Insert two socket head capscrews into the CLA outer holes not blocked by the dowel.

6. Remove the alignment dowel and insert the last socket head capscrew into the CLA hole.

______________________________________________________________ A6474X378 REV 0 39

Centrifugal Loading Arm __________________________________________ 7. Tighten the six capscrews to secure the CLA to the gear case turntable.

8. Use the hammer to install three hog rings into the counterbore around each of the three outer socket head capscrews of the CLA.. The rings should be tapped down until they are below the chamfer of the socket head capscrews.

9. Insert the twelve (12) 1 X 2 3/4” socket head capscrews into CLA hub bolt holes and tighten.

10 Use the hammer to install hog rings into the counterbore around each of the socket head capscrews of the CLA hub (Fig. 17). The rings should be tapped down until they are below the chamfer of the socket head capscrews.

Fig. 16: Alignment dowel placement Alignment dowel placement location

Inner hub

Alignment key

Gear case turn table

Fig. 17: Hog ring installation Hog ring

Capscrew chamfer

Bottom of Hog ring counterbore

________________________________________________________________ 40 CM235 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm CLA tip installation

To replace a CLA tip (Fig. 18): 1. Lower the conveyor tail section until it is level with the floor. Lower the gathering head until it touches the floor.

2. Raise the cutter head assembly to its highest position. Place blocking under the cutter head assembly, both on the floor and on the gathering head.

Lower the cutter head assembly onto the blocking.

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

4. Locate the CLA tip (Fig. 18) which requires replacement.

5. Remove the hex head capscrews (Fig. 18) and mounting plate that secure the tip to the CLA. 6. Use force as necessary to remove the tip from the CLA. 7. Slide the new tip onto the CLA. 8. Insert and tighten the hex head capscrews through the tip and the CLA.

Fig. 18: CLA tip installation

CLA CLA tip

Mounting plate

Hex head capscrews

______________________________________________________________ A6474X378 REV 0 41

Swivel Pin Assembly______________________________________________ Introduction

The following procedure is for the removal and installation of the swivel pin assembly.

Tool Set

Basic Tool Set

Safety

When removing or installing a swivel pin assembly, observe the following safety precautions:

Slide Hammer

!

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

!

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

________________________________________________________________ 42 CM235 Mechanical - Gathering Head and Conveyor

_____________________________________________ Swivel Pin Assembly

swivel pin assembly removal

To remove the swivel pin assembly (Fig. 18): 1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section to the extreme right or left of the miner so that the chain is drawn to one side as far as possible and the conveyor swivel pin is exposed.

3. Lower the conveyor tail section until it is level with the floor.

4. Insert blocking between the conveyor tail section and the floor.

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

6. Remove the six (6) 5/8 X 3” socket head capscrews from the upper swivel pin.

7. Remove the 5/8 X 7/8” center setscrew from the center of the upper conveyor swivel pin.

8. Use a slide hammer to remove the upper conveyor swivel pin.

9. Remove the 5/8 X 7/8” center setscrew from the center of the lower conveyor swivel pin.

10. Remove the six (6) 5/8 X 3” socket head capscrews from the lower conveyor swivel pin.

11. Use a slide hammer to remove the lower conveyor swivel pin.

12. Using a retrieval tool, retrieve both upper and lower swivel pin retainers from the conveyor chain return channel.

______________________________________________________________ A6474X378 REV 0 43

Swivel Pin Assembly______________________________________________ Fig. 18: Conveyor swivel pin

Dowel pins

________________________________________________________________ 44 CM235 Mechanical - Gathering Head and Conveyor

_____________________________________________ Swivel Pin Assembly swivel pin assembly installation

To install the swivel pin assembly (Fig. 18): 1. Working first on the upper swivel pin assembly, insert the dowel pin, 5/8 X 7/8” center setscrew, and the grease fitting into the swivel pin.

2. Lower the swivel pin into the hole in the conveyor bed making sure the dowel pin is positioned in the notch and the top of the swivel pin is flush with the top surface of the conveyor bed.

3. Holding the swivel pin retainer with the flanged side downward, using a retrieval tool, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

4. Insert the six (6) 5/8 X 3” socket head capscrews and tighten.

5. Working on the lower swivel pin assembly, insert the dowel pin, 5/8 X 7/8” center setscrew and the grease fitting into the swivel pin.

6. Lift the swivel pin into the hole in the lower side of the conveyor making sure the dowel pin is positioned in the notch and the lower side of the swivel pin is flush with the lower surface.

7. Holding the swivel pin retainer with the flanged side upward, reach into the conveyor chain return channel and fit the swivel pin retainer into the hole.

8. Insert the six (6) 5/8 X 3” socket head capscrews and tighten.

______________________________________________________________ A6474X378 REV 0 45

Tail Roller _______________________________________________________ Introduction

The following procedure is for the removal and installation of the tail roller.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the tail roller, observe the following safety precautions:

Blocking Puller Cable

!

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

!

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

!

WARNING Improper conveyor chain tension can lead to excessive wear, mechanical problems and miner downtime. Always keep the conveyor chain at the proper tension.

________________________________________________________________ 46 CM235 Mechanical - Gathering Head and Conveyor

_______________________________________________________ Tail Roller Tail Roller Removal

To remove the tail roller (Fig. 19): 1. Lower the gathering head and cutter head assemblies until they rest on the floor.

2. Slowly advance the conveyor chain until a connecting link moves onto the conveyor tail section slide pan.

3. Loosen tension on the conveyor chain as much as possible.

4. Lower the conveyor tail section onto blocking so it is level with the floor.

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

6. With conveyor chain tension removed, remove the retaining rings from the connecting link.

7. Remove the connecting link and its strap. The conveyor chain should now be separated. Move the two pieces of the conveyor chain out of the way to allow for easier removal of the conveyor tail roller assembly.

8. Remove the four (4) M20 X 55 socket head capscrews that secure the tail roller assembly to the slide pan.

9. Remove the tail roller assembly from its location in the slide pan.

______________________________________________________________ A6474X378 REV 0 47

Tail Roller _______________________________________________________ Fig. 19: Tail roller

Tail roller Tail Roller Installation

Socket head capscrews

To install the tail roller (Fig. 19): 1. Insert the tail roller assembly into the proper location in the slide pan.

2. Insert and tighten the four (4) M20 X 55 socket head capscrews through the holes in the tail roller shaft and into the threaded holes in the slide pan.

3. Reattach the two ends of the conveyor chain by replacing the connecting link.

4. Secure the connecting link by replacing the side strap and the retaining rings onto the ends of its pins.

5. Tighten the conveyor chain to the proper.

________________________________________________________________ 48 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Introduction

The following procedure is for the removal and installation of the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the conveyor chain, observe the following safety precautions:

Blocking Puller Cable

!

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

!

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

______________________________________________________________ A6474X378 REV 0 49

Conveyor Chain __________________________________________________ Conveyor Chain Replacement

To replace the conveyor chain (Fig. 20): 1. Lower the cutter head and gathering head assemblies until they touch the ground.

2. Position the conveyor tail section directly behind the miner and raise it. Insert the blocking under the tail section and lower the tail section onto the blocking.

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

4. Loosen the tension of the conveyor chain as much as possible.

5. Remove the two retaining rings from a connecting link located near the rear of the conveyor bed.

6. Remove the connecting link. The chain is now separated.

7. Connect the come-along to the end of the chain on the conveyor bed.

8. Connect the new chain to the end of the lower chain and allow the new chain to extend behind the miner on the floor.

9. Use the come along to pull the old chain out of the miner. The new chain will follow the old through the conveyor return channel around the gathering head foot shaft and out onto the conveyor tail section.

10. When the entire length of old chain has been pulled through the miner and the replacement chain is in position, disconnect the old chain from the new and remove the come along.

11. Connect both ends of the new chain by replacing the connecting link, pins and retaining rings (Fig. 20).

12. Tighten the conveyor chain.

________________________________________________________________ 50 CM235 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Fig. 20: Conveyor chain installation Retaining rings

Attach Come along

Attach New chain

Chain connecting link

Pins

Retaining rings

______________________________________________________________ A6474X378 REV 0 51

A6474X379 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X (Mechanical - Cutter)

SAFETY.CAT.COM

__________________________________________________________

This manual is intended to provide GENERAL product information for the CM235 Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillarreserves the right to revise models and designs without prior notice.

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

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

Strict compliance with all 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 Safety Instructions............................................................................. 4 Torque Values ................................................................................... 6 Component Weights.......................................................................... 8 Cutter Head (Boom) Assembly ......................................................... 9 Cutter Head Boom Pivot Pin ............................................................. 13 Cutter Head Shear Cylinder .............................................................. 16 Cutter Head Center Drum ................................................................. 21 Cutter Head End Drum...................................................................... 27 Cutter Head Drum Drive Motor ......................................................... 31 Cutter Head Drum Drive Torque Limiting Clutch .............................. 35 Cutter Head Drum Drive Gear Case ................................................. 40 Scrubber Fan/Motor .......................................................................... 45

________________________________________________________________ A6474X379

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 lifting and blocking devices and keep a safe distance from suspended loads.

!

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

!

WARNING Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.

!

WARNING Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

!

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

________________________________________________________________ 4 CM235 Mechanical - Cutter

_______________________________________________ Safety Instructions Introduction

The following general guidelines, in addition to specific procedural instructions, should be followed whenever performing maintenance on this machine.

The procedures for the removal and installation of components are for a typical machine and conditions. Tools available, work conditions, or other factors may require procedures to vary from those given.

Tools

It is the responsibility of the mine operator or the employee to provide the necessary tools required for routine maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts book supplied with your machine.

Before Maintenance

Before performing maintenance on this machine, observe the following: 1. Shutdown the machine on level ground.

2. Turn circuit breaker to the "OFF" position and disconnect the trailing cable.

Follow all applicable lockout/tagout procedures.

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

4. Block any and all elevated assemblies before working under them. Make sure that the blocking can support the weight of the assembly without slipping or failing.

Important Notes

1. Use only suitable and approved tools for maintenance work.

2. Use only original spare parts when replacing components.

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

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

5. Always refer to the appropriate engineering drawing when replacing components.

______________________________________________________________ A6474X379 REV 0 5

Torque Values ___________________________________________________ Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Table 1: Imperial Bolts

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

________________________________________________________________ 6 CM235 Mechanical - Cutter

___________________________________________________ Torque Values Table 2: Metric Bolts

Metric Bolts Torque Recommendations (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

______________________________________________________________ A6474X379 REV 0 7

Component Weights ______________________________________________ Component Weights

Following are the approximate weights of the major components of the cutter head assembly. Be certain that adequate lifting and blocking is available whenever a component is being removed or installed as serious injury or death can result from falling loads. Never work under a component that is not adequately and correctly supported.

Table 3: Component weights Component Cutter head (shear) cylinder Cutter head (boom) assembly Cutter motor Cutter drum, end (left or right) Cutter drum, center (half) Cutter drum, center (whole) Cutter head gear case

Approximate Weight 625 lbs (283 kg) 46,500 lbs (21,092 kg) 2,300 lbs (1,043 kg) 1,277 lbs (579 kg) 1,036 lbs (470 kg) 2,072 lbs (940 kg) 5,100 lbs (2,313 kg)

________________________________________________________________ 8 CM235 Mechanical - Cutter

_____________________________________ Cutter Head (Boom) Assembly Introduction

The following procedure is for the removal and installation of the cutter head (boom) assembly.

Tool Set

Basic Tool Set Slide Hammer

Safety

When removing or installing the cutter head (boom) assembly, observe the following safety precautions:

Blocking Grease gun with Spec. 100-3 grease

!

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

!

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

!

WARNING Do not test the alignment of the shear cylinder rod end bearings and the cutter boom clevis using your fingers. Shifting of the aligned pieces could cause serious injury.

!

WARNING When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

!

WARNING Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.

!

WARNING Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.

______________________________________________________________ A6474X379 REV 0 9

Cutter Head (Boom) Assembly______________________________________

Cutter Head Assembly Removal

To remove the cutter head assembly (Fig. 1): 1. Lower the gathering head and conveyor to the floor.

2. Raise the cutter head to allow access to the upper shear cylinder pin.

Securely block the cutter head.

3. Attach an appropriate lifting device to the boom assembly. Take up the slack in the lift assembly so that the weight is supported as the assembly is unpinned from the miner.

4. Disconnect and lock out the electrical power to the miner. Follow all applicable mine regulations regarding lockout/tagout procedures.

5. Turn off the water supply to the machine.

6. Disconnect and tag power cables from the cutter motors (see Cutter motor removal procedure in this chapter). Be sure to tape up the power cables since electrical power will be restored to the miner.

7. Disconnect, tag and cap water hoses from both cutter motors.

8. Disconnect the water hoses to the dust suppression sprays.

9. Remove the two (2) boom pivot pins (see the boom pivot pin removal procedure in the chapter).

10. Connect electrical power to the miner.

11. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

12. Block the boom and shear cylinders to keep them stationary during their pin removal.

13. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

14. Remove the shear cylinder boom clevis pins (see Shear cylinder removal procedure in this chapter).

15. Connect electrical power to the miner.

16. Retract the shear cylinders to pull their bearings free from the boom clevises.

17. Disconnect power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

18. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.

19. Slowly tram the mine backwards until the cutter boom pivot points clear the front of the gathering head.

________________________________________________________________ 10 CM235 Mechanical - Cutter

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

Shear cylinder

Drum drive motor

Drum drive gear case

Shear cylinder clevis pin

______________________________________________________________ A6474X379 REV 0 11

Cutter Head (Boom) Assembly______________________________________ Cutter Head Assembly Installation

To install the cutter head assembly (Fig. 1) 1. Slowly tram the miner forward toward the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their boom clevises. Block the boom to keep it in a secure position.

3. Extend the shear cylinders until their cylinder end bearings can be inserted into the cutter boom clevises.

4. Disconnect the trailing cable to de-energize the miner. Follow all regulations regarding lockout/tagout procedures.

5. Position the right cylinder’s end bearing in the boom clevis.

6. Insert the cylinder end pin through the aligned clevis bushings and cylinder end bearing.

IMPORTANT The pin should be inserted so that its retaining channel remains outside the bushing.

7. Insert the pin retaining plate and secure to the boom clevis with four (4) M20 X 40 hex head capscrews and lock washers, and torque to 261 ft-lb (354 N-m).

8. Repeat the previous three steps from the left shear cylinder.

9. Connect the trailing cable to energize the miner.

10. Once the shear cylinders are secured to the cutter boom, remove the boom blocking to allow the cylinders to move the boom.

11. Contract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

IMPORTANT In addition to the shear cylinders, the stabilizer and gathering head can also be used to

adjust the cutter boom’s position to allow easier insertion of the cutter boom pivot pins.

