DOWNLOAD PDF : Cat CM340 Continuous Miner Operation and Maintenance Manual

A6474X319 October 2012

Operation and Maintenance Manual CM340 Continuous Miner A6474X319

SAFETY.CAT.COM

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model CM340 Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine.

Caterpillar reserves the right to revise models and designs without prior notice.

This Continuous Miner was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

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

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

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

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

© CATERPILLAR ALL RIGHTS RESERVED

_________________________________________________Table of contents

Table of contents 1. About this manual About this manual................................................................... 1.2 Before starting to work ......................................................... 1.2 Who is this operating manual intended for?......................... 1.2 What is the purpose of this operating manual?.................... 1.3 Characters and symbols ...................................................... 1.4

2. Your safety Your safety............................................................................... 2.2 Personnel ............................................................................. 2.3 Operation......................................................................... 2.3 Installation and repair ...................................................... 2.3 Operating conditions ............................................................ 2.4 Intended use.................................................................... 2.4 Unauthorized use ............................................................ 2.4 Safety instructions ................................................................ 2.5 General rules ................................................................... 2.5 Storage and transport...................................................... 2.6 Pre-start inspection ......................................................... 2.6 Installation and start-up ................................................... 2.7 Operation......................................................................... 2.7 Stopping ........................................................................ 2.8 Maintenance and repair................................................. 2.8 Overview of the safety instructions .................................... 2.13 Chapter 3: Storage and transport.................................. 2.13 Chapter 4: Installation ................................................... 2.13 Chapter 5: Operation..................................................... 2.14 Chapter 6: Technical data ............................................. 2.28

3. Storage and transport Storage and transport............................................................. 3.2 Storage................................................................................. 3.2 Storage of the machine and spare parts ......................... 3.2 Long-term storage of spare components ........................ 3.3 Transport .............................................................................. 3.4 Lifting points .................................................................... 3.5

4. Installation Installation ............................................................................... 4.2 Points to observe prior to installation ................................... 4.2 Who is allowed to carry out installation? ......................... 4.2 Which tools are required for installation? ........................ 4.2 Notes on installation ........................................................ 4.3 Pre-installation check list................................................. 4.4 Safety features ................................................................ 4.5

________________________________________________________________ A6474X319

Rev 1

Table of contents _________________________________________________ 5. Operation Operation ..............................................................................5.2 How to operate the Continuous Miner...............................5.2 Who is allowed to operate the Continuous Miner .............5.2 When can operation be started? .......................................5.2 Controls and indicators......................................................5.3 Machine control system ..............................................5.11 Operating procedures........................................................5.25 Red zone.....................................................................5.25 Safety precautions for underground operation ...........5.30 Tramming safety rules ................................................5.30 Starting procedure ......................................................5.31 Shutdown procedure...................................................5.33 Tramming the miner....................................................5.34 Cutter head operation .................................................5.36 Blowing system operation...........................................5.37 Conveyor operation ....................................................5.38 Area and headlight operation .....................................5.39 Fire suppression (optional) .........................................5.40 Shear up/down............................................................5.41 Gathering head raise/float ..........................................5.41 Stabilizer cylinder raise/lower .....................................5.41 Conveyor raise/lower and swing left/right...................5.42 Breaker “ON/OFF” in radio remote .............................5.43 Typical cutting sequence ............................................5.44 Mining operations .......................................................5.45 Mechanical assemblies .....................................................5.50 Hydraulic system ...............................................................5.57 Water system ....................................................................5.87 Electrical system ...............................................................5.96 Instructions on the maintenance .......................................5.121 Important notes ............................................................5.121 Before maintenance .....................................................5.121 Torque values...............................................................5.123 Lubricants, fluids and capacities ..................................5.124 Specific lubrication and maintenance instructions ............5.129 Every shift.....................................................................5.129 Every third shift (daily) ..................................................5.133 Weekly..........................................................................5.142 Every 2 weeks ..............................................................5.146 Monthly .........................................................................5.148 Every three months ......................................................5.154 Every six months ..........................................................5.161 Instructions on the adjustment procedures .......................5.163 Pilot/auxiliary pump circuit relief ...................................5.165 Main control valve ........................................................5.166 Tram track ....................................................................5.170 Tail shim .......................................................................5.175 Conveyor chain tension................................................5.178 Sump tramming ............................................................5.179

________________________________________________________________ CM340 Continuous Miner

_________________________________________________Table of contents Replacement of wear parts ...............................................5.183 Cutter head (boom) assembly......................................5.183 Cutter head assembly removal/installation .............5.184 Shear cylinder..........................................................5.187 Center cutter drum...................................................5.192 End cutter drum .......................................................5.195 Drum drive motor.....................................................5.197 Drum drive gear case ..............................................5.204 Gathering head assembly ............................................5.207 Gathering head assembly removal/installation .......5.208 Gathering head drive motor.....................................5.213 Gathering head gear case.......................................5.216 Gathering head foot shaft........................................5.221 CLA..........................................................................5.224 CLA tip replacement ................................................5.226 Gathering head lift cylinder......................................5.227 Crawler assembly.........................................................5.231 Tram motor ..............................................................5.231 Tram case................................................................5.237 Crawler 242 .............................................................5.242 Tram track front idler ...............................................5.243 Conveyor assembly......................................................5.249 Conveyor chain........................................................5.250 Conveyor assembly removal/installation .................5.254 Discharge conveyor.................................................5.257 Tail roller ..................................................................5.263 Troubleshooting procedures .............................................5.266 Typical hydraulic problems...........................................5.267 Contaminants in hydraulic systems..............................5.268 Specific hydraulic circuits .............................................5.269 General safety procedures for shutdown .....................5.273 Excessive noise............................................................5.274 Excessive heat .............................................................5.275 Incorrect flow ................................................................5.276 Incorrect pressure ........................................................5.277 Faulty operation............................................................5.278 Restarting checklist ......................................................5.279 Water system ...............................................................5.280 Electrical system ..........................................................5.282 Bearings .......................................................................5.285 Control system .............................................................5.287 Fault codes ..............................................................5.287

________________________________________________________________ A6474X319

Rev 1

Table of contents _________________________________________________ 6. Technical data Technical data..........................................................................6.3 Tightening torques ................................................................6.5 Permissible data ...................................................................6.7 Lubrication fluids and greases .........................................6.7

7. For your information For your information ...............................................................7.3 Our service ...........................................................................7.3 Service address ...............................................................7.3

________________________________________________________________ CM340 Continuous Miner

_______________________________________________________________

1

About this manual

________________________________________________________________

________________________________________Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. It contains information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Model CM340 Continuous Miner and is only permitted to be used for equipment of this type.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

operate the machine

■

are in charge of transport

■

perform assembly/disassembly work

■

find/fix faults

■

perform daily routine work at the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X319 Rev 1 1.2

Before starting to work ________________________________________ What is the purpose of this operating manual?

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

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

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

safety

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

________________________________________________________________ 1.3 CM340 Continuous Miner

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

Try to memorize the symbols and their meanings.

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

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

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

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

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

■

Items in lists are marked with bullets.

–

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

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

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

______________________________________________________________ A6474X319 Rev 1 1.4

_______________________________________________________________

2

Your safety

________________________________________________________________

___________________________________________________Personnel

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

alterations

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

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

Do not make any alterations or modifications which could impair the safe operation and maintainability of the machine. All modifications and changes must be approved by the manufacturer and all appropriate regulatory agencies.

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

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

Observe the safety and accident prevention regulations

further operating manuals

■

of the mine,

■

of the mine’s inspectors, and

■

of the mining supervisory authorities.

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

______________________________________________________________ A6474X319 Rev 1 2.2

Personnel ___________________________________________________ Personnel Operation training

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

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

________________________________________________________________ 2.3 CM340 Continuous Miner

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

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

■

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

■

operation on grades of less than 10 degrees

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

■

the transport of persons

■

stone development or extraction

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

______________________________________________________________ A6474X319 Rev 1 2.4

___________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

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

symbol plates

Observe the symbol plates on the machine.

emergency stop

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

lock-out and tag

Disconnect, lockout, and tag the power system while performing: ■

maintenance

■

inspection

■

repair work

Follow all applicable regulations regarding lockout/tag out procedures.

Cordon off your working area widely for the machine. cordon off working area moving parts

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

chains, flights, and chain sprockets

■

pivot points

■

crawler assemblies and conveyors

■

cutter and gathering head assemblies

______________________________________________________________ A6474X319 Rev 1 2.5

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

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

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

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

mobile handling equipment

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

Pre-start inspection operation

Read this entire manual before attempting to operate this machine.

inspection

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

maintenance instruction and safety tags

Verify that all maintenance has been performed.

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

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

________________________________________________________________ 2.6 CM340 Continuous Miner

___________________________________________ Safety instructions Installation and start-up inclined face

environmental acceptability

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

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

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

controls

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

starting procedures

Follow the starting procedure instructions in the operations manual.

red zone

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

Operation training

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

before start-up

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

protective devices

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

traveling

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

passengers

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

safety rules

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

problems and malfunctions

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

______________________________________________________________ A6474X319 Rev 1 2.7

Safety instructions ____________________________________________ Stopping parking

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

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

radio

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

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

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

securing

Before attempting any repairs, a DANGER sign must be attached to the appropriate circuit at the power distribution box. It is mandatory that the trailing cable be uncoupled, tagged and locked-out from the power source to provide visual evidence that the miner is de-energized. Follow all applicable regulations regarding lockout/tagout.

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

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

Protect your work area against falling rocks.

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

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts. Please refer to the spare parts lists or parts catalog for the order numbers.

methane monitoring

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

________________________________________________________________ 2.8 CM340 Continuous Miner

___________________________________________ Safety instructions lifting

handling of hydraulic fluids

For raising the Continuous Miner use only: ■

crib blocks with adequate load-holding capacity.

■

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

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

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

maintenance/repair

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

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

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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

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

______________________________________________________________ A6474X319 Rev 1 2.9

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

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

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

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

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

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

Flush out the hydraulic lines thoroughly before connecting. permissible hoses

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

________________________________________________________________ 2.10 CM340 Continuous Miner

___________________________________________ Safety instructions installing hydraulic hoses

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

Always install hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Installing hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Installing hydraulic hoses, twisting Right

■

Wrong

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

Fig. 3: Installing hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X319 Rev 1 2.11

Safety instructions ____________________________________________ ■

always have a little slack.

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

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

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

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

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

Wrong

________________________________________________________________ 2.12 CM340 Continuous Miner

_________________________________Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport IMPORTANT! Take care to insure that new maintenance supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

WARNING! Do not use the eyebolt to lift the component AND its related assemblies.

Chapter 4: Installation CAUTION! Serious damage can be caused to the Continuous Miner as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists.

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

NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

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

______________________________________________________________ A6474X319 Rev 1 2.13

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

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

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

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

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

DANGER! The Continuous Miner is radio remote controlled during production operations. Manual operation via controls at the operator’s station is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only. Tramming via the Emergency tram pendant is only permitted in situations when the radio remote system is inoperable. Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in severe injury or death.

NOTICE! Once a hydraulic control valve handle is released by the operator, the lever will automatically return to the centered (“HOLD”) position.

DANGER! Power to the machine must always be isolated to the trailing cable at the section power center before either socket is removed or the main circuit breaker case is opened. Whenever any work is performed on the continuous miner, all mine, State, and Federal regulations regarding lockout/tagout of the machine.

IMPORTANT! It is the responsibility of the continuous miner owner/operator to know and follow all Mine, State, and Federal regulations regarding methane monitoring requirements, including, but not limited to, daily operation, maintenance and testing.

________________________________________________________________ 2.14 CM340 Continuous Miner

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

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

NOTICE! Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

IMPORTANT! All functions and motors are shut down and disable when the system menu is selected.

IMPORTANT! It is not recommended that the fault log be cleared unless the receiver has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a receiver is sent for service.

Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

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

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

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

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

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

______________________________________________________________ A6474X319 Rev 1 2.15

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

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 26 through Fig. 30).

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

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

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

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

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

WARNING! The Continuous Miner is operated by radio remote control. Manual operation is not allowed for production operation. Manual operation is for troubleshooting and maintenance under roof support.

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

WARNING! Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that the area is clear before starting the machine.

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

WARNING! After turning off the power to the machine, never walk away and leave the transmitter turned on. Failure to turn the transmitter off could result in an accident causing serious injury or loss of life

________________________________________________________________ 2.16 CM340 Continuous Miner

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

WARNING! Tramming requires cooling water to the tram motors. Failure to cool the motors will result in motor damage and premature failure.

WARNING! Adjust conveyor boom to allow clearance from roof, walls, and floor. Failure to do so will result in damage to the conveyor boom.

WARNING! Never start cutter head motors under a load. Starting motors under load may result in motor damage or premature failure.

WARNING! Warn ALL CLEAR before starting the cutter head. Failure to do so may result in serious injury or death.

IMPORTANT! Both cutter motors do not start at the same time. There is a preset timed delay between the left cutter motor starting and the right cutter motor starting.

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

WARNING! Warn ALL CLEAR before starting the conveyor. Failure to do so may result in serious injury or death.

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

IMPORTANT! The “FAN/OFF” button must be released before “SHIFT”. If “SHIFT” is released first, the fan motor will shut off.

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

CAUTION! Always ensure operator safety while operating the machine. Be alert for hazardous conditions and take corrective action as necessary. Failure to be alert and correct hazardous situations may result in serious injury.

______________________________________________________________ A6474X319 Rev 1 2.17

Overview of safety instructions _________________________________ IMPORTANT! Care should be taken not to stall cutters or conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.

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

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

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

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

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

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

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

________________________________________________________________ 2.18 CM340 Continuous Miner

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

IMPORTANT! The two inch locking ball valve must be locked open in normal operation.

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! 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.

NOTICE! To jack-knife the miner, the stabilizer shoe is first lowered with the bypass valve opened. The cutter head is then lowered with the bypass opened. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

DANGER! Never run the conveyor without the needle valve closed. Injury or death may occur.

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. All electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing the cover from the controller case or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

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

______________________________________________________________ A6474X319 Rev 1 2.19

Overview of safety instructions _________________________________ WARNING! Never run over an unprotected trailing cable. Damaged cables should be repaired immediately.

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

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

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

IMPORTANT! Never use a spare breaker without properly labeling its new function.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the trailing cable disconnected.

Follow all Mine, State, and Federal regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

IMPORTANT! “MAINTENANCE” mode of operation is not for use during normal maintenance or replacement of wear parts procedures.

“MAINTENANCE” mode is for use during motor vibration analysis only.

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

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

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

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

________________________________________________________________ 2.20 CM340 Continuous Miner

_________________________________Overview of safety instructions WARNING! Use extreme caution when inspecting for leaks with the machine running. Unexpected machine movement, or contact with moving parts, could result in injury.

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

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.

NOTICE! Switch assembly seals beneath the engraved plate are the primary seal; a secondary seal within the switch itself and an integral neoprene seal operate as a barrier to moisture ingress.

IMPORTANT! Do not use caustic solvents or displacement solutions, as this may cause premature seal failure.

IMPORTANT! Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

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.

IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting (Fig. 122) 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.

______________________________________________________________ A6474X319 Rev 1 2.21

Overview of safety instructions _________________________________ IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting to prevent the accidental use of multipurpose lithium complex grease at these locations.

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.

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.

WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

IMPORTANT! 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, A1.

CAUTION! Do not adjust the main relief over 3,000 psi. Destruction of the valve bank and the main pump could result.

________________________________________________________________ 2.22 CM340 Continuous Miner

Overview of safety instructions _________________________________ CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

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

IMPORTANT! Machine power must be disconnected during installation of the current generator. Cutter motor feedback adjustment is normally set with the crawler tracks off the mine floor, stabilizer and cutter head down (machine jack-knifed). To jack knife the machine you should be familiar with the hydraulic circuits on the miner, and in particular, the cutter head cylinder circuit and the shear down/ maintenance valve (anti-chatter) operation as described in the Hydraulic section of this chapter.

NOTICE! The reference voltage will be approximately 0.55 VDC. Adjust the sump voltage using the adjustment screws marked “S” on the tram interface. Set the left and right tram voltages the same.

________________________________________________________________ 2.23 CM340 Continuous Miner

Overview of safety instructions _________________________________ CAUTION! Disassembly and assembly procedures listed in the Replacement of wear parts section are specialized and, as such, should only be performed by qualified personnel.

WARNING! The shear cylinder is extremely heavy. Make sure that it’s weight is supported and that the cylinder will not swing free or move.

Failure to follow this warning may result in machine damage or in severe injury or death to personnel.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.

WARNING! Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.

IMPORTANT! In addition to the shear cylinders, the stabilizer and gathering head can be used to adjust the cutter boom’s position to allow easier installation of the cutter boom pivot pins.

WARNING! The following steps will disconnect the shear cylinder from the frame. The shear cylinder is extremely heavy. Make sure that it’s weight is supported and that the cylinder will not swing free or move. Failure to follow this warning may result in machine damage or in severe injury or death to personnel.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.

CAUTION! If the assembly is seized, it may be necessary to pry on the edges.

Care must be taken not to damage the o-ring or its seal land.

IMPORTANT! Before detaching these three (3) lugs, tag the wires to make reconnection easier.

WARNING! Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.

WARNING! Federal law requires that mining equipment electrical components must be inspected by a certified electrician before the equipment can be operated.

________________________________________________________________ 2.24 CM340 Continuous Miner

Overview of safety instructions _________________________________ WARNING! This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation. Follow all Mine, State, and Federal lockout/tagout procedures. Failure to do so may result in serious injury or death.

IMPORTANT! An MSHA certified electrician must inspect all work and check for permissibility.

IMPORTANT! During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.

WARNING! Stand clear of the miner and the gear case while tramming the miner. You could be seriously injured or killed by falling loads.

WARNING! Do not attempt to start the cutter head motors. You could be seriously injured or killed.

CAUTION! Use care when tramming the miner away from the gear case.

While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

NOTICE! The gathering head cylinders do not have to be removed from the frame. Rotate them away from the gathering head and securely fasten them to the main frame.

WARNING! Do not attempt to start the cutter head or gathering head motors.

IMPORTANT! Make sure that the lower section of the conveyor chain is free of the foot shaft so that when the miner is trammed away from the gathering head, the chain will pull free of the return deck.

NOTICE! When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.

DANGER! All personnel must stay clear of the miner while it is tramming and being aligned with the gathering head assembly. Standing under the cutter head or in the path of the miner while it is tramming may result in severe injury or death.

________________________________________________________________ 2.25 CM340 Continuous Miner

Overview of safety instructions _________________________________ CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.

IMPORTANT! Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.

WARNING! Stay clear of the blocked miner while the machine is energized.

Failure to follow this warning may result in sever injury or death.

WARNING! This procedure involves the alignment of cylinder clevises with mounting clevises in order to install retaining pins. Do not check for alignment with your fingers. Shifting of the aligned pieces could cause serious injury.

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.

IMPORTANT! If the miner and the gear case assembly are not both level and aligned correctly, installing the gear case assembly into the machine will be very difficult.

WARNING! The end of the chain, just forward of the separation point, should be blocked. Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.

IMPORTANT! Be sure that the rousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.

NOTICE! The conveyor chain does not have a right or wrong running directions, only a correct up and down side. The flat side of the flight chains must run on the deck.

WARNING! Make sure all personnel are clear of the miner before performing the following checks. Do not stand behind the conveyor when the chain is running.

________________________________________________________________ 2.26 CM340 Continuous Miner

Overview of safety instructions _________________________________ NOTICE! If the pivot pin is tight, be sure the lifting device is not binding the pivot. If the pivot is not in a bind, use the puller hole to aid in pin removal.

WARNING! Be sure all conveyor components are correctly installed and that the conveyor chain is properly engaged by the foot shaft before starting the miner.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

________________________________________________________________ 2.27 CM340 Continuous Miner

_________________________________Overview of safety instructions Chapter 6: Technical data IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy!

NOTICE! Use only lubrication fluids and greases! These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! The approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be stored and disposed of per your local EPA standards.

______________________________________________________________ A6474X319 Rev 1 2.28

_______________________________________________________________

3

Storage and transport

________________________________________________________________

________________________________________ Storage and transport

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

For specific procedures for your environment, contact Engineering.

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

Storage corrosion protection

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

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

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

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

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

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

short-term storage

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

long-term storage

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

■

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

Completely fill the hydraulic oil tank with oil.

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

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

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

______________________________________________________________ A6474X319 Rev 1 3.2

Storage and transport _________________________________________ machine electrical components traction drives

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

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

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

random sample inspection

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

On request, the inspection can be carried out.

natural aging

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

HFA fluids

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

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

Long-term storage of spare components hydraulic components

miscellaneous components

motors

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).

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.

________________________________________________________________ 3.3 CM340 Continuous Miner

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

dimensions,

■

weights,

■

lifting points, etc.

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

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

Table 1: Lifting weights of Continuous Miner Assemblies

removal and installation of heavy components

Description

Approximate Weight

Complete Machine

160,370 lbs (72,742 kg)

Tractor Frame Assembly

75,000 lbs (34,019 kg)

Cutting Head Assembly

47,000 lbs (21,319 kg)

Gathering Head Assembly

19,300 lbs (8,754 kg)

Conveyor Assembly

15,800 lbs (7,167 kg)

Conveyor Chain Assembly

3,270 lbs (1,483 kg)

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

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

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

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

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

______________________________________________________________ A6474X319 Rev 1 3.4

Storage and transport _________________________________________ Fig. 5: Lifting points Lifting eye (2) (100 ton)

Frame lifting points

Lifting eye (30 ton)

Lifting eye (30 ton)

Bumper lifting points

________________________________________________________________ 3.5 CM340 Continuous Miner

________________________________________ Storage and transport Fig. 5: Lifting points, continued Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Lifting eye (4.5 ton)

Conveyor lifting points

Lifting eye (10 ton)

Lifting eye (10 ton)

Lifting eye (10 ton)

Lifting eye (10 ton)

Gathering head lifting points

______________________________________________________________ A6474X319 Rev 1 3.6

Storage and transport _________________________________________ Fig. 5 (continued): Lifting points Lifting eye (16 ton)

Lifting eye (16 ton)

Cutter head lifting points

Before transport temperatures below freezing

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

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

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

electronic components

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

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

________________________________________________________________ 3.7 CM340 Continuous Miner

_______________________________________________________________

4

Installation

________________________________________________________________

__________________________________________________ Installation

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

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

Work on: ■

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

■

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

■

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

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

Which tools are required for installation? tool box

General tools are required to put the Continuous Miner into service.

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

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock and crib blocks

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X319 Rev 1 4.2

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

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

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

reassembly instructions

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

________________________________________________________________ 4.3 CM340 Continuous Miner

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

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

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

■

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

■

check the full length of the trailing cable for damage

■

ensure that the trailing cable is properly suspended across intersections and that the trailing cable clamp at the Continuous Miner is secure

■

clean any foreign material from the conveyor and gathering pan

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check safety provisions for operational condition on fire suppression system

■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

start up the machine and check for correct operation of all stop and emergency stop buttons (both on the machine and on the transmitter)

■

after starting the machine, allow the hydraulic system to warm up for five (5) to ten (10) minutes and then check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

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

■

check the tension of the conveyor chain and crawler chain

______________________________________________________________ A6474X319 Rev 1 4.4

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

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

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

There is also an emergency stop button located on the transmitter. See the manual for your radio controls for further information.

fire suppression (optional)

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

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

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

fire sprays (optional)

Water can be directed to the fire spray nozzles (optional) manually from a fire spray valve. If equipped, see Chapter 5 for operating instructions and locations of the valves.

If equipped with fire sprays, an electronically actuated solenoid is used to actuate the fire spray system from the remote position.

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

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

________________________________________________________________ 4.5 CM340 Continuous Miner

__________________________________________________ Installation blowing system (optional)

The Continuous Miner is equipped with an optional blowing system that allows the Miner operator to apply fan induced air to the face during operation. The fan draws the air from either intake located at the left and right rear of the Miner. Air is then drawn from the rear intakes through the fan and ductwork, to the crossover hood, which is located on the cutter head support frame. The blowing system assembly is located on the left hand side of the Miner.

guards and covers

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

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

cutter boom safety supports

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

conveyor safety supports

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

methane monitor

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

______________________________________________________________ A6474X319 Rev 1 4.6

Installation___________________________________________________ Fig. 6: Safety features on the Continuous Miner

“MAIN CIRCUIT BREAKER” reset

Machine stop

“TRAM CIRCUIT BREAKER” reset

Dual methane monitor displays

________________________________________________________________ 4.7 CM340 Continuous Miner

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

Machine stop (location typical)

Machine stop (location typical)

Radio control transmitter

Hand-held tram pendant

______________________________________________________________ A6474X319 Rev 1 4.8

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

Conveyor safety support (storage location)

Conveyor safety support (installed location)

________________________________________________________________ 4.9 CM340 Continuous Miner

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

Cutter boom safety support (2) (installed location - typical both sides)

Cutter boom safety support (2) (installed location - typical both sides)

______________________________________________________________ A6474X319 Rev 1 4.10

Installation___________________________________________________ Fig. 7: Overview of the Continuous Miner Conveyor boom

Operator’s station Cutter boom

Crawler assembly

Gathering head assembly

________________________________________________________________ 4.11 CM340 Continuous Miner

_______________________________________________________________

5

Operation

________________________________________________________________

___________________________________________________ Operation

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

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

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

Who is allowed to operate the continuous miner?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

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

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

______________________________________________________________ A6474X319 Rev 1 5.2

Operation____________________________________________________ Controls and indicators Operator’s station DANGER! The Continuous Miner is radio remote controlled during production operations. Manual operation via controls at the operator’s station is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only. Tramming via the tram pendant is only permitted in situations when the radio remote system is inoperable. Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in severe injury or death.