12. Install both cutter boom pivot pins.

13. Disconnect the trailing cable to de-energize the miner. Follow all regulations regarding lockout/tagout procedures.

14. Connect power and water cables to both cutter motors (see Cutter motor installation procedure in this chapter).

15. Connect the water hoses to the dust suppression sprays.

16. Ensure all hydraulic and lubrication hoses are securely connected.

17. Lubricate all pins with Spec. 100-3 grease.

18. Check hydraulic oil level and add Spec. 100-1 oil as required.

19. Restore electrical power to the miner. ________________________________________________________________ 12 CM235 Mechanical - Cutter

_______________________________________ Cutter Head Boom Pivot Pin Introduction

The following procedure is for the removal and installation of a cutter head boom pivot pin.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter head boom pivot pin, observe the following safety precautions:

Blocking

!

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

!

WARNING When the pivot pin pull point is found, block the cutter boom to prevent it from dropping or moving when the pivot pin is removed.

!

WARNING Use extreme caution when adjusting the boom with the shear cylinder to find the pivot pin’s pull point.

!

WARNING Use extreme caution when adjusting the clevis and boom alignment with the shear cylinders.

______________________________________________________________ A6474X379 REV 0 13

Cutter Head Boom Pivot Pin________________________________________ Boom Pivot Pin Removal

To remove the boom pivot pin: 1. Lower the conveyor tail section until it is level with the floor and gathering head and cutter head until they rest on the floor.

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

3. Locate the boom pivot pin (accessible from top of machine).

IMPORTANT Pressure from the cutter boom onto the pivot pin can make its removal very difficult.

The shear cylinders can be used to find the boom position that puts the least pressure on the pin.

A. Remove the four (4) M20 X 50 hex head capscrews (Fig. 2) and lock washers that secure the boom pivot pin retaining plate to the tractor frame.

B. Remove the pin retaining plate (Fig. 2) and its support block.

C. Insert a slide hammer adapter into the threaded hole in the end of the boom pivot pin.

IMPORTANT Pressure from the cutter boom onto the boom pivot pin can make its removal very diffi-

cult. The shear cylinders can be used to find the boom position that puts the least pressure onto the pin. This position can be determined by striking the pin, slightly contracting or extending the shear cylinder, then striking the pin again and comparing the “ring”; as boom pressure on the pin decreases, the “ring” of the pin when it is struck becomes lower. When the “ring” of the pin becomes short and low, pin removal is much easier.

D. When the pivot pin’s pull point is found, block the cutter boom to keep it from dropping or moving when the pin is pulled.

E. Attach the slide hammer to its adapter and pull the boom pivot pin.

________________________________________________________________ 14 CM235 Mechanical - Cutter

_______________________________________ Cutter Head Boom Pivot Pin Boom Pivot Pin Installation

To install the boom pivot pin: 1. Position the boom pivot pin so that the end with the two flats (the end without the adapter) is inserted first. The single flat of the pin’s opposite end must face the four retaining plate holes.

IMPORTANT On the back of the tractor frame clevis there is a welded strap that keeps the boom pivot

pin from rotating. One of the flats of the boom pivot pin must parallel this strap or the pin cannot be completely inserted.

2. Use the hammer to insert the boom pivot pin through the aligned tractor frame clevis and boom pivot bushings.

IMPORTANT If it is extremely difficult to insert the boom pivot pin through the aligned tractor frame

clevis and boom pivot bushings, extend or contract the shear cylinders to improve the alignment between the clevis and boom.

3. Replace the support block over the four threaded holes in the tractor frame.

4. Place the retaining plate (Fig. 2) onto the support block. The end of the retaining plate L-extension should be positioned against the flat of the boom pivot pin.

5. Insert and tighten the four (4) M20 X 50 hex head capscrews (Fig. 2) and lockwashers to secure the boom pivot pin retaining plate to the tractor frame, and torque to 261 ft-lbs (354 N-m).

Fig. 2: Cutter head boom pivot pin removal and installation

Hex head capscrews Cutter boom pivot pin retaining plate

______________________________________________________________ A6474X379 REV 0 15

Cutter Head Shear Cylinder ________________________________________ Introduction

The following procedure is for the removal and installation of the cutter head (shear) cylinder.

Tool Set

Basic Tool Set Slide Hammer Lifting Device

Safety

When removing or installing a cutter head (shear) cylinder, observe the following safety precautions:

Cutter Head Safety Support Blocking Grease gun with Spec. 100-3 grease

!

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

!

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

!

WARNING Replacement of the shear cylinder involves working around a raised cutter head assembly. Never work under any raised assembly without proper blocking. Always block between the raised assembly and the tractor frame in addition to between the raised assembly and the floor.

!

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

!

WARNING The shear cylinder is very heavy. Verify its weight can be supported.

!

WARNING Stand clear of the blocked cutter head assembly during shear cylinder contraction.

!

WARNING Stand clear of the shear cylinder and the blocked cutter head assembly during extension of the shear cylinder.

________________________________________________________________ 16 CM235 Mechanical - Cutter

________________________________________ Cutter Head Shear Cylinder Shear Cylinder Removal

To remove the shear cylinder: 1. Lower the gathering head until it touches the floor and lower the conveyor tail section until it is level with the floor. Advance the conveyor chain so that its flights do not block the shear cylinder piston end pin access plates on the conveyor bed.

2. Raise the cutter head assembly until it reaches its highest point. Place blocking underneath the cutter head. Lower the assembly onto the blocking at a level where the shear cylinder is partially but not fully contracted.

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

4. Attach an appropriate lifting device to the shear cylinder. Take up all slack in the lifting device so that the weight of the cylinder is supported by the lifting device.

5. On the boom clevis of the shear cylinder’s piston end, locate the piston end pin and its retaining bracket.

6. Remove the four (4) M20 X 40 hex head capscrews (Fig. 3) and lock washers that secure the pin retaining plate to the cutter boom.

7. Remove the retaining plate (Fig. 3).

8. Insert the slide hammer’s adapter into the threaded hole in the end of the pin.

9. Attach the adapter to the slide hammer and pull the pin from the clevis bushings.

10. Connect the trailing cable to energize the miner.

11. Slowly retract the shear cylinder until the piston end comes free from its clevis.

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

13. Raise and lower the shear cylinder to release any pressure from the shear cylinder.

14. Locate the miner’s front rub rail and remove the hex head capscrew and lock washer that secures the rub rail to the tractor frame (Fig. 3) and open the rub rail.

15. Locate the front idler take-up jack bracket assembly which is mounted directly to the rear of the idler shim channel .

16. Pull the flip pin from the half link to release the take-up jack bracket from the tractor frame.

17. 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.

______________________________________________________________ A6474X379 REV 0 17

________________________________________ Cutter Head Shear Cylinder 18. Locate the shear cylinder’s rod end pin and pin retaining plate.

19. Remove the four (4) M20 X 50 hex head capscrews and lockwashers that secure the pin retaining plate to the frame.

20. Remove the pin retaining plate.

21. Locate the shear cylinder pin.

22. Insert the slide hammer adapter into the threaded hole in the end of the pin.

23. Attach the adapter to the slide hammer and pull the pin.

24. Disconnect, tag, and cap the grease hoses going to the cylinder.

25. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

26. Remove the hydraulic fittings from the shear cylinder and store in a clean place.

27. The shear cylinder is now free to lift clear of the miner.

______________________________________________________________ A6474X379 REV 0 18

Cutter Head Shear Cylinder ________________________________________ Fig. 3: Shear cylinder piston end

Hex head Capscrews (both sides)

Retaining Plate (both sides)

________________________________________________________________ 19 CM235 Mechanical - Cutter

Cutter Head Shear Cylinder ________________________________________ Shear Cylinder Installation

To install the shear cylinder: 1. Verify that the miner is de-energized and that the trailing cable is disconnected and locked out.

2. Verify that the cutter head assembly is sufficiently and securely blocked.

3. Using an appropriate lifting device, position the shear cylinder rod end close to the frame mounting clevis.

4. Insert the hydraulic fittings into the cylinder and reconnect hydraulic hoses.

5. Reattach all grease lines to the cylinder.

6. Position the shear cylinder’s rod end into the frame clevis.

7. Insert the shear cylinder rod end pin, retaining channel end first, through the aligned frame clevis and rod end. Rap the pin with a hammer until the retaining channel emerges from the gushing on the other side of the clevis.

8. Insert the pin retaining plate in the pin’s channel to secure the pin in the clevis.

9. Insert and tighten the (4) M20 X 50 hex head capscrews and lock washers that secure the pin retaining plate to the frame clevis, and torque to 261 lbft (354 N-m).

10. Replace the take-up jack bracket assembly into the frame and secure by inserting the flip pin through the half link.

11. Close the front rub rail and secure to the frame with hex head capscrews and lock washers.

12. Connect the trailing cable to energize the miner.

13. Slowly extend the shear cylinder so that the piston end is near the boom mounting clevis.

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

15. Position the shear cylinder’s piston end bearing in the boom clevis.

16. Insert the pin through the aligned mounting clevis and bushing, ensuring that the retaining channel remains outside the bushing.

17. Insert the pin retaining plate (Fig. 3) in the pin’s channel to secure the pin in the clevis.

18. Insert and tighten the four (4) M20 X 40 hex head capscrews and lock washers to secure the pin retaining plate to the boom clevis, and torque to 261 lb-ft (354 N-m).

19. Reconnect the trailing cable and cycle the shear cylinder to ensure correct operation.

________________________________________________________________ 20 CM235 Mechanical - Cutter

__________________________________________Cutter Head Center Drum Introduction

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

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter head center drum, observe the following safety precautions:

!

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

!

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

!

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

!

WARNING Always be aware of whether or not the miner is energized when disconnecting and reconnecting the miner’s trailing cable. Never perform maintenance on an energized miner.

______________________________________________________________ A6474X379 REV 0 21

Cutter Head Center Drum __________________________________________ Center Drum Removal

To remove the center drum (Fig. 4): 1. Lower the gathering head completely until its touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Rotate the cutter head slowly until one of the center drum seams appears directly in front and one appears directly in rear of the cutter head.

3. Lower the cutter head assembly until it touches the floor.

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

5. Attach an appropriate lifting device to the upper half of the center drum.

6. Remove the fourteen (14) M30 X 70 bolts and nuts that secure the two center drum halves together. Store the nuts and bolts in a safe place to use in reassembly.

7. Using a pry bar and other force as necessary, break the seal between the center drum so that the top half is free from the bottom half.

8. Lift the upper half of the center drum off of the lower half.

9. Measure and record the following dimensions (as shown on Fig. 5) to two (2) places of accuracy: LD1 = _________ LD2 = _________ GD1 = (LD1 - LD2)/2 = _______ 10. Remove the alignment keys and store in a safe place for use in reassembly.

11. Connect the trailing cable to energize the miner.

12. Slowly raise the cutter head assembly until it completely clears off of the lower half of the center drum.

13. Slowly tram the miner back away from the lower half of the center drum.

________________________________________________________________ 22 CM235 Mechanical - Cutter

__________________________________________Cutter Head Center Drum Fig. 4: Center cutter drum removal/installation

Bolt locations

Nuts

Center drum upper half

Spacer

Shim Alignment keys

Capscrew

Shim Shim

Center drum lower half

Bolts

______________________________________________________________ A6474X379 REV 0 23

Cutter Head Center Drum __________________________________________ Fig. 5: Center drum removal and installation

LD1 1

4

7

10

LD2

GD1

GD+2

GD1

11

5

13

14

6

12

9

3

8

2

GD+2

________________________________________________________________ 24 CM235 Mechanical - Cutter

__________________________________________Cutter Head Center Drum Center Cutter Drum Installation

To install the center cutter drum (Fig. 6): 1. Slowly position the miner so that the cutter head assembly is positioned in the lower half of the center cutter drum.

2. Using the calculated value of GD1 found during removal, select a combination of shims and spacers to allow for a float gap (GB) between the center drum and the gear case struts that is between 0.40 and 1.00 mm (one set of shims and spacers per side). Note that the shims should be located between spacers.

3. Record the following to two (2) places of accuracy: GD = Total sum length of spacers and shims = ________ GB = GD1 (found during removal) - GD = _________ GB must be between 0.40 and 1.00 mm 4. Apply thread locker (Loctite 271) to a 5/8-11 UNC X 2.00 inch hex head cap screw and use the screw to secure the spacer/shim pack to the boom assembly.

5. Place the center drum keys in position in the lower half of the center drum.

6. Slowly lower the upper half of the center drum onto the lower half using the match marks scribed on the outside of the drum halves to ensure correct alignment.

7. Insert the fourteen (14) M30 X 70 hex head bolts and nuts through the two halves of the center drum and torque to 1,350 ft-lbs (1,830 N-M) using the pattern shown in Fig. 6.

8. Check the total float and verify it is within 0.40 to 1.00 mm. If float is outside these parameters, take the drum apart and insert new spacer/shim pack to obtain the correct total float. Reassemble and torque bolts to 1,350 ft-lbs (1830 N-m) using the pattern shown in Fig. 6.

9. When the total float is verified between 0.40 and 1.00 mm, tighten the bolts and nuts to a final torque of 2,800 ft-lbs (3,796 N-m) using the pattern shown in Fig. 6.

______________________________________________________________ A6474X379 REV 0 25

Cutter Head Center Drum __________________________________________ Fig. 6: Center drum bolt torque pattern

1

4

7

10

11

5

13

14

6

12

9

3

8

2

________________________________________________________________ 26 CM235 Mechanical - Cutter

____________________________________________ Cutter Head End Drum Introduction

The following procedure is for the removal and installation of a cutter head end drum. The procedure is the same for the right and the left drums.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing a cutter head end drum, observe the following safety precautions:

Blocking

!

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

!

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

______________________________________________________________ A6474X379 REV 0 27

Cutter Head End Drum ____________________________________________ To remove an end drum (Fig. 7): 1. Lower the gathering head completely until it touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Raise the cutter head assembly to its highest position. Place blocking underneath the cutter head assembly and lower the cutter head assembly onto the blocking.

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

4. Remove the tack welding and bolt cap plate.

5. Remove the fourteen M30-2.0 6G X75 hex head capscrews that secure the end drum to the cutter drum drive gear case.

6. Using the pry bar and other necessary force, remove the end drum from the cutter head assembly.

7. Retrieve the two alignment keys and store in a safe place for use in installation of the end drum.

Fig. 7: End drum removal

Bolt cap plate

Alignment key End drum Bolts

________________________________________________________________ 28 CM235 Mechanical - Cutter

____________________________________________ Cutter Head End Drum End Drum Installation

To install an end drum (Fig. 8): 1. Place the end drum alignment keys into the required position.

2. Install the end drum on the gear case. Ensue that the timing mark of the end drum is aligned with the timing mark on the center drum.

3. Thread fourteen (14) reusable M30-2.0X75 hex head bolts into the end drum and torque to 878 ft-lbs (1,190 N-m) using sequence pattern shown in Fig. 8.

4. Individually remove the fourteen (14) reusable M30-2.0X75 bolts in sequence pattern shown in Fig. 136 and replace with identical bolts for final assembly. Before threading bolts, apply thread locker (Loctite 277) to the bolts. Torque bolts to 1,755 ft-lbs (2380 N-m).

5. Place bolt cap plate, with holes positioned over bolt heads, on the end of the end drum and tack weld in place. Fill holes as shown in Fig. 9.

Fig. 8: End drum bolt torque pattern

1

7

5

11

9

13

3

4

14 10

12 6 2

8

______________________________________________________________ A6474X379 REV 0 29

Cutter Head End Drum ____________________________________________ Fig. 9: Bolt cap plate

Grind flush after filling with weld

________________________________________________________________ 30 CM235 Mechanical - Cutter

_____________________________________ Cutter Head Drum Drive Motor Introduction

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

Tool Set

Basic Tool Set Lifting Device

Safety

When removing or installing a cutter head drum drive motor, observe the following safety precautions:

Blocking

!

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

!

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

!

WARNING While the power cable is detached from the motor, the trailing cable should not be reconnected to energize the miner. Damage to the miner, personal injury or death could result.

!

WARNING Federal law requires that mining equipment electrical connections must be inspected by a certified electrician before the equipment can be operated.

______________________________________________________________ A6474X379 REV 0 31

Cutter Head Drum Drive Motor______________________________________ Drum Drive Motor Removal

To remove the drum drive motor: 1. Lower the gathering head until it touches the floor. Lower the conveyor tail assembly until it is level with the floor.

2. Level the cutter head assembly and place blocking underneath.

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

4. Remove the seven (7) 1/2 X 1 1/4” hex head caps crews and lockwashers that secure the junction box cover and remove the cover and O-ring.

5. Locate the three taped power connections. Tag the connections for reconnection and then strip off the three layers of tape covering these lug connections.

6. Tag the lugs for correct reconnection then remove the hex head capscrew, flat washer, lock washer and hex head nut that secure the three power cable lugs to the three motor lugs.

IMPORTANT Before detaching the lugs, mark the wires to facilitate reconnection during motor instal-

lation.

7. Remove the socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

8. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

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

10. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using hex head capscrews and lock washers.

11. Disconnect the two cooling water hoses from the front and rear motor cooling water fittings and plug the hose ends to keep them clean.

12. Remove the two water fittings from the motor and store in a clean place and plug the two motor cooling water ports to keep them clean.

13. Place blocking under the motor to support it as it is pulled out of the gear case.

14. Remove the ten (10) bolts and washers that secure the motor to the gear case.

15. Using four (4) of the bolt holes as pusher holes, insert four bolts and push the motor out of the gear case.

16. Using appropriate pulling devices, pull the motor from the gear case, making sure to keep the motor properly blocked and supported as it is pulled from the case.

________________________________________________________________ 32 CM235 Mechanical - Cutter

_____________________________________ Cutter Head Drum Drive Motor Drum Drive Motor Installation

To install the drum drive motor: 1. Block up cutter head drum drive motor into position against the rear of the boom so that the motor’s mounting holes align with the boom’s threaded motor mounting holes.

2. Install the two motor cooling water fittings into the front and rear cooling water ports of the motor.

3. Attach the two motor cooling water hoses to the fittings.

4. Remove the seven (7) 1/2 X 1 1/4” hex head capscrews and lock washers that secure the junction box cover and remove the cover and o-ring.

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

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

7. Tighten the two socket head capscrews to secure clamp to the junction box.

8. Inside the junction box, locate the motor’s lug connections and match the motor lug connections to the corresponding power cable lugs.

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lock washer. Secure the capscrew with a hex nut.

10. Repeat this step for the other two lugged connections.

11. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and then a layer of glass tape.

12. Replace the junction box o-ring and cover.

13. Insert the seven (7) 1/2 X 1 1/4” hex head capscrews and lockwashers to secure the junction box cover and torque to 91 ± 15 lb-ft (124 N-m).

14. An MSHA certified electrician must inspect all work and check for permissibility.

15. Slide the motor into the gear case.

16. Coat the twenty (20) M20 X 200 bolts with thread locker (Loctite 271) and install the bolts and washers to secure the motor to the gear case. Torque the bolts to 403 ± 57 lb-ft (540 ± 70 N-m).

______________________________________________________________ A6474X379 REV 0 33

Cutter Head Drum Drive Motor______________________________________ Fig. 10: Drum drive motor (typical both sides)

Junction box

Motor

Capscrews (7) (both sides)

________________________________________________________________ 34 CM235 Mechanical - Cutter

_______________________ Cutter Head Drum Drive Torque Limiting Clutch Introduction

The following procedure is for the removal and installation of the cutter head drum drive torque limiting clutch.

Tool Set

Basic Tool Set Blocking Snap Ring Pliers

Safety

When removing or installing the cutter head drum drive torque limiting clutch, observe the following safety precautions:

!

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

!

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

______________________________________________________________ A6474X379 REV 0 35

Cutter Head Drum Drive Torque Limiting Clutch _______________________ Drum Drive Motor Torque Limiting Clutch Removal

To remove the drum drive torque limiting clutch (Fig. 11): 1. Lower the gathering head completely until it touches the floor and lower the conveyor tail section until it is level with the floor.

2. Raise the cutter head assembly to its highest position and block appropriately. Lower the cutter head assembly onto the blocking.

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

4. Remove the seven (7) 1/2 X 1 1/4” socket head capscrews and lock washers that secure the cover to the cutter head boom.

5. Locate the clutch housing on the rear of the cutter head drum drive motor assembly (Fig. 12).

6. Remove the two (2) M20 X 40 hex head capscrews and lock washers that secure the clutch housing to the motor housing.

7. Remove the clutch housing to expose the clutch assembly.

8. At the center of the clutch assembly, locate the drum drive shaft.

9. Using the screwdriver, remove the retaining ring that secure the drum drive shaft inside the clutch assembly.

10. Pull the drum drive shaft from the motor and clutch assemblies.

11. Store the drum drive shaft in a clean, safe place.

12. Remove the six (6) M20 X 70 socket head capscrews (Fig. 13) on the outside of the pressure plate.

13. Remove the pressure plate and the output hub assembly.

14. Using a screwdriver, remove the fillister head machine screw that retains the center drive hub.

15. Loosen the clutch retaining nut and slide the clutch off of the motor.

________________________________________________________________ 36 CM235 Mechanical - Cutter

_______________________ Cutter Head Drum Drive Torque Limiting Clutch Fig. 11: Drum drive torque limiting clutch

Clutch cover

Socket head capscrews

Fig. 12: Clutch housing

______________________________________________________________ A6474X379 REV 0 37

Cutter Head Drum Drive Torque Limiting Clutch _______________________ Fig. 13: Pressure plate removal

Pressure plate

Socket head capscrews

Fig. 14: Drum drive shaft installation

Drum drive shaft inserted here

________________________________________________________________ 38 CM235 Mechanical - Cutter

_______________________ Cutter Head Drum Drive Torque Limiting Clutch Drum Drive Motor Torque Limiting Clutch Installation

To install the drum drive torque limiting clutch (Fig. 14): 1. Position the clutch on the motor.

2. Insert and tighten the fillister head machine screw that retains the center drive hub.

3. Place the seal and then the bearing onto the output hub (with friction disc).

4. Place the output assembly against the input assembly.

5. Slide the pressure plate onto the input assembly’s spring shafts.

6. Secure the pressure plate to the spring shafts with the six (6) M20 X 70 socket head capscrews and torque to 2936 ft-lbs (3981 N-m).

7. Slide the drum drive shaft through the clutch assembly (Fig. 14) , through the motor, and into the cutter head drum drive gear case. The shaft may require some adjustment so that its end fits into the gear case.

8. When the drum drive shaft is positioned in the motor and clutch assemblies, insert the retaining ring to secure it in place.

9. Place the clutch housing against the motor housing.

10. Secure the clutch housing to the motor housing with the two (2) M20 X 40 hex head capscrews and lock washers.

11. Insert the seven (7) 1/2 X 1 1/4” socket head capscrews and lock washers that secure the cover to the cutter head boom and torque to 91±15 lb-ft (124±18 N-m).

______________________________________________________________ A6474X379 REV 0 39

Cutter Head Drum Drive Gear Case __________________________________ Introduction

The following procedure is for the removal and installation of the cutter head drum drive gear case. The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter head drum drive gear case, observe the following safety precautions:

Blocking

!

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

!

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

!

WARNING Use extreme caution when tramming the miner forward to position the boom face against the gear case.

________________________________________________________________ 40 CM235 Mechanical - Cutter

__________________________________Cutter Head Drum Drive Gear Case Drum Drive Gear Case Removal

To remove the drum drive gear case (Fig. 15): 1. Remove the cutter head center drum (See Center cutter drum removal procedure in this chapter).

2. Remove the water spray manifold.

3. Remove the cutter head end drum (See End cutter drum removal procedure in this chapter).

4. Carefully lower the cutter head assembly (now with the cutter drum drive gear case exposed) onto blocking.

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

6. Remove both the drum drive key retainers and the drum drive keys from their key slots in the center drum drive shaft. Store the keys and retainers in a safe place.

7. Remove the drum drive clutch (see Drum drive clutch removal procedure in this chapter).

8. Locate the clutch housing and the drum drive shaft access cover plate on the side of the cutter drum drive motor.

9. Securely block the cutter drum drive gear case to support it when it becomes separated from the boom.

10. Remove the weld strap holding the gear case mounting bolts in place.

11. Remove the twenty-eight (28) M12 X 30 bolts that secure the gear case to the frame.

12. Connect the trailing cable to energize the miner.

13. Slowly tram the miner in reverse away from the blocked gear case.

______________________________________________________________ A6474X379 REV 0 41

Cutter Head Drum Drive Gear Case __________________________________ Fig. 15: Drum drive gear case

Capscrews

Drum drive gear case oil cover

Drum drive gear case cover

Capscrews

________________________________________________________________ 42 CM235 Mechanical - Cutter

__________________________________Cutter Head Drum Drive Gear Case Drum Drive Gear Case Installation

To install the drum drive gear case: 1. Securely block the gear case so that the miner’s boom can be trammed forward into position behind it.

2. Insert four guides into the cutter boom face, spacing the guides equally over the boom face.

3. Mark the holes on the exterior of the gear case mounting brace that corresponds to the positions of the guides on the boom face.

4. Connect the trailing cable to energize the miner.

5. Using the guide pins to direct placement, tram the miner forward until the gear case is positioned against the cutter boom face. The guide pins (Fig. 15) should come out of the marked holes in the mounting brace.

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

7. Insert the twenty-eight (28) M12 X 30 hex head capscrews into the open holes (those not blocked by the guides) in the cutter drum drive gear case mounting brace.

8. Remove the alignment guides and insert the remaining four hex head capscrews through the gear case mounting brace and into the threaded holes in the cutter boom face.

9. Using the pattern shown in Fig. 16, torque the capscrews in two steps as follows: Step 1: 500 lb-ft (675 N-m) Step 2: 2,138 ± 150 lb-ft (2,900 ± 200 N-m) 10. Install the cutter drum motor (see Cutter motor installation procedure in this chapter).

11. Install the drum drive clutch (see Drum drive clutch installation procedure in this chapter).

12. Locate the fill plugs and fill the gear case to the proper level with lubricant.

13. Replace the plugs.

14. Examine the cutter drum drive gear case and cutter boom face for leaking oil, which indicates improper installation or gear case damage.

15. Install the cutter head end drum (see Cutter head end drum installation procedure in this chapter).

16. Install the cutter head center drum (see Center drum installation procedure in this chapter).

17. Connect the water spray manifold.

______________________________________________________________ A6474X379 REV 0 43

Cutter Head Drum Drive Gear Case __________________________________ Fig. 16: Cutter head gear case bolt torque pattern 1

7

11 13

10

6

4

18

20

24

27

25 21

15

3

5

9

12

8

2

16

22

26

28

23 19

17

14

________________________________________________________________ 44 CM235 Mechanical - Cutter

______________________________________________ Scrubber Fan/Motor Introduction

The following procedure is for the removal and installation of the scrubber fan/ motor.

Tool Set

Basic Tool Set

Safety

When removing or installing the scrubber fan/motor, observe the following safety precautions:

!

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

______________________________________________________________ A6474X379 REV 0 45

Scrubber Fan/Motor ______________________________________________ Scrubber Fan/Motor Removal

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

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

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

4. Locate the rub rail on the fan exhaust side at the rear of the miner (Fig. 17) and remove the pin that secures the rear rub rail to the rail adjacent to it.

Open both rub rails.

Fig. 17: Scrubber fan motor location

Scrubber fan motor (behind cover)

5. Locate the scrubber fan motor junction box and remove the four (4) M12 X 25 hex head capscrews and lockwashers that secure the junction box cover. Remove the cover and o-ring.

6. Locate the three taped power connections inside the junction box.

7. Strip off the three layers of tape covering each of the three lug connections inside the junction box.

8. Tag the three lugs to facilitate reconnection during motor installation.

9. Remove the twelve (12) M12 X 1.75 X 35 socket head capscrews and lockwashers that secure the scrubber fan/motor assembly to the tractor frame.

10. Carefully remove the scrubber fan/motor assembly from the tractor frame.

________________________________________________________________ 46 CM235 Mechanical - Cutter

______________________________________________ Scrubber Fan/Motor Scrubber Fan/Motor Installation

To install the scrubber fan/motor: 1. Carefully insert the scrubber fan/motor assembly into the tractor frame so the motor face is toward the scrubber’s mist eliminator box.

2. Orient the scrubber fan/motor so the motor drain is directly at the bottom of the assembly. Ensure that the scrubber fan/motor is positioned correctly for airflow out the rear vent of the miner.

3. Insert and tighten the twelve (12) M12 X 1.75 X 35 socket head capscrews and lockwashers to secure the scrubber fan/motor assembly to the tractor frame. Torque socket head capscrews to 65 ft-lbs 4. Remove the four (4) M12 X 25 hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its o-ring.

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

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

7. Tighten the two (2) M12 X 25 socket head capscrews to secure the clamp to the junction box.

8. Inside the junction box, locate the motor’s lug connections. Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in the parts manual).

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut. Repeat this step for the other two lugged connections.

10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.