The operator’s station (Fig. 8) is located on the right hand side of the machine, near the rear bumper.

Fig. 8: Operator’s station “MACHINE STOP”

“MINER” selector switch

Machine lighting

Control breakers

Gauge panel

“CONVEYOR HOUR METER” “CUTTER HOUR METER”

Main circuit breaker

Graphics display Text display “WASH DOWN HOSE” valve “CUTTER MOTOR CIRCUIT BREAKER”

Valve bank “TRAM CIRCUIT BREAKER”

________________________________________________________________ 5.3 CM340 Continuous Miner

___________________________________________________ Operation “MACHINE STOP”

The “MACHINE STOP” button (Fig. 9) is a large red push button located on the left of the operator’s case. Pushing “MACHINE STOP” will shut down the pump, causing the miner to shut down. To restart the miner after pushing the “MACHINE STOP” button, follow the normal start up procedure for the pump (see Start up procedures in this chapter).

“MINER” operation selector switch

The “MINER” operation selector switch (Fig. 9) is located to the right of the “MACHINE STOP” button. The selector switch has three positions:

“MACHINE LIGHTING” operation selector switch

■

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

■

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

■

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

The “MACHINE LIGHTING” operation selector switch (Fig. 9) is located to the right of the “MINER” operation selector switch. The selector switch has four positions: ■

“ALL ON” - Located at 3 o’clock, turning the switch to this position allows all machine lighting to be turned on, including headlights and area lights. (The headlights can be turned on or off from the transmitter. The area lights are hard-wired and cannot be turned off by the transmitter.)

■

“ALL OFF” - Located at 12 o’clock and 6 o’clock, turning the switch to this position allows all machine lighting to be turned off.

■

“AREA LIGHTS ONLY” - Located at 9 o’clock, turning the switch to this position allows only area lights to be turned on.

Fig. 9: “MACHINE STOP,” “MINER” and “MACHINE LIGHTING” selector switches

“MACHINE STOP”

“MINER” selector switch

“MACHINE LIGHTING” selector switch

______________________________________________________________ A6474X319 Rev 1 5.4

Operation____________________________________________________ control breaker switches

There are sixteen control breaker reset buttons located across the top of the operator’s case (Fig. 10). The button will pop out when the circuit breaker trips. To reset a circuit breaker, push the button in.

See the Electrical section in this chapter for detailed information on the individual breakers.

Fig. 10: Control breaker reset switches

“CONVEYOR HOUR METER”

The “CONVEYOR HOUR METER” (Fig. 11) indicates the hours of running time for the conveyor motors.

“CUTTER HEAD HOUR METER”

The “CUTTING HEAD HOUR METER” (Fig. 11) indicates the hours of running rime for the cutter head motors.

“CUTTER MOTOR CIRCUIT BREAKER”

The “CUTTER MOTOR CIRCUIT BREAKER” lever (Fig. 11) is used to turn the circuit breaker for the cutter motors. This breaker must be on before the cutter motors will start. To turn the circuit breaker on, move the lever to the right. To turn the circuit breaker “OFF”, move the lever to the left.

“TRAM CIRCUIT BREAKER”

The “TRAM CIRCUIT BREAKER” lever (Fig. 11) is used to turn the circuit breaker for the tram motors. This breaker must be on before the tram motors will start. To turn the circuit breaker on, move the lever to the right. To turn the circuit breaker “OFF”, move the lever to the left.

Fig. 11: “CONVEYOR HOUR METER,” “CUTTER HEAD HOUR METER”, “CUTTER MOTOR CIRCUIT BREAKER” and “TRAM CIRCUIT BREAKER” “CONVEYOR HOUR METER”

“CUTTER HEAD HOUR METER”

“CUTTER MOTOR CIRCUIT BREAKER”

“TRAM CIRCUIT BREAKER”

________________________________________________________________ 5.5 CM340 Continuous Miner

Operation____________________________________________________ Valve bank The manually operated valve bank (Fig. 12) is located on the right hand side of the operator’s station and is used to operate the miner during maintenance and troubleshooting functions while under supported roof.

NOTICE! Once a hydraulic control valve handle is released by the operator, the lever will automatically return to the centered (“HOLD”) position.

“CUTTING HD”

The first lever from the operator’s left, “CUTTING HD”, controls the cylinders that raise and lower the cutting head. To raise the cutting head, pull the lever toward the operator. To lower the cutting head, push the lever away from the operator.

“CONVEYOR” “RAISE/LOWER”

The second lever from the operator’s left, “CONVEYOR”-”LOWER/ RAISE”, controls the cylinders that raise and lower the conveyor boom.

To raise the conveyor, pull the lever toward the operator. To lower the conveyor, push the lever away from the operator.

“CONVEYOR” “LEFT/RIGHT”

The third lever from the operator’s left, “CONVEYOR”-”LEFT/RIGHT”, controls the conveyor swing cylinders. To swing the conveyor boom to the left, push the lever away from the operator. To swing the conveyor boom to the right, pull the lever toward the operator.

“GATH HD”

The fourth lever from the operator’s left, “GATH HD”, controls the cylinders that position the gathering head. To raise the gathering head, push the lever away from the operator. To float the gathering head, pull the lever toward the operator.

“STABILIZER”

The fifth lever form the operator’s left, “STABILIZER”, controls the cylinder that raises and lowers the stabilizer shoe. To raise the stabilizer shoe off of the floor, pull the lever toward the operator. To lower the stabilizer shoe to the floor, push the lever away from the operator.

Fig. 12: Valve bank “CUTTING HD” “CONVEYOR” “RAISE/LOWER” “CONVEYOR” “LEFT/RIGHT” “STABILIZER” “GATH HD”

________________________________________________________________ 5.6 CM340 Continuous Miner

___________________________________________________ Operation Gauge panel There is a gauge panel (Fig. 13) consisting of nine (9) gauges located above the operator’s station that is used to monitor hydraulic and water pressure throughout the miner.

“LH HEAD SPRAY PRESSURE”

The first gauge from the operator’s left on the row of gauges is “LH HEAD SPRAY PRESSURE.” This gauge is used to monitor the water pressure at the left hand cutter head spray manifold in the dust suppression system. The gauge settings are dependent on the individual mine requirements. Consult the schematic in the parts manual for your machine.

“RH HEAD SPRAY PRESSURE”

The second gauge from the operator’s left on the top row of gauges is “RH HEAD SPRAY PRESSURE.” This gauge is used to monitor the water pressure at the right hand cutter head spray manifold in the dust suppression system. The gauge settings are dependent on the individual mine requirements. Consult the schematic in the parts manual for your machine.

“OUTBY WATER FILTER PRESSURE”

The third gauge from the operator’s left on the row of gauges is “OUTBY WATER FILTER PRESSURE.” This gauge monitors the pressure of the supply water coming into the water system from the mine.

The pressure should be a minimum of 250 psi under dynamic conditions and should not exceed 500 psi. If the pressure exceeds 500 psi, immediately adjust the supply water pressure or shutdown the machine (see Shutdown procedure in this chapter).

“MAIN PRESSURE”

The fourth gauge from the operator’s left on the row of gauges is “MAIN PRESSURE.” This gauge is used to measure the pressure in main flow - primary pressure circuit. See the Main flow - primary pressure circuit in the Hydraulic section of this chapter for further information.

“PILOT CIRCUIT PRESSURE”

The fifth gauge from the operator’s left on the row of gauges is “PILOT CIRCUIT PRESSURE.” This gauge is used to monitor the supply pressure for all pilot functions. See the Pilot pressure circuit in the Hydraulic section of this chapter for further information.

“ACCUMULATOR PRESSURE”

The sixth gauge from the operator’s left on the top row of gauges is “ACCUMULATOR PRESSURE.” This gauge is used to monitor the accumulator pressure. The purpose of the accumulator is to store the necessary pilot pressure to allow remote operation of the fire suppression and breaker on/off control valves (optional) when the pump is not operational. The accumulator pressure should closely track the pilot circuit pressure. If the accumulator does not hold pressure when the pump is shut down, call maintenance. See the accumulator circuit in the Hydraulic section of this chapter for further information.

“GH FLOAT PRESSURE”

The seventh gauge from the operator’s left on the row of gauges is “GH FLOAT PRESSURE.” This gauge is used to monitor the pressure in the gathering head circuit during gathering head float operations. See the Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter for further information.

______________________________________________________________ A6474X319 Rev 1 5.7

Operation____________________________________________________ “CONVEYOR CHAIN TAKE-UP PRESSURE”

The eighth gauge from the operator’s left on the row of gauges is “CONVEYOR TAKE-UP PRESSURE.” This gauge is used to monitor the pressure of the automatic conveyor chain tensioner. See the Conveyor take-up circuit in the Hydraulic section of this chapter for further information.

“SHEAR DOWN PRESSURE”

The ninth gauge from the operator’s left on the row of gauges is “SHEAR DOWN PRESSURE.” This gauge is used to monitor the pressure of the cutting head cylinder circuit during shear down operations.

See the Shear down/maintenance (anti-chatter) valve in the Cutter head cylinder circuit in the Hydraulic section of this chapter for further information.

Fig. 13: Gauge panel “LH HEAD SPRAY PRESSURE”

“RH HEAD SPRAY PRESSURE”

“OUTBY WATER FILTER PRESSURE”

“ACCUMULATOR PRESSURE”

“MAIN PRESSURE”

“PILOT CIRCUIT PRESSURE”

“GH FLOAT PRESSURE” “CONVEYOR CHAIN TAKE-UP PRESSURE”

“SHEAR DOWN PRESSURE”

________________________________________________________________ 5.8 CM340 Continuous Miner

___________________________________________________ Operation main circuit breaker

The main circuit breaker case (Fig. 14) is located at the right hand of the operator’s station. Incoming cable is connected to the machine via the cable handler and or cable socket.

The case contains a circuit breaker providing 600A overload and 1500A short circuit protection to the machine. The circuit breaker also functions as an isolation device for the machine.

DANGER! Power to the machine must always be isolated from the trailing cable at the section power center before either socket is removed or the main circuit breaker case is opened. Whenever any work is performed on the continuous miner, follow regulations regarding lockout/tagout of the machine.

Fig. 14: Main circuit breaker

Main circuit breaker

______________________________________________________________ A6474X319 Rev 1 5.9

Operation____________________________________________________ methane monitor displays (typical)

The machine is equipped with a methane monitoring system (Fig. 15) which, when energized, maintains a continuous check on methane gas concentration. This machine has two LED indicator displays which show the percentage of methane gas in larger numerals.

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

IMPORTANT! It is the responsibility of the continuous miner owner/operator to know and follow all regulations regarding methane monitoring requirements, including, but not limited to, daily operation, maintenance and testing.

Fig. 15: Methane monitor displays (typical)

Methane gas concentration percentage

________________________________________________________________ 5.10 CM340 Continuous Miner

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

Receiver control unit

■

Power supply

■

Input/Output (I/O) modules

■

Remote control transmitter

■

Graphics display

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

power supply

Input/Output modules

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

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

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

Cutter motors (left and right)

■

Gathering head motors (left and right)

■

Traction motors (left and right)

■

Pump motor

■

Hydraulic oil level

■

Methane monitoring

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

______________________________________________________________ A6474X319 Rev 1 5.11

Operation____________________________________________________ radio control transmitter

The radio control transmitter (Fig. 16) is a battery powered remote used to control the continuous miner during normal operations.

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

Fig. 16 Radio control transmitter (typical)

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

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

________________________________________________________________ 5.12 CM340 Continuous Miner

___________________________________________________ Operation There are two displays located on the machine: a graphics display located at the operator’s case and a text display located near the back right hand side of the machine (Fig. 17). Both screens are used to display diagnostic information on the miner.

Fig. 17: Control system display locations (typical)

Graphics display

Text display

displays

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

The text display, located on the near the back right hand side of the machine, has the same functions as the graphics display. If the control system loses power, the text display will remain powered through the battery back up.

NOTICE! Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

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

Normal display pages The main diagnostic screen (Fig. 18) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

______________________________________________________________ A6474X319 Rev 1 5.13

Operation____________________________________________________ Fig. 18: Main page, example

Graphics display

Text display

________________________________________________________________ 5.14 CM340 Continuous Miner

___________________________________________________ Operation System Menu The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 19). The system menu is accessed by using either display module and a remote control handset.

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

IMPORTANT! All functions and motors are shut down and disable when the system menu is selected.  Press CONV UP or CONV DOWN to move the cursor up and down the list.  Press SHIFT and MENU to select the highlighted item  To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 19: System menu, example

Graphics display

______________________________________________________________ A6474X319 Rev 1 5.15

Operation____________________________________________________ Fig. 19: System menu, example, continued

Text display

________________________________________________________________ 5.16 CM340 Continuous Miner

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

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

Main monitor Production monitor Pump monitor Cutter monitor Conveyor monitor I/O monitor - relay outputs I/O monitor - digital inputs I/O monitor - analog outputs Solenoid 6 - breaker reset monitor Solenoid 5 - dust spray and fire suppression Solenoid 4 - stab lift monitor Solenoid 3 - gathering head monitor Solenoid 2 - conveyor lift monitor Solenoid 1 - conveyor swing monitor Solenoid 0 - cutter lift monitor Inverter right monitor Inverter left monitor Rectifier monitor Smart slice monitor Thermistor monitor Motor mate network monitor CAN network monitor

See Fig. 20 for example screen shots of various diagnostic pages.

______________________________________________________________ A6474X319 Rev 1 5.17

Operation____________________________________________________ Fig. 20: Graphics display diagnostic pages, examples

________________________________________________________________ 5.18 CM340 Continuous Miner

___________________________________________________ Operation Fig. 20: Graphics display diagnostic pages, examples, continued

______________________________________________________________ A6474X319 Rev 1 5.19

Operation____________________________________________________ Text diagnostics includes the following pages: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Main monitor Machine information Pump diagnostics Cutter diagnostics Conveyor diagnostics Fan diagnostics Tram diagnostics 24VDC digital input I/O monitor - relay board I/O monitor - solenoid board I/O monitor - analog outputs Solenoid board diagnostics Relay board status Power supply status Thermistor module status

Fig. 21: Text display diagnostic pages, examples

________________________________________________________________ 5.20 CM340 Continuous Miner

Operation____________________________________________________ Fault log The fault log (Fig. 22) allows the user to view the last 100 faults that have occurred since the log was last cleared.

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

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

IMPORTANT! It is not recommended that the fault log be cleared unless the receiver has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a receiver is sent for service.

Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 23).

Fig 22: Fault log, example

Graphics display

________________________________________________________________ 5.21 CM340 Continuous Miner

___________________________________________________ Operation Fig. 22: Fault log, examples, continued

Text display Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 20).

Fig. 23: Fault detailed information, example

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

______________________________________________________________ A6474X319 Rev 1 5.22

Operation____________________________________________________ Hour meters Selecting hour meters (Fig. 24) from the Main Menu will display runtime for the following motors: pump, fan, left cutter, right cutter, and conveyor. Time is displayed in hours:minutes:seconds format. This runtime only reflects accumulated time since the receiver has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

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

Fig. 24: Hour meters, examples

Setup Menus There are three password protected setup menus available: Tradesman, Engineering, and OEM. Information regarding the adjustable parameters accessed on each screen is given in the machine specific training.

________________________________________________________________ 5.23 CM340 Continuous Miner

Operation____________________________________________________ Tram pendant

The machine can be operated using a pendant control (Fig. 25) connected to the miner by an umbilical cable. This control is used in the event that the operator loses radio link with the mine to safely recover the miner from the face to an area under supported roof for troubleshooting and maintenance.

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

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

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

Fig. 25: Tram pendant

________________________________________________________________ 5.24 CM340 Continuous Miner

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

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

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

Miner operator danger areas, or Red zones Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone (Fig. 26) is indicated by alternating red and white diagonal stripes.

Fig. 26: Red zone

________________________________________________________________ 5.25 CM340 Continuous Miner

___________________________________________________ Operation Tramming the miner (Fig. 27) 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. 27) 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. 27: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

Sumping in the left hand side of the cut (Fig. 28). 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. 28). 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. 28). 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.

______________________________________________________________ A6474X319 Rev 1 5.26

Operation____________________________________________________ Fig. 28: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

________________________________________________________________ 5.27 CM340 Continuous Miner

___________________________________________________ Operation Crosscut red zones (Fig. 29). Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle while at awkward positions. Crosscuts also result in newlyexposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

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

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

Fig. 29: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

______________________________________________________________ A6474X319 Rev 1 5.28

Operation____________________________________________________ Pillaring red zones (Fig. 30) 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. 30: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

________________________________________________________________ 5.29 CM340 Continuous Miner

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

■

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

■

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

■

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

■

Make a visual check of the Continuous Miner before energizing.

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

■

When operating the blowing system, the operator should stand to the left hand rear of the miner to avoid air flow and debris moving across cutting head and right hand side of the Miner.

■

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

Tramming safety rules ■

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

■

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

■

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

■

Position the cutter and gathering head for tramming.

■

Position the stabilizer shoe and booms for tramming.

■

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

■

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

______________________________________________________________ A6474X319 Rev 1 5.30

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

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

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

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

WARNING! Before starting the Continuous Miner, make sure that no one is in the red zone (Fig. 26 through Fig. 30).

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

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

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

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

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

WARNING! When operating the blowing system, the operator should stand to the left hand rear of the miner to avoid air flow and debris moving across cutting head and right hand side of the Miner.

________________________________________________________________ 5.31 CM340 Continuous Miner

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

The Continuous Miner is typically operated by radio remote control.

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

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

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

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

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

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

______________________________________________________________ A6474X319 Rev 1 5.32

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

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

________________________________________________________________ 5.33 CM340 Continuous Miner

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

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

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

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

Be award of people, equipment, and cables.

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

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

______________________________________________________________ A6474X319 Rev 1 5.34

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

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

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

Spilt track tramming is limited to SPEED 1 when cutter motors are not running.

■

Single track tramming is normally limited to SPEED 1.

■

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

■

Tramming is limited to sump speed while the cutters are on.

■

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

________________________________________________________________ 5.35 CM340 Continuous Miner

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

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

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

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

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

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

______________________________________________________________ A6474X319 Rev 1 5.36

Operation____________________________________________________ Blowing system operation To operate the blowing system  Place damper lever and bi-directional intake lever on the plenum box in desired position.  Ensure that the pump motor is running as the blowing system fan motor will not start if the pump motor is not running.  Press “SHIFT” and wait 1/4 second.

IMPORTANT! Holding the “SHIFT” button for two (2) seconds or longer will result in a radio switch fault. If this occurs, all buttons must be released and the start re-attempted.  While holding shift, press “FAN/OFF”. The pre-start warning horn will sound. Continue to hold until the blowing system fan motor turns on.  Release the “FAN/OFF” button. The pre-start warning horn will stop.

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

To stop the blowing system fan motor  Press and hold the “FAN/OFF” button. The fan motor will shutdown immediately.  Release the “FAN/OFF” button.

________________________________________________________________ 5.37 CM340 Continuous Miner

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

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

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

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

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

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

________________________________________________________________ 5.38 CM340 Continuous Miner

Operation____________________________________________________ Control headlights and area lights The light switch has three positions: area lights only, all on and all off.

When the power is turned on to the continuous miner, the methane monitor relay is closed and the light switch is off. When the light switch is turned to the all on position, the headlights and the area lights will come on. When the light switch is turned to the area lights only position, the headlights only (not the area lights) can be turned on and off with the radio.

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

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

________________________________________________________________ 5.39 CM340 Continuous Miner

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

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

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

______________________________________________________________ A6474X319 Rev 1 5.40

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

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

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

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

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

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

________________________________________________________________ 5.41 CM340 Continuous Miner

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

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

The solenoid controlling the conveyor lower function will remain energized until the key is released.  Press the “CONVEYOR UP” key to raise the conveyor boom. The solenoid controlling the conveyor raise function will remain energized until the key is released.

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

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

______________________________________________________________ A6474X319 Rev 1 5.42

___________________________________________________ Operation Typical cutting sequence CAUTION! Always ensure operator safety while operating the machine. Be alert for hazardous conditions and take corrective action as necessary. Failure to be alert and correct hazardous situations may result in serious injury.

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

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

IMPORTANT! Tram is limited in the forward direction while the cutters are running with the cutter head feedback circuit. As the cutter head begins to cut the material from the face, the sump speed will automatically slow the tram down to prevent over sumping the machine.  Continue to sump until the desired depth of cut is achieved. The depth of the sump will depend on the type of material being cut, the diameter of the cutter drum, and bit lacing.  Release tram levers.

______________________________________________________________ A6474X319 Rev 1 5.43

Operation____________________________________________________  Shear down (lower cutter head). The shear down rate is controlled by a shear down relief valve to limit the hydraulic pressure being applied to the cylinders. This is an adjustable feature and can be easily changed as mining conditions change.  To maintain smooth, level floor conditions, it may be necessary to tram the machine backward approximately 36 in., thus trimming ridges and smoothing the floor. This may or may not be necessary each cut sequence depending on mine conditions.  Repeat this procedure to desired depth of cut.  Turning crosscuts is accomplished by making a series of partial cuts (sumps) until the machine can be turned to the desired angle.

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

________________________________________________________________ 5.44 CM340 Continuous Miner

___________________________________________________ Operation Mining operations It is presumed that the operator of this machine is experienced in continuous mining techniques. This section of the manual will present some basic rudiments of Continuous Miner mining operations, but should not be considered in any way as a complete how-to of mining techniques. It is recognized that each mine will have their own methods and techniques which work best for them.

One of the keys to good productivity with a Continuous Miner is to know the correct depth of sump which, when the cutting cycle is completed with shear-down, gives enough coal to adequately fill one haulage vehicle.

Another important factor is to do as much advance cutting as possible, while awaiting the haulage vehicle, to load up the gathering head pan.

When the vehicle arrives, the gathering head can then work at maximum efficiency to load out the accumulated coal while the remainder of the cutting cycle is being completed.

The following discussion outlines the various steps of an efficient Continuous Miner mining cycle.

Preparation of the face for the next cut The first view in Fig. 31 shows a continuous miner approaching a freshly cut face. The operator has the cutter head lowered to prepare for making a 2 to 3 inch deep sump cut at the bottom of the face. This is done to make clearance for the gathering head blade when the miner is sumping at the top of the face. In this manner, the miner can make a deeper sump into the top of the face.

The next view in the figure shows the miner having made a 30 inch sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutter head to the mine roof.

In the final view, the operator has backed out of the bottom cut and raised the cutter head to the roof, positioning the miner for making a top sump.

______________________________________________________________ A6474X319 Rev 1 5.45

Operation____________________________________________________ Fig. 31: Preparation of the face for the next cut

Approaching a freshly cut face

30” sump cut at the bottom of the face

Positioning for top sump

________________________________________________________________ 5.46 CM340 Continuous Miner

___________________________________________________ Operation The next face cut Having cut bottom clearance for the gathering head blade, the operator can now make a deep sump at the top such as a full drum diameter as shown in the first view of Fig. 32. He can commence his down-cut until his gathering head pan is full. Optimally, all this is being done while awaiting the next haulage car so that maximum loading rate can be achieved when the car arrives.

While loading the haulage car, the operator completes the down-cut to the mine bottom as shown in the second view of Fig. 32.

Depending on the depth of the top sump, a small cusp of coal will be left behind the drum on the mine bottom. This cusp is removed by backing the miner out of the face a small distance while the cutter head is running.

The miner is now in a similar position as that shown in the first view of Fig. 31 and the operator can proceed with the next cutting cycle.

Using the stabilizer shoe The stabilizer shoe is located under the rear deck of the main frame and beneath the conveyor. It is hinged at its front edge and is lowered by a hydraulic cylinder.

The stabilizer shoe serves two purposes: ■

To elevate the rear of the miner for maintenance work.

■

To provide stability, if necessary, during sumping.

■

To provide a higher down-cut force at the coal face while shearing down during mining operations.

The advantage of increasing down-cut force at the face while shearing down is important particularly when cutting hard coal seams. Fig. 33 illustrates the advantage of the stabilizer shoe in the down-cut application.

Fig. 32: The next face cut

Miner sumps in at top and begins down cut

Miner completes down cut with small cusp remaining

______________________________________________________________ A6474X319 Rev 1 5.47

Operation____________________________________________________ The miner is shown in the middle of its shearing down cycle in Fig. 33.