11. Replace the junction box o-ring and cover.

12. Insert the four (4) M12 X 25 hex head capscrews and lockwashers to secure the junction box cover.

13. Replace the rub rail hinge post.

14. Close both rub rails and secure with the rub rail pin.

______________________________________________________________ A6474X379 REV 0 47

__________________________________________________________

A6474X380 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X380 (Electrical)

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 Safety Instructions ............................................................................. 4 Introduction........................................................................................ 6 Electrical Component Locator ........................................................... 7 Electrical Block Diagram ................................................................... 8 Specifications .................................................................................... 10 Circuits............................................................................................... 11 Power ........................................................................................ 11 Control and Lighting .................................................................. 13 Methane Monitor ....................................................................... 15 Low Oil ...................................................................................... 16 Emergency Stop........................................................................ 17 Emergency Stop Bypass ........................................................... 18 Pump ......................................................................................... 20 Cutter......................................................................................... 24 Conveyor ................................................................................... 27 Scrubber .................................................................................... 33 Tram .......................................................................................... 35 Emergency Tram....................................................................... 38 Solenoid Module........................................................................ 39 Operator’s Case ................................................................................ 40 Main Case ......................................................................................... 42 Tram Case......................................................................................... 45

________________________________________________________________ A6474X380

REV 1

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, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

!

WARNING Follow all applicable laws that require temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

!

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

!

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

!

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

!

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

!

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

________________________________________________________________ 4 CM235 Electrical

_______________________________________________ Safety Instructions

!

WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

!

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

!

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

!

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

______________________________________________________________ A6474X380 REV 1 5

Introduction _____________________________________________________ Introduction

The purpose of this manual is to give an overview the electrical circuits of the 25C continuous miner. This manual is only intended to familiarize the user with the electrical system. All electrical maintenance must be performed by a qualified person.

Electrical Overview

950VAC, 3-phase power is supplied to the machine via a trailing cable. During normal mining operations, the machine is operated by a radio remote. If required, and under certain circumstances, the control system allows limited functions to be operated from controls located on the machine or from an tram pendant.

Control System Overview

The control system consists of a machine controller, a power supply, input/ output modules, the radio remote, a text display, and an optional graphics display.

The control system monitors machine operating parameters and has the ability to prevent motors from starting or to shut down motors based upon preset parameter values. It will also issue faults, warnings, and alarms based on these parameters. Note: For more information on the control system, see the Graphics Display and Control System manuals in this book.

VFD Overview

The variable frequency drive (VFD) system uses 3-phase, 950 VAC motors for tramming. The motors respond to changes in frequency from the control system to tram the machine at infinitely variable speeds.

________________________________________________________________ 6 CM235 Electrical

_____________________________________________________ Introduction Fig. 1: Electrical component locator

1 11

10 9 7 6

8

3

4

5

2

1.

2.

3.

4.

5.

Tram case Text display Controller case Programming port Main breaker case

6. Tram motor (2) 7. Main case 8. Pump motor 9. Gathering head motor (2) 10. Cuter motor (2) 11. Scrubber motor

______________________________________________________________ A6474X380 REV 0 7

Introduction _____________________________________________________ Fig. 2: Electrical block diagram 1

6

9

4

2

12 11

3

10 5

14

13

7

8

1.

2.

3.

4.

5.

6.

7.

Left emergency stop Left CLA motor Right CLA motor Left cutter motor Right cutter motor Left tram motor Right tram motor

8. IS tram switch 9. Main controller 10. Methane monitor display 11. Pump motor 12. Valve bank 13. Transmitter pendant 14. Operator’s case

________________________________________________________________ 8 CM235 Electrical

_____________________________________________________ Introduction Fig. 2: Electrical block diagram (continued)

16 18

23

15

22 19 20 21

17

15

16

15. Headlights 16. Area lights 17. Text display 18. Scrubber motor 19. Scrubber solenoid

20. Fire spray solenoid 21. Cutter dust solenoid 22. Breaker on/off 23. Antenna

______________________________________________________________ A6474X380 REV 0 9

Installation ______________________________________________________ Specifications

Specifications for the 25C are as follows: Nominal Line Power ..........................................950VAC, 60 hz Control Transformer ..........................................950 VAC to 120VAC and 12VAC Pump Motor Power............................................50 hp/41 KW Left Cutter Motor Power ....................................275 hp/205 KW Right Cutter Motor Power..................................275 hp/205 KW Left Gathering Head/Conveyor Motor Power....60 hp/44.7 KW Right Gathering Head/Conveyor Motor Power .60 hp/44.7 KW Left Traction Motor Power .................................110 hp/82 KW Right Traction Motor Power ..............................110 hp/82 KW

________________________________________________________________ 10 CM235 Electrical

________________________________________________ Electrical Circuits Power Circuit

All machine motors operate on 950VAC power which is supplied to the machine via the trailing cable. The trailing cable is energized when connected to the power center and the four power center trip contactors are closed.

The machine is protected by a 600 amp main circuit breaker, CB1, set to instantaneously trip at 1250 amps. Once CB1 is closed, the machine is energized.

Power is active in the lighting and control circuits, as well as the cutter motor circuit.

The conveyor, scrubber and pump circuits are protected by a 600 amp circuit breaker, CB2, set to instantaneously trip at 800 amps. The pump motor is further protected by an overload.

The tram circuit is protected by a 400 amp circuit breaker, CBT, instantaneously set to trip at 300 amps.

Each motor has a contactor that opens and closes in response to an ON/OFF command. No motor can be started until the pump motor is started (contactor F is closed).

!

WARNING The schematics in this manual are typical and are for reference only. Do not use these schematics to troubleshoot or perform maintenance on the machine. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X380 REV 1 11

Electrical Circuits ________________________________________________ Fig. 3: Power circuit

________________________________________________________________ 12 CM235 Electrical

________________________________________________ Electrical Circuits Control and Lighting Circuits

The control and lighting circuits are supplied by transformer, T1. The 950VAC incoming power is stepped down through the transformer to 120VAC and 12VAC circuits.

120VAC

The 120VAC circuit supplies power to control system, including the PLC, the battery backup, and the displays, as well as the headlight relay. It is also the power source for the emergency tram module and the VFD system.

Individual 120VAC circuits are protected by circuit breakers as follows: 1. The main 120VAC supply lines are protected by two 15A circuit breakers, CB4 and CB5.

2. Area lights are protected by two 10A circuit breakers, CB6 and CB7.

3. The solenoids are protected by two 5A circuit breakers, CB12 and CB13.

12VAC

The 12VAC circuit supplies power to the headlights and the thermistor module.

The individual 12VAC circuits are protected by circuit breakers as follows: 1. The headlights and thermistor module are protected two 20A circuit breakers, CB8 and CB9.

Headlights

The headlights can be turned on using the light switch on the front of the controller case or the radio remote. When the rotary light switch on the front of the control case is rotated to the “MANUAL” position, the headlight relay is energized, turning on the headlights. Note: the area lights will also be turned on.

When the headlight switch on the radio remote is activated, the control system sends a digital output (X1-H) to energize the headlight relay, which turns on the headlights.

Area Lights

The area lights are turned on using the light switch on the front of the controller case. Turning the switch to “RADIO” position turns on the area lights. Turning the rotary switch on the controller case to “OFF” turns of all lights.

______________________________________________________________ A6474X380 REV 1 13

Electrical Circuits ________________________________________________ Fig. 4: Headlights and Area Lights Circuits

________________________________________________________________ 14 CM235 Electrical

________________________________________________ Electrical Circuits Methane Monitor Circuit

The methane monitor detects methane gas when the continuous miner is powered up. Before any motor or function occurs, the methane monitor checks for methane gas. If the methane monitor shows zero methane, the methane monitor relay will close. The methane monitor is powered from the control transformer.

The schematic shown in Fig. 5 is a typical methane monitor circuit. Always refer to the schematic in the parts book for your machine.

Fig. 5: Methane Monitor Circuit

______________________________________________________________ A6474X380 REV 1 15

Electrical Circuits ________________________________________________ Low Oil Circuit

The low oil circuit indicates when the oil is low in the hydraulic oil tank. The float switch energizes the LOR (low oil relay) and turns on the LOL (low oil light) in the case that the oil level becomes too low. The electrical circuit components are not located within an explosion proof enclosure are considered intrinsically safe circuits. A permissible ISC (intrinsically safe circuit) is incapable of producing a spark or a thermal effect.

The schematic shown in Fig. 6 is a typical low oil circuit. Always refer to the schematic in your parts book for your machine.

Fig. 6: Low Oil Circuit

________________________________________________________________ 16 CM235 Electrical

________________________________________________ Electrical Circuits Emergency Stop Circuit

Power to the motor control circuits is isolated by an emergency stop relay, ESR. Relay ESR is controlled by two machine stop switches, one located on the right side of the machine on the front of the control case and the other on the left rear corner of the machine. Pressing either switch interrupts power to the motor relay, stopping all machine functions.

Fig. 7: Emergency Stop Circuit

______________________________________________________________ A6474X380 REV 1 17

Electrical Circuits ________________________________________________ Emergency Stop Bypass Circuit

There is an emergency stop bypass function available from the radio remote that allows the operator to temporarily override an activated emergency stop button.

Pressing SHIFT and BYPASS on the radio remote activates the bypass function (see the Introduction-Operation Manual for Emergency Stop Bypass Operation Procedure). Activating the emergency stop bypass causes the control system to issue a digital output at X1-G that is sent to the emergency stop relay bridge rectifier, BR5, causing the emergency stop relay, ESR, to close. A digital output at X1-J will close the pump contactor. Once the pump has started, the trams drives will be energized, allowing the machine to be trammed.

Note: This feature is only for use under supported roof to temporarily bypass an accidentally pushed emergency stop switch.

________________________________________________________________ 18 CM235 Electrical

________________________________________________ Electrical Circuits Fig. 8: Emergency Stop Bypass Circuit

Neutral AC DC

______________________________________________________________ A6474X380 REV 1 19

Electrical Circuits ________________________________________________ Pump Control Circuit

When the circuit breaker CB2, and all emergency stop relays, ESR, are open, the operator can start the pump. When the pump start button is pushed, the control system sends a signal from location X1-J to the pump relay, F. A thermistor module monitors the pump RTD at inputs A16-M and A16-N. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming pump power supply, send a signal to the control system at inputs X4-T, X4-U, and X4-V. If the values received from the thermistor module or the current transducer exceed preset values, the control system will de-energize the relay, F, and shut down the pump motor.

________________________________________________________________ 20 CM235 Electrical

________________________________________________ Electrical Circuits Fig. 9: Pump Control Circuit

Neutral AC

______________________________________________________________ A6474X380 REV 1 21

Electrical Circuits ________________________________________________ Pump Power Circuit

When the normally open pump contactor, F, is energized, the contactor closes.

The pump contactor supplies 950VAC power to the pump motor through lines ZL21, ZL22, and ZL23. The pump is also equipped with an RTD, OL-11, to provide thermal overload protection. If the control system reads an overload condition, contactor F is opened and the pump is shut down.

Note: There are three pump thermal overloads, CT4, CT5, and CT6, located on each leg of incoming pump power. These thermal overloads protect the pump motor during emergency tramming operations with the remote tram.

________________________________________________________________ 22 CM235 Electrical

________________________________________________ Electrical Circuits Fig. 10: Pump Power Circuit

Ground AC

______________________________________________________________ A6474X380 REV 1 23

Electrical Circuits ________________________________________________ Cutter Control Circuit

When the main circuit breaker, CB1, and all emergency stop relays (ESR), are open, and the pump motor is running, the operator can start the cutter motors.

The control system issues a command at X1-L and X1-S to energize the left and right cutter motor relays, A and B, closing contacts A and B and starting the cutter motors.

A thermistor module monitors the cutter motor RTDs at inputs A16-C, A16-D, A16-E, and A16-F. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A16-C and A16-D for the left cutter motor and at inputs A16-E and A16-F for the right cutter motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relays, A and B, opening contacts A and B, and shutting down the left and right cutter motors.

________________________________________________________________ 24 CM235 Electrical

________________________________________________ Electrical Circuits Fig. 11: Cutter Control Circuit

Neutral AC

______________________________________________________________ A6474X380 REV 1 25

Electrical Circuits ________________________________________________ Cutter Power Circuit

When the pump motor is running and circuit breaker CB1 is open, the cutter motor contactors, A and B, are energized. 950VAC power is supplied to the left cutter motor through lines BBL11, BBL12, and BBL13 and to the right cutter motor through lines CCL11, CCL12, and CCL13. There are motor mates and thermistors on both motors that provide feedback to the control system on the operating state of the motors. In the event an operating perameter exceeds a preset value, the operating system can shut down the motors.

Fig. 12: Cutter Power Circuit

Ground AC

________________________________________________________________ 26 CM235 Electrical

________________________________________________ Electrical Circuits Conveyor Forward Control Circuit

When the pump motor is running, the operator can start the gathering head/ conveyor motors in either forward or reverse direction. When started in the forward direction, the control system issues a command at X1-N to energize the left and right conveyor forward motor relay, CF, closing contact CF and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-L. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A16-H and A16-J for the left conveyor motor and at inputs A16-K and A16-L for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CF, opening contact CF, and shutting down the left and right conveyor motors.

______________________________________________________________ A6474X380 REV 1 27

Electrical Circuits ________________________________________________ Fig. 13: Conveyor Forward Control Circuit

Neutral AC

________________________________________________________________ 28 CM235 Electrical

________________________________________________ Electrical Circuits Conveyor Forward Power Circuit

When CB1 and CB2 are closed, and the pump motor is running, the conveyor motors can be started. When the control circuit energizes the forward contactor, CF, the contactor closes. 950VAC power is supplied to the left conveyor motor through lines XL21, XL22, and XL23 and to the right motor through lines YL21, YL22, and YL23.

There are motor mates and thermistors on both motors that provide feedback to the control system on the operating state of the motors. In the event that an operating parameter exceeds a preset value, the operating system can shut down the motors.

Fig. 14: Conveyor Forward Power Circuit

Ground AC

______________________________________________________________ A6474X380 REV 1 29

Electrical Circuits ________________________________________________ Conveyor Reverse Control Circuit

When CB1 and CB2 are closed, and the pump motor is running, the operator can start the gathering head/conveyor motors in either forward or reverse direction. When started in the reverse direction, the control system issues a command at X1-P to energize the left and right conveyor reverse motor relay, CR, closing contact CR and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-L. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs A16-H and A16-J for the left conveyor motor and at inputs A16-K and A16-L for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CR, opening contact CR, and shutting down the left and right conveyor motors.

________________________________________________________________ 30 CM235 Electrical

________________________________________________ Electrical Circuits Fig. 15: Conveyor Reverse Control Circuit

Neutral AC

______________________________________________________________ A6474X380 REV 1 31

Electrical Circuits ________________________________________________ Conveyor Reverse Power Circuit

When CB1 and CB2 are closed and the pump motor is running, the conveyor motors can be started. When the control circuit energizes the reverse contactor, CR, the contactor closes. 950VAC power is supplied to the left conveyor motor through lines XL21, XL22, and XL23 and to the right motor through lines YL21, YL22, and YL23.

There are motor mates and thermistors on both motors that provide feedback to the control system on the operating state of the motors. In the event that an operating parameter exceeds a preset value, the operating system can shut down the motors.

Fig. 16: Conveyor Reverse Power Circuit

Ground

________________________________________________________________ 32 CM235 Electrical

________________________________________________ Electrical Circuits Scrubber Control Circuit

When CB1 and CB2 are closed and the pump motor is running, the scrubber motor can be started. When the control system issues a command at X1-M to energize the scrubber motor relay, contactor E, the contactor closes, starting the scrubber motor. When the pump motor is running, the operator can start the scrubber motor.

Fig. 17: Scrubber Control Circuit

Neutral AC

______________________________________________________________ A6474X380 REV 1 33

Electrical Circuits ________________________________________________ Scrubber Power Circuit

When CB1 and CB2 are closed, and the pump motor is running, the scrubber motor can be started. When the control circuit energizes the contactor, E, the contactor closes. 950VAC power is supplied to the scrubber motor through lines QL21, QL22, and QL23.

There are motor mates on the motor that provide feedback to the control system on the operating state of the motor. In the event that an operating parameter exceeds a preset value, the operating system can shut down the motor.

Fig. 18: Scrubber Power Circuit

Ground AC

________________________________________________________________ 34 CM235 Electrical

________________________________________________ Electrical Circuits Tram Control Circuit

The tram control circuit uses two three-phase, 950VAC tram motors that respond to change in frequency from the controls to tram in forward or reverse at varying speeds.

The machine control system provides tram control through CAN communication. The drives are equipped with software that has built in protection for the drive itself, allows communication with the control system, and displays information on the graphics display.

Tram speed is limited by the control system based on the following: Cutters not Running

Tramming Operation

Speed Limitation

Both remote control levers forward or reverse

Tram speed selected (1,2, or 3)

One lever forward, one reverse (split track tramming)

Both motors limited to 1st speed

One lever engaged (forward or reverse), one lever home (single track tramming)

Speed of engaged motor limited to 1st or 2nd speed

Cutter Running and Cutter Amps < Cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

FWD CLEANUP speed regardless of speed selected

Both remote control levers reverse

Tram speed selected (1,2, or 3) IF HIGH SPEED DISABLE mode = Yes, Speed shall be limited to 2nd Speed when Both Tram Levers are in the Reverse position.

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited to FWD CLEANUP speed regardless of speed selected Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

FWD CLEANUP speed regardless of speed selected

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

Cutters Running and Cutter Amps > Cutter in Face Parameter Tramming Operation

Speed Limitation

Both remote control levers forward

Speed limited by control system

Both remote control levers reverse

Tram speed selected (1,2, or 3) IF HIGH SPEED DISABLE mode = Yes, Speed shall be limited to 2nd Speed when Both Tram Levers are in the Reverse position.

One lever forward, one lever reverse (split track tramming)

Speed of motor going forward limited by control system Speed of motor going reverse limited to REV SLEW speed regardless of speed selected

One lever forward, one lever home (single track tramming)

Speed is limited by control system

One lever reverse, one lever home (single track tramming)

REV SLEW speed regardless of speed selected

______________________________________________________________ A6474X380 REV 1 35

Electrical Circuits ________________________________________________ Fig. 19: Tram Control Circuit

________________________________________________________________ 36 CM235 Electrical

________________________________________________ Electrical Circuits Tram Power Circuit

When CB1 and CB2 are closed, the pump motor is running, and the traction breaker, CBT, is open, the control system can operate the traction system.

950VAC power is fed to the VFD components, located in the tram case enclosure and out to the left and right tram motors. Power is supplied to the rectifier/ brake through lines HL1, HL2 and HL3, and then on to the left and right tram motors.

Fig. 20: Tram Power Circuit

AC DC Ground

______________________________________________________________ A6474X380 REV 1 37

Electrical Circuits ________________________________________________ Emergency Tram Control Circuit

In the event that the machine cannot be trammed using the remote control, an emergency tram pendant, connected to the machine through and umbilical cord, can be used to start the pump and perform tramming operations.

When the RADIO/E-TRAM mode of operation switch, located on the front of the operator’s case, is turned to the “E-TRAM” position, the emergency tram relay, ETR, is energized and the emergency tram and lighting contactors, ETR and HR, are closed. Pushing the “PUMP START ENABLE” and “PUMP ON” buttons on the tram pendant will energize the pump relay, F, closing contactors F, and starting the pump motor. Once the pump motor is started, the tram pendant can be used to tram the miner forward or in reverse.

Fig. 21: E-Tram Control Circuit

________________________________________________________________ 38 CM235 Electrical

________________________________________________ Electrical Circuits Solenoid Module Control Circuit

The PLC controls hydraulic functions through a solenoid module. When the operator engages a hydraulic function on the radio remote, the solenoid shifts, directing pilot oil to shift the main hydraulic valve.

Fig. 22: Solenoid Module Control Circuit

______________________________________________________________ A6474X380 REV 1 39

Operator’s Case _________________________________________________ Introduction

The operator’s case is located on the back right hand side of the machine. The rear wall of the operator’s case (Fig. 23) is accessed by opening the case cover.

Typically mounted on the rear wall are bridge rectifiers, methane monitor relay, and a transformer.

Fig. 23: Operator’s case

Operator’s Case - Rear Wall

The following components are mounted on the operator’s case rear wall (Fig. 24): BR1 - The bridge rectifier for the methane monitor relay, “BR1”, converts 120VAC to DC. BR2 (not pictured) - The bridge rectifier for the dust spray relay, “BR2”, converts 120VAC to DC. BR4 (not pictured) - The bridge rectifier for the scrubber relay, “BR4”, converts 120VAC to DC. BR5 - The bridge rectifier for the e-stop relay, “BR5”, converts 120VAC to DC. MMR - The methane monitor relay, “MMR”, interlocks with the cutter contactors. When “MMR” opens, the cutter contacts will open, stopping the cutters when the methane monitoring system determines there is high methane concentrations.

XFMR - Transformer “XFMR” converts the incoming 950V to 120VAC and 12 VAC. HLR - “HLR” is the contactor for the machine headlights.

OE - “OE” is the relay controlling the power center trip.

CB1 - Circuit breaker “CB1” isolates the entire machine from power supplied via the trailing cable. “CB1” is a 600 amp breaker set to instantaneously trip at 1250 amps.

CB2 - Circuit breaker “CB2” isolates the gathering head, scrubber fan and pump motor circuits. “CB2” is a 600 amp circuit breaker set to instantaneously trip at 800 amps.

________________________________________________________________ 40 CM235 Electrical

__________________________________________________Operator’s Case Fig. 24: Operator’s Case - Rear Wall

HLR

MMR

ESR BR1 OE

CB1 (on inside bottom of case)

BR5

XMFR

CB2 (on inside bottom of case)

______________________________________________________________ A6474X380 REV 1 41

Main Case ______________________________________________________ Introduction

The main case is located on the left hand side of the machine. Typically mounted on the rear wall are cutter and pump motor contactors, cutter and pump motor mates, and a thermal overload for the pump motor.

Main Case - Rear Wall

The rear wall of the main case (Fig. 25) is accessed by opening the case cover and then opening the swing panel. The following components are mounted on the main case rear wall: A - Contactor for the left cutter motor B - Contactor for the right cutter motor F - Contactor for the pump motor MMA - Left cutter motor mate MMB - Right cutter motor mate MMF - Pump motor mate OL11 - Thermal overload for the pump motor OL11

Fig. 25: Main Case - Rear Wall

MMA

MMB

A

B

F

MMF

________________________________________________________________ 42 CM235 Electrical

_______________________________________________________Main Case Main Case - Swing Panel (front)

The following components are mounted in the main case on the front side of the swing panel (Fig. 26): CF - Forward contactor for the gathering head motors (left and right) CR - Reverse contactor for the gathering head motors (left and right) E (not pictured) - Scrubber motor contactor MMC - Left gathering head motor mate MMD - Right gathering head motor mate MME (not pictured) - Scrubber motor mate THERMISTOR MODULE - The thermistor module provides receives inputs from the motors and sends information to the machine control system.

Fig. 26: Main Case - Swing panel

E (not pictured)

MMC

MMD

CF

CR

MME (not pictured)

THERMISTOR MODULE

______________________________________________________________ A6474X380 REV 1 43

Main Case ______________________________________________________ Main Case - Swing Panel (back)

The following components are mounted on the back of the controller swing panel (Fig. 27): Power supply - Power supply, with battery back-up, for the machine controller.

Machine controller - Houses the control system software.

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

Fig. 27: Main Case - Swing Panel (rear)

Machine controller

ETR

Power supply

________________________________________________________________ 44 CM235 Electrical

______________________________________________________ Tram Case Introduction

The tram case (Fig. 28) is typically located on the right hand side of the machine, and is accessed by opening the case cover. Typically mounted inside are tram motor drives, tram circuit breaker, a bridge rectifier, intrinsically safe barrier, brake rectifier and brake resistor.

Tram Case

The following components are mounted on the tram case rear wall (Fig. 28): LD - Left traction drive “LD” controls the left traction motor.

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

CBT - Tram breaker “CBT” is a 400A breaker for the tram drives.

TPI - The tram pendant interface, “TPI”, is the communication interface between the tram pendant and the control system when the “MINER MODE” selector switch is in the “E-TRAM” position.

BR7 - The bridge rectifier for the e-TRAM relay, “BR7”, converts 120VAC to DC. ISB - “ISB” is an intrinsically safe (IS) barrier that provides an approved IS circuit between the emergency tram pendant and the control system.

R1, R2 - “R1” and “R2” are braking resistors on the brake rectifier.

L1, L2, L3 - “L1”, “L2” and “L3” are 3-phase AC power connections from the tram breaker to the brake rectifier.

P1, N1 - “P1” and “N1” are brake rectifier connections for the left AC drive motor.

P2, N2 - “P2” and “N2” are brake rectifier connections for the right AC drive motor.

______________________________________________________________ A6474X380 REV 1 45

Tram Case ______________________________________________________ Fig. 28: Tram Case CBT

L1

L2

L3

P1 P2 N1 N2

BR7 ISB TPI R1

R2 LD RD

________________________________________________________________ 46 CM235 Electrical

A6474X381 February 2012

Operation and Maintenance Manual CM235 Continuous Miner A6474X381 (Hydraulic)

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 Introduction........................................................................................ 6 Cylinder locations .............................................................................. 7 Component locations......................................................................... 8 Main control valve ............................................................................. 10 Hydraulic schematics ........................................................................ 11 Hydraulic pump ......................................................................... 11 Main flow/primary pressure ....................................................... 12 Pilot pressure ............................................................................ 13 Cutter head ............................................................................... 14 Conveyor raise/lower ................................................................ 17 Conveyor swing......................................................................... 19 Gathering head ......................................................................... 21 Stabilizer shoe........................................................................... 24 Conveyor chain take-up ............................................................ 26 Dust sprays ............................................................................... 27 Water schematics.............................................................................. 28 Water component location ........................................................ 29 Water supply circuit................................................................... 30 Deluge water fire circuit............................................................. 31 Scrubber sprays and sump dump circuit................................... 32 Tram trickle circuit ..................................................................... 33 Dust-cooling left and right hand chassis ................................... 34 Hydraulic pump ................................................................................. 35 Hydraulic pump motor ....................................................................... 39 Adjustment procedures ..................................................................... 44 Troubleshooting................................................................................. 51

________________________________________________________________ A6474X381

REV 1

Safety instructions _______________________________________________ Safety Precautions

!

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

IMPORTANT

!

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

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

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

IMPORTANT

The two inch locking ball valve between the pump and main control valve must be locked open in normal operation.

!

DANGER

Never run the conveyor without the needle valve closed. Injury or death may occur.

!

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

!

DANGER

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

!

DANGER

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

!

WARNING

!

WARNING Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

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

IMPORTANT

Always use the proper tools when adjusting valve cartridges.

IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

________________________________________________________________ 4 CM235 Hydraulics

______________________________________________ Safety instructions IMPORTANT

!

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

IMPORTANT

!

Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Before making any further adjustments, verify that the hydraulic oil is at operating temperature.

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

IMPORTANT

The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section.

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

IMPORTANT

Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

!

WARNING Keep body parts clear of machine while in raised position or serious injury could result.

!

WARNING Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An certified electrician must supervise and inspect all work performed.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

______________________________________________________________ A6474X381 REV 1 5

Hydraulic _______________________________________________________ Introduction

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

Fig. 1 gives an overview of hydraulic cylinders located on the 35M3L Continuous Miner. Fig. 2 shows the location of other hydraulic components.

Schematics

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions. The schematics in this section are general; always refer to the hydraulic schematic in your parts manual supplied with your machine.

Hydraulic Maintenance

In order for a hydraulic system to function correctly, it must be properly maintained. Maintenance of the hydraulic system includes: 1. maintaining atmospheric pressure in the tank by keeping the breather clean and free of obstructions; 2. maintaining a sufficient oil level in the tank; 3. maintaining tight, leak-proof pump suction lines to prohibit air being pumped through the system; and 4. changing filters and fluids at prescribed intervals.

For complete maintenance procedures, see the Maintenance Manual.

!

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

________________________________________________________________ 6 CM235 Hydraulics

_______________________________________________________Hydraulic Fig. 1: Cylinder locations

1

1

2

7

2 1

3

4

4

3

3

4

5 5

6

1. Cutter head raise cylinder 2. Gathering head raise cylinder 3. Conveyor lift cylinder

6

6

4. Stabilizer shoe cylinder 5. Conveyor swing cylinder 6. Conveyor chain take-up cylinder

______________________________________________________________ A6474X381 REV 1 7

Hydraulic _______________________________________________________ Fig. 2: Hydraulic component location

4 1

9

2

7

1

6

3 10 8 11 5

12

1.

2.

3.

4.

5.

6.

Breather Tank magnet Oil level switch Gathering head float valve Conveyor chain take-up valve Relief valve, pilot pressure

7. Pilot pressure filter 8. Main pressure gauge 9. Hydraulic pump 10. Valve bank 11. Anti-chatter/maintenance valve 12. Dust cooling solenoid valve

________________________________________________________________ 8 CM235 Hydraulics

_______________________________________________________Hydraulic Main Control Valve

The Main Control Valve (MCV) (Fig. 3), typically located on the right side of the machine, consists of a series of directional control valves assembled in a row.

Typically, there are (5) five working sections. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy. Control may be initiated manually or electrically (through the solenoid pilot valve).

If the valve sections are separated for any reason, make sure that all reassembled parts are in their proper location and that all mating surfaces are free of burrs and foreign items (paint, dirt, etc.). Assembly stud nuts or screws should be tightened to specified torques.

IMPORTANT

!

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

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

______________________________________________________________ A6474X381 REV 1 9

Hydraulic _______________________________________________________ Fig. 3: Main control valve

2

1

3

8

9

10

11

12 7

6

4

1.

2.

3.

4.

Main inlet relief Pressure supply Tank return “A” port relief (typical)

5.

6.

7.

8.