Without the stabilizer shoe deployed, the machine will tend to rock back on the rear of the crawlers. The distance from the miner’s center-ofgravity to the rear of the crawlers is noted as “Lever Arm w/o Stab Shoe”.

Conversely, with the stabilizer shoe deployed, the miner will now tend to rock back on the shoe, providing a longer lever arm. In the case of this miner, the lever arm with the stabilizer shoe down is more than twice the lever arm without the stabilizer shoe, thus doubling the down force available for shearing down. This increase in down-cut force will improve the speed and efficiency of the shear down portion of the cutting cycle.

The miner is configured with an optional automatic stab function which will lower the stab during the shear down cycle and raise it again automatically.

Fig. 33: Effect of using stabilizer shoe on down cut force

Downcut Force Machine Weight

Lever Arm W/O Stab Shoe Lever Arm With Stab Shoe

Shearing down Most Continuous Miners have their center-of-gravity located forward of the center of the crawler footprint. This weight distribution makes the miner inherently more effective in shearing down because shearing down takes advantage of the miner’s weight to maximize down-cut force.

The first view in Fig. 34 shows the miner having sumped in at the top of the coal face. The second view shows the miner in the middle of the down cut.

________________________________________________________________ 5.48 CM340 Continuous Miner

___________________________________________________ Operation Fig. 34: Shearing down

______________________________________________________________ A6474X319 Rev 1 5.49

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

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

Main Chassis The main chassis of the machine (Fig. 35) is a heavy duty box type structure of high-strength steel that provides the following: ■

Mounting of the right and left hand crawler tracks and their independent drive systems and take-up provisions.

■

Independent pivots for mounting the cutting head, gathering head, conveyor components, and their associated hydraulic cylinders for articulation.

■

An integral hydraulic oil tank, along with an electric motor/hydraulic pump assemblies and associated valves and piping.

■

A rear stabilizer and its hydraulic cylinder for improving leverage forces during shear down in the cutting sequence.

■

Mounting provisions for all major electrical system components and their associated wiring.

■

Mounting provisions for conveyor lift, cutter raise, and gathering head raise cylinders.

Fig. 35: Main Chassis Stabilizer shoe cylinder clevis

Left rear deck Blowing system components

Cutter head pivot

Gather head cylinder clevis Crawler idler guides

Rear bumper plate

Crawler idler guides Cutter head cylinder clevis

Right rear deck Electrical control case

Oil tank

Gather head cylinder clevis

______________________________________________________________ A6474X319 Rev 1 5.50

Mechanical assemblies ________________________________________ Gathering head assembly The gathering head assembly (Fig. 36) is attached to the main chassis at right and left hand pivot points. The assembly is articulated around these pivot points to adjust the gathering head for uneven floor conditions and when tramming the miner. The independent pivots allow removal of the gathering assembly without disturbing the cutting head or discharge conveyor.

The gathering head assembly includes: ■

Upper mounting clevises for the two externally mounted gathering head raise cylinders.

■

(2) Water cooled electric motors, input gear cases, and a gathering head pot which drives a rotating centrifugal loading arm device.

The gathering head assembly is raised and lowered by two hydraulic cylinders which are mounted to the main chassis at their lower ends and to the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head (see the general arrangement drawing for you machine for dimensions).

The right and left hand gear cases are connected to a common foot shaft which provides proper timing of the CLAs and drive power to a sprocket which drives the conveyor chain. The conveyor chain drives is reversible to aid in clearing debris which might restrict conveyor chain movement. The CLA input case is driven by a shear shaft which is designed to prevent damage to gearing as a result of jamming.

Fig. 36: Gathering head assembly

Foot shaft Motor

CLA

________________________________________________________________ 5.51 CM340 Continuous Miner

_______________________________________ Mechanical assemblies Conveyor assembly The conveyor assembly (Fig. 37) is attached to the main chassis at right and left hand independent pivot points. The conveyor is articulated vertically around these pivot points to assist in optimum loading into a haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

The conveyor assembly includes the following: ■

An intermediate conveyor structure that includes the right and left hand pivot points for attaching to the main chassis, upper mounting clevises for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.

■

A rear conveyor subassembly that includes: –

a mating horizontal pivot arrangement allowing sideward swinging movement up to 45° on either side of the machine center line to assist in optimum loading into a haulage vehicle, and

–

a tail roller shaft for the conveyor chain and two hydraulic cylinders to maintain proper tension in the chain when the geometry of the conveyor assembly changes during the operation.

The intermediate and discharge conveyor structures each include a special noise dampening running deck for the conveyor chain and a throat clearance designed for optimum loading rates (see the general arrangement drawing for you machine for dimensions).

Fig. 37: Conveyor assembly

Intermediate conveyor section Chassis pivot points Conveyor pivot pin Rear conveyor section

______________________________________________________________ A6474X319 Rev 1 5.52

Mechanical assemblies ________________________________________ Traction drive system The traction drive system (Fig. 38) provides the mobility for mining operations and for tramming from place to place. It includes: ■

Independent right and left drive systems, each consisting of a water cooled electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective right or left crawler chain.

■

A forward mounted crawler chain idler roller on each side which is equipped with a grease powered piston to adjust the crawler chain to its proper tension.

■

An electrical drive system which provides the operator with three variable speed ranges: –

3rd speed - used mainly for tramming from one working face to another.

–

2nd speed - used mainly for rapid repositioning of the miner within the face area.

–

Sump speed - fully adjustable by the operator to a preset value - used for sumping the miner into the face. The adjustable sump speed allows the operator to select an optimum cutting speed based on varying hardness conditions. The sumping speed is maximized through a proportional and differential cutter feedback system.

The traction drive control system provides the operator with the capability to run either right or left hand crawler chain in forward or reverse independently for maximum maneuverability (for example, the miner may be pivoted about its central vertical axis). Both drive trains are equipped with fully enclosed, multiple disc, fail safe, hydraulic flushed parking brakes that are spring applied and hydraulically released (optional).

The crawler chains are manufactured from high alloy, wear resistant steel for maximum life and are equipped with grouser ridges to enhance traction in both hard and soft floor conditions.

Fig. 38: Traction drive system

Crawler track Drive gear case

Electric motor

________________________________________________________________ 5.53 CM340 Continuous Miner

_______________________________________ Mechanical assemblies Stabilizer shoe A stabilizer shoe (Fig. 39), located beneath and at the rear of the tractor frame, may be lowered to anchor the back end of the machine and provides a greater downward thrust of the cutter head for hard-cutting while preventing backward creep of the miner. The stabilizer shoe is raised and lowered hydraulically by a double acting cylinder that moves the shoe bracket up or down.

Fig. 39: Stabilizer shoe

Stabilizer shoe

______________________________________________________________ A6474X319 Rev 1 5.54

Mechanical assemblies ________________________________________ Cutting head assembly The cutting head assembly (Fig. 40) is attached to the main chassis at right and left hand independent pivot points around which the assembly is articulated for vertical ranging cutting. The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

The cutting head assembly consists of the following: ■

The cutting head support frame. The frame is a heavy duty box structure which includes the right and left pivot points for attaching to the main chassis, upper mounting clevises for the two cutting head raise cylinders, and a bolting flange to which the cutting head drive assembly mounts.

■

The cutting head gear case assembly, which consists of an input gear case and water-cooled electric drive motor for each of the right and left hand sides, a final drive gear case which includes drive gearing, a main drive shaft, and mounting points for the right, left, and center drums, and a bolting flange for mounting onto the cutting head support frame.

■

Provides for both front and rear flange support of the cutter motors.

The cutting head assembly is raised and lowered by two (2) heavy duty hydraulic cylinders mounted to the main chassis at their lower ends and to the main longitudinal structural members of the cutting head support frame at their upper ends. These cylinders enable the cutting head assembly over a predesigned range (see the general arrangement drawing for you machine for dimensions).

The power train of the cutting head consists of right and left sides, which tie together at the common main drive shaft, allowing the combined power of both electric drive motors to be available at one point on the cutting drums.

Fig. 40: Cutting head assembly

Cutter head pivot Cutter head cylinder

Cutter head motor Cutter head gear case

Cutter head drum

________________________________________________________________ 5.55 CM340 Continuous Miner

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

Fig. 41 gives an overview of hydraulic cylinders located on the CM340 Continuous Miner. Fig. 42 shows the location of other hydraulic components.

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

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

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

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

■

maintaining a sufficient oil level in the tank;

■

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

■

changing filters and fluids at prescribed intervals.

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

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

______________________________________________________________ A6474X319 Rev 1 5.56

Hydraulic ____________________________________________________ Fig. 41: Cylinder locations

Cutter head raise cylinder

Gathering head raise cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Cutter head raise cylinder

Gathering head raise cylinder

Gathering head cylinder

Cutter head raise cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Conveyor lift cylinder

Stabilizer shoe cylinder

Conveyor swing cylinder

Conveyor chain take-up cylinder

Conveyor chain take-up cylinder Conveyor chain take-up cylinder

________________________________________________________________ 5.57 CM340 Continuous Miner

___________________________________________________ Hydraulic Fig. 42: Hydraulic component location

Pilot pressure filter Return filter (3 and 10 micron replacement elements)

Hydraulic pump

Gathering head float valve

Tank magnet Breather Breather

Oil level switch

0-4000 psi pressure gauge Main control valve Anti-chatter/maintenance valve 0-600 psi pressure gauge Relief valve

Conveyor take-up chain valve 0-600 psi pressure gauge

Solenoid valves (2) 2-unit solenoid manifold Shuttle valve Ball valve Check valve 3-way direction valve Water boost pump assembly PC flow control valve Oil filter bypassing 10 micron replacement element Relief valve 0-4000 psi pressure gauge

______________________________________________________________ A6474X319 Rev 1 5.58

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

Graphic symbols denote the type of function a component performs but do not necessarily s h o w its s h a pe o r c ons tr uc t i on . T h es e schematic symbols are used to trace the system flow from the reservoir to the actual work being performed and then back to the reservoir.

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

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

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

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

________________________________________________________________ 5.59 CM340 Continuous Miner

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

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

The MCV (Fig. 43) is typically located on the right side of the machine.

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

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

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

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

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

■

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

■

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

______________________________________________________________ A6474X319 Rev 1 5.60

Hydraulic ____________________________________________________ Fig. 43: Main control valve

________________________________________________________________ 5.61 CM340 Continuous Miner

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

To follow oil flow through a system, visually imagine the valve spool shifting as shown in Fig. 44.

Fig. 44: Oil flow through a spool

______________________________________________________________ A6474X319 Rev 1 5.62

Hydraulic ____________________________________________________ accumulator

An accumulator (Fig. 45) is essentially a fluid pressure storage chamber in which the potential energy of a fluid under pressure can be stored against a compressible force of a gas to do useful work.

The stored fluid is readily available to perform a given task when called upon by the requirements of the system in which it is used.

breather

A breather (Fig. 45) permits air to move in and out of the oil tank reservoir to maintain atmospheric pressure.

cylinders

Cylinders (Fig. 45) are bored and honed steel tubes enclosing a piston connected to a rod that extends out the end of the cylinder.

Working surfaces are ground and finely finished, with seals and gask ets incorporated to prevent leakage. Fig. 41 illustrates the location of the hydraulic cylinders on the miner.

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

Fig. 45: Accumulator and cylinder hydraulic symbols

Accumulator

Cylinder, single acting

Breather

Cylinder, single acting

Cylinder, single acting telescopic with dry pocket and load holding valve with external thermal atmosphere relief

Cylinder, double acting

Cylinder, single acting with dry pocket

Cylinder, double acting with load holding valve with internal thermal atmosphere relief

________________________________________________________________ 5.63 CM340 Continuous Miner

___________________________________________________ Hydraulic filters

Filters and strainers (Fig. 46) are designed to protect a hydraulic oil system from harmful levels of particulate contamination. High levels of contaminants accelerate wear of components, cause improper functioning, and add to system sluggishness. Other problems such as seizure of parts, higher temperatures due to increased fluid friction, leakage, and loss of control may occur. Contamination also contributes to oxidation and chemical breakdown of the fluid.

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

When a non by-passing filter element starts clogging with trapped particles, the radio system/solenoid functions will slow down, indicating it is time to change the element. For filter element maintenance and changing schedules, see the Maintenance section in this chapter.

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

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

Fig. 46: Filter hydraulic symbols

Filter, bypassing

Filters, non-bypassing

______________________________________________________________ A6474X319 Rev 1 5.64

Hydraulic ____________________________________________________ flow meter orifice

A flow meter (Fig. 47) is a visual device which indicates the volume of fluid passing through it per unit of time.

An orifice (Fig. 47) is a device that restricts flow.

pressure/return manifold

A pressure manifold (Fig. 47) has one inlet port and many outlet ports to supply flow to many circuits. A return manifold has many inlet ports and only one outlet port for flow to return to tank. Note: You can have the same part number for a pressure or return manifold.

pressure gauge

A pressure gauge (Fig. 47) is a visual device used to indicate the pressure in a hydraulic or water circuit.

pump

The purpose of a pump (Fig. 47) is to produce flow; it does not pump pressure. Pressure is caused by a resistance to flow. All system components have some resistance to flow. Hydraulic cylinders, which power machine functions, are the major components causing this resistance.

Each circuit is protected by a relief valve so that the pressure in the system will not exceed the rating of its components. To ensure that everything works correctly and in proper sequence, relief valve pressure settings closely match the load requirements.

The miner is equipped with a multi-section gear-type fixed displacement hydraulic pump assembly. Each section consists of two closely-meshed gears inside a tightly-fitted housing.

quick disconnect female/male coupling

A quick disconnect (Fig. 47) is a coupling which can quickly join or separate lines.

Fig. 47: Hydraulic symbols

Flow meter

Pump, hydraulic two section

Orifice

Pressure gauge

Pressure/return manifold

Pump, jet

Quick disconnect male half coupling

Quick disconnect female half coupling

________________________________________________________________ 5.65 CM340 Continuous Miner

___________________________________________________ Hydraulic Valves The hydraulic symbols for the different types of valves are given in Fig. 48. ball valve check valve directional control valve

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

A valve that allows fluid flow in one direction only.

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

flow control valve

A valve with a primary function of controlling flow rate.

flow control valve with internal check

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

load holding valve (load lock valve) (overcenter valve)

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

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

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

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

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

______________________________________________________________ A6474X319 Rev 1 5.66

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

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

There are no adjustments required on the load holding valves.

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

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

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

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

relief valve

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

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

Some relief valves are atmospheric. These valves are used for overpressure protection only. Should the preset pressure be reached, they discharge oil into the air. An example of this is on the conveyor raise circuit where the pressure is set to relieve at 2,800 psi, which is well above expected operating pressures.

________________________________________________________________ 5.67 CM340 Continuous Miner

___________________________________________________ Hydraulic There are a number of relief valves in the hydraulic system that are set for individual sub-circuit protection (conveyor elevation, gathering head, etc.). Each pump section also has a main relief valve for protection against over-pressurization. The main hydraulic pump section is typically set at 2,800 ps. The pilot section is typically set at 600 psi. .

For relief valve adjustment procedures, see the Adjustment section of this chapter. shuttle valve

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

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

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

When the bottom coil is energized, the spool shifts and allows oil flow to “A” port. When the top coil is energized, the spool shifts and allows oil flow to “B” port. Unless a detent spool is being used, the spool will spring return to the neutral position when the coil is de-energized.

solenoid valve (with radio option)

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

water valve, hydraulic piloted

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

water valve, detent hydraulic piloted

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

______________________________________________________________ A6474X319 Rev 1 5.68

Hydraulic ____________________________________________________ Fig. 48: Valve hydraulic symbols

Check valve

Flow control valve

Flow control valve with internal check

Ball valve

Pressure reducing/ relieving valve Multipurpose valve

Shuttle valve

Relief valve Solenoid valve 2-unit

Water valve, hydraulically piloted, detented

Water valve, hydraulically piloted

________________________________________________________________ 5.69 CM340 Continuous Miner

___________________________________________________ Hydraulic Y-strainers hydraulic y- strainer

main water reverse flushing strainer

There is a y-strainer (Fig. 49) in the supply line of the hydraulic oil fill circuit. The y-strainer contains a replaceable element to filter out contaminants when adding oil to the system. Nevertheless, oil stocked to be added to this system should be kept in closed containers to prevent contamination of the hydraulic system.

There is a reverse flushing strainer on the water inlet supply circuit.

Fig. 49: Y-strainer symbol

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

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

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

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

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

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

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

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

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

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

Viscosity: A measure of the internal friction, or resistance to flow, of a fluid.

______________________________________________________________ A6474X319 Rev 1 5.70

Hydraulic ____________________________________________________ Hydraulic pump assembly circuit Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 50). This pump utilizes two working sections designated as follows: A1 (main flow) and A3 (pilot flow). Oil is supplied from the oil reservoir through a suction line and a locking ball valve to the pump inlet ports.

IMPORTANT! The two inch locking ball valve must be locked open in normal operation.

The two inch locking ball (shut-off) valve to the pump is to assist the field personnel in changing the pump. The ball valve will reduce loss of hydraulic oil and minimize contamination of the hydraulic circuit. After changing the pump, always be sure the shut-off valve is turned to open and the locking device is replaced.

Fig. 50: Hydraulic pump circuit

________________________________________________________________ 5.71 CM340 Continuous Miner

___________________________________________________ Hydraulic Main flow - primary pressure circuit The main flow-primary pressure circuit is powered by hydraulic pump gear section A1. The A1 gear section is rated at 114 Lpm at a pressure of 172 bar (30 gpm at 2,800 psi). This open-center circuit supplies oil flow to the main control valve. The main control valve operates the cutter head, conveyor raise and swing, gathering head, and stabilizer shoe cylinders. From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 193 bar (2,800 psi).

The pilot pressure circuit is powered by hydraulic pump gear section A3. The A3 gear section is rated at 28 Lpm at a pressure of 35 bar (75 gpm at 500 psi). This open center circuit supplies oil to the mid-inlet section of the main control valve. The mid-inlet section feeds the booster pump/high speed cutter head raise control valve. From the pump, oil enters a 10 micron by-passing pressure filter and continues to the mid-inlet section of the main control valve, whose relief is set at 156 bar (2,300 psi).

Oil from both the main and pilot circuits exits the main control valve and passes through a tank return manifold to a 10 micron by-passing return filter before entering the oil reservoir. Once in the reservoir, the oil is forced to flow through and around baffle plates for cooling and deaerating before re-entering the suction line. Also, there are floor magnets located in the reservoir to trap ferrous metal particles.

The schematic shown in Fig. 51 is a typical primary pressure circuit.

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

Fig. 51: Main flow-primary pressure circuit

______________________________________________________________ A6474X319 Rev 1 5.72

Hydraulic ____________________________________________________ Pilot pressure circuit The pilot hydraulic section is a closed-center system powered by pump section A3. It supplies oil flow to the following: ■

hydraulic tension conveyor chain take-up

■

gathering head float circuit, and

■

all solenoid valves, which control the dust sprays and all main control valve functions.

The pilot gear section is rated at 31 Lpm at a pressure of 34 bar (8 gpm at 500 psi). A relief valve is used to set the pump to this pressure. From the pump, oil flows to the hydraulic tension conveyor chain take-up through a reducing/relieving valve that is set at 14 bar (200 psi). Pilot pressure oil also flows to a 3 micron non by-passing pressure filter and on to the solenoid valves and the gathering head float circuit.

The schematic shown is Fig. 52 is typical for a pilot pump circuit. Always refer to the schematic in your parts book for your machine.

Fig. 52: Pilot pressure circuit

________________________________________________________________ 5.73 CM340 Continuous Miner

___________________________________________________ Hydraulic Tank Ports The manufacturer filters the oil system on all new Continuous Miners according to a minimum ISO code 19/17/14 for cleanliness. Return oil from hydraulic system components connect to a common tank return manifold. Oil flows from the return manifold to a 10 micron by-passing return filter before entering the oil reservoir. The oil tank reservoir includes the oil level switch, a dipstick and two tank breathers.

The schematic shown is Fig. 53 is typical for tank port connections.

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

Fig. 53: Tank port connections

______________________________________________________________ A6474X319 Rev 1 5.74

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

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

Oil is supplied by hydraulic pump section A1 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. The cutter head cylinder is a double acting cylinder with a load holding cartridge. there are two (2) cutter head cylinders, one on each side of the machine.

To manually raise the cutter head (extend the cutter head cylinders), move the handle on the remote control valve down. This increases the pressure in the B port on the remote control valve which increases the pressure in the pilot cylinder (raise) on the cutter head directional control valve moving the spool to allow oil to flow to the B port on the cutter head directional control valve. Oil flows from the B port on cutter head directional control valve to Port P2 on anti-chatter/maintenance section of the Multipurpose Valve free flowing through the check valve to Port P1 on to the extend port on the cutter head cylinders, free flowing through the check valve of the load holding cartridge to extend the cylinders and raise the cutter head. Oil from the retract side of the cutter head cylinder returns to the A port of the cutter head directional valve. The cutter head raise circuit is protected by a port relief that is set at 207 bar (3,000 psi).

To manually lower the cutter head (retract the cutter head cylinders), move the handle on the remote control valve up. This increases the pressure in the A port on the remote control valve which increases the pressure in the pilot cylinder (lower) on the cutter head directional control valve moving the spool to allow oil to flow to the A port on the cutter head directional control valve. Oil flows from the A port on cutter head directional control valve to the retract port on the cutter head cylinders, piloting open the load holding cartridge to allow flow out of the extend port on the cylinder. Oil from the extend side of the cutter head cylinder flows to the P1 Port on the anti-chatter/maintenance section of the Multipurpose Valve through a counterbalance valve to Port P2 then to the B port of the cutter head directional valve.

________________________________________________________________ 5.75 CM340 Continuous Miner

___________________________________________________ Hydraulic The anti-chatter/maintenance section of the multipurpose valve has three primary functions: ■

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

■

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

■

It allows for bypassing of the counterbalance valve to eliminate the back pressure against the shear cylinder pistons. This provides the maximum pressure differential between the two sides of the shear cylinders which allows the machine to be raised off the ground(jack -knifed).

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

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

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

This schematic shown is Fig. 54 is a typical cutter head cylinder circuit.

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

______________________________________________________________ A6474X319 Rev 1 5.76

Hydraulic ____________________________________________________ Fig. 54: Cutter head raise circuit

________________________________________________________________ 5.77 CM340 Continuous Miner

Hydraulic ____________________________________________________ Conveyor raise/lower circuit Reference Fig. 55. conveyor raise/lower

Oil is supplied by hydraulic pump section A1 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. The conveyor raise/lower cylinder is a single acting cylinder with a relief valve and a pilot operated check valve on the extend port. There are two (2) conveyor raise/lower cylinders.

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 124 bar (1,800 psi).

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 through a 10-micron bypassing return filter to tank. The conveyor lower circuit is protected by a port relief that is set at 97 bar (1,400 psi).

Fig. 55 is typical conveyor raise/lower circuit schematic. Always refer to the schematic in your parts book for your machine.

________________________________________________________________ 5.78 CM340 Continuous Miner

___________________________________________________ Hydraulic Fig. 55: Conveyor raise/lower

______________________________________________________________ A6474X319 Rev 1 5.79

Hydraulic ____________________________________________________ Conveyor swing circuit Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The conveyor swing cylinder is a double-acting cylinder. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions. The descriptions below for left and right movement are based on an individual standing at the rear of the machine looking forward to the cutter head.

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 125 bar (1,800 psi).

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 125 bar (1,800 psi).

The schematic shown is Fig. 56 is a typical conveyor swing cylinder circuit. Always refer to the schematic in your parts book for your machine.

Fig. 56: Conveyor swing cylinder circuit

________________________________________________________________ 5.80 CM340 Continuous Miner

___________________________________________________ Hydraulic Gathering head raise/hold/float-lower circuit Reference Fig. 57.

Oil is supplied by hydraulic pump A2 through a 10 micron by-passing pressure filter 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/hold/float-lower circuit. The gathering head cylinder is a single acting cylinder. There are two (2) gathering head cylinders, one on each side of the machine.

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 with the number “7” in the gathering head float section of the Multipurpose valve and is directed to both cylinder extend ports. Counterbalance Valve number 7 also is marked with a stamped “VR” on the Manifold block.

At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the valve (or deenergizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 152 Bar (2,200 psi) when in the raise and hold position.

To put the gathering head pan in the float-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 section of the Multipurpose valve to tank and allows control of the gathering head lower via the valves in the block. Counterbalance valve “7” (VR) is set to relieve at 83 bar (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-lower 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. This condition also moves the machine’s center of gravity forward when mining.

The relief valve that is designated by the number “6” in the gathering head float section of the Multipurpose valve is set to relieve at 124 bar (1,800 psi). This valve is also marked with a stamped “CR” on the manifold block. This fixed setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head. This can occur if the cutter head is lowered onto a raised gathering head pan or by some other external force. The “CR” valve will relieve pressure in the circuit regardless of the position of the control valve (raise, hold or float-lower).