“B” port relief (typical) “B” pressure solenoid (5 places) “A” pressure solenoid (5 places) Stabilizer shoe section

5

9. Conveyor swing section 10. Conveyor raise section 11. Gathering head section 12. Cutter raise section

________________________________________________________________ 10 CM235 Hydraulics

_______________________________________________________Hydraulic Hydraulic Pump Assembly

Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 4). Always be sure the shut-off valve (if equipped) is turned to open and the locking device is replaced before starting the machine.

Hydraulic Pump On Circuit

This pump utilizes two working sections: main flow and pilot flow. Oil is supplied from the oil reservoir through a suction line to the pump inlet ports. The main flow is monitored by a pressure gauge and moves through a bypass filter set at 40 psi and before entering the main control valve. After leaving the pump, the pilot flow enters a bypass filter. Before continuing on to a nonbypassing filter and the conveyor take-up circuit, scrubber and dust spray circuit, gathering head circuit, tram breaker and main control valve, pilot oil passes through a relief valve set at 500 psi (34 bar).

IMPORTANT

The two inch locking ball valve must be locked open in normal operation.

Fig. 4: Hydraulic pump circuit

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 11

Hydraulic _______________________________________________________ Main Flow Primary Pressure Circuit

The main flow-primary pressure circuit is powered by the hydraulic pump.

From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 3,000 psi (204 bar). The main control valve operates all cylinder functions.

The auxiliary pressure circuit is powered by the hydraulic pump. Oil from both the primary and auxiliary circuits exits the main control valve and passes to the oil reservoir.

Fig. 5: Main flow-primary pressure circuit (pump running)

Pressure Return Suction

________________________________________________________________ 12 CM235 Hydraulics

_______________________________________________________Hydraulic Pilot Pressure Circuit

The pilot hydraulic section is a closed-center system powered by the hydraulic pump. It supplies oil flow to the following: 1. hydraulic tension conveyor chain take-up 2. gathering head float circuit, and 3. all solenoid valves, which control the scrubber and dust sprays, tram breaker, gathering head circuit and all main control valve functions.

From the pump, oil flows through a 10 micron non-bypassing filter and a pressure reducing valve set at 500 psi (34 bar) before being distributed to the conveyor take-up, scrubber and dust sprays, tram breaker and main control valve. Pilot pressure oil also flows on to the solenoid valves and the gathering head float circuit.

Fig. 6: Pilot pressure circuit (pump running)

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 13

Hydraulic _______________________________________________________ !

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

Cutter Head Cylinder

Oil is supplied from the hydraulic pump through a 10-micron bypassing pressure filter to the cutter head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the cutter head cylinder circuit.

Circuit Operation - Raise

Reference Fig. 8: To manually raise the cutter head (extend cylinders), pull the valve’s handle. Remote operation is achieved by energizing the cutter head raise solenoid (CHU). Oil goes to port “P2” and continues to the extend port of the cylinders, free flowing through the check valve of the load holding cartridge to extend the cylinders. The cutter head raise circuit is protected by a port relief that is set at 2,800 psi (193 bar).

Circuit Operation - Lower

Reference Fig. 9: To manually lower the cutter head (retract cylinders), push the valve’s handle. Remote operation is achieved by energizing the cutter head lower (CHD) solenoid. Oil goes to the retract port of the cylinders and also pilots open the load holding cartridge, allowing oil to exit through the extend ports on the cylinders. The extend port oil continues to the anti-chatter/maintenance valve block, where it passes through a counterbalance valve, which is set to relieve at 1,200 psi (83 bar), then through the main control valve and into the oil tank.

!

DANGER

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

!

DANGER

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

!

WARNING

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

________________________________________________________________ 14 CM235 Hydraulics

_______________________________________________________Hydraulic Fig. 8: Cutter head raise circuit

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 15

Hydraulic _______________________________________________________ Fig. 9: Cutter head lower circuit

Pressure Return Suction

________________________________________________________________ 16 CM235 Hydraulics

_______________________________________________________Hydraulic conveyor Raise/Lower Circuit

Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter to the conveyor raise/lower working section of the main valve control. By manual or remote solenoid control, the valve spool allows oil to enter the conveyor raise/lower cylinder circuit

Circuit Operation - Raise (extend)

Reference Fig. 10: To manually raise the conveyor (extend the cylinders), pull the valve’s handle. Remote operation is achieved by energizing the conveyor raise (CU) solenoid. Oil free flows through pilot operated check valves to the extend port of the cylinders. The conveyor raise circuit is protected by a port relief that is set at 1,800 psi (124 bar).

Circuit Operation Lower (retract)

Reference Fig. 11: To manually lower the conveyor (retract the cylinders), push the valve’s handle. Remote operation is achieved by energizing the conveyor lower (CD) solenoid. Oil is directed to the pilot port on the pilot operated check valve on the cylinders. This “pilots” the check valve open and allows oil to exit the cylinders through the main control valve and return to tank. The conveyor lower circuit is protected by a port relief that is set at 1,400 psi (97 bar).

Oil Tank Fill

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

Fig. 10: Conveyor raise

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 17

Hydraulic _______________________________________________________ Fig. 11: Conveyor lower

Pressure Return Suction

________________________________________________________________ 18 CM235 Hydraulics

_______________________________________________________Hydraulic Conveyor Swing Cylinder

Oil is supplied by hydraulic pump to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions.

Circuit Operation Right (extend)

Reference Fig. 12: To manually move the conveyor to the right (extend the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the conveyor swing left (CSL) solenoid. Oil free flows to the extend port of the cylinder. The conveyor swing right circuit is protected by a port relief that is set at 1,800 psi (25 bar).

Circuit Operation Left (retract)

Reference Fig. 13: To manually move the conveyor to the left (retract the cylinder, push the valve’s handle. Remote operation is achieved by energizing the conveyor swing right (CSR) solenoid. Oil free flows to the retract port of the cylinder. The conveyor swing left circuit is protected by a port relief that is set at 1,800 psi (125 bar).

Fig. 12: Conveyor swing cylinder circuit - left

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 19

Hydraulic _______________________________________________________ Fig. 13: Conveyor swing cylinder circuit - right

Pressure Return Suction

________________________________________________________________ 20 CM235 Hydraulics

_______________________________________________________Hydraulic Gathering Head Raise/ Hold/Float/Lower Circuit

Circuit Operation Raise (extend)

Circuit Operation Lower (retract)

Oil is supplied by the hydraulic pump to the gathering head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the gathering head raise circuit.

Reference Fig. 14: To manually raise the gathering head pan (extend the cylinder), push the valve’s handle. Remote operation is achieved by energizing the gathering head up solenoid (GHU). Oil free flows through the check valve in counterbalance valve designated “VR” in the gathering head float valve block and is directed to both cylinder extend ports. At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the valve (or de-energizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 1,700 psi (117 bar).

Reference Fig. 15: To put the gathering head pan in the lower mode, pull the valve’s handle. Remote operation is achieved by energizing the gathering head down (GHD) solenoid. This vents the port labeled “V” on the gathering head float valve block to tank and allows control of the gathering head lower via the valves in the block. The counterbalance valve “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve.

Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine and moves the machine’s center of gravity forward when mining. The gathering head lower circuit is protected by a port relief that is set at 1,700 psi (117 bar).

The counterbalance valve that is designated “CR” is set to relieve at 1,800 psi (124 bar). This setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head.

The pilot pressure supply for the gathering head float comes from the hydraulic pump through a 2 micron non-bypass filter and a pressure reducing valve, to the pressure manifold and the gathering head float valve. The pilot pump provides make up oil for the gathering head cylinders. When the pan goes over uneven terrain, it may raise quickly and extend the gathering head cylinders at a rapid rate. This temporary condition can create high demand for pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are engaged. It is, therefore, possible to experience a momentary loss of radio control of the machine.

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

______________________________________________________________ A6474X381 REV 1 21

Hydraulic _______________________________________________________ Fig. 14: Gathering head raise circuit

Pressure Return Suction

________________________________________________________________ 22 CM235 Hydraulics

_______________________________________________________Hydraulic Fig. 15: Gathering head lower circuit

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 23

Hydraulic _______________________________________________________ Stabilizer Shoe Cylinders

Oil is supplied by the hydraulic pump to the stabilizer shoe working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the stabilizer shoe circuit.

Circuit Operation - Raise (retract)

Reference Fig. 16: To manually raise the stabilizer shoe (retract the cylinder), pull the valve’s handle. Oil free flows to the retracted port of the cylinder. The stabilizer raise circuit is protected by a port relief that is set at 1,150 psi (79 bar).

Circuit Operation - Lower (extend)

Reference Fig. 17: To manually lower the stabilizer shoe (extend the cylinders), push the valve’s handle.

Fig. 16: Stabilizer shoe circuit - raise (retract)

Pressure Return Suction

________________________________________________________________ 24 CM235 Hydraulics

_______________________________________________________Hydraulic Fig. 17: Stabilizer shoe circuit - lower (extend)

Pressure Return Suction

______________________________________________________________ A6474X381 REV 1 25

Hydraulic _______________________________________________________ Conveyor Chain TakeUp Circuit (optional)

Reference Fig. 18: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil provides hydraulic power to the hydraulic tension conveyor chain take-up and to the four pilot pressure circuits.

The oil continues to the conveyor chain take-up valve where it passes thru a free flow check valve cartridge out to (2) two conveyor chain take-up cylinder assemblies. The conveyor chain take-up valve consist of a check valve to hold pressure in the circuit, a pressure reducing/relieving cartridge to reduce the pilot pressure to 200 psi for conveyor chain tension and relieves pressure build up above 200 psi. A needle valve cartridge relieves pressure from the circuit for maintenance.

!

DANGER

Never run the conveyor without the needle valve closed. Injury or death may occur.

Fig. 18: Conveyor chain take-up circuit

Pressure Return Suction

________________________________________________________________ 26 CM235 Hydraulics

Hydraulic _______________________________________________________ Dust Sprays Hydraulic Circuit

Reference Fig. 20: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil passes through a 2 micron bypassing filter and a pressure reducing valve set at 500 psi (34 bar). The oil continues to a solenoid manifold which has a normally closed cartridge which is used for the dust spray system .

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

When the solenoid cell is de-energized, the spool in the hydraulic pilot valve shifts back to its neutral position, venting the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

Fig. 20: Dust sprays hydraulic circuit

Pump running

Pump running, pilot operated water valve on

Pressure Return Suction

________________________________________________________________ 27 CM235 Hydraulics

__________________________________________________________ Water Introduction

A water supply to the continuous miner is required for the following purposes: 1. cooling water for all motors, control case and the VFD case 2. spray water for dust suppression The water supplied by the mine must meet the following requirements: 1. minimum flow rate of 25 gpm for cooling 2. total flow rate: based on customer dust plan 3. minimum pressure of 250 psi (dynamic), 500 psi maximum

Schematics

The water system circuits described below are for a typical CM235 miner. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X381 REV 1 28

__________________________________________________________ Water Fig. 22: Dust-cooling component locations 1

1

1

2 2

3

4

5

8,9

8,9 6 7

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cutter head front spray manifold Cutter head side spray manifold Right hand chassis side spray manifold Relief valve 0-400 psi pressure gauges (2) Atmospheric relief Ball valve 2-unit pressure manifold 2-way pilot operated valve

______________________________________________________________ A6474X381 REV 1 29

Water___________________________________________________________ Water Supply Circuit

Mine water is supplied to the miner from a connection located on the right side of the miner (typical). The water supply to the miner is controlled through a 2 position, manually-operated ball valve.

Water then flows through a water filter and a flow meter to a pilot operated valve for dust sprays. A gauge measures the pressure of the mine water. Water is then directed to the sump dump, left and right fire sprays, scrubber sprays, tram trickle, dust sprays, left and right hand chassis, and cutter head spray cooling circuits.

Fig. 21: Water supply circuit

________________________________________________________________ 30 CM235 Hydraulics

__________________________________________________________ Water Deluge Water Fire Circuit

The deluge fire suppression circuit (Fig. 22) can be operated by manual or remote solenoid control (see Electrical section in this manual). When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to travel to a 2-way, 2position water valve. The hydraulic fluid shifts the spool, allowing the water to pass through it to the deluge fire spray manifolds. For the hydraulic portion of this circuit, see the Hydraulic section of this chapter. The water valve has a detent spool, which keeps the valve open. The 2-way, 2-position valve can be operated manually and must be manually reset to reset the fire suppression circuit.

In addition, there are two ball valves used to manually operate the fire suppression circuit typically located on the right hand side of the machine. The valves must be manually turned off to reset the fire suppression system.

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

Fig. 22: Deluge water fire circuit

______________________________________________________________ A6474X381 REV 1 31

Water___________________________________________________________ Scrubber Sprays and Sump Dump Circuit

The scrubber spray circuit (Fig. 23) can be operated by manual or remote solenoid control (see Electrical section in this manual). When the scrubber spray solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the scrubber spray circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this manual.

The scrubber sprays automatically turn on when the scrubber motor starts. The valve can also be actuated by turning the manual valve handle.

The final portion of this circuit is used to empty the excess water from the scrubber sump box (slurry water). Located in the bottom of the scrubber sump box are a stir spray nozzle, a flow control valve, a jet pump, and a water suction strainer. The flow control valve is used to control the amount of water stirring, which keeps the water strainer from becoming clogged and keeps the jet pump clean to discharge the slurry water. The pressure regulator valve and gauge are used to operate this circuit, which is normally set at 75 psi.

Fig. 23: Scrubber sprays and sump dump circuit

________________________________________________________________ 32 CM235 Hydraulics

__________________________________________________________ Water Tram Trickle Circuit

The tram trickle circuit (Fig. 24) can be operated by manual or remote solenoid control (see Electrical section in this manual). When the solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the tram trickle circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this manual.

The tram trickle automatically turns on when the scrubber motor starts. There is a flow control valve that controls the tram trickle.

Fig. 24: Tram trickle circuit

______________________________________________________________ A6474X381 REV 1 33

Water___________________________________________________________ Dust Cooling Left and Right Hand Chassis Circuit

The dust-cooling circuit can be operated by manual or remote solenoid control (see Electrical section in this manual). When the dust-cooling solenoid coil is energized, it shifts a spool, allowing hydraulic oil to flow to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts a spool, allowing water to pass though it to the dust cooling circuit. For the hydraulic portion of this circuit, see the Hydraulic section of this manual.

The dust-cooling valve can also be actuated by turning the manual valve handle.

The dust-cooling left and right hand chassis circuit (Fig. 25) continues from the dust cooling water supply circuit. From the dust-cooling pressure manifold, the water flows through the pump motor, the tram motor, the gathering head motor, and the cutter head motor. Water branches off of the gathering head motor to the pan sprays and from the cutter head motor to the head spray, throat spray, side spray, and relief valve.

The throat spray manifold helps keep dust from flowing up the conveyor as the coal is being transported. There is an atmospheric relief located before the (optional) dust spray direction (left or right) diverter valve in case pressure builds up from clogged spray nozzles.

The dust-cooling circuit shown in Fig. 25 is typical for a miner containing straight ahead spray manifolds and side sprays. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in your parts book for your machine.

Fig. 25: Dust cooling left and right hand chassis circuit

________________________________________________________________ 34 CM235 Hydraulics

_________________________________________________ Hydraulic Pump Introduction

The following procedure is for the removal and installation of the hydraulic pump.

Tool Set

Basic Tool Set

Safety

When removing or installing the hydraulic pump, observe the following safety precautions:

Blocking

!

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

!

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

______________________________________________________________ A6474X381 REV 1 35

Hydraulic Pump __________________________________________________ Hydraulic Pump Removal

To remove the hydraulic pump (Fig. 204): 1. Lower the conveyor tail section until it is level with the floor.

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

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

4. Locate the rub rail directly behind the tram case on the operator’s side of the miner. Remove the two rub rail pins that secure the rub rail to the two rub rail sections adjacent to it and remove the rub rail.

5. Swing the operator’s case outward and locate the hydraulic pump and motor assembly.

6. Using the adjustable wrench, disconnect the inlet hose from the pump. Plug the hose end to keep it clean.

7. Using the adjustable wrench, disconnect the pilot and valve hoses from the pump fittings. Plug the hose ends to keep them clean.

Fig. 204: Hydraulic pump

Rub rail Operator’s case

________________________________________________________________ 36 CM235 Hydraulics

_________________________________________________ Hydraulic Pump Fig. 205: Hydraulic pump installation

Motor

Pump

Lockwasher Hex head capscrew

______________________________________________________________ A6474X381 REV 1 37

Hydraulic Pump __________________________________________________ Hydraulic Pump Installation

To install the hydraulic pump: 1. Slide the pump assembly into the pump motor (Fig. 205).

2. Insert and tighten, hex head capscrews and lockwashers to secure the pump assembly to the motor.

3. Insert the hydraulic hose fittings into the pump assembly and tighten.

4. Attach and tighten the exit pilot and valve hoses to the pump fittings.

5. Attach the inlet hose to the pump.

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

7. Check the hydraulic fluid level.

8. Jog pump motor on and off a few times to prime the pump before starting.

________________________________________________________________ 38 CM235 Hydraulics

___________________________________________ Hydraulic Pump Motor Introduction

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

Tool Set

Basic Tool Set

Safety

When removing or installing the hydraulic pump motor, observe the following safety precautions:

!

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

!

WARNING The hydraulic pump motor is extremely heavy. Prepare to support its weight before removing it from the tractor frame.

______________________________________________________________ A6474X381 REV 1 39

Hydraulic Pump Motor _____________________________________________ Hydraulic Pump Motor Removal

To remove the hydraulic pump motor (Fig. 206): 1. Lower the conveyor tail section it is level with the floor.

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

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

4. Remove the hydraulic pump (see Hydraulic pump removal procedure in this chapter).

5. Remove the four (4) 3/4 X 1 1/2” hex head capscrews that secure the motor to the pump stand.

6. Remove the two (2) 1/2 X 1 1/2” hex head capscrews and lockwashers that secure the pump stand to the tractor frame and remove the pump stand.

Fig. 206: Hydraulic pump stand removal

Hex head capscrew

Motor

Pump stand Lockwashers Hex head capscrew

________________________________________________________________ 40 CM235 Hydraulics

___________________________________________ Hydraulic Pump Motor 7. Tag, disconnect, and cap the two cooling water hoses from the cooling water fittings on the pump motor.

8. Remove the cooling water fittings from the top left and right surface of the pump motor and store in a safe place.

9. Remove the cover and its o-ring from the motor’s junction box by removing four hex head capscrews and lockwashers.

10. Locate the three taped power connections inside the junction box.

11. Strip off the three layers of tape covering each of the three lug connections inside the junction box.

12. Tag the three lugs to facilitate reconnection during motor installation.

13. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.

14. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

15. Remove the clamp and slide the stuffing box out of the junction box.

The power cable should be completely disconnected from the motor.

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

17. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

18. Carefully slide the hydraulic pump motor out of the tractor frame.

______________________________________________________________ A6474X381 REV 1 41

Hydraulic Pump Motor _____________________________________________ Hydraulic Pump Motor Installation

To install the hydraulic pump motor (Fig. 202): 1. Slide the hydraulic pump motor into position in the tractor frame.

2. Remove the four hex head capscrews and lockwashers that secure the junction box cover and remove the cover and its o-ring.

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

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

5. Tighten the two socket head capscrews to secure the clamp to the junction box.

6. Inside the junction box, locate the motor’s lug connections. Match the motor lug connections to the corresponding power cable lugs (refer to the wiring diagram supplied in your parts manual).

7. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, through the power cable lug, through a flat washer, and through a lockwasher. Secure the capscrew with a hex nut. Repeat this step for the other two lugged connections.

8. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape and finally a layer of glass tape.

9. Replace the junction box o-ring and cover.

10. Insert the four hex head capscrews and lockwashers to secure the junction box cover and tighten.

11. Insert the two motor cooling water fittings into the pump motor cooling water ports.

12. Attach the two motor cooling water hoses to the fittings.

13. Position the pump stand against the motor and attach to the motor with four (4) 3/4 X 1 1/2” hex head capscrews.

14. Insert and tighten the two (2) 1/2 X 1 1/2” hex head capscrews and lockwashers to secure the pump stand to the tractor frame.

15. Install the hydraulic pump (see hydraulic pump installation procedure in this chapter).

16. Remove the hex head capscrew, flat washer, lockwasher, and hex head nut that secures the three power cable lugs to the three motor lugs.

________________________________________________________________ 42 CM235 Hydraulics

___________________________________________ Hydraulic Pump Motor 17. Remove the two socket head capscrews and lockwashers that secure the stuffing box’s half-moon clamp to the junction box.

18. Remove the clamp and slide the stuffing box out of the junction box. The power cable should be completely disconnected from the motor.

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

20. To protect the motor’s electrical connections, replace the motor junction box cover and secure it using four hex head capscrews and lockwashers.

21. Carefully slide the scrubber fan/motor out of the tractor frame.

______________________________________________________________ A6474X381 REV 1 43

Adjustment procedures ___________________________________________ Introduction

1. Always refer to the hydraulic schematic in the parts book supplied with your miner.

2. Most relief valves are set to factory specifications and should require no further adjustment.

3. Generally speaking, when adjusting relief valves, turning the adjusting screw in (clockwise) will increase the pressure setting.

4. If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will create flow and prove the potential for pressure.

!

WARNING Use extreme caution when performing test procedures and making adjustments.

Unless noted in the procedures, all controls are to be in the neutral position.

Gauges

The miner is equipped with an isolator hydraulic pressure gauge to aid in setting relief pressures. The gauge measures the following pressures: 1. main pressure (all functions of the MCV) 2. pilot pressure 3. conveyor chain take-up pressure 4. anti-chatter/maintenance (shear down) pressure 5. gathering head float/relief pressure 6. cylinder load pressure

Setting Relief Valves

Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted. To properly adjust a relief valve, the circuit must be “dead-headed”.

Setting Hydraulic Pressures

The adjustment procedure should start with the pilot pressure circuit. This system will build pressure as soon as the pump is started. The main relief valve on the main control valve (MCV) and high speed cutter head raise control valve, as well as the pilot pressure relief and brake cooling circuit pressure reducing valve, should all be adjusted to their lowest setting prior to initial start up and adjustment. Reference circuit descriptions, abbreviations, and terms in the Hydraulic Components section of this chapter.

________________________________________________________________ 44 CM235 Hydraulics

___________________________________________ Adjustment procedures IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load Holding Valve Adjustment IMPORTANT

The load holding valve is factory preset and should not be field adjusted.

Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Adjustment procedure should start with the pilot/auxiliary pressure circuit, which will build pressure as soon as the pump is started.

Pilot/Auxiliary Pump Circuit Relief Valve Adjustments !

The following procedure is for start up of new and rebuilt machines:

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

1. Pilot pressure circuit 1: Loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit. Remove the hose and cap or plug the outlet port of the relief valve. Take care to prevent dirt from entering the system.

2. Pilot pressure circuit 2: Loosen the nut on the relief cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.

3. Conveyor chain take-up circuit: Open the needle valve by turning the knob counter-clockwise, opening flow to tank.

4. Start the pump motor (see startup procedure in this manual) and adjust the pilot pressure 2 relief valve. a. Turn the cartridge in until the pressure reading is 3,000 psi (207 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut. c.

Stop the pump motor and reconnect the hose to the pilot pressure 1 relief outlet.

______________________________________________________________ A6474X381 REV 1 45

Adjustment procedures ___________________________________________

IMPORTANT Before making any further adjustments, verify that the hydraulic oil is at operating

temperature.

5. Start the pump motor (See startup procedure in this manual) and adjust the pilot pressure 2 relief valve. a. Turn the cartridge in until the pressure reading is 500 psi (34 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.

6. Adjust the conveyor chain take-up pressure reducing valve (optional). a. Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 200 psi (14 bar). b. If adjustment is required, remove the hex socket head plug to adjust the inner spool. Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. c.

Replace the hex socket head plug.

7. Adjust the sequence valve for the Accumulator/Brake circuit. a. Turn the cartridge clockwise until the pressure reading on the accumulator circuit reads 2,500 psi (172 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.

8. Re-adjust the pilot pressure 2 relief valve, if necessary, to 500 psi (34 bar).

________________________________________________________________ 46 CM235 Hydraulics

___________________________________________ Adjustment procedures Pilot Relief Valve Replacement Conveyor Chain Take-Up Valve Replacement:

Set the pilot relief to 500 psi (34 bar), per step 3 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).

Set the pilot relief to 200 psi (14 bar), per step 4 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure the conveyor chain takeup needle valve is closed (turn clockwise to close).

Main Control Valve Working Each valve bank section, with the exception of the gathering head and the Port Relief Adjustment stabilizer shoe, has two (2) working port reliefs (Fig 25). When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

Fig. 25: Main control valve Port reliefs

“A” port relief

!

“B” port relief

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

IMPORTANT The main relief is set higher than the port reliefs and will only relieve if a spike occurs in

the system or if the port relief does not function properly. This provides protection of the main pump section.

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

IMPORTANT Reference the Hydraulic section in this chapter for individual circuit information. Al-

ways refer to the hydraulic schematic in your parts manual for your miner.

Always allow cylinder Two people functions are required to bottom to adjust out (stop pressure moving) settings. before adjusting One person anywill pressure. make the Pressure adjustWARNING ! ! WARNING ments adjustments while the will second only be person accurate must when remain the at cylinder the machine is in this stop condition. at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

______________________________________________________________ A6474X381 REV 1 47

Adjustment procedures ___________________________________________ Main Control Valve Adjustment

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). To set the main system relief, it is recommended that the stabilizer shoe cylinder be extended until it is dead headed. Since the stabilizer section of the main control valve is equipped with a port relief in the extend circuit, the port relief must be temporarily adjusted to a pressure setting higher than the main relief. This procedure is described in detail below.

1. During the adjustment procedure, pump output pressure and flow will be relieved past either the main relief or the stabilizer extend port relief which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

2. It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted.

Main Relief Adjustment

1. Remove the protective cap on the rear port relief of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.

2. Loosen the nut on the main relief cartridge. Turn the main relief adjusting screw two turns clockwise.

3. Start the pump (see Startup procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

4. With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 3,000 psi (207 bar) is obtained.

!

WARNING Keep body parts clear of machine while in raised position or serious injury could result.

5

With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place.

Check the pressure setting to verify that the screw was not moved while tightening the nut.

6. Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).

7. Replace the protective cap.

________________________________________________________________ 48 CM235 Hydraulics

___________________________________________ Adjustment procedures Port Relief Valve Adjustment If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief (Fig 26) for that function must be adjusted. The port reliefs shown are typical for each section of the valve. The adjustment procedure for each port relief is the same and is: 1. Remove the protective cap on the port relief and loosen the nut on the adjusting screw.

2. Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.

3. Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Fig. 26: Main control valve - port reliefs

“A” port relief

“B” port relief

Stabilizer Conveyor swing Conveyor raise Gathering head

Cutter raise

______________________________________________________________ A6474X381 REV 1 49

Adjustment procedures ___________________________________________ Pressure readings 1. Cutter Head

1. Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi (193 bar).

2. Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi (193 bar).

2. Conveyor Raise/Lower

1. Activate the conveyor raise circuit to fully raise the conveyor. The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor lower circuit to fully lower the conveyor. The main control valve pressure gauge should read 1,400 psi (96 bar).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

3. Conveyor Swing

1. Activate the conveyor swing left circuit to fully swing the conveyor to the left.

The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi (124 bar).

4. Gathering Head

1. Activate the gathering head raise circuit to fully raise the gathering head.

The main control valve pressure gauge should read 1,700 psi (117 bar).

2. If 1,700 psi (117 bar) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (124 bar) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

5. Stabilizer Shoe

1. Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe.

The main control valve pressure gauge should read 1,150 psi (79 bar).

2. Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe.

________________________________________________________________ 50 CM235 Hydraulics

_________________________________________________Troubleshooting Introduction

!

The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems. This section covers basic components, with each listed in a trouble-cause-remedy format.

WARNING Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An certified electrician must supervise and inspect all work performed.

Hydraulic Troubleshooting Procedures

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: 1. Before removing the controller covers, remove power from the system by disconnecting the trailing cable.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: 1. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the “POWER OFF” button must be pushed.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

______________________________________________________________ A6474X381 REV 1 51

Troubleshooting _________________________________________________ Typical Hydraulic Problems

The most common causes for improper function are: 1. contaminated oil or poor oil quality; 2. low or insufficient oil in the system; 3. using the wrong type of oil or wrong viscosity grade; 4. air in the hydraulic system; 5. internal or external leakage of the hydraulic system; 6. improper mechanical adjustments, such as reliefs; 7. mechanical or structural damage leading to component failure; and 8. components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components.

The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine.

Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

Each component in the system has a maximum rated speed, flow, torque, or pressure. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge.

________________________________________________________________ 52 CM235 Hydraulics

_________________________________________________Troubleshooting The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy. Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: 1.

general safety procedure for shutting down the machine;

2.

troubleshooting excessive noise;

3.

troubleshooting excessive heat;

4.

troubleshooting incorrect flow;

5.

troubleshooting incorrect pressure;

6.

troubleshooting faulty movement/operation; and

7.

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contamination

Cleanliness must be a high priority when servicing the hydraulic system. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where customers have made improvements in the past include: 1.

implementing ISO Cleanliness Code standards for bulk hydraulic oils;

2.