The pilot pressure supply for the gathering head float comes from hydraulic pump A3 through a 3 micron non by-passing filter, to the “pilot” port of the gathering head float section of the Multipurpose valve. The pilot pump provides make-up oil for the gathering head cylinders when the pan goes over uneven terrain and raises quickly. and extend the gathering head cylinders at a rapid rate. ______________________________________________________________ A6474X319

Rev 1

5.81

Hydraulic ____________________________________________________ This temporary condition can create high demand for pilot oil. An orifice is located in the pilot supply circuit of the Multipurpose valve to prevent the pilot demand from reducing the pilot pressure to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are energized. If this demand were to be too great, it is possible to experience a momentary loss of radio control of the machine. If counterbalance valve “7” (“VR”) is set to a pressure below the pilot pressure setting, it will create a path for the pilot pressure to return to tank and may result in loss of pilot pressure.

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.

Each single acting gathering head raise cylinder is equipped with a dry pocket to provide additional stroke beyond its normal hydraulic stroke.

This feature provides protection in the event that the gathering head is trammed into an obstruction forcing it to raise beyond its hydraulic stroke limit.

The schematic shown in Fig. 57 is a typical gathering head circuit. Always refer to the schematic in your parts book for your machine.

________________________________________________________________ 5.82 CM340 Continuous Miner

___________________________________________________ Hydraulic Fig. 57: Gathering head circuit

______________________________________________________________ A6474X319 Rev 1 5.83

___________________________________________________ Hydraulic Stabilizer shoe cylinders circuit Oil is supplied by hydraulic pump section A1 through a 10-micron bypassing pressure filter 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. The stabilizer shoe cylinder is a double-acting cylinder with a load holding cartridge and integrated thermal relief. There are two stabilizer shoe cylinders.

To manually raise the stabilizer shoe (retract the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the stabilizer raise (SSU) solenoid. Oil flows to port “P2” on the stab shoe soft touch valve block, free flowing through the check valve out of port “P1” and continues to the retract port of the cylinders. This oil also pilots open the load holding cartridge, allowing oil to exit the extend port of the cylinders. The stabilizer raise circuit is protected by a port relief that is set at 193 Bar (2,800 psi).

To manually lower the stabilizer shoe (extend the cylinders), push the valve’s handle. Remote operation is achieved energizing the stabilizer lower solenoid (SSD). Oil flows to the extend port of the cylinders by free flowing through the check valve on the load holding cartridge.

NOTICE! To jack-knife the miner, the stabilizer shoe is first lowered with the bypass valve opened. The cutter head is then lowered with the bypass opened. At this point, the machine can be inspected, adjustments can be made to the crawler tracks, and the tram voltage can be adjusted.

The schematic shown is Fig. 58 is a typical stabilizer shoe cylinder circuit. Always refer to the schematic in your parts book for your machine.

Fig. 58: Stabilizer shoe circuit

______________________________________________________________ A6474X319 Rev 1 5.84

___________________________________________________ Hydraulic Conveyor chain take-up circuit (optional) The pilot-auxiliary hydraulic pressure circuit is powered by hydraulic pump gear section A3 which is rated at 28Lpm at 35 bar (7.5 gpm at 500 psi). From the pump, oil flows from the 10 micron by-passing pilot pressure filter to the “In” port of the hydraulic conveyor chain take-up section of the Multipurpose valve and “Out” to the two conveyor chain take-up cylinders. The conveyor chain take-up section consists of a check valve to hold pressure in the circuit and a pressure reducing/ relieving cartridge maintain a constant pressure of 200 psi in the circuit.

The reducing/relieving valve reduces pilot pressure to 200 psi and relieves any pressure spikes caused by forces acting against the conveyor of the miner.

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 is incorporated into the valve block for maintenance and troubleshooting.

DANGER! Never run the conveyor without the needle valve closed. Injury or death may occur.

Fig. 59 is a typical conveyor chain take-up circuit. Always refer to the schematic in your parts book for your machine.

______________________________________________________________ A6474X319 Rev 1 5.85

Hydraulic ____________________________________________________ Fig. 59: Conveyor chain take-up circuit

________________________________________________________________ 5.86 CM340 Continuous Miner

______________________________________________________ Water Water system overview A water supply to the continuous miner is required for the following purposes: ■

cooling water for motors, transformers, etc.

■

spray water for dust and fire suppression

■

wash down hoses

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

minimum flow rate of 30 gpm for cooling

■

total flow rate: based on customer dust plan

■

minimum pressure of 70 psi (dynamic), 500 psi maximum

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

The water system circuits described below are for a typical CM340 series 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.

______________________________________________________________ A6474X319 Rev 1 5.87

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. Immediately after are connections for two optional wash down hoses, one on the left hand side of the miner and one on the right side. The mine water then passes through a strainer that is equipped with an automatic back-flush feature.

From the strainer, the water is directed to the water distribution manifold where it supplies the dust spray/cooling valves. The supply to the water distribution manifold is monitored with a flow meter to provide protection to other critical components on the machine. Please refer to the electrical control section of this manual for further information.

Gauges measure the pressure of the mine water. For component location see Fig. 61.

The water supply circuit described above (Fig. 60) is for a typical CM340 series 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.

Fig. 60: Water supply circuit

________________________________________________________________ 5.88 CM340 Continuous Miner

Water _______________________________________________________ Fig. 61: Dust-cooling component locations CH front spray manifold

CH front spray manifold

CH front spray manifold

LH cutter side spray manifold

CH bottom spray manifold

GH spray manifold

CH bottom spray manifold

GH spray manifold

Washdown manifold

Atmospheric relief

Cleaning spray manifold

Washdown manifold

________________________________________________________________ 5.89 CM340 Continuous Miner

Water _______________________________________________________ Dust-cooling water supply circuit The dust-cooling water circuit utilizes water supplied from the water distribution manifold and is operated by remote solenoid control (see Electrical section in this chapter). When the dust-cooling solenoid is energized, it shifts a spool, allowing hydraulic oil to travel to the hydraulic pilot operated normally closed water valve. The hydraulic oil shifts the spool, allowing water to pass through it to the secondary dustcooling pressure manifold. The secondary dust-cooling pressure manifold distributes water to four dust-cooling circuits: 1. relief valve 2. right cutting motor 3. left cutting motor 4. left tram, pump and CLA motors.

For the hydraulic portion of this circuit, see the Hydraulic section of this chapter. The dust-cooling water circuit is protected by a relief valve that is set at 24 bar (350 psi).

The dust-cooling circuit described above is for a typical CM340 series 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.

Fig. 62: Dust-cooling water supply circuit

________________________________________________________________ 5.90 CM340 Continuous Miner

______________________________________________________ Water Right hand chassis spray cooling circuit From the secondary dust-cooling pressure manifold, water is supplied to the right hand chassis spray cooling circuit where it supplies spray/ cooling water to the following components: control case, RH tram motor, transformer, RH CLA motor, RH GH pan sprays, bottom cutter head sprays, RH cutter head sprays and the throat sprays.

The right hand chassis spray cooling circuit described above is for a typical CM340 series 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.

Fig. 63: Dust-cooling right hand chassis circuit

______________________________________________________________ A6474X319 Rev 1 5.91

Water _______________________________________________________ Left hand chassis spray cooling circuit From the secondary dust-cooling pressure manifold, water is supplied to the left hand chassis spray cooling circuit where it supplies spray/ cooling water to the following components: LH tram motor, pump motor, LH CLA motor, LH GH pan sprays, LH bottom cutter head spray, LH cutter head sprays and throat sprays.

The left hand chassis spray cooling circuit described above is for a typical CM340 series 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.

Fig. 64: Dust-cooling left hand chassis circuit

________________________________________________________________ 5.92 CM340 Continuous Miner

______________________________________________________ Water Left hand cutter head spray cooling circuit From the secondary dust-cooling pressure manifold, water is supplied to the left hand cutter head spray cooling circuit where it supplies spray/ cooling water to the following components: LH cutter head motor, LH cutter head sprays and center cutter head sprays.

The left hand cutter head spray cooling circuit described above is for a typical CM340 series 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.

Fig. 65: Left hand cutter head spray cooling circuit

______________________________________________________________ A6474X319 Rev 1 5.93

Water _______________________________________________________ Right hand cutter head spray cooling circuit From the secondary dust-cooling pressure manifold, water is supplied to the right hand cutter head spray cooling circuit where it supplies spray/cooling water to the following components: RH cutter head motor, RH cutter head sprays and center cutter head sprays.

The right hand cutter head spray cooling circuit described above is for a typical CM340 series 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.

Fig. 66: Right hand cutter head spray cooling circuit

________________________________________________________________ 5.94 CM340 Continuous Miner

Water _______________________________________________________ Blowing system cleaning spray circuit From the water distribution manifold, water is supplied to the blowing system cleaning spray circuit where it supplies spray water to the plenum in 2 places.

The blowing system cleaning spray circuit described above is for a typical CM340 series 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.

Fig. 66: Blowing system cleaning head spray circuit

________________________________________________________________ 5.95 CM340 Continuous Miner

___________________________________________________ Electrical Electrical system The following pages contain a brief description of the electrical components and assemblies located on the CM340 continuous miner.

WARNING! This section is intended only to familiarize the user with the electrical components of the continuous miner. All electrical maintenance should only be performed by a qualified electrician with knowledge of the functions of the components involved.

WARNING! Before removing the cover from the controller case or attempting any maintenance or troubleshooting, the main power must be disconnected and locked out at the main power center.

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

Schematics A schematic diagram is an illustration which shows the electrical relationship of the various components and the circuits. A schematic diagram does not show the physical location of the components. In an electrical schematic, components are shown in their de-energized position. A set of normally open contacts (N.O.) close when the coil is energized and a set of normally closed (N.C.) open when the coil is energized. Related components share the same designation. In tracing a particular circuit, it may be helpful to think of the flow of electricity as being similar to the flow of water through a hose. When a set of contacts are open, the current cannot flow across them, and when contacts are closed, the current can flow. When three (3) lines are connected in a tee, the current will flow in whatever direction that it can. Like water or hydraulic fluid, an electrical current will tend to follow the path of least resistance through a circuit. Finally, for a circuit to work, the electrical current must make a complete loop, similar to hydraulic fluid going through a circuit and returning to a tank.

______________________________________________________________ A6474X319 Rev 1 5.96

Electrical ____________________________________________________ Fig. 67: Standard electrical symbols

________________________________________________________________ 5.97 CM340 Continuous Miner

___________________________________________________ Electrical Fig. 68: Electrical component locator

Left cutter motor Right cutter motor

Inclinometer Left conveyor motor

Right conveyor motor

Pump motor Tram transformer

Hydraulic tank float switch

Conveyor junction box

Left tram motor Right tram motor

Main 3-phase circuit breaker enclosure Right antenna Blowing system (fan) motor Main control case Left antenna (optional)

Graphic display

Case machine stop Left machine stop

______________________________________________________________ A6474X319 Rev 1 5.98

Electrical ____________________________________________________ Fig. 69: Electrical component layout

1. Left cutter motor 2. Right cutter motor 3. Left CLA motor 4. Right CLA motor 5. Pump motor 6. Blowing system motor 7. Tram transformer case 8. Left tram motor 9. Right tram motor 10. Left emergency stop 11. Hydraulic oil level switch 12. Headlights 13. Headlights 14. Area lights

15. Area lights 16. Graphic display 17. Text display 18. Emergency tram pendant 19. Antenna 20. Solenoid junction box 21. Dust Spray 22. Fire spray 23. Methane displays 24. Methane sensors 25. Methane warning light

________________________________________________________________ 5.99 CM340 Continuous Miner

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

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

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

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

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

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

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

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

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

Temporary splices Trailing cables may only be repaired under certain conditions and following specific guidelines which are outlined in MSHA 30 CFR Part 75, Subpart G (Trailing Cables).

______________________________________________________________ A6474X319 Rev 1 5.100

Electrical ____________________________________________________ General The incoming 995V power supply is connected to the machine via the cable handler and the incoming main circuit breaker. AC power is then transferred to the main case where it is distributed via contactors to the pump, fan, cutter, and CLA motors. Power to the DC tram motors comes from the drives. A tram transformer reduces the incoming power to 350V for the drives. The control system operates at 110V AC and consists of the control transformer, the radio control unit, the graphic display, 110V control solenoids, and various power supplies and barriers. In addition to the control system, a methane and water monitoring system is installed as an additional safety system. The machine is controlled by the radio transmitter of the emergency tram pendant.

Controller case The controller case (Fig. 70) is located on the right rear side of the machine and houses the major electrical components of the miner. The control circuit breakers and the tram/fan circuit breaker can be reset from the front of the controller case. There is a machine stop button located on the front of the controller case along with a mode of operation switch.

The electrical components are mounted inside the controller on the top, bottom, front, rear, right, and left walls and on the front and rear side of the swing panel.

Fig. 70: Controller case

Controller case assembly

________________________________________________________________ 5.101 CM340 Continuous Miner vacuum contactors

___________________________________________________ Electrical Controller case - left wall The left wall of the controller case (Fig. 71) is accessed by opening the cover of the controller enclosure and then opening the swing panel.

Typically mounted on the left wall are three vacuum contactors and three motors mates.

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

Vacuum contactor “CF” is the forward contactor for the left and right gathering head motors.

vacuum contactor “CR”

Vacuum contactor “CR” is the reverse contactor for the left and right gathering head motors.

vacuum contactor “P”

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

From the vacuum contactors, each leg of the motor is fed to a motor mate. Each motor mate is triple output inductive current transducer. It takes the current from each leg of the motor and reduces it to a 4 to 20mA output that is sent to the control system.

motor mate “CT3”

Motor mate “CT3” is the current transducer for the left gathering head motor.

motor mate “CT4”

Motor mate “CT4” is the current transducer for the right gathering head motor.

motor mate “CT5”

Motor mate “CT5” is the current transducer for the pump motor.

Fig. 71: Controller case left wall Vacuum contactor “CF”

Vacuum contactor “CR”

Vacuum contactor “P”

Motor mate “CT3”

Motor mate “CT4”

Motor mate “CT5”

______________________________________________________________ A6474X319 Rev 1 5.102

Electrical ____________________________________________________ Controller case - rear wall The rear wall of the controller case (Fig. 72) is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear wall are vacuum contactors, motor mates, a control transformer , and a terminal block.

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

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

vacuum contactor “A”

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

vacuum contactor “B”

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

From the vacuum contactors, each leg of the motor is fed to a motor mate. Each motor mate is triple output inductive current transducer. It takes the current from each leg of the motor and reduces it to a 4 to 20mA output that is sent to the control system.

motor mate “CT6”

Motor mate “CT6” is the current transducer for the fan motor.

motor mate “CT1”

Motor mate “CT1” is the current transducer for the left cutter motor.

motor mate “CT2”

Motor mate “CT2” is the current transducer for the right cutter motor.

current transformer “T1”

Transformer “T1” is a current transformer which converts the incoming 1140V to 120VAC and 12VAC.

Fig. 72: Controller case rear wall Current transformer “T1”

Vacuum contactor “F”

Vacuum contactor “A”

Vacuum contactor “B”

Motor mate “CT6”

Motor mate “CT1”

Motor mate “CT2”

________________________________________________________________ 5.103 CM340 Continuous Miner

___________________________________________________ Electrical Controller case - right wall The right wall of the controller case (Fig. 73) is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the right wall is the tram circuit breaker.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine. circuit breaker “TRAM BREAKER”

Circuit breaker “TRAM BREAKER” is a 400A circuit breaker for the tram motors. The circuit breaker can be reset from the cover of the controller case with the breaker handle (Fig. 83).

When looking directly at the “TRAM BREAKER” (without the cover), the breaker is on when the switch is up all the way. When the circuit breaker has tripped, the switch will be located in the middle, between on and off. When the circuit breaker is off, the switch will be all the way down.

Fig. 73: Controller case right wall Cutter circuit breaker

“TRAM BREAKER”

Breaker reset handle

______________________________________________________________ A6474X319 Rev 1 5.104

Electrical ____________________________________________________ Controller case swing panel - front side The front side of the swing panel (Fig. 74) is accessed by opening the controller cover. Typically mounted on the front of the swing panel are ground fault monitors, contactors, overloads, miniature circuit breakers, the tram pendant interface, an intrinsically safe barrier and relays.

IMPORTANT! This component location information is typical. Always verify component layout with the information in the parts book for your machine. e-stop relay “ESR”

E-stop relay “ESR” is an 18A contactor in the emergency stop circuit.

When this contactor is opened, all machine functions capable of producing a machine movement will shutdown.

methane monitor relay “MMR”

Methane monitor relay “MMR” is an 18A relay in the methane monitoring circuit and interlocks with cutter contactors A and B. When “MMR” opens, the cutter contacts will open, stopping the cutters when the methane monitoring system determines there is high methane concentrations.

ground fault monitor “GFM”

The machine is equipped with a ground fault monitor for the protection of human life and equipment. The ground fault monitor “GFM” monitors for ground in the 1040V circuit.

contactor “L”

Contactor “L” is a 32A contactor for the front lights.

pump e-tram mode overload “PTOL”

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

left tram e-tram mode overload “LTOL”

The left tram e-tram mode overload “LTOL” is the left tram thermal overload for ETRAM only. If the left tram motor is overloaded during emergency tramming operations, “LTOL” will shut the pump motor down.

right tram e-tram mode overload “RTOL”

The right tram e-tram mode overload “RTOL” is the right tram thermal overload for ETRAM only. If the right tram motor is overloaded during emergency tramming operations, “RTOL” will shut the pump motor down.

methane monitor power supply “MMPS”

The methane monitor power supply “MMPS” supplies power to the methane monitor system.

I.S. relay “ISL”

I.S. relay “ISL” is the back intrinsically safe relay for the tram pendant.

I.S. relay “IST”

I.S. relay “IST” is the front intrinsically safe relay for the tram pendant.

e-tram mode relay “ETR”

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

________________________________________________________________ 5.105 CM340 Continuous Miner

___________________________________________________ Electrical miniature circuit breakers

spare contactor

There are four (4) miniature circuit breakers located on the front of the swing panel. Two of these circuit breakers, both 15A, are spares.

“MCB19” and “MCB20”, both 5A, serve as supplementary protection on the reverse lighting circuit.

There are two (2) contactors located on the front of the swing panel.

One of these contactors, contactor “L”, is a 32A contactor for the front lights, and the other is a spare.

IMPORTANT! Never use a spare breaker without properly labeling its new function.

emergency tram pendant Interface “TPI”

The tram pendant interface, “TPI”, is the communication interface between the tram pendant and the control system when the “MINER” mode of operation switch is in “ETRAM” mode.

power center trip relay “PCT”

The power center trip relay, “PCT”, is used to trip the power center relay by the e-stop button.

Bridge rectifier - methane monitor relay “BRM”

The bridge rectifier for the methane monitor relay, “BRM”, converts 120V AC current to DC.

Bridge rectifier - e-stop relay “BRE”

The bridge rectifier for the e-stop relay, “BRE”, converts 120V AC current to DC.

______________________________________________________________ A6474X319 Rev 1 5.106

Electrical ____________________________________________________ Fig. 74: Controller case swing panel - front side Emergency tram pendant interface “TPI”

Back I.S. relay “ISL”

Methane monitor power supply “MMPS”

Front I.S. relay “IST” Spare miniature circuit breaker

Bridge rectifier – methane monitor relay “BRM”

Spare miniature circuit breaker

Bridge rectifier – E-stop relay “BRE”

Ground fault monitor “GFM”

Miniature circuit breaker “MCB19”

Power center trip relay “PCT” Miniature circuit breaker “MCB20”

Contactor “L” - lights

Spare contactor

E-stop relay “ESR”

Methane monitor relay “MMR”

Pump E-tram mode overload “PTOL”

Left tram E-tram mode overload “LTOL”

Right tram E-tram mode overload “RTOL”

E-tram mode relay “ETR”

________________________________________________________________ 5.107 CM340 Continuous Miner

___________________________________________________ Electrical Controller case swing panel - rear side The rear side of the swing panel (Fig. 75) is accessed by opening the controller cover and then opening the swing panel. Typically mounted on the rear of the swing panel are the control system components.

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

The power supply module converts a 110VAC input to 24VDC output for the control system.

central processor

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

relay module

The relay module, also called an I/O module, receives both digital and analog inputs and communicates them to the central processor.

thermistor module

The thermistor module communicates the RTD/thermistor inputs (various temperature readings on the machine) to the central processor.

Fig. 75: Controller case swing panel - rear side Power supply

Thermistor module

Central processor

Relay module

______________________________________________________________ A6474X319 Rev 1 5.108

Electrical ____________________________________________________ Controller case - front wall Mounted on the front wall of the controller case (Fig. 76) are an e-stop button, the “MINER” mode of operation selector switch, control breakers, conveyor and cutter motor hour meters, and the tram circuit breaker. main rotary switch “RS1”

The main rotary switch, “RS1”, is the mode of operation selector switch.

The machine can be operated in “REMOTE”, which means it is controlled by the remote transmitter, “ETRAM”, which means it can only be operated by the emergency tram pendant and that there are limited functions available or “GND CHECK”, which is used to perform a control voltage ground check of the machine.

e-stop “CASE ES”

The control case e-stop button, “CASE ES”, can be used to quickly shut down the machine. Depressing the button will shut the pump motor down, thereby shutting down all machine functions.

lighting rotary switch “LS1”

cutter hour meter “HM1” conveyor hour meter “HM2”

The lighting rotary switch, “LS1”, can be used to turn all lights on, all lights off, or can be set to turn on area lights only.

The cutter hour meter, “HM1”, records the total number of running hours for the cutter motors.

The conveyor hour meter, “HM2”, records the total number of running hours for the conveyor motors.

There are sixteen (16) circuit breakers mounted with their shafts through the wall so that they can be reset from the front of the controller case.

circuit breaker “MCB1”

“MCB1” is a 15A breaker for the 120VAC+ side of the control power circuit.

circuit breaker “MCB2”

“MCB2” is a 15A breaker for the 120VAC- side of the control power circuit.

circuit breaker “MCB3”

“MCB3” is a 15A breaker for the 120VAC+ side of the area light circuit.

circuit breaker “MCB4”

“MCB4” is a 15A breaker for the 120VAC- side of the area light circuit.

circuit breaker “MCB5”

“MCB5” is a 25A breaker for the 12VAC+ side of the head light circuit.

circuit breaker “MCB6”

“MCB6” is a 25A breaker for the 12VAC- side of the head light circuit.

circuit breaker “MCB7”

“MCB7” is a 5A breaker for the 12VAC+ side of the RTD module circuit.

circuit breaker “MCB8”

“MCB8” is a 5A breaker for the 12VAC- side of the RTD module circuit.

circuit breaker “MCB9”

“MCB9” is a 5A breaker for the 120VAC+ side of the contactor circuit.

circuit breaker “MCB10”

“MCB10” is a 5A breaker on the 90VDC+ side of the solenoid circuit.

circuit breaker “MCB11”

“MCB11” is a 5A breaker on the 0VDC- side of the solenoid circuit.

________________________________________________________________ 5.109 CM340 Continuous Miner

___________________________________________________ Electrical circuit breaker “MCB12”

“MCB12” is a 5A breaker on the 24VDC+ side of the PLC power supply circuit.

circuit breaker “MCB13”

“MCB13” is a 5A breaker on the 0VDC- side of the PLC power supply circuit.

circuit breakers “MCB14”, “MCB15”, and “MCB16”

“MCB14”, MCB15”, and “MCB16” are 5A breakers on the communication circuit.

Fig. 76: Controller case - front wall “MACHINE STOP”

Main rotary switch “RS1”

Lighting rotary switch “LS1”

Circuit breakers “MCB1” - “MCB16”

Cutter hour meter “HM1”

Conveyor hour meter “HM2”

______________________________________________________________ A6474X319 Rev 1 5.110

Electrical ____________________________________________________ Power circuit with control Electric power is supplied to the motors and the lighting and control transformer as soon as the trailing cable is connected and the main circuit beaker is turned on.

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

Fig. 77: Power circuit with control

________________________________________________________________ 5.111 CM340 Continuous Miner

___________________________________________________ Electrical Methane monitor circuit The methane monitor is powered by power supply “MMPS” (Fig. 78). If the methane concentration exceeds the preset value, the cutter motors will shutdown (or, if not running, will not be able to be started).

For more information on the methane monitor, see the methane monitor manual in the parts book that shipped with your machine.

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

Fig. 78: Methane monitor circuit

______________________________________________________________ A6474X319 Rev 1 5.112

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

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

Fig. 79: Power center trip relay control circuit

________________________________________________________________ 5.113 CM340 Continuous Miner

___________________________________________________ Electrical Machine 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, on located at the operator’s station on the front of the controller case and the other on the off side of the machine. The second pole on each switch is also monitored by the control system. The control system will prevent motor start if either machine emergency stop is pressed.

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

Fig. 80: Machine emergency stop circuit

______________________________________________________________ A6474X319 Rev 1 5.114

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

The schematic shown in Fig. 91 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 81: Tram pendant circuit

________________________________________________________________ 5.115 CM340 Continuous Miner

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

The schematic shown in Fig. 82 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 82: Thermistor module control

______________________________________________________________ A6474X319 Rev 1 5.116

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

The schematic shown in Fig. 83 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 83: Solenoid module control circuit

________________________________________________________________ 5.117 CM340 Continuous Miner

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

The schematic shown in Fig. 84 is a typical. Always refer to the schematic in the parts book for your machine.