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records;

3.

minimizing drum usage by utilizing tote tanks and five gallon pails;

4.

utilizing plastic versus steel storage tanks, if possible;

5.

installing desiccant breathers on all bulk tanks;

6.

using sealed plastic containers for adding oil to small sumps;

7.

locating bulk tanks near equipment and pump directly to reservoirs;

______________________________________________________________ A6474X381 REV 1 53

Troubleshooting _________________________________________________ 8.

utilizing filter carts to maintain oil cleanliness standards;

9.

properly training personnel on the importance of clean oil and best practices for storage and handling; and

10.

monitoring the program closely and looking for continuous improvement.

Eliminate contamination source through “clean” maintenance practices best achieved by maintenance and troubleshooting given below:

Multi-Function Failure

1.

always clean the area around the component that is to be removed and inspected;

2.

store components in a plastic bag after inspection and prior to replacement on machine;

3.

cap off all open hoses/fittings;

4.

never touch a filter with bare hands when installing it back onto the machine; and

5.

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame.

If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi.

This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multifunction failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement).

________________________________________________________________ 54 CM235 Hydraulics

_________________________________________________Troubleshooting Cutter Head Raise Failure

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.

3

Check the directional control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.

6. Check to see that there is no mechanical bind.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this)

Cutter Head Lower Failure

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the Lower pilot cylinder on the cutter head directional control valve when the remote control valve is in the Lower position.

3. Check the direction control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check to see that there is no mechanical bind or hydraulic block.

6. Check flow control valve cartridge.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank.

Note: cylinder removal will be required to safely achieve this.

______________________________________________________________ A6474X381 REV 1 55

Troubleshooting _________________________________________________

Gathering Head Raise Failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing.

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check in-line counterbalance valve for proper operation or blockage.

Gathering Head Float Failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing (they will leak out the top).

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check counterbalance valve for proper operation (see the schematic in the parts book supplied with your machine for the proper setting).

Conveyor Raise Failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.

4. Check to see that there is no mechanical bind.

5. Verify that cylinders are not bypassing.

________________________________________________________________ 56 CM235 Hydraulics

_________________________________________________Troubleshooting Conveyor Lower Failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Verify that pilot pressure is being applied to open the piloted built-in checks.

4. Verify that cylinders are not bypassing.

Conveyor Swing Failure

1. Check the directional control valve for proper operation.

2. Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.

3. Verify that the cylinder is not bypassing.

Stabilizer Raise Failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

Stabilizer Lower Failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

______________________________________________________________ A6474X381 REV 1 57

Troubleshooting _________________________________________________ Table 7: Flow chart I for troubleshooting excessive noise Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies A. Any or all of the following: 1. replace dirty filters 2. wash strainers in solvent compatible with system fluid 3. clean clogged inlet line 4. clean reservoir breather vent 5. change system fluid 6. change to proper pump drive motor speed 7. check fluid temperature B. Any or all of the following: 1. tighten leaky inlet connections 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir 3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: 1. align unit 2. check condition of seals, bearings, and coupling D. Install and/or adjust pressure gauge E. Overhaul or replace defective parts

________________________________________________________________ 58 CM235 Hydraulics

_________________________________________________Troubleshooting Table 8: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies 3. locate and correct mechanical binding A. Any or all of the following: 4. check for workload in excess of circuit design 1. replace dirty filters 2. clean clogged inlet line

D. Install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings

3. clean reservoir breather vent

E. Overhaul or replace defective parts

4. change system fluid

F. 1. change filters

5. change to proper pump drive motor speed

2. check system fluid viscosity; change if necessary

6. overhaul or replace supercharge pump 3. fill reservoir to proper level B. Any or all of the following: G. 1. clean cooler and/or strainer 1. tighten leaky inlet connections 2. replace cooler control valve 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir

3. repair or replace cooler

3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: 1. align unit 2. check condition of seals, bearings, and coupling

______________________________________________________________ A6474X381 REV 1 59

Troubleshooting _________________________________________________ Table 9: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:

F. Any or all of the following

1. replace dirty filters

1. check position of manually operated controls

2. clean clogged inlet line

2. check electrical circuit on solenoid operated controls

3. clean reservoir breather vent 3. repair or replace pilot pressure pump 4. fill reservoir to proper level G. Reverse rotation 5. overhaul or replace supercharge pump H. Replace with correct unit B. Any or all of the following: 1. tighten leaky inlet connections 2. bleed air from system C. All of the following: 1. check for damaged pump or pump drive 2. replace and align coupling D. Adjust setting on valve E. Overhaul or replace part

________________________________________________________________ 60 CM235 Hydraulics

_________________________________________________Troubleshooting Table 10: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Cause

Remedy

Cause

No flow

See Table 5 Pressure relief path exists

Erratic Pressure

Remedy See Table 5

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve set too low

D

Worn relief valve

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A. Replace dirty filters and system fluid B. 1. tighten leaky connections 2. fill reservoir to proper level and bleed air from system C. 1. gas valve for leakage 2. charge to correct pressure 3. overhaul if defective D. Adjust valve E. Overhaul or replace part

______________________________________________________________ A6474X381 REV 1 61

Troubleshooting _________________________________________________ Table 11: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A. 1. check fluid temperature 2. check system fluid viscosity; change if necessary B. Locate bind and repair C. Adjust, repair, or replace part D. 1. clean and adjust or replace part 2. check condition of system fluid and filters E. Overhaul or replace part F. Repair command console or interconnecting wires G. Lubricated H. Adjust, repair, or replace counterbalance valve

________________________________________________________________ 62 CM235 Hydraulics

_________________________________________________Troubleshooting Table 12: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed

Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

______________________________________________________________ A6474X381 REV 1 63

Troubleshooting _________________________________________________ Water System including Circuits Table 12: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume (gpm) 1. Dynamic water pressure (psi) is not cannot be maintained being supplied to the recommended psi.

Test, check and/or remedy 1. Change setting to the recommended psi.

2. Water supply hose is not the minimum diameter

2. Change hose to the recommended diameter size.

3. Incoming supply of water has a problem.

3. Check the water supply itself to see if there is an issue & fix.

damaged or clogged filter, contaminates 1. Dirt in the system. in the water system

1. Remove the filter and clean it thoroughly; flush the system as necessary.

2. Change water filter frequently.

plugged water nozzles are restricting 1. Dirt in the system. the flow of water or pressure fluctuates

1. Remove the nozzles and clean thoroughly; flush the system as necessary.

2. Change water filter frequently.

pressure fluctuates and there is ex- 1. Air in the system. treme noise in the system 2. Pressure too high. excessive water blowing from scrubber 1. Excessive pressures on scrubber exhaust screen sprays.

1. Check for leaks.

2. Adjust the pressure.

1. Adjust psi setting.

2.

Pressure setting on jet pump too low.

2. Adjust psi setting.

3.

Damaged screen or mist eliminator.

3.

Replace.

4.

Mist eliminator not sealing.

4.

Replace seal.

5.

Sump needs cleaned.

5.

Remove mist eliminator and clean sump.

6.

Mist eliminator baffles dirty.

6.

Remove mist eliminator and clean.

7.

Verify that material is exiting from sump dump. Clean line if required.

1.

Clean or replace.

2.

Replace.

3.

Replace toggle switch.

7. Clogged sump line. water function will not shut “OFF” with 1. Hydraulic pilot operated water valve radio remote stuck closed.

2.

Faulty solenoid.

3.

Radio remote toggle switch faulty.

no water pressure on the 1. pressure gauge 2.

Water filter plugged.

1.

Replace or clean.

Main water ball valve “OFF”.

2.

Close valve.

3.

No incoming water.

3.

Fix water supply issue.

Contaminated water supply

1.

Clean or filter the incoming water supply to the miner.

Faulty solenoid plug connection.

1.

Check the connection.

Faulty solenoid.

2.

Replace.

No hydraulic pilot pressure to water valve.

3.

Check for pinched hose and check the hydraulic pilot valve.

water filter stopping up 1. frequently scrubber water will not turn “ON” when 1. scrubber motor is running 2.

3.

________________________________________________________________ 64 CM235 Hydraulics

_________________________________________________Troubleshooting Table 12 (continued): Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

scrubber water will not shut “OFF” 1. after scrubber motor stops

Test, check and/or remedy

Hydraulic pilot operated water valve stuck open.

1.

Clean or replaced valve.

Faulty solenoid

2.

Replace.

Incorrect pressure reducing valve setting.

1.

Adjust psi.

Low water volume to scrubber circuit.

2.

Check water volume gpm.

3.

Pressure reducing valve internal strainer dirty.

3.

Remove strainer and clean.

4.

Jet pump nozzle plugged with dirt.

4.

Backflush pump, remove nozzle and clean.

5.

Excessive pressure setting on scrubber screen sprays.

5.

Adjust psi.

6.

Suction hose from sump to jet pump plugged 6. with sludge or hose has a loose connection.

Remove restriction or tighten hose connection.

7.

Incorrect hose size from jet pump to manifold.

7.

Check for correct hose size.

8.

Manifold plugged.

8.

Clean.

Incorrect pressure reducing valve setting.

1.

Adjust psi.

2.

Low water volume to scrubber circuit.

2.

Check water volume gpm.

3.

Pressure reducing valve internal strainer dirty.

3.

Remove strainer and clean.

4.

Spray nozzles clogged or incorrect nozzle size.

4.

Clean nozzles and check nozzle part size.

2. jet pump not removing 1. water from sump 2.

scrubber screen dirty 1.

______________________________________________________________ A6474X381 REV 1 65

Troubleshooting _________________________________________________ Bearings Table 13: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing 1.

Test, check and/or remedy

Wrong type of grease or oil.

1.

Consult the lubrication chart for the proper lubricant.

2.

Low oil level; loss of lubricant through seal; excessive grease.

2.

Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

3.

Insufficient clearance in bearing.

3.

Replacement bearing should be identical to original equipment to ensure proper internal clearance.

4.

Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

4.

Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

5.

Shaft out of line.

5.

Correct alignment and be sure shafts are coupled in a straight line.

Insufficient clearance in bearing.

1.

Replacement bearing should be identical to original equipment to ensure proper internal clearance.

2.

Foreign matter acting as abrasive.

2.

Clean bearing housing and replace worn seals.

3.

Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

3.

Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

4.

Shaft and other parts of bearing assembly distorted.

4.

Replace bearing, shaft and other parts as needed.

Enlarged housing bore causing spinning of outer ring in housing.

1.

Re-bore housing and press steel bushing in bore, then machine bore to correct size.

2.

Foreign matter acting as abrasive.

2.

Clean bearing housing and replace worn seals.

3.

Unbalanced loading.

3.

Check balance of rotating parts and rebalance as needed.

Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.

1.

Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

noisy bearing 1.

vibrating bearing 1.

unsatisfactory 1. performance

________________________________________________________________ 66 CM235 Hydraulics

_________________________________________________Troubleshooting Electrical System Table 14: Electrical system troubleshooting Trouble, symptom or cause

Probable cause

motor contact chatter 1.

Test, check and/or remedy

Low voltage

1.

Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.

2.

Poor contact in control circuit.

2.

Replace the contact or use holdingcircuit interlock.

(3-wire control)

3.

Broken shading coil.

3.

Replace magnet and armature assemblies.

Abnormal in rush current.

1.

Use the next larger size contactor or check for grounds, shorts or excessive motor current.

2.

Rapid jogging.

2.

Install larger device rated for jogging service.

3.

Insufficient contact pressure.

3.

Replace contacts and springs, check for contacts for abnormal wear or damage.

4.

Low voltage preventing magnet from sealing.

4.

Check supply voltage to coil, especially for momentary voltage dip during starting.

5.

Foreign matter preventing contacts from closing.

5.

Clean contacts with Freon. Contacts used at low current and voltage levels should be cleaned with Freon.

6.

Vibration in starter mounting.

6.

Insulate starter from shock and vibration.

7.

Short circuit.

7.

Remove fault and check to be sure fuse or breaker size is correct.

chart contact life or 1. overheating of motor contactor 2.

Filing or dressing.

1.

Do not file silver contacts. Rough spots or discoloration will not harm contacts or impair their efficiency.

3.

Excessive jogging.

2.

Install larger unit. Check for grounds, shorts or excessive motor currents.

4.

Weak contact pressure.

3.

Install larger unit rated for jogging service.

4.

Replace contacts and springs. Check contacts for abnormal wear or damage.

5.

Clean contacts with Freon. Take steps to reduce entry of foreign matter into enclosure.

6.

Remove fault and check to be sure fuse or breaker size is correct.

7.

Clean and tighten.

8.

Check for excessive motor load current or install larger unit.

welding of motor contactor tips 1.

Interrupting excessively high currents.

5.

Foreign matter on contact surface.

6.

Short circuit or ground fault.

7.

Loose connections in power circuit.

8.

Sustained overload.

______________________________________________________________ A6474X381 REV 1 67

Troubleshooting _________________________________________________ Table 14 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

failure to pick-up and seal 1.

Low voltage.

1.

Check system voltage and voltage dips during starting.

2.

Check coil marking and wiring.

3.

With power off, check for free movement of armature and contacts.

4.

Replace.

1.

Clean pole faces with Toluol and seal with a drop of DC200 silicone fluid.

2.

Check coil circuit or length of leads from supply voltage to coil. May be excessive.

3.

Replace unit.

4.

See welding under contacts section.

Mechanical damage.

1.

Handle and store coils carefully.

Three phase power not present at contactors.

1.

Check three phase input to contactors.

2.

Check contactor tips.

3.

Start pump.

4.

Check oil level and level indicator light.

2.

Wrong coil or wrong connection.

3.

Mechanical obstruction.

4.

Coil open or overheated.

failure to drop out 1.

Sticky substance on pole faces.

2.

Voltage not removed.

3.

Worn or rusted parts causing binding.

4.

Contacts welded.

open circuit 1. both cutter head motors do not start 1.

Test, check and/or remedy

2.

Contactor tips damaged.

3.

Pump not running.

4.

Low hydraulic level.

5.

Failed control relay contacts.

5.

Check contacts

6.

Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.

6.

Check for faulty switches.

7.

Check coil and contacts.

7.

Control relay malfunction.

8.

Check overload relays.

8.

Overload relay.

9.

Check contactor coil. Verify that contacts are free to move.

9.

Failed left cutter head motor contactor.

1.

Check contactor auxillary contacts and wiring.

2.

Check coil and timed closed contacts and wiring.

3.

Verify that normally closed load current relays are NOT open.and check wiring.

4.

Check contactor coil and contact tips and wiring.

5.

Check overload relays and wiring.

1.

Check right cutter head motor contactor auxillary contacts and associated wiring.

2.

Check overcurrent relays.

left cutter head motor starts but 1. right cutter head motor does not 2.

Auxillary contacts not closing.

Time delay malfunction.

3.

Load current relay problem.

4.

Failed contactor.

5.

Overload relay problem.

both cutter head motors start but 1. stop when pump start and cutter head start switches are released 2.

Problem with auxillary contacts.

Overcurrent relays.

________________________________________________________________ 68 CM235 Hydraulics