Fig. 84: Motor control

______________________________________________________________ A6474X319 Rev 1 5.118

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

The headlights are energized when power is applied to the machine and the main circuit breaker is closed. The remote control transmitter can then be used to turn the headlights on or off.

Fig. 85 is a typical light schematic. Always refer to the schematic in the parts book for your machine.

Fig. 85: Headlights and area lights

________________________________________________________________ 5.119 CM340 Continuous Miner

___________________________________________________ Electrical Oil level circuit The hydraulic oil float switch is located within the hydraulic oil tank and has two settings: an alarm level and a shutdown level. When the oil in the tank reaches the alarm level, an audible alarm will sound. When the oil reaches the shutdown level, the pump motor will shutdown.

Fig. 86 is a typical schematic. Always refer to the schematic in the parts book for your machine.

Fig. 86: Oil level circuit

______________________________________________________________ A6474X319 Rev 1 5.120

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

Important notes Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Turn circuit breaker to the "OFF" position and disconnect the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Before performing maintenance on the machine the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all Mine, State, and Federal regulations for lockout/tagout procedures. Accidental machine movement or electrical shock can result in serious injury or death to you or other personnel.

IMPORTANT! “MAINTENANCE” mode of operation is not for use during normal maintenance or replacement of wear parts procedures.

“MAINTENANCE” mode is for use during motor vibration analysis only.

______________________________________________________________ A6474X319 Rev 1 5.121

Maintenance _________________________________________________ ■

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

■

Block any and all elevated assemblies before working under them.

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

■

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

■

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

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

■

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

■

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

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

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

■

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

■

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

■

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

________________________________________________________________ 5.122 CM340 Continuous Miner

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

Lubricants and fluid capacities Table 2: Lubricants and fluid capacities Location

Specification

Approximate capacity

Hydraulic oil tank GH Assembly CLA Primary

Spec. 100-1 Spec. 100-15

100 gals. (379 L) 1 gal (3.79 L)

GH Assembly CLA POT Tram Drive Assembly

Spec. 100-15 Spec. 100-15

2.5 gal (9.46 L) 3 gal (11.36 L)

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

Spec. 100-15

0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

Variable

Notes

1

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.

______________________________________________________________ A6474X319 Rev 1 5.123

Maintenance _________________________________________________ Table 3: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pin, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pin, 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 pivot pin

2

Lithium based grease

Spec. 100-3

6

Cutter head bits

Inspect

7

Blowing system screen

Clean

8

Daily Conveyor take-up shaft

2

Lithium based grease

Spec. 100-3

9

Gathering head pivot pin

2

Lithium based grease

Spec. 100-3

10

Crawler idler roller

2

Lithium based grease

Spec. 100-3

11

Conveyor raise pivot pin

2

Lithium based grease

Spec. 100-3

12

Stabilizer shoe cylinder pin, upper

2

Lithium based grease

Spec. 100-3

13

Stabilizer shoe cylinder pin, lower

2

Lithium based grease

Spec. 100-3

14

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

15

Conveyor raise cylinder pin, lower

2

Lithium based grease

Spec. 100-3

16

Conveyor swing pivot pins

8

Lithium based grease

Spec. 100-3

17

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

18

Gathering head cylinder pin, lower

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

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

24

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

25 26

Stab shoe pivot, frame Charge remote control Weekly Return filter element (Change)

2

Lithium based grease

Spec. 100-3

1

See Parts Book

1

See Parts Book

29

Pilot circuit primary filter element (Change) Pressure filter element (Change)

2

See Parts Book

30

Crawler chain

Inspect

31

Conveyor chain

Inspect

32

Fasteners (nuts, bolts, screws)

Inspect

33

Electrical cables, conduits, and glands

Inspect

34

Hydraulic/water hoses and connections

Inspect

35

Lighting

Inspect

36

Reflectors and warning tags

Inspect

37

Machine stop switch (Inspect)

38

Blowing system screen

27 28

2 Clean

________________________________________________________________ 5.124 CM340 Continuous Miner

________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance Item

Description

Places

Lubricant

Specification

Every 2 Weeks

39

Clean remote control console / inspect switch seals

40 41

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

42 43

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

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

44 45

CLAs Input cutter head gear case

Inspect 2

Sample

See Note 1

46 47

Main cutter head gear case CLA head pot assembly

2 2

Sample Sample

See Note 1 See Note 1

48 49 50

CLA head transfer case Tram gear case Main hydraulic tank

2 2 1

Sample Sample Sample

See Note 1 See Note 1 See Note 1

51

Every three months Cutter motor

4

Spec. 100-14

52

Gathering head motor

4

53

Pump motor

2

54

Blowing system motor

2

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

55

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

56 57 58 59

Hydraulic oil (Change) Suction strainer, hydraulic oil tank (Change) Breathers Water filter (strainer) (Change)

1 2 All 2

AW hydraulic oil

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

60

Gathering head float valve filter (Change)

1

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

See Parts Book

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

______________________________________________________________ A6474X319 Rev 1 5.125

Maintenance _________________________________________________ Fig. 87: Lubrication and maintenance chart 23,43,46

6

45 45

24

24

13 13

3

4

8

________________________________________________________________ 5.126 CM340 Continuous Miner

________________________________________________ Maintenance Fig. 87: Lubrication and maintenance chart, continued

22 52

52 53

1

17

18 2

10

9 5

32

11

21

3 14 16

4

______________________________________________________________ A6474X319 Rev 1 5.127

Maintenance _________________________________________________ Fig. 87: Lubrication and maintenance chart, continued

16 16

13 12

27 15 50

54

21

11 5 9 2 1

18

42 17

52 53 46

________________________________________________________________ 5.128 CM340 Continuous Miner

________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift cutter head lift cylinder pins (upper and lower)

Lubricate the upper and lower cutter head cylinder pins (right and left).

The upper pins are lubricated through the grease fittings located on each pin (Fig. 88). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 88). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 88: Cutter head cylinder pins (typical both sides)

Cutter head lift cylinder pin, upper (2)

Cutter head lift cylinder pin, lower (2)

______________________________________________________________ A6474X319 Rev 1 5.129

Maintenance _________________________________________________ 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. 89). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

Fig. 89: Conveyor swing cylinder pin lubrication

Conveyor swing cylinder pin, front

Conveyor swing cylinder pin, rear

cutter head pivot pin (left and right)

Lubricate left and right cutter head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 90). Pump approximately 3 cu. in. (50 cu. cm) of grease into each fitting.

Fig. 90: Cutter head pivot pins (typical both sides)

Cutter head frame pivot pin lube block

________________________________________________________________ 5.130 CM340 Continuous Miner

________________________________________________ Maintenance cutter head bits

Inspect the cutter head bits to ensure that they will rotate in their holders and for damaged or missing bits (Fig. 91). Replace bits immediately if any are missing or damaged.

Fig. 91: Cutter head bits Bit holder

Bit

______________________________________________________________ A6474X319 Rev 1 5.131

Maintenance _________________________________________________ Washdown hose connection location

The location of the washdown hose connection is noted below (Fig. 92).

Fig. 92: Washdown hose location

Washdown hose connection

________________________________________________________________ 5.132 CM340 Continuous Miner

________________________________________________ Maintenance Daily conveyor take-up shaft

Lubricate the conveyor take-up shaft through the two (2) grease fittings located on the shaft (Fig. 93). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.

Fig. 93: Conveyor take-up shaft lubrication

Grease fitting

gathering head pivot pin (right and left)

crawler idler roller (right and left) conveyor raise pivot (right and left)

Grease fitting

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 94). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Lubricate the left and right crawler idler rollers (Fig. 94) through the grease fittings located on the outside face of the crawler idler roller.

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 94). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 94: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides) Conveyor pivot pin

Gathering head pivot pin

Crawler idler roller

______________________________________________________________ A6474X319 Rev 1 5.133

Maintenance _________________________________________________ upper stabilizer shoe cylinder pin (right and left)

Lubricate the upper stabilizer shoe cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 95). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

lower conveyor raise cylinder pin (right and left)

Lubricate the lower conveyor raise cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 95). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 95: Lubrication block - stabilizer shoe and conveyor lift pins Lower conveyor raise cylinder pin

Lower conveyor raise cylinder pin

Upper stabilizer shoe cylinder pin

Upper stabilizer shoe cylinder pin

lower stabilizer shoe cylinder 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. 96).

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

Fig. 96: Lower stabilizer shoe cylinder pin (typical both sides)

Lower stabilizer shoe cylinder pin (2)

________________________________________________________________ 5.134 CM340 Continuous Miner

________________________________________________ Maintenance upper 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. 97). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 97: Upper conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fitting (2)

conveyor swing pivot pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 98). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 98: Conveyor swing pivot pin Conveyor swing pivot pins lubrication fittings (2) (typical both sides)

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

______________________________________________________________ A6474X319 Rev 1 5.135

Maintenance _________________________________________________ gathering head raise cylinder pins

Lubricate the upper gathering head raise cylinder pins (Fig. 99) 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. 99: Gathering pan raise cylinder pins (typical both sides) Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

________________________________________________________________ 5.136 CM340 Continuous Miner

________________________________________________ Maintenance CLA head pot assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 100).

If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA head transfer case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 100). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 100: CLA head pot assembly and transfer case lubrication Oil check, pot assembly

Oil fill, transfer case

tram gear case (right and left)

Oil fill, pot assembly

Oil check, transfer case

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 101). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Fig. 101: Tram gear case oil level (typical both sides) Oil fill pipe

Oil check Oil check

Oil fill plug

______________________________________________________________ A6474X319 Rev 1 5.137

Maintenance _________________________________________________ input cutter gear case

With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 102). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 102: Input cutter gear case (s) oil level Oil fill plug (top view - one per side)

main cutter gear case

Oil check plug (side view one per side)

With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 103). 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. 103: Main cutter head gear case(s) oil level Oil fill plug (one per side)

Oil check plug (one per side)

________________________________________________________________ 5.138 CM340 Continuous Miner

________________________________________________ Maintenance hydraulic oil level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 104). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 104: Hydraulic oil tank level Hydraulic oil tank

Hydraulic oil tank

stabilizer shoe pivot pins

Dip stick location

Lubricate the stabilizer shoe pivot pins through the two (2) grease fittings located on left rear lubrication block (Fig. 105). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 105: Stabilizer shoe pivot pin lubrication Stabilizer shoe pivot pin Stabilizer shoe pivot pin

______________________________________________________________ A6474X319 Rev 1 5.139

Maintenance _________________________________________________ charging the remote control console

The remote console contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be re-charged using the battery charger (Fig. 106). Recharge times for the unit are typically 1-4 hours, depending on the remaining charge in the battery.

Fig. 106: Remote control battery charger

 Plug one of the 4 Charging Cables into the Transmitter.  Red and Green Lights will flash for a few moments.  Charger will begin charging.  While charging is in process, the red light will be on.  When charging is complete, the green light will come on.  During charging, the screen shows how long each transmitter has been on charge.

________________________________________________________________ 5.140 CM340 Continuous Miner

Maintenance _________________________________________________ plugging in the remote console

 Look at the socket on the transmitter and the charging plug.  Ensure that the charging socket (Fig. 107) and plug are free from dirt and coal.  Line up the plug so that it slides gently into the socket.  Push gently until you feel or hear the plug “click” into the socket.

Fig. 107: Charging socket

unplugging the remote console

 Hold the outside tube of the plug firmly.  The tube should be slightly loose.  Pull backwards on the tube so it slides outwards from the Transmitter (Fig. 108).  The Plug should release itself from the transmitter.

Fig. 108: Disconnecting from the charging socket

________________________________________________________________ 5.141 CM340 Continuous Miner

Maintenance _________________________________________________ Weekly pressure filters

Change the two pressure filter elements (Fig. 109). If the elements are extremely dirty, a more frequent change interval may be required.

return filter

Change the return filter element (Fig. 109). If the element is extremely dirty, a more frequent change interval may be required.

pilot filter

Change the pilot circuit primary filter element (Fig. 109). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 109: Filters

Pilot filter

Pressure filter (2)

Return filter

________________________________________________________________ 5.142 CM340 Continuous Miner

________________________________________________ Maintenance crawler track tension

Check the crawler tracks for proper tension. If adjustment is necessary, see the Crawler track adjustment procedure in this chapter.

To check the track for proper tension:  Raise the complete crawler assembly off of the ground and securely block under the machine. The machine must be securely supported off the ground.  Chain sag should be 4 – 5” (100 to 125 mm) at the center of the crawler (Fig. 110).

Fig. 110: Crawler track tension measurement Bottom of tractor wear shoe

conveyor chain tension

4 – 5” (100 to 125 mm) gap

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. 111). If adjustment is necessary, see the Conveyor chain tension adjustment procedure in this chapter.

Fig. 111: Conveyor chain tension measurement

Chain measurement area

______________________________________________________________ A6474X319 Rev 1 5.143

Maintenance _________________________________________________ fasteners

electrical cables, conduits, and glands hoses and fittings

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: ■

Cutter head gear case: hex head bolts

■

Cutter head motors: socket head capscrews

■

Center drums: socket head capscrews

■

End drums: hex head bolts

■

Tram cases: socket head capscrews

■

Tram motors: hex head bolts

■

Gathering head CLAs: hex head bolts

■

Gathering head pots: hex head bolts

■

Gathering head motors: socket head capscrews

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

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

Relieve pressure before disconnecting hoses.

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

Do not exceed the working pressure of hydraulic hoses.

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

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

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

reflectors and warning tags

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

machine stop switches

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

Repeat for the other switch.

________________________________________________________________ 5.144 CM340 Continuous Miner

________________________________________________ Maintenance blowing system cleaning

To clean out the blowing system (Fig. 112):  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.

WARNING! Follow all Federal and mine regulations regarding lockout/tagout procedures. Failure to do so may result in serious injury or death.  4. Insert a hose in the blowing system air intakes at the left and right rear of the miner. Thoroughly flush the blowing system inlet duct.  5. Remove any accumulated debris from inside the duct. Insert the hose into the duct and thoroughly flush it with water.

Fig. 112: Blowing system cleaning Blowing system intake

Blowing system intake

______________________________________________________________ A6474X319 Rev 1 5.145

Maintenance _________________________________________________ Every 2 weeks cleaning the remote console

To extend the service life of the control switches and ensure that switches remain free of mud and debris, regular cleaning of the switch plate is recommended.

Typically, the cleaning procedure should be observed once every 2 weeks, or as often as required.

Disassemble the remote console as follows: 

Remove the M3 bolts.



Remove the switch guard (Fig. 113).



Remove the switch caps.



Remove the comfort knobs by loosening the grub screw.



Remove the engraved plate.

Fig. 113: Remote control console with bolts, guard, caps, knobs, screws and plate removed M3 Bolt

Switch Guard Switch Cap Comfort Knob Grub Screw Engraved Plate Splash Seal M2 Bolt

________________________________________________________________ 5.146 CM340 Continuous Miner

________________________________________________ Maintenance Clean the console and inspect the switch seals:  Expunge heavy debris from the switch assembly with a soft bristle cleaning brush.  Wash the transmitter with warm soapy water.  Inspect the switch seals for signs of deterioration.

Seals exhibiting wear require the equipment to be scheduled for factory service.  Dry the transmitter with light compressed air or cloth.

NOTICE! Switch assembly seals beneath the engraved plate are the primary seal; a secondary seal within the switch itself and an integral neoprene seal operate as a barrier to moisture ingress.

IMPORTANT! Do not use caustic solvents or displacement solutions, as this may cause premature seal failure.

IMPORTANT! Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.

Reassemble the console:  Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm.  Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.  Install the engraved plate.  Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm.  Install the switch caps.  Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.  After reassembly, test the unit on the Remote Control Battery Charger.

______________________________________________________________ A6474X319 Rev 1 5.147

Maintenance _________________________________________________ Monthly CLA head pot assembly

Change the oil in both CLA head pot assemblies (Fig. 114).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

CLA head transfer case

Change the oil in both CLA head transfer cases (Fig. 114).  Level the miner, raise the gathering head pan, and secure in place.  Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to ravel through the gear case when filling.  Clean and reinstall the check and fill plugs.

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

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

________________________________________________________________ 5.148 CM340 Continuous Miner

________________________________________________ Maintenance Fig. 114: CLA pot assembly and input transfer case Oil fill, transfer case

Oil check, transfer case

Oil check, pot assembly

Oil fill, pot assembly

Drain plugs located behind cover

______________________________________________________________ A6474X319 Rev 1 5.149

Maintenance _________________________________________________ input cutter head gear case

Change the oil in both input cutter head gear cases (Fig. 115).  Position the cutter head horizontally (flat back in a vertical position).

Clean dirt and debris from around the drain plug located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time for the oil to travel throughout the gear case when filling. Fill level should be between the two site glasses on either side.  Clean and reinstall the check and fill plugs.

Fig. 115: Input cutter head gear case Oil fill plug (not shown) (one per side)

Oil check plug

Flat back Drain plug (not shown) (one per side)

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

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

________________________________________________________________ 5.150 CM340 Continuous Miner

________________________________________________ Maintenance main cutter head gear case

Change the oil in both main cutter head gear cases (Fig. 116).  Lower the cutter head completely to the ground. Clean dirt and debris from around the drain plug, located under the gear case.  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Clean dirt and debris from around the check plug and remove the plug.  Clean dirt and debris from around the fill plug and remove the plug.  Slowly add oil through the fill plug until oil begins to flow from the check plug hole. Allow sufficient time fro the oil to travel throughout the gear case when filling.  Clean and reinstall the check and fill plugs.

Fig. 116: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X319 Rev 1 5.151

Maintenance _________________________________________________ CLAs

Inspect the CLAs (Fig. 117) for damage. If a CLA needs replaced, see CLA removal and installation procedure in this chapter.

Fig. 117: 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. 114) sufficient to sample each identified gear case (every sixty shifts).

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

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

Each oil sample should be taken while the oil is at normal operating temperature. If the machine has not been operating just prior to sampling, run the machine until oil temperature reaches approximate normal operating temperature. Shutdown the machine and allow 2 - 3 minutes for the oil to drain back and stabilize it’s level.

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

________________________________________________________________ 5.152 CM340 Continuous Miner

________________________________________________ Maintenance IMPORTANT! Always use the collection hose provided with each bottle. Always discard hose immediately following collection of the oil and do not use it for the next sample. To do so will contaminate the next sample with oil from the previous sample.

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

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

Recommended gear cases to be sampled: ■

Input cutter head gear case (left and right)

■

Main cutter head gear case (left and right)

■

Input gathering head gear case (left and right)

■

Main gathering head gear case (left and right)

■

Main hydraulic oil tank

Fig. 118: 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

______________________________________________________________ A6474X319 Rev 1 5.153

Maintenance _________________________________________________ Every three months IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting (Fig. 129) 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. 119) using the following procedure:  Open the cover (Fig. 119) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

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

________________________________________________________________ 5.154 CM340 Continuous Miner

________________________________________________ Maintenance Fig. 119: Cutter motor bearing lubrication (typical each side)

Cutter motor lubrication (2)

Button type grease fitting

Motor located behind cover

Spring loaded grease relief fitting

______________________________________________________________ A6474X319 Rev 1 5.155

Maintenance _________________________________________________ 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. 120).

To lubricate the motors:  Open the cover (Fig. 120) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings, then  Lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  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:  Remove the plug and lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  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.

________________________________________________________________ 5.156 CM340 Continuous Miner

________________________________________________ Maintenance Fig. 120: Gathering head motor bearing lubrication (typical each side)

Motor access cover

Button type grease fitting

Spring loaded grease relief fitting

______________________________________________________________ A6474X319 Rev 1 5.157

Maintenance _________________________________________________ pump motor bearings

Lubricate the pump motor (Fig. 121) 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:  Open the cover (Fig. 121) to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.

If the exit side motor bearing ports are equipped with spring load relief fittings, then  Lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  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:  Remove the plug and lubricate both motor bearings using the button type grease fitting until new grease appears out of the relief ports on the exit side of the bearing.  Operate the motor for five (5) minutes and then inspect for grease leaks in the bearing area.  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.

Fig. 121: Pump motor bearings

Spring loaded grease relief fitting

Motor located behind cover

________________________________________________________________ 5.158 CM340 Continuous Miner

________________________________________________ Maintenance blowing system motor bearings

Lubricate the blowing system motor bearings (Fig. 122) with high temperature lithium complex grease (Spec. 100-14) as follows: IMPORTANT! For motor bearings that require high temperature lithium complex grease (Spec. 100-15), The manufacturer provides a special “button” style lubrication fitting to prevent the accidental use of multi-purpose lithium complex grease at these locations.  Remove the cover to access the motor.  Inspect the grease fittings on the exit side of the front and rear motor bearing.  If the exit side motor bearing ports are equipped with spring loaded relief fittings:  Lubricate both motor bearings using the button type fittings until new grease appears out of the relief port on the exit side of the bearing.  Operate the motor for five minutes.  Inspect for any grease leakage in the area around the bearing.

Fig. 122: Blowing system motor

Spring loaded grease relief fitting

Blowing system motor

______________________________________________________________ A6474X319 Rev 1 5.159

Maintenance _________________________________________________ Every six months tram gear case

Change the oil in both tram gear cases (Fig. 123).  Remove the drain plug and allow oil to completely drain from the gear case.  Clean and reinstall the drain plug.  Replace the breather.  Remove the fill plug located on top of the gear case or on the fill tube.  Add oil through the fill plug hole until oil is visible in the sight glass.

When filling, allow sufficient time for the oil to travel throughout the gear case.  Clean and reinstall the fill plug.

Fig. 123: Tram gear case

Oil fill plug Fill tube

Oil check

Breather

Oil drain plug (not shown, located on bottom of case)

________________________________________________________________ 5.160 CM340 Continuous Miner

________________________________________________ Maintenance hydraulic oil, suction strainer, and breather

Change the oil in the hydraulic oil tank (Fig. 124).  Clean all dirt and debris from around the fill cap and the drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Remove and replace the suction strainer.  Clean and reinstall the drain plug.  Replace both breathers.  Add oil to the tank until the oil level is correct on the dipstick.  After filling, start the machine and engage all hydraulic cylinders for their full length of travel (full extend and retract) in order to purge the hydraulic system of air.  Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 124: Hydraulic oil tank Hydraulic oil tank

Hydraulic oil tank

Dip stick location

______________________________________________________________ A6474X319 Rev 1 5.161

Maintenance _________________________________________________ gear case breathers

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases (Fig. 125).

Fig. 125: Gear case breather locations

Main cutter head gear case breather

Input cutter gear case breather

Main gathering head gear case breather

CLA head pot and transfer case breathers

________________________________________________________________ 5.162 CM340 Continuous Miner

_______________________________________ Adjustment procedures Setting hydraulic pressures ■

Always refer to the hydraulic schematic in the parts book supplied with your miner.

■

Most relief valves are set to factory specifications and should require no further adjustment. If a problem occurs which requires the reliefs to be adjusted, make certain the correct procedures are followed and all work is performed by a qualified person.

■

Remember when adjusting relief valves that turning the adjusting screw in (clockwise) will increase the pressure setting.

■

If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will cause the pressure to increase. This will allow the pressure setting to be achieved in a safe, controlled manner.

WARNING! Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

The miner is equipped with eight hydraulic pressure gauges to aid in setting relief pressures (typical). The gauges measure the following pressures: ■

main flow - primary pressure circuit (all functions of the main control valve can be read from this gauge),

■

auxiliary pressure circuit,

■

pilot pressure circuit

■

conveyor chain take-up,

■

anti-chatter/maintenance (shear down) valve for cutter head,

■

gathering head float valve

There will be occasions when relief valves, or other pressure control valves, must be set or adjusted. Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted, for example, during the course of troubleshooting a hydraulic system fault. This section describes the proper procedure for setting the relief valves.

______________________________________________________________ A6474X319 Rev 1 5.163

Adjustment procedures ________________________________________ IMPORTANT! Always use the proper tools when adjusting valve cartridges.

IMPORTANT! Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load holding valve adjustment The load holding valve is factory preset and should not be field adjusted.

Always refer to your parts manual when ordering load holding valves for the cutter, stabilizer, or conveyor cylinders.

Never rely on the load holding valve as a means of supporting the cutter boom or conveyor boom while making repairs. Always support the cutter boom and conveyor boom with adequate material before working around or underneath the cutter or conveyor.

WARNING! Never rely on the load holding valve as a means of supporting the cutter or conveyor boom while making repairs. Severe injury or death could result.

Adjustment procedure should start with the pilot/auxiliary pressure circuit because this system is a “closed center circuit” and will build pressure as soon as the pump is started. The main flow-primary pressure circuit is an “open-center circuit” and no pressure is present in this circuit until a function is activated.

Reference Pilot/auxiliary circuit descriptions, abbreviations, and terms in the Hydraulic section of this chapter.

________________________________________________________________ 5.164 CM340 Continuous Miner

_______________________________________ Adjustment procedures Pilot/auxiliary pump circuit relief valve adjustments The following procedure is for start up of new and rebuilt machines.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  1. Pilot pressure circuit: loosen the nut on the relief valve cartridge and turn the screw fully out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.  2. Conveyor chain take-up circuit: open the needle valve by turning the knob fully counter-clockwise, opening flow to tank.  3. Start the pump motor (see Startup procedure in this chapter) and adjust the pilot relief valve.  Loosen the nut on the valve cartridge and, using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. The pressure should be set at 35 bar (500 psi).

IMPORTANT! Before making any further adjustments, verify that the hydraulic oil is at operating temperature.  4. Adjust the conveyor chain take-up valve.  Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 14 bar (200 psi).  Remove the hex socket head plug to adjust the inner spool.

Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure.  Replace the hex socket head plug.  5. Readjust the pilot relief valve, if necessary, to 35 bar (500 psi).

______________________________________________________________ A6474X319 Rev 1 5.165

Adjustment procedures ________________________________________ Relief valve replacement  Pilot relief valve replacement: Set the pilot relief to 35 bar (500 psi), per Step 3, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).  Conveyor chain take-up valve replacement: Set the pilot relief to 12 bar (175 psi), per Step 4, making sure the conveyor chain take-up needle valve is closed (turn clockwise to close).

Main control valve working port relief adjustment Each valve bank section has two (2) working port reliefs except for the gathering head section and the booster pump/high speed raise sections. When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

WARNING! Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

Main control valve adjustment IMPORTANT! The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section, A1.

CAUTION! Do not adjust the main relief over 207 bar (3,000 psi). Destruction of the valve bank and the main pump could result.

CAUTION! Always be alert for any unintended machine movement.

IMPORTANT! Reference the Hydraulic section in this chapter for individual circuit information. Always refer to the hydraulic schematic in your parts manual for your miner.

WARNING! Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure.

Failure to do so may result in serious injury or death.

________________________________________________________________ 5.166 CM340 Continuous Miner

_______________________________________ Adjustment procedures 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. Caution must be exercised when performing this procedure with particular attention being paid to the following: ■

The procedure will raise the machine off the ground. Be careful to keep body parts clear from under the machine while it is raised off the ground.

■

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.

■

It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted. This procedure is described in detail below.

Main relief adjustment  Remove the protective cap on the rear port relief of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.  Loosen the nut on the main relief cartridge. Turn the main relief adjusting crew two turns clockwise.  Start the pump (see Start up procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.  With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 207 bar (3,000 psi) is obtained.  With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place. Check the pressure setting to verify that the screw was not moved while tightening the nut.  Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).  Replace the protective cap.

______________________________________________________________ A6474X319 Rev 1 5.167

Adjustment procedures ________________________________________ Port relief valve adjustment Port relief valves are functional when operating the circuit in which they are installed. As the particular function is activated and the pressure reaches the adjusted setting, the port relief will relieve excessive pressure to the tank cavity within the valve bank, preventing damage to the circuit.

WARNING! Always allow function to bottom out and stop moving before adjusting any pressure.

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief for that function must be adjusted.

The adjustment procedure for each port relief is the same and is:  Remove the protective cap on the port relief and loosen the nut on the adjusting screw.  Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.  Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Pressure readings: 1. Cutter head port relief  Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 193 bar (2,800 psi).  Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 193 bar (2,800 psi).

WARNING! Keep body parts clear of machine while in raised position or serious injury could result.

2. Conveyor raise/lower port relief  Activate the conveyor raise circuit to fully raise the conveyor.

The main control valve pressure gauge should read 145 bar (2,100 psi).  Activate the conveyor lower circuit to fully lower the conveyor.

The main control valve pressure gauge should read 96 bar (1400 psi).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

________________________________________________________________ 5.168 CM340 Continuous Miner

_______________________________________ Adjustment procedures 3. Conveyor swing port relief  Activate the conveyor swing left circuit to fully swing the conveyor to the left. The main control valve pressure gauge should read 124 bar (1,800 psi).  Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 124 bar (1,800 psi).

4. Gathering head port relief  Activate the gathering head raise circuit to fully raise the gathering head. The main control valve pressure gauge should read 117 bar (1,700 psi).  If 117 bar (1,700 psi) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 124 bar (1,800 psi) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

5. Stabilizer shoe port relief  Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe. The main control valve pressure gauge should read 83 bar (1,200 psi).  Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The main control valve pressure gauge should read 193 bar (2,800 psi).

______________________________________________________________ A6474X319 Rev 1 5.169

Adjustment procedures ________________________________________ Tram track adjustment  1. Lower the conveyor tail section until it is level with the floor.  2. Raise the gathering head and cutter head and block both assemblies following standard blocking procedures.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  3. Lower the gathering head and cutter head onto the blocking so that the front end of the miner lifts off the floor.  4. Extend the stabilizer completely so that the rear end of the miner lifts off the floor.  5. Securely block under the machine. The machine must be securely supported off the ground with the tram track free to turn.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load of all blocking devices.  6. Raise the stabilizer, gathering head, and cutter head assemblies so that the weight of the miner rests on the blocking.  7. Disconnect the trailing cable to de-energize the miner. Follow all Federal and mine lockout/tagout regulations.

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  8. Double check the tractor frame support blocking now that the weight of the tractor frame is completely upon it.  9. Evaluate the tram track for proper tension (Fig. 126). 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 13, 14, or 15 provides the appropriate sub-procedure to correct improper track tension.

Fig. 126: Tram track adjustment

Bottom of tractor wear shoe

64 - 89 mm gap (2-1/2 to 3-1/2 inches) Top of tram track

________________________________________________________________ 5.170 CM340 Continuous Miner

_______________________________________ Adjustment procedures  10. Remove the hex head capscrews and lock washers that secure the front rub rail to the tractor frame (Fig. 127) and open the front rub rail cover.

Fig. 127: Rub rail removal

Rub rail

 11. Remove the cover plate to allow access to the idler assembly.  12. Locate the front idler take-up jack grease fitting and attach the grease gun to the fitting.  13. If the tram track tension is too tight, readjust the idler position using the following steps: ■

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

■

Remove one or more idler adjustment shims from the idler slide channel.

■

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

■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

______________________________________________________________ A6474X319 Rev 1 5.171

Adjustment procedures ________________________________________  14. If the tram track is too loose, readjust the idler position using the following steps: ■

Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 31/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor.

■

Insert shims (Fig. 128) into the idler slide channel until the space between the tractor frame and the pusher plate is filled.

■

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

■

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

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

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

Fig. 128: Tram track adjustment Take-up cylinder Crawler chain take-up lubrication

Shims

Pressure relief fitting

Idler assembly

________________________________________________________________ 5.172 CM340 Continuous Miner

_______________________________________ Adjustment procedures  15. If the tram track tension is still too loose when the entire 5” shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps:  Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims.  Remove all of the idler adjustment shims from the idler slide channel.  Open the pressure release fitting for the front idler take-up jack and allow the cylinder to contract.  The tram track tension should now be reduced and separation of the tram track will be easier.  Locate a tram track link near the tram idler.  Using the hammer and punch, remove the four roll pins of the two tram track pins (Fig. 139) that secure the tram track link to the track.  Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link.  Store the tram track link, one of the tram track pins and two of the roll pins in a safe place.  Connect the two ends of the tram track and using the hammer and punch, secure the two end links together with the remaining tram track pin.  Using the hammer and punch, secure the tram track pin between the two links with the remaining two roll pins.  Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct tension. The tram track is at the proper tension when it hangs approximately 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.  Insert shims into the idler slide channel until the space between the tractor frame and the pusher plate is filled.  Open the pressure release valve for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.  The idler adjustment shims will keep the idler stationary and the track tensioned.  Evaluate the resulting track tension and repeat until the track reaches proper tension.

______________________________________________________________ A6474X319 Rev 1 5.173

Adjustment procedures ________________________________________ Fig. 129: Tram track adjustment Pad

Track retention pin

Lock pin

 15. When the tram track has been adjusted to the proper tension, remove the grease gun from the idler take-up jack grease fitting.  16. Open pressure release to take pressure off of take-up cylinder.  17. 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.

________________________________________________________________ 5.174 CM340 Continuous Miner

_______________________________________ Adjustment procedures Tail shim adjustment As the conveyor wears the tail section may sag relative to the conveyor front section. The conveyor has been designed to allow correction of the sag by adding shims.  1. Lower the cutter head and gathering head assemblies until they touch the floor.  2. Position the conveyor tail section directly behind the miner and raise it to its highest position.  3. Insert blocking under the tail section and lower the tail onto the blocking. The conveyor should be at an angle with the rear end of the tail section slightly higher than the front.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  4. Insert blocking between the top of the tractor frame and the bottom of the conveyor, leaving about 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.

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

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 130).

Fig. 130: Shim removal

Socket head capscrews

Lower pivot plate

Shim retainer

Shims

______________________________________________________________ A6474X319 Rev 1 5.175

Adjustment procedures ________________________________________  7. Connect the trailing cable to energize the miner.

WARNING! The following steps releases the shims, which will fall free. Watch out for falling shims when loosening the capscrews.  8.

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

 9.

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

WARNING! Follow all Federal and mine lockout/tagout regulations and procedures. Failure to do so could result in machine damage or serious injury or death to personnel.  10. Replace the removed shims (Fig. 131) and add the number of shims required to level the conveyor front and tail sections.  11. Tighten the socket head capscrews.

Fig. 131: Tail shim adjustment Socket head capscrews

Shim retainer

Lower pivot plate

Shims

 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. 128). If the sections are not horizontally aligned, then add or subtract shims as required.

________________________________________________________________ 5.176 CM340 Continuous Miner

_______________________________________ Adjustment procedures Fig. 132: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

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

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all blocking devices.  17. Securely retighten the socket head capscrews.

______________________________________________________________ A6474X319 Rev 1 5.177

Adjustment procedures ________________________________________ 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. See the Conveyor chain take-up valve adjustment procedure (Pilot/ auxiliary pump circuit relief valve adjustments) in this section. 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.

________________________________________________________________ 5.178 CM340 Continuous Miner

_______________________________________ Adjustment procedures Cutter motor feedback adjustment The tram motor speed voltages are limited in the forward direction when the cutter motors are running. How much the tram speed is limited is controlled by the load on the cutter motors. When the load is light, as in a clean-up operation, the tram speed is less limited that when there is high cutter motor loading, as in a sumping operation.

The cutter motor loading is monitored by using a current transformer, and electronic overload CTs. The following procedure should be used to properly set the sump speed when using a Super Simpson control system.  1.

Enter the “SUMP SETUP MENU” (Fig. 133) in the Engineering level and record all existing parameter values.

 2.

Set the “Max Left Hand Sump Speed” and “Max Right Hand Sump Speed” at 20%.

 3.

Set the “Min Left Hand Sump Speed” and “Min Right Hand Sump Speed” at 5% below the max speed.

 4.

Start the cutter head and observe and record the running cur rent in free air for the cutter motors.

 5.

Go to the “SUMP CONFIG MENU” (Fig. 133) and set the “Cutter in Face Current” at approximately 30 amps above the free air current observed in Step 4.

 6.

Operate the miner in the face and observe the peak current reached during sumping operation on the “PRODUCTION MONITOR” screen (Fig. 1333).

 7.

Enter the peak current observed in Step 6 as the “Sump Tram Max Cutter Current” on the “SUMP CONFIG MENU”.

 8.

Set the “Sump Tram Min Cutter Current” 30 amps below the max value obtained in Step 7.

 9.

Raise the max sump tram cutter current in small increments until the cutter current levels out, as seen on the “PRODUCTION MONTIOR”.

 10. Enter the current observed in Step 9 as the “Sump Tram Max Cutter Current”.  11. Set the “Sump Tram Min Cutter Current” 30 amps below the value obtained in Step 10.  12. Start raising the “Max Left Hand Sump Speed” and “Max Right Hand Sump Speed” on the “SUMP SETUP MENU” until the crawlers start to break traction. This is the max sump speed.  13. Set the “Min Left Hand Sump Speed” and “Min Right Hand Sump Speed” at 5% below the max speed obtained in Step 12.

______________________________________________________________ A6474X319 Rev 1 5.179

Adjustment procedures ________________________________________  14. The miner may start cutting with a lurching motion while sumping. If this occurs, raise the “Sump Speed Delta” value, located on the “SUMP SETUP MENU”, in small increments until the lurching subsides.

These parameter values are the optimum values for the machine in the current cutting conditions.

Clean up speed allows faster tram when approaching the face with the cutters running, pulling only free air current. Once the “Cutter in Face Current” is met, the algorithm for the sump configuration is activated.

IMPORTANT! Machine power must be disconnected during installation of the current generator. Cutter motor feedback adjustment is normally set with the crawler tracks off the mine floor, stabilizer and cutter head down (machine jack-knifed). To jack knife the machine you should be familiar with the hydraulic circuits on the miner, and in particular, the cutter head cylinder circuit and the shear down/ maintenance valve (anti-chatter) operation as described in the Hydraulic section of this chapter.

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

Fig. 133: Sump displays

Sump setup menu

________________________________________________________________ 5.180 CM340 Continuous Miner

Adjustment procedures ________________________________________ Fig. 133: Sump displays (cont.)

Sump configuration menu

Production monitor

________________________________________________________________ 5.181 CM340 Continuous Miner

____________________________________ Replacement of wear parts Instructions on the replacement of wear parts It is essential that wear parts be replaced before reaching the lowest wear limit. To ensure that this happens, wear parts must be inspected at regular intervals.

CAUTION! Disassembly and assembly procedures listed in this section are specialized and, as such, should only be performed by qualified personnel.

Cutter head (boom) assembly The cutter head assembly (Fig. 134) is powered by two AC electric motors mounted on each side of the cutting head support frame. Each motor drives through a torque limiting clutch to an input gear case, which in turn drives a common shaft, allowing the two drive motors to share the cutting load. Each input gear case is removable as a separate unit from the main cutting head gear case. The cutting head is attached to the main frame at a heavy-duty pivot. Two hydraulic cylinders raise and lower the cutting head.

The cutter head assembly can be removed as an assembly or as individual components.

Fig. 134: Cutter head assembly Boom Input cutter gear case (2) End drum (2)

Boom pivot pin (2)

Center drum

Shear cylinder (2) Torque limiting clutch (2)

Cutter head motor (2)

______________________________________________________________ A6474X319 Rev 1 5.182

Replacement of wear parts _____________________________________ Cutter head assembly removal and installation cutter head assembly removal

To remove the cutter head assembly (Fig. 135):  Attach an appropriate lifting device to the boom assembly. Take up the slack in the lifting device so that the weight is supported as the assembly is unpinned from the miner.

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.  Lower the gathering head and the cutter head to the floor and position the conveyor tail section level with the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Disconnect and tag the power cables from the motors. Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the water hoses from the cutter motors  Disconnect, tag, and cap the lubrication and hydraulic lines going to the cutting head.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Disconnect the water hoses to the dust suppression sprays.  Remove the two (2) boom pivot pins.  Remove the two (2) socket head cap screws from the retaining plate on the right and left pivot pins and remove the retaining plate.  On either side, force the main pivot pin inward from the outboard side, using the two (2) tapped jack screw holes, if necessary.  Connect electrical power to the machine.  Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

________________________________________________________________ 5.183 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Block the boom and shear cylinders to keep them stationary during pin removal.

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.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder boom clevis pins.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plates on each side of the machine.  Insert a slide hammer into the treaded hole in the end of the pin and remove the pin from each side of the machine.  Connect electrical power to the machine.  Retract the shear cylinders to pull their bearings free from the boom clevises.  Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.  Slowly tram the machine backwards until the cutter boom pivot points clear the front of the gathering head.

Fig. 135: Cutter head assembly Cutter boom

Cutter boom pivot (2)

Shear cylinder (2)

Shear cylinder clevis pin (2)

______________________________________________________________ A6474X319 Rev 1 5.184

Replacement of wear parts _____________________________________ cutter head assembly installation

To install the cutter head assembly (Fig. 135):  Slowly tram the machine forward towards the raised end of the boom until the pivot pins clear the gathering head backboard.  Lower the boom pivot points until the shear cylinders can reach their clevises. Block the boom to keep it in a secure position.

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.  Extend the shear cylinders until the rod end bearings can be inserted into the cutter boom clevises.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Install the shear cylinder boom clevis pin on each side of the machine.  Position the right shear cylinder’s rod end bearing in the boom clevis.

WARNING! Do not use your fingers to check the alignment of the rod bearing in the clevis. Shifting of the parts could result in serious injury.  Insert the rod end pin through the aligned clevis bushing and rod end bearing.  Insert the keeper plate and secure to the boom clevis with the two (2) socket head cap screws lock washers.  Connect electrical power to the machine.  Once the shear cylinders are secured to the cutter boom remove the boom blocking to allow boom movement.  Retract 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 be used to adjust the cutter boom’s position to allow easier installation of the cutter boom pivot pins.

________________________________________________________________ 5.185 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Install both cutter boom pivot pins.  Insert the main pivot pin from the inside toward the outboard side of the clevis.  Insert the retainer plate and secure with the two (2) socket head cap screws.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Connect the power cables and water cables to the cutter motors (see Cutter motor installation procedure in this chapter).  Connect the water hoses to the dust suppression sprays.  Connect all hydraulic and lubrication hoses.  Connect electrical power to the machine.

______________________________________________________________ A6474X319 Rev 1 5.186

Replacement of wear parts _____________________________________ Shear cylinder assembly removal and installation shear cylinder removal

To remove a shear cylinder (Fig. 135):  Lower the gathering head until it touches the floor. Lower the conveyor tail section until it is even with the floor.  Raise the cutter head assembly and install the cutter boom safety supports (Fig. 134).  Support the shear cylinder so that when it is unpinned from the machine, it does not move.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the shear cylinder frame mounting pin:  Locate the shear cylinder retainer plate and pin inside the front cover.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plate.  Disconnect and cap the grease line going to the pin.  Remove the grease fitting adapter from the end of the pin.  Insert a slide hammer into the treaded hole in the end of the pin and pull the pin.  Connect electrical power to the machine.  Retract the shear cylinder to pull the bearing free from the boom clevis.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Cycle the shear cylinder control lever several times to release hydraulic pressure from the shear cylinder.

________________________________________________________________ 5.187 CM340 Continuous Miner

____________________________________ Replacement of wear parts WARNING! The following steps will disconnect the shear cylinder from the frame. The shear cylinder is extremely heavy. Make sure that it’s weight is supported and that the cylinder will not swing free or move. Failure to follow this warning may result in machine damage or in severe injury or death to personnel.  Open the front cover on the side of the machine by removing the two (2) socket head cap screws.  Disconnect and cap the hydraulic line to the shear cylinder.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the shear cylinder boom clevis pin.  Remove the two (2) socket head cap screws and lock washers that secure the cylinder pin keeper plate.  Remove the grease fitting adapter from the end of the pin.  Insert a slide hammer into the treaded hole in the end of the pin and pull the pin.

______________________________________________________________ A6474X319 Rev 1 5.188

Replacement of wear parts _____________________________________ Fig. 136: Cutter head safety supports

Cutter head safety support (installed two (2) locations)

Cutter head safety support (installed two (2) locations)

________________________________________________________________ 5.189 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 137: Shear cylinder removal and installation

Shear cylinder boom clevis pin

Shear cylinder frame mounting pin

______________________________________________________________ A6474X319 Rev 1 5.190

Replacement of wear parts _____________________________________ shear cylinder installation

To install a shear cylinder (Fig. 137):  Attach an appropriate lifting device to the shear cylinder and position the cylinder so that the cylinder clevis is aligned in the mounting clevis on the cutter head.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Install the boom clevis pin.  Install the pin from the inside, toward the outside, of the machine with the threaded hole end of the pin toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.  Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers.  Install the grease fitting into the end of the pin.  Attach the hydraulic hoses to the cylinder.  Connect the trailing cable to energize the machine.  Slowly extend the shear cylinder so that the rod clevis can be inserted into the frame mounting clevis.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Install the frame clevis pin.  Install the pin from the inside, toward the outside, of the machine so that the threaded hole end is toward the outside of the machine.

IMPORTANT! The pin should be inserted so that it’s retaining channel remains outside the bushing.  Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers.  Install the grease fitting into the end of the pin.  Attach the grease line to the grease fitting in the pin.  Close and secure the front cover.

________________________________________________________________ 5.191 CM340 Continuous Miner

____________________________________ Replacement of wear parts center cutter drum removal

Center cutter drum removal and installation To remove the center cutter drum (Fig. 138):  Lower the gathering head until it touches the floor. Lower the conveyor assembly until it is level with the floor.  Slowly rotate the cutter head until on of the center drum seams appears directly in front and one appears directly in the rear of the cutter head.  Lower the cutter head assembly until it is resting on the floor.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the twenty-four (24) socket head bolts from that secure the two halves of the center drum to each other. Make sure to collect the bolts, the forty-eight (48) flat washers, and the twenty-four nuts for use in reassembly.  Attach a lifting device to the top half of the center drum and lift the it off of the assembly. It may be necessary to use a pry bar or other force to break the seal between the top and bottom halves of the center drum before the top half can be lifted off.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads.  Remove the four (4) alignment keys from the bottom half of the center drum and store for use in reassembly.  Connect the trailing cable to energize the machine.  Slowly raise the cutter head assembly until it is clear of the bottom half of the center drum.  Slowly tram the miner backwards away from the bottom half of the center drum.

______________________________________________________________ A6474X319 Rev 1 5.192

Replacement of wear parts _____________________________________ Fig. 138: Center drum removal and installation

Center drum seam

Socket head bolts (24)

Center drum, upper half

Alignment keys (4) Center drum, lower half

________________________________________________________________ 5.193 CM340 Continuous Miner

____________________________________ Replacement of wear parts center cutter drum installation

To install the center cutter drum (Fig. 139):  Place the four (4) alignment keys into the keyway slots around the outer edges of the bottom half of the center drum.  Slowly rotate the cutter head until the center drum drive keys are positioned directly on top and bottom of the cutter head assembly.  Slowly lower the cutter head assembly onto the bottom half of the center drum.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the upper half of the center drum.

WARNING! You could be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and stay clear of suspended loads.  Lower the upper half of the center drum onto the cutter head assembly, making sure that the keyways align with the keys on the bottom half.  Check that the upper half of the center drum is fully seated on the bottom half. Using a rod, check the bolt holes for alignment. Adjust the position of the upper half of the center drum as necessary to align the bolt holes.  Install the twenty-four (24) socket head bolts that secure the two halves of the center drum to each other, placing a flat washer under the head of the bolt and between the bolt and the nut. Install the bolt heads in the direction of rotation, if lacing permits.  Torque the bolts appropriately using the pattern shown in Fig. 145.

Fig. 139: Center drum bolt torque pattern

______________________________________________________________ A6474X319 Rev 1 5.194

Replacement of wear parts _____________________________________ end drum removal

End drum removal and installation To remove an end drum (Fig. 140):  Place the miner so that the cutting head is easily accessible and there is side clearance to pull the end drum off of the cutting head.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  There may be an optional cap on the end of the drum. If the end cap is present, remove the eight (8) socket head cap screws that secure it to the drum. Apply heat as necessary to liquefy Loctite used when the cap screws were installed.  Using the four puller holes in the end cap and four of the eight socket head screw just removed, remove the end cap.

CAUTION! If the assembly is seized, it may be necessary to pry on the edges.

Care must be taken not to damage the o-ring or its seal land.  Attach a lifting device to the end drum and apply tension so that the weight of the drum is supported by the lifting device.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Loosen the eighteen (18) socket head cap screws that secure the wedge block assembly and the drum to the cutting head hub.  Match mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon reassembly.  Remove the six (6) socket head cap screws securing each key retainer plate to the end drum.  Remove the spacers and then the keys.  Slowly pull the end drum off of the main assembly, maneuvering it away from the miner.

________________________________________________________________ 5.195 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 140: End drum removal and installation

Puller hole (4)

Key plate retainer (2) Socket head cap screw (8)

End cap (optional)

______________________________________________________________ A6474X319 Rev 1 5.196

Replacement of wear parts _____________________________________ end drum installation

To install an end drum (Fig. 140)  Verify that power is disconnected and that the trailing cable is properly locked and tagged out. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the end drum.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Using the match marks made when the end drum was removed, align the end drum and the cutting head hub.  Install the two (2) spacers and the two (2) keys.  Install the two (2) key retainer plates and secure to the drum using the twelve (12) socket head capscrews.  Install the eighteen (18) socket head cap screws to secure the wedge block assembly and the drum to the cutting head hub and torque appropriately.  Coat the threads of the eight socket head cap screws with Loctite 242 (blue) and install the eight socket head cap screws to secure the end cap. Torque appropriately.

________________________________________________________________ 5.197 CM340 Continuous Miner

____________________________________ Replacement of wear parts Cutter drum drive motor removal and installation cutter drum drive motor removal

To remove the cutter drum drive motor (Fig. 141):  Lower the gathering head until the front of the pan rests on the floor.  Lower the cutter head to a comfortable working height. Block it in this position under the support frame.

WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

______________________________________________________________ A6474X319 Rev 1 5.198

Replacement of wear parts _____________________________________ Fig. 142: Cutter motor cover removal

Side

Top

 Remove the hex head capscrews that secure the junction box cover and then remove the cover (Fig. 143)  Locate the three (3) lug power connections.

IMPORTANT! Before detaching these three (3) lugs, tag the wires to make reconnection easier.  Tag the lugs for correct reconnection and then remove the hex head capscrews that secure the three power cable lugs to the three motor lugs.  Remove the socket head capscrews that secure the global plug to the junction box (Fig. 143).  Slide the global plug out of the junction box. At this point, the power cable should be completely disconnected from the motor.

WARNING! Power should not be reconnected to the miner while the motor power cable is disconnected. Damage to the miner or personal injury or death could result.

________________________________________________________________ 5.199 CM340 Continuous Miner

____________________________________ Replacement of wear parts  To prevent damage to the motor power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.  Disconnect, tag, and cap the two (2) water hoses from the motor cooling water fittings (Fig. 143).  Remove the two water fittings from the motor and store for reuse during installation.  Plug the motor cooling water ports to prevent contamination.  Disconnect, tag, and cap the motor bearing grease lines.  Attach an appropriate lifting device to the motor and take up the slack so that the weight of the motor is resting on the lifting device.

WARNING! Always observe the safe working load limits of all lifting devices.

You could be seriously injured or killed by falling loads.  Remove the hex head capscrews that secure the cutter motor clutch cover and then remove the clutch cover.  Remove the seal cap and internal retaining ring which restrains the motor input shaft. Remove the motor input shaft from the inside of the motor going into the input gear case.  Remove the motor mounting bolts.  Carefully lift motor out of the frame.

______________________________________________________________ A6474X319 Rev 1 5.200

Replacement of wear parts _____________________________________ Fig. 143: Cutter drum drive motor removal and installation

Mounting bolts Clutch cover

Junction box cover

Cooling water inlet/ outlet port (2)

________________________________________________________________ 5.201 CM340 Continuous Miner

____________________________________ Replacement of wear parts cutter drum drive motor installation

To install the cutter drum drive motor (Fig. 143): WARNING! Federal law requires that mining equipment electrical components must be inspected by a certified electrician before the equipment can be operated.

WARNING! This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation. Follow all Mine, State, and Federal lockout/tagout procedures. Failure to do so may result in serious injury or death.  Block up the cutter head drum drive motor in position against the rear of the boom so that the motor’s mounting holes align with the boom’s motor mounting holes.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Insert the mounting bolts to secure the motor to the boom. Torque appropriately.  Install the two motor cooling water fittings into the cooling water ports on the motor.  Attach the cooling water hoses to the fittings.  Remove the four (4) hex head capscrews that secure the junction box cover and then remove the junction box cover.  Insert the three lugs of the power cable (with gland and stuffing box already installed) into the motor’s junction box.  Tighten the two socket head capscrews to secure the gland to the junction box.  Inside the junction box, locate the motor’s lug connections.  Match the motor lugs with the corresponding power cable lugs.  Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, the power cable lug, a flat washer, and a lock washer. Secure the capscrew with a hex nut. Repeat for the other two lugs.  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.  Verify correct phasing.

______________________________________________________________ A6474X319 Rev 1 5.202

Replacement of wear parts _____________________________________  Replace the junction box o-ring and cover and secure with the four hex head capscrews.

IMPORTANT! An MSHA certified electrician must inspect all work and check for permissibility.  Attach the grease lines to the grease fittings on the motor.  Insert the motor input shaft.  Replace the clutch cover and secure with hex head capscrews.  Replace the top cover and secure with hex head capscrews.  Replace the side cover and secure with hex head capscrews.

________________________________________________________________ 5.203 CM340 Continuous Miner

____________________________________ Replacement of wear parts cutter drum drive gear case removal

The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

To remove the cutter drum drive gear case (Fig. 144):  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the cutter head center drum (see Center cutter drum removal procedure in this chapter).  Remove the cutter head end drums (see End drum removal procedure in this chapter).  Remove the spray blocks by removing the cap screws that secure them to the miner.  Ensure that the cutter head assembly is adequately blocked.  Securely block the cutter head gear case so that it will not fall when it is unbolted from the frame.

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

IMPORTANT! During the removal of the cap screws that secure the gear case to the frame, it may be necessary to adjust the blocking under the gear case. Ensure that the gear case is securely blocked at all times and that it does not shift as it is unbolted.  Carefully loosen and remove the forty (40) capscrews that secure the cutter head gear case to the cutter head support frame.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the miner and the gear case while tramming the miner. You could be seriously injured or killed by falling loads.

WARNING! Do not attempt to start the cutter head motors. You could be seriously injured or killed.

CAUTION! Use care when tramming the miner away from the gear case.

While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

______________________________________________________________ A6474X319 Rev 1 5.204

Replacement of wear parts _____________________________________ Fig. 144: Cutter drum drive gear case removal and installation

Top spray block (3)

Side spray block (2) Cutter drum drive gear case Mounting capscrew (40)

________________________________________________________________ 5.205 CM340 Continuous Miner

____________________________________ Replacement of wear parts cutter drum drive gear case installation

To install the cutter drum drive gear case (Fig. 144):  Ensure that the gear case is securely blocked so that the miner can be trammed into position behind it.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Slowly tram the miner into position behind the gear box.  Disconnect and lockout the trailing cable. Follow all Mine, State, and Federal lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Using a metal rod, check for alignment between the mounting holes on the miner and the mounting holes in the gear case.  Install the forty capscrews that secure the gear case to the miner.

Torque appropriately.  Install the five (5) spray blocks.  Install the end drums (see End drum installation procedure in this chapter).  Install the center drum (see Center drum installation procedure in this chapter).

______________________________________________________________ A6474X319 Rev 1 5.206

Replacement of wear parts _____________________________________ Gathering head assembly The gathering head assembly (Fig. 145) consists of the gathering pan, the continuous loading arms (CLAs), lift cylinders, and two drive motors connected to an input gear case through a torque shaft.

The gathering head can be removed as an assembly or as individual components.

Fig. 145: Gathering head assembly

Gathering pan Foot shaft Motor (behind cover) Continuous loading arm (CLA)

________________________________________________________________ 5.207 CM340 Continuous Miner

____________________________________ Replacement of wear parts Gathering head assembly removal and installation gathering head assembly removal

To remove the gathering head assembly (Fig. 145):  Place the machine in a position where both sides in front of the crawlers are accessible.  Lower the gathering head until the pan rest on the mine floor.  Raise the cutter head and block it securely.

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.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the motor access cover on the side of the gathering head frame by removing the capscrews that secure it to the frame.  Wash motor compartment thoroughly for easier removal of motor and prevent contamination of water system.  Disconnect and tag the power cables to the gathering head motors.

Be sure to tape the power cables as power will be restored to the machine.  Disconnect, tag, and cap the water hoses going to the gathering head motors.  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter). The chain does not have to be completely removed from the miner. After disconnecting the chain from the foot shaft, the top strand must be pulled back clear of the gathering head conveyor section. The bottom of the chain can be left where it is.  Securely block the gathering head frame. The gathering head frame must be blocked at the rear of the frame, as close to the pivot as possible, to prevent falling when the pivot pins are removed.

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.

______________________________________________________________ A6474X319 Rev 1 5.208

Replacement of wear parts _____________________________________  Support the rod end of the gathering head raise cylinders.

NOTICE! The gathering head cylinders do not have to be removed from the frame. Rotate them away from the gathering head and securely fasten them to the main frame.  Remove the upper cylinder pins.  Remove the pivot pin retainer.  Force the gathering head hinge pin out from the outboard side going in. If the pin does not come out, check to see that support under the rear of the gathering head is adequate but is not forcing.  Reconnect the trailing cable to energize the miner.

WARNING! Do not attempt to start the cutter head or gathering head motors.

IMPORTANT! Make sure that the lower section of the conveyor chain is free of the foot shaft so that when the miner is trammed away from the gathering head, the chain will pull free of the return deck.  Slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.  Lower the cutting head to the floor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

________________________________________________________________ 5.209 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 146: Gather head assembly removal and installation

Hinge pin

Motor access cover

______________________________________________________________ A6474X319 Rev 1 5.210

Replacement of wear parts _____________________________________ gathering head assembly installation

To install the gathering head assembly (Fig. 146):  Reconnect the trailing cable to energize the miner.

NOTICE! When the gathering head was removed, the lower length of the conveyor chain was pulled free of the gathering head. This end of the conveyor chain must be brought forward when the miner is trammed to the gathering head.  Tram the miner to the gathering head frame. Using a puller cable or wire, feed the lower end of the conveyor chain through the gathering head return deck and up to the foot shaft.  Position the miner to align the pivots in the main frame with those on the gathering head.

DANGER! All personnel must stay clear of the miner while it is tramming and being aligned with the gathering head assembly. Standing under the cutter head or in the path of the miner while it is tramming may result in severe injury or death.  Once the miner is aligned with the gathering head assembly, block the cutting head in its raised position.

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.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Coat the pivot pins and their bushings with grease to aid in installation.  Install both the right and left hand pivot pins. Be sure that the pivot bores in the gathering head and the main frame are aligned and that you do not damage the end of the pivot bushing during installation.  Position each pivot pin so that it is flush with the main frame bushing.  Insert the pivot pin retainer and secure with capscrews. Tighten the capscrews to the appropriate torque.

________________________________________________________________ 5.211 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Align the gathering had frame clevises with the gathering head cylinder rod end clevises. Install the upper cylinder pins through the clevises and secure.  Lubricate the cylinder and pivot pins.  Install the conveyor chain (see Conveyor chain installation procedure in this chapter).  Connect all water lines to the motors.  Connect the electrical leads to the motor.  Secure the motor access cover to the gathering head frame with the capscrews.  Check the oil levels in the gathering head pot cases and the gathering head input gear cases.

______________________________________________________________ A6474X319 Rev 1 5.212

Replacement of wear parts _____________________________________ gathering head motor removal

Gathering head motor removal and installation To remove a gathering head motor (Fig. 147):  Lower the gathering head until the pan rests on the mine floor.  Raise the cutter head and block it securely.

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.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the top cover over the input gear case.  Remove the motor access cover on the side of the gathering head frame.  Wash out compartment thoroughly.  Disconnect and tag the power cables to the gathering head motors.  Disconnect, tag, and cap the water hoses going to the gathering head motors.  Remove the bearing cap cover from the exposed end of the motor.  Remove the snap ring and plug from the end of the motor, exposing the torque shaft.  Remove the torque shaft.  Securely block the motor to prevent it from falling when the mounting bolts are removed.

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.  Remove the motor mounting bolts and carefully back the motor out of the frame.

________________________________________________________________ 5.213 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 147: Gathering head motor removal and installation

Top access cover

Motor access cover

______________________________________________________________ A6474X319 Rev 1 5.214

Replacement of wear parts _____________________________________ gathering head motor installation

To install a gathering head motor (Fig. 147):  Ensure mating surfaces of the frame and motor are clean and free of contaminants.  Carefully position the motor in the frame.  Insert the motor mounting bolts and torque appropriately.  Insert the torque shaft into the motor.  Replace the plug and snap ring over the end of the torque shaft.  Replace the bearing cap cover.  Reconnect the water hoses to the motor.  Reconnect the power cable to the motor.  Replace the motor access cover on the side of the gathering head frame.  Replace the top cover over the input gear case.

________________________________________________________________ 5.215 CM340 Continuous Miner

____________________________________ Replacement of wear parts Gathering head gear case and pot removal and installation gathering head gear case and pot removal

To remove a gathering head gear case and pot (Fig. 148):  Disconnect the conveyor chain (See Conveyor chain removal procedure in this chapter).  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the gathering head motor (see Gathering head motor removal procedure in this chapter).  Securely block the input gear case in position to prevent the gear case from falling when the capscrews that secure it are removed.

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.  Disconnect any oil fill lines connected to the pot.  Attach a lifting device to the top surface of the pot and input gear case.

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.  Remove the CLA (see CLA removal procedure in this chapter).  Remove all covers from over the pot assembly (Fig. 149).  Foot shaft connector must be detached from output shaft on pot.  Loosen the pot case attachment from the frame by removing the capscrews that secure the corners of the pot. Removing these screws will also remove the three wedge blocks which secure the pot in position (Fig. 150).  Remove the foot shaft cover (Fig. 150).  Remove foot shaft locking collar and slide splined coupling off pot output shaft.  Lift the pot and input case from the gathering head frame.

______________________________________________________________ A6474X319 Rev 1 5.216

Replacement of wear parts _____________________________________ Fig. 148: Gathering head gear case and pot removal and installation

Top access cover

Motor access cover

________________________________________________________________ 5.217 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 149: Wedge block removal and installation

Deck plate (removed for motor is removal)

Cap screws

Covers

______________________________________________________________ A6474X319 Rev 1 5.218

____________________________________ Replacement of wear parts Fig. 150: Pot removal

Foot shaft cover

Cap screws

Wedge block

______________________________________________________________ A6474X319 Rev 1 5.219

____________________________________ Replacement of wear parts gathering head gear case and pot installation

To install a gathering head gear case and pot (Fig. 148):  Align the input gear case with the pot case (if separated) and secure with capscrews.  Attach a lifting device to the gear case assembly.

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.  Position the gear case assembly in the gathering head frame.  Ensure mating surfaces are clean.  Position the four wedge blocks which secure the pot in position and secure to the frame by installing capscrews through the four (4) corners of the pot (Fig. 150).  Connect the oil fill lines to the pot.  Install the gathering head motor (see Gathering head motor installation procedure in this chapter).  Reconnect foot shaft to output shaft on pot.  Install CLA.

______________________________________________________________ A6474X319 Rev 1 5.220

Replacement of wear parts _____________________________________ Foot shaft removal and installation foot shaft removal

To remove the foot shaft (Fig. 151):  Lower the gathering head assembly until it touches the floor.  Position the conveyor tail section directly behind the miner so that it is level with the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Open the needle valve on the left hand side of the machine to release the oil from the conveyor take-up cylinders. This will relax the tension on the conveyor chain.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.  On the conveyor chain, remove the two retaining pins from the closest connecting pin to the foot shaft and then remove the connecting pin.  Pull the top half of the conveyor chain away from the foot shaft sprocket (fold it back).  Remove the four (4) socket head capscrews that secure the two foot shaft covers to the gathering head assembly and remove the covers.  Remove the four socket head capscrews from each clamp ring on the foot shaft assembly and remove the clamp rings.  Slide both adapter shafts from the ends of the foot shat toward the sprocket in the center. This will free the foot shaft from the gear case.  Remove the foot shaft from the gathering head.

________________________________________________________________ 5.221 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 151: Foot shaft assembly removal and installation

Sprocket Clamp ring

Adapter shaft (collar)

Foot shaft cover Socket head cap screws

______________________________________________________________ A6474X319 Rev 1 5.222

Replacement of wear parts _____________________________________ foot shaft installation

To install the foot shaft (Fig. 151):  Slide an adapter shaft onto each end of the foot shaft.  Slide the foot shaft into position between the two gathering head gear case bevel pinions.

IMPORTANT! Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.  Align the foot shaft splines with the bevel pinion splines.  Slide the right adapter shaft over the foot shaft spline onto the bevel pinion splines until it touches the gear case seal carrier. Repeat for the left side.  Place a collar onto each end of the foot shaft so that the adapter shaft is secured against the bevel gear case seal carriers.  Insert and tighten the capscrews through both halves of the collars to secure the collars to the foot shaft.  Replace the foot shaft covers and secure with the four (4) M20X60 socket head capscrews.  Reattach the two ends of the conveyor chain by replacing the connecting pin.  Close the needle valve to the conveyor take-up cylinders.  Reconnect the trailing cable to energize the miner.  Start the pump so that the conveyor chain take-up cylinders are pressurized.  Turn on the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right. Check that the conveyor chain is running smoothly.  Shutdown the machine and check the conveyor chain tension. If adjustment is necessary, see the Conveyor chain adjustment procedure in this chapter.

________________________________________________________________ 5.223 CM340 Continuous Miner

____________________________________ Replacement of wear parts CLA removal and installation CLA removal

To remove a continuous loading arm (CLA) (Fig. 152):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the eight (8) M24 socket head capscrews from the CLA retainer plate and remove the retainer plate. There are two puller holes, protected by cup-point set screws, in the retainer plate to assist with it’s removal.  Remove the three capscrews located where the arms meet the CLA hub. There are three puller holes, protected by cup-point set screws, in the arm to assist with it’s removal.  Remove the three dowel pins, which position the CLA to the pot disc and keep for reassembly.  The CLA is now free and can be removed.

______________________________________________________________ A6474X319 Rev 1 5.224

Replacement of wear parts _____________________________________ Fig. 152: CLA removal and installation

Puller hole (3)

CLA arm to hub capscrews (3)

CLA arm to hub capscrews (3)

Puller hole (2)

CLA retainer plate capscrews (8)

CLA tip

Retainer plate CLA retainer plate capscrews (8)

________________________________________________________________ 5.225 CM340 Continuous Miner

____________________________________ Replacement of wear parts CLA installation

To install a continuous loading arm (CLA) (Fig. 152):  Install the three dowel pins into the pot disc.  Position the CLA on the gathering head ensuring that CLAs are aligned as shown in the top view of Fig. 152.  Insert the three capscrews into the arms and tighten.  Insert the retainer cap into the center of the arm.  Apply Loctite 262 to the eight (8) M24 socket head capscrews and install the capscrews into the retainer plate. Torque incrementally and evenly in a crossing pattern to 734 lb-ft as follows: Step 1: Snug Step 2: 245 ft-lb Step 3: 500 ft-lb Step 4: 734 ft-lb  Reconnect the trailing cable.

CLA tip replacement

CLA tip replacement To replace a CLA tip (Fig. 152):  Lower the gathering head assembly until it touches the floor.  Raise the cutter head assembly to its highest position and block.

WARNING! Observe the safe work load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the two (2) hex head capscrews that secure the tip to the arm and remove the tip.  Slide a new tip onto the arm and secure with two (2) hex head capscrews.  Reconnect the trailing cable.

______________________________________________________________ A6474X319 Rev 1 5.226

Replacement of wear parts _____________________________________ Gathering head cylinder removal and installation gathering head cylinder removal

To remove a gathering head cylinder (Fig. 153):  Raise the gathering head off the ground by fully extending the gathering head cylinder and securely block.  Raise the cutter head and securely block.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a lifting device to the gathering head cylinder so that when the cylinder is unpinned, the lifting device will support the cylinder.  Remove the spiral pin from the upper (rod end) cylinder pin and then remove the upper pin.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly contract the cylinder until the rod eye is free of the gathering head clevis.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Check the cutter head and the gathering head are still securely blocked.  Move the gathering head lift cylinder valve handle to extend and retract the cylinder in order to release any hydraulic pressure from the cylinder.

________________________________________________________________ 5.227 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Disconnect and plug the hydraulic hose from the cylinder.

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 under load, the load will fall. Machine damage or serious injury or death to personnel may result.  Remove the two (2) capscrews that secure the pin retainer plate to the frame and remove the retainer plate.  Remove the pin from the clevis.  The cylinder is now free and can be lifted off of the machine.

______________________________________________________________ A6474X319 Rev 1 5.228

Replacement of wear parts _____________________________________ Fig. 153: Gathering head cylinder removal and installation

Cylinder rod pin

Gathering head cylinder

Frame mounting pin

________________________________________________________________ 5.229 CM340 Continuous Miner

____________________________________ Replacement of wear parts Gathering head cylinder installation

gathering head cylinder installation

To install the gathering head cylinder (Fig. 153):

 Check that the gathering head and cutter head assemblies are securely blocked.  Insert the cylinder end clevis of the gathering head cylinder into the frame mounting clevis.

WARNING! This procedure involves the alignment of cylinder clevises with mounting clevises in order to install retaining pins. Do not check for alignment with your fingers. Shifting of the aligned pieces could cause serious injury.  Insert the retaining pin through the cylinder and mounting clevises.  Insert the pin retaining plate over the end of the pin and secure to the clevis with two socket head capscrews.  Attach the hydraulic hose to the cylinder.  Connect the trailing cable to energize the miner.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Slowly extend the cylinder so that the rod end clevis can be inserted into the gathering head assembly mounting clevis.

WARNING! Stand clear of the blocked cutter head and gathering head assemblies whenever the miner is energized.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Insert the retaining pin through the rod and mounting clevis.  Insert the spiral lock pin through the retaining pin.

______________________________________________________________ A6474X319 Rev 1 5.230

Replacement of wear parts _____________________________________ Crawler assembly Each (left or right) crawler assembly (Fig. 154) consists of a tram drive motor, a tram drive gear case, a crawler chain, a chain take-up roller, and a grease adjusted, shim lock take-up system. These components are mounted in a crawler frame, which is an integral part of the main frame.

Fig. 154: Crawler assembly

Gear case Motor

Roller

Crawler track (chain)

________________________________________________________________ 5.231 CM340 Continuous Miner

____________________________________ Replacement of wear parts Tram motor removal and installation tram motor removal

To remove a tram motor (Fig. 155):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and is free to turn. Be sure that the miner is level when blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the two (2) bolts that secure the top cover to the tram rub rail and slide the top cover off of the tram rub rail.  Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.  Remove the capscrews that secure the end cap on the motor.  Remove the snap ring inside the motor shaft.  Remove the shaft plug and o-ring, exposing the quill shaft.  Carefully remove the quill shaft and store in a safe place.  Remove the two (2) socket head capscrews, two hardened steel washers, and the clamp bar that secure the motor to the tram case.  Remove the two (2) socket head capscrews and two (2) hardened steel washers that secure the motor to the tram case.  Replace the end cap on the motor and secure with the four capscrews.  Disconnect, tag, and cap the cooling water hoses from the cooling water fittings located on the right and left top corners of the motor.

______________________________________________________________ A6474X319 Rev 1 5.232

Replacement of wear parts _____________________________________  Disconnect the power cable lugs from the motor.

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.  Carefully remove the motor from the tram case, be careful not to damage the motor during removal.

________________________________________________________________ 5.233 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 155: Tram motor removal and installation

Top cover

Tram rub rail

Clamp bar Motor

______________________________________________________________ A6474X319 Rev 1 5.234

Replacement of wear parts _____________________________________ tram motor installation

To install the tram motor (Fig. 155):  Clean the motor and the motor cavity in the tram case thoroughly.  Install a new o-ring (lubricated) on the motor mounting flange (rear bell).  Oil the bore of the input planetary (in the motor cavity) to ease installation.  Carefully position the motor in the tram case, being careful not to damage the motor or the o-ring on the rear bell.  Continue to position the motor into the bore of the input planetary and the flange ears on the motor are flush with the tram case. If the ears are not flush within 0.5 mm (0.020 inches), the motor is not seated properly.  Install the motor quill shaft, rotating it until the splines on the end inside the motor mesh with the internal splines of the pinion ear in the input planetary assembly.  Install the shaft plug and o-ring and the snap ring on the end of the shaft.  Install the motor end cap and secure with capscrews. Tighten to the correct torque.  Install the two (2) clamp bars, two (2) hardened steel washers, and two (2) socket head capscrews to secure the motor to the tram case. Tighten to the correct torque.  Install the two (2) socket head capscrews and two (2) hardened steel washers to secure the motor to the tram case. Tighten to the correct torque  Refill the tram gear case with high demulsibility, extreme pressure gear oil (Spec. 100-15) to the correct level. Check the oil level using the sight gauge on the outer face of the gear case.  Reconnect the power cable to the motor.  Reconnect the cooling water lines to the motor.  Reconnect power to the miner and check for tram correct operation.

WARNING! Stay clear of the blocked miner while the machine is energized.

Failure to follow this warning may result in sever injury or death.

________________________________________________________________ 5.235 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Replace the tram rub rail and secure with the two (2) pins.  Place the top cover onto the posts on the tram rub rail and secure with two (2) capscrews.

______________________________________________________________ A6474X319 Rev 1 5.236

Replacement of wear parts _____________________________________ Tram gear case removal and installation tram drive gear case removal

To remove a tram drive gear case (Fig. 156):  Position the miner so that there is adequate work space on the side from which the motor is being removed.  Block the miner so that the tram track is clear of the floor and free to turn. Make sure the miner is level.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Remove the two (2) bolts that secure the top cover to the tram rub rail and slide the top cover off of the tram rub rail.  Remove the two (2) rub rail pins that secure the tram rub rail to the two rub rail sections adjacent to it and then remove the tram rub rail to expose the tram gear case.  Separate the crawler chain (see Crawler chain removal procedure in this chapter) at a place near the tram gear case and move the chain clear of the drive sprocket. For ease of re-connection, attach a small steel cable to upper crawler pad so that it is accessible to be pulled back into place upon installation.  Disconnect, tag, and cap all water and lubrication lines from the gear case.  The main gear case and final planetary gear case may be drained, if desired, but it is not necessary.  Disconnect and tag the power cable lugs from the motor.

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.  Remove the screws insert in the jacking holes on each side of the gear case.  Remove the socket head capscrews and wedge blocks.

________________________________________________________________ 5.237 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Remove the nine (9) screws from the mounting plate (four (4) on the rear/sprocket side and five (5) on the forward/motor side).  Insert a screw into the four jacking holes and, using these holes, slowly jack the main case free of the frame.  Position a loading device, such as a scoop, at the bottom edge of the main case. Connect a couple of chains between the loading device and the back of the mounting plate.

WARNING! Observe the working load limits of chains. Overstressing the chains could cause the chain to break, resulting in serious injuries.  Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.  Cover the tram case compartment in the crawler assembly to keep out dirt and debris.

______________________________________________________________ A6474X319 Rev 1 5.238

Replacement of wear parts _____________________________________ Fig. 156: Tram case removal and installation

Top cover Tram case Tram rub rail

________________________________________________________________ 5.239 CM340 Continuous Miner

____________________________________ Replacement of wear parts tram drive gear case installation

To install the tram gear case (Fig. 156);  Ensure that the crawler frame mounting area is cleared of dirt and debris. Pay special attention to the keyways and the bore in the inner face of the main frame. Apply a light coating of Molykote G-N past to aid re-installation.  Ensure that the mounting faces on both the tram drive gear case and the crawler frame are clean.  Coat the mounting keys on the gear case and the bearing carrier on the inboard end of the main gear case with Molykote G-N paste.

The bearing carrier serves as a plug to fit into the bore in the main frame.  Slowly maneuver the gear case into position next to the machine, aligning the keys on the gear case with the keyways/slots on the frame.

IMPORTANT! If the miner and the gear case assembly are not both level and aligned correctly, installing the gear case assembly into the machine will be very difficult.  Slowly push the gear case assembly into the crawler frame, allowing the keys on the gear case to engage the keyways in the main frame. Be sure that cap screw mounting holes line up.  Install the nine (9) socket head capscrews and washers and torque appropriately.  Install the wedge blocks and secure with capscrews. Tighten to the correct torque.  Install four set screws into the jacking holes and tighten to the correct torque.  Reconnect all water and lubrication lines to the gear case.  Reconnect the electrical leads to the motor.  Check the oil level in the gear case and add high demulsibility, extreme pressure gear oil (Spec. 100-15) as required.  Reconnect the crawler chain (see Crawler chain installation procedure in this chapter).

______________________________________________________________ A6474X319 Rev 1 5.240

Replacement of wear parts _____________________________________  Connect the trailing cable to energize the miner.  Operate the tramming function on the side where the tram gear case assembly was installed. Check for correct operation.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Replace the tram rub rail, securing it with the two (2) pins.  Position the top cover over the posts on the tram rub rail and secure with two (2) bolts.

________________________________________________________________ 5.241 CM340 Continuous Miner

____________________________________ Replacement of wear parts Crawler chain removal and installation (with grease take-up) crawler chain removal

To remove the crawler chain (Fig. 157):  Position the miner so that there is sufficient clearance to work and enough space to pull the chain off.  Block the machine so that the crawler assembly is off of the mine floor. Do not place blocking under the crawler track.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Attach a grease gun to the crawler grease take-up fitting and pump grease into the take-up cylinder to extend the cylinder and remove pusher plate pressure on the idler shims (Fig. 158).  Remove the hex head cap screw securing the shims to the take-up housing and remove all shims and store them in a safe place (Fig. 163).  Bleed off pressure in the grease take-up cylinder by opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain (Fig. 158).

______________________________________________________________ A6474X319 Rev 1 5.242

Replacement of wear parts _____________________________________ Crawler chain take-up lubrication

Fig. 158: Idler take-up

Pressure relief valve

Take-up cylinder

Shims

Idler assembly

WARNING! The end of the chain, just forward of the separation point, should be blocked. Personnel should stay clear of the chain during separation to avoid injury when the chain is disconnected.  Locate a tram track link near the track opening at the bottom of the tram case. Remove the two (2) capscrews and nuts, one on each side of the crawler pad, and drive the two crawler pins out of the crawler pad.  Lay out new chain behind machine with grousers on floor and chain fully assembled.  Back miner to new crawler chain as close as possible.  Block as instructed and relieve tensions at crawler take-up.  Break chain at bottom of drive sprocket.  Unblock the loose length of chain and lower it to the mine floor.  Attach new crawler to bottom portion of old crawler.  Attach top of old crawler to a pull vehicle.  Tram crawler in reverse as pull vehicle holds just enough tension to “tram” on new crawler chain.  Disconnect from old chain and pin new chain together.

________________________________________________________________ 5.243 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Pull the cable until the crawler chain assembly is tensioned, then slowly pull the crawler chain until it has rotated the tram drive sprocket, gearing, and motor and is free to slide off the crawler frame.  Pull the crawler chain clear of the crawler frame and away from the machine.

Fig. 159: Crawler chain removal and installation

Pin, bolt, and nut

______________________________________________________________ A6474X319 Rev 1 5.244

Replacement of wear parts _____________________________________ crawler chain installation

To install the crawler chain (Fig. 159):  Ensure that the miner is correctly cribbed.  Lay the crawler chain on the mine floor under the crawler frame and extending forward in front of the mine. The grousers should be on the facing down.

IMPORTANT! Be sure that the rousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.  Attach a pull cable to the rear of the crawler chain.  Feed the loose end of the pull cable around the drive sprocket and into the upper crawler chain return deck. Continue feeding the pull cable forward until it is at the front of the crawler frame and past the take-up roller. Run the cable forward where it can be attached to a vehicle or other pulling device.  Slowly pull the crawler chain into position on the drive sprocket so that the sprocket teeth engage the pockets in the first crawler pad.

Continue pulling the chain slowly as it engages the rest of the exposed sprocket teeth and moves forward on the upper crawler chain return deck. Pull the end of the chain clear of the take-up roller until it drapes over the roller.  Block the bottom of the chain near the front.  Coat the connecting pins with EP#2 multi-purpose grease.  Remove the pull cable and mate the two ends of the chain using the two connecting pins.  Apply Loctite 271 to the bolts then secure the pins with the flat head socket capscrews and nuts.  Ensure that the needle valve on the grease take-up cylinder has been closed (Fig. 160).  Pump grease into the take-up cylinder grease fitting until the proper chain sag is achieved (Fig. 160).

Fig. 160: Crawler chain sag measurement

Bottom of tractor wear shoe

4 – 5” (100 to 125 mm) gap

Top of tram track

________________________________________________________________ 5.245 CM340 Continuous Miner

____________________________________ Replacement of wear parts Crawler take-up roller removal and installation crawler take-up roller removal

To remove the crawler take-up roller (Fig. 161):  Position the miner so that there is sufficient clearance to work.  Block the machine so that the crawler assembly is off of the mine floor. Block under the crawler chain, just behind the crawler takeup roller.  Raise the gathering head assembly to its highest position and securely block it.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lower the cutter head assembly so that it rests on the gathering head.  Lower the conveyor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Separate near bottom of roller and use a hoist to raise top of crawler off of roller.  Place a lifting device around both sides of the take-up roller and slide the roller forward until it clears the frame.

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

______________________________________________________________ A6474X319 Rev 1 5.246

Replacement of wear parts _____________________________________ Fig. 161: Crawler track take-up idler removal and installation

Crawler takeup roller

________________________________________________________________ 5.247 CM340 Continuous Miner

____________________________________ Replacement of wear parts crawler take-up roller installation

To install the crawler chain take-up idler roller (Fig. 161):  Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.  Verify the proper oil fill on the inside of the take-up roller housing.

Place the assembly on its side with the roller shaft vertical. Remove both pipe plugs visible on the side of the roller. Pour gear oil into one hole until it runs out the other hole.  Position the crawler take-up assembly in front of the slide area of the crawler frame.  Slide the assembly into the main frame, then rearward until it stops against the piston of the take-up cylinder.  Ensure that the piston end of the take-up cylinder fits properly into the take-up plug in the roller assembly.  Reconnect the crawler chain.  Unblock the chain and check for proper tension (Fig. 163). If necessary, adjust the shims until the required sag is achieved.  Connect the trailing cable to energize the miner.  Remove all blocking.  Check the crawler assembly for correct operation.

______________________________________________________________ A6474X319 Rev 1 5.248

Replacement of wear parts _____________________________________ Conveyor assembly The conveyor assembly (Fig. 162) can be raised and lowered with hydraulic cylinders. The assembly is attached to the main frame at a pair of raised pivots. The discharge section of the conveyor has a double clevis swing pivot and can swing 45° to the left or right.

Fig. 162: Conveyor assembly Conveyor swing cylinder

Conveyor pivot

Conveyor attachment pivots

________________________________________________________________ 5.249 CM340 Continuous Miner

____________________________________ Replacement of wear parts Conveyor chain removal and installation conveyor chain removal

To remove the conveyor chain (Fig. 163):  Position the miner so that the top of the conveyor and both ends of the machine can be reached. Allow sufficient room at the back of the miner to pull the conveyor chain off.  Raise the cutter head and block it following all Mine and Federal regulations WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Position the discharge conveyor in line with the intermediate conveyor and lower it to it’s lowest point.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Open the needle valve to release tension on the conveyor chain take-up cylinders, thereby relaxing tension on the conveyor chain.

CAUTION! To avoid injury while relieving tension off of the conveyor chain, wear proper personal protective equipment, to include, at a minimum, safety glasses and gloves.  Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.  Position new chain fully assembled behind miner (new chain should be upside down on mine floor) fully stretched out.  Break old chain at tail shaft.  Connect new chain to the bottom half of the old chain.  Hook puller cable to top half of old chain.  Using pull vehicle, pull old chain off the top as new chain pulls in on return deck.  Re-connect new chain approximately two feet in from tail shaft.

______________________________________________________________ A6474X319 Rev 1 5.250

Replacement of wear parts _____________________________________ Fig. 163: Conveyor chain removal and installation

Connecting pin

Retaining pin

________________________________________________________________ 5.251 CM340 Continuous Miner

____________________________________ Replacement of wear parts conveyor chain installation

To install the conveyor chain (Fig. 163):  Ensure that the cutting head is adequately blocked.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Lay the new chain, uncoiled and upside down, behind the conveyor with the nearest end near the tail roller.

NOTICE! The conveyor chain does not have a right or wrong running directions, only a correct up and down side. The flat side of the flight chains must run on the deck.  Connect the pulling cable (attached to the old chain still in the machine) to the nearest end of the new conveyor chain.  Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.  Pull the conveyor chain up over the foot shaft sprocket and lay it in the gathering pan.  Disconnect the pulling cable from the front end of the chain and run it along the top conveyor deck to the back of the miner.  Connect the pulling cable to the other end of the conveyor chain on the mine floor. Pull it over the tail roller, through the conveyor deck, and up to the other end of the chain on the gathering pan.  Connect the chain using a connecting pin and two retaining pins. bend the retaining pins opposite the direction of conveyor chain travel.  Close the bleed valve in the conveyor chain take-up circuit so that the circuit can be pressurized when power is reapplied.

WARNING! Make sure all personnel are clear of the miner before performing the following checks. Do not stand behind the conveyor when the chain is running.  Connect the trailing cable to energize the miner.  Start the pump motor.  Swing the discharge conveyor full right and left to ensure that the chain is clear.  Turn on the gathering head motors to run the conveyor. Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the chain is running smoothly.

______________________________________________________________ A6474X319 Rev 1 5.252

Replacement of wear parts _____________________________________  Observe the chain as it comes off the foot shaft and ensure that there is no excessive slack and that the chain does not contact the CLA arms.  If the chain slack is excessive, adjust the chain tension (see Chain tension adjustment procedure in this chapter).

________________________________________________________________ 5.253 CM340 Continuous Miner

____________________________________ Replacement of wear parts Conveyor assembly removal and installation conveyor assembly removal

To remove the conveyor assembly (Fig. 164):  Raise the conveyor to an elevated position so at to provide access to the upper conveyor raise cylinder pins.  Block the elevated conveyor following all Mine and Federal regulations.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Attach lifting devices to both the intermediate and discharge conveyor sections. Take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Disconnect the conveyor chain (see Conveyor chain removal procedure in this chapter) and remove it from the machine.  Support the rod end of each conveyor raise cylinder.  Remove the pins from each upper cylinder pin and remove the cylinder pins.  Appropriately secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines to the swing cylinders are removed.  Remove and cap the hydraulic lines going to the swing cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.

______________________________________________________________ A6474X319 Rev 1 5.254

Replacement of wear parts _____________________________________  Disconnect, tag, and cap the lubrication lines going to the right and left pivot pins.  Release any pressure that might exist between the lateral sway guides and the guide discs by backing out the set screw on each side.  Remove the capscrews from the conveyor pivot pin retainer and remove the retainer.  Push the conveyor pivot pins toward the center until they are free.

NOTICE! If the pivot pin is tight, be sure the lifting device is not binding the pivot. If the pivot is not in a bind, use the puller hole to aid in pin removal.  With the lifting device, slowly maneuver the conveyor assembly away from the machine.

________________________________________________________________ 5.255 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 164: Conveyor assembly removal and installation

Conveyor raise cylinder

Main frame pivot

______________________________________________________________ A6474X319 Rev 1 5.256

Replacement of wear parts _____________________________________ conveyor assembly installation

To install the conveyor assembly (Fig. 164):  Attach a lifting device to the conveyor assembly and slowly maneuver it onto the machine.

WARNING! Observe the safe working load limits of all lifting devices. You can be seriously injured or killed by falling loads.  With the conveyor pivot in position, grease the conveyor pivot pins to ease installation and then drive the pins into the pivot bores.  Install the pivot pin retainer and secure with hex head cap screws.  Reconnect the grease lines to each pivot pin.  Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Connect the hydraulic lines to the swing cylinders.  Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the conveyor raise cylinder pins.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).  Apply nominal pressure of the guide discs to the lateral sway guides.  Clear all tools and debris from the area and remove the lifting and blocking devices.

WARNING! Be sure all conveyor components are correctly installed and that the conveyor chain is properly engaged by the foot shaft before starting the miner.  Connect the trailing cable to energize the miner.  Start the pump motor.  Start the gathering head motors to run the conveyor chain.  Elevate the conveyor full up and down and swing the discharge conveyor full left and right and check that the conveyor chain is running smoothly.

________________________________________________________________ 5.257 CM340 Continuous Miner

____________________________________ Replacement of wear parts Discharge conveyor removal and installation discharge conveyor removal

To remove the conveyor discharge (Fig. 165):  Position the machine so that the top and bottom of the conveyor can be reached and there is enough room at the back for removal of the conveyor chain and the discharge conveyor.  Raise the conveyor far enough to provide adequate work space under the swing pivot. Securely block the intermediate conveyor section ensuring that the swing pivot remains accessible.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  Align the discharge conveyor straight with the centerline of the intermediate conveyor.  Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).  Attach lifting devices to the discharge conveyor take up slack in the lifting device without raising the conveyor.

WARNING! Observe the safe working load limits of all lifting devices. You may be seriously injured or killed by falling loads.  Disconnect the conveyor chain at a connecting pin close to the end of the discharge conveyor (see Conveyor chain removal procedure in this chapter).  Disconnect, tag, and cap the hydraulic lines from the conveyor swing cylinders. Cap the ports in the cylinders.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized. If a hose is disconnected while the circuit is pressurized, machine damage or severe injury may result.  Remove the forward swing cylinder pin at the intermediate conveyor section.  Remove the bolts and stop nuts that attach flexible sideboards to each side of the intermediate conveyor.

______________________________________________________________ A6474X319 Rev 1 5.258

Replacement of wear parts _____________________________________  Slide each sideboard from its guide on the discharge conveyor and remove it. If the sideboards are not free to slide, remove the hex head capscrews and spring lock washers from each flexible sideboard guide assembly and remove them from the top of the discharge conveyor on each side.  Remove the capscrews from the top pivot pin and remove the pin.

Two puller holes, protected by set screws and located on the top and bottom of each pivot pin, are provided to aid in removing the pivot pin. A pivot retainer will remain in the top pivot bore. If not already released, this retainer can be tapped loose and removed from the area between the top and bottom conveyor decks.  Repeat this procedure for the bottom pivot pin and pivot retainer. If the bottom pin is not free to come out, check the tension on the lifting device to make sure the pin is not in a bind.  Slowly and carefully maneuver the discharge conveyor away from the intermediate conveyor section.

________________________________________________________________ 5.259 CM340 Continuous Miner

____________________________________ Replacement of wear parts Fig. 165: Discharge conveyor removal and installation Flexible guide

Pivot pin

Bolt (3 each side)

Bolt (4 each side)

Washer (3 each side)

Sideboard

Nut (3 each side)

Conveyor swing cylinder pin

______________________________________________________________ A6474X319 Rev 1 5.260

Replacement of wear parts _____________________________________ discharge conveyor installation

To install the discharge conveyor (Fig. 165):  Ensure that the trailing cable is still disconnected and properly locked/tagged out.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  Ensure that the intermediate conveyor is still securely blocked.  Attach a lifting device to the discharge conveyor and slowly lift and maneuver it into the intermediate conveyor section.

WARNING! Observe the safe working load limits of all lifting and blocking devices. You can be seriously injured or killed by falling loads.  Check the top and bottom pivot pins and bushings for wear or damage and replace as necessary. Lubricate all pins and bushings with grease prior to installation.  Install the top pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the top conveyor deck.  Install the bottom pivot pin and pivot retainer. Secure the retainer with capscrews. Note that the pivot pin has an anti-rotation dowel which must be positioned in the slot in the bottom conveyor deck.  If necessary, use adjustment shims to align the decks of the intermediate and discharge conveyors. Misalignment can occur due to wear or damage of the discharge conveyor.  Using the lifting device, swing the discharge conveyor fully to the left and right to make sure that it does not bind.  Grease the four pivot surface lubrication points (two on each side) until grease is visible on the mating sections of the conveyor. This will lubricate the pivot pins and bushings as well as the large plates which slide on each other.  Using the lifting device, position the conveyor to align the swing cylinder clevises with both swing cylinder eyes. Lubricate the cylinder pins with grease and insert them through the clevises and eyes.

Secure each pin with a cotter pin.  Connect the hydraulic lines to the cylinders.  With the discharge conveyor straight, reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).

________________________________________________________________ 5.261 CM340 Continuous Miner

____________________________________ Replacement of wear parts  Install a flexible sideboard on each side of the conveyor. Secure with carriage bolts and heavy elastic stop nuts.  Connect the trailing cable to energize the miner.  Raise the conveyor and remove the blocking.  Operate the conveyor raise, lower, swing left, and swing right functions and check for smooth operation.

______________________________________________________________ A6474X319 Rev 1 5.262

Replacement of wear parts _____________________________________ Tail roller removal and installation tail roller removal

To remove the tail roller (Fig. 166):  1. Position the machine so that the tail roller can be comfortably reached and there is enough room available for its removal.  2. Align the discharge conveyor straight with the centerline of the intermediate conveyor.  3. Lower the conveyor to a comfortable working height and then securely block.

WARNING! Observe the safe working load limits of all blocking devices. You can be seriously injured or killed by falling loads.  4. Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

WARNING! Failure to follow all Mine, State, and Federal lockout/tagout procedures may result in machine damage or serious injury or death of personnel.  5. Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure in this chapter).  6. Use a pry bar to lift the chain off the conveyor deck several times to relieve tension in the chain.  7. Disconnect the conveyor chain at a connecting pin close to the tail roller (see Conveyor chain removal procedure in this chapter) and clear the chain from the roller.  8. Attach a lift device to the tail roller and take up the slack so that the weight of the tail roller is supported by the lifting device.  9. Remove the cover over each side of the tail roller by removing the capscrews from each cover.  10. Remove the cotter pin from the end of the take-up cylinder.  11. Remove the attachment block by removing the two (2) socket head bolts that secure it.  12. Slide the take-up cylinder back and out of the tail roller assembly.  13. Repeat steps 9 through 12 for the other side.  14. Drive out the roll pin on each end of the tail roller to free the inserts.

________________________________________________________________ 5.263 CM340 Continuous Miner

____________________________________ Replacement of wear parts  15. Slide the insert of each end of the tail roller.  16. The tail roller should now be free of the conveyor.

Fig. 166: Conveyor tail roller removal and installation

Tail roller

Cover Socket head capscrew (2)

Capscrew (4)

Take-up cylinder

Insert

Attachment block

Roll pin

______________________________________________________________ A6474X319 Rev 1 5.264

Replacement of wear parts _____________________________________ tail roller installation

To install the tail roller (Fig. 166):  Position the tail roller in in the conveyor.  Slide the insert into each end of the tail roller.  Insert a roll pin into each end of the tail roller to secure the insert to the roller.  Slide the take-up cylinders back into position with the end of the cylinder sliding through the hole in the tail roller insert.  Insert a cotter pin into the end of each take-up cylinder rod  Secure the attachment block to the end of each cylinder with socket head capscrews (two (2) on each side).  Install the side cover over each side of the tail roller and secure with four (4) capscrews.  Make sure the valve is closed in the conveyor chain take-up circuit.  Reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).  Connect the trailing cable to energize the miner.  Operate the conveyor and check for correct chain tension.

________________________________________________________________ 5.265 CM340 Continuous Miner

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems.

This section covers basic components, with each listed in a troublecause-remedy format.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller cover, remove power from the system by disconnecting the trailing cable. Follow all Local, State, and Federal regulations regarding the lockout/tagout of electrical power.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position.. Once the circuit breaker is in the “OFF” position, adjustments or parts replacements can be made.

■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to 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.

______________________________________________________________ A6474X319 Rev 1 5.266

Troubleshooting ______________________________________________ WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

Typical hydraulic problems The most common causes for improper function are: ■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as reliefs

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component in the system has an intended purpose. The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine. For example, understanding that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective solenoid. Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

It is also important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge. Refer to the hydraulic schematic in the parts manual supplied with your machine for the correct operating parameters. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system function(s) while remaining below the maximum rating of the machine’s components.

________________________________________________________________ 5.267 CM340 Continuous Miner

_____________________________________________ 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: ■

general safety procedure for shutting down the machine

■

troubleshooting excessive noise

■

troubleshooting excessive heat

■

troubleshooting incorrect flow

■

troubleshooting incorrect pressure

■

troubleshooting faulty movement/operation

■

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION! Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where customers have made improvements in the past include: –

implementing ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimizing drum usage by utilizing tote tanks and five gallon pails

–

utilizing plastic versus steel storage tanks, if possible

–

installing desiccant breathers on all bulk tanks

–

using sealed plastic containers for adding oil to small sumps

–

locating bulk tanks near equipment and pump directly to reservoirs

______________________________________________________________ A6474X319 Rev 1 5.268

Troubleshooting ______________________________________________ –

utilizing filter carts to maintain oil cleanliness standards

–

properly training personnel on the importance of clean oil and best practices for storage and handling

–

monitoring the program closely and looking for continuous improvement

2. Eliminate contamination source through “clean” maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

Specific hydraulic circuit troubleshooting Multi-function failure If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi. This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 - 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multi-function failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement or splicing).

________________________________________________________________ 5.269 CM340 Continuous Miner

_____________________________________________ Troubleshooting Individual hydraulic circuit failures Perform the following checks on the individual circuits in conjunction with the general troubleshooting: Oil tank fill  Check to see that the oil fill strainer is clean.  Check for low oil in the new oil supply.

Cutter head raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this)

______________________________________________________________ A6474X319 Rev 1 5.270

Troubleshooting ______________________________________________  Check the inlet relief section on the MCV (item 44) for correct relief valve setting and no high pressure bypassing.  Check the port relief on the cutter head raise section of the MCV for correct setting and no high pressure bypassing.  Re-check to see that there is no mechanical bind in the cutter head raise pivot.  Re-check cutter head cylinders for bypassing.  Re-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  Check the direction control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind or hydraulic block.  Check flow control valve cartridge.  Check cylinders for bypassing.  Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank. Note: cylinder removal will be required to safely achieve this.

Gathering head raise  Check the directional control valve for proper operation.  Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.  Check pressure at the LH pressure gauge.  Check to see that there is no mechanical bind.  Check cylinders for bypassing.  Check accumulator for 300 psi pre-charge, and that the bladder is functioning properly.  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check in-line counterbalance valve for proper operation or blockage.

________________________________________________________________ 5.271 CM340 Continuous Miner

_____________________________________________ Troubleshooting Gathering head float  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check to see that there is no mechanical bind.  Check accumulator for 500 psi pre-charge, and that the bladder is functioning properly.  Check cylinders for bypassing (they will leak out the top).  Check needle valve on pilot circuit to verify that it is not open or leaking off.  Check counterbalance valve for proper operation (see the schematic in the parts book supplied with your machine for the proper setting).

Conveyor Raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.  Check to see that there is no mechanical bind.  Verify that cylinders are not bypassing.

Conveyor Lower  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Verify that pilot pressure is being applied to open the piloted builtin checks.  Verify that cylinders are not bypassing.

Conveyor Swing  Check the directional control valve for proper operation.  Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.  Verify that the cylinder is not bypassing.

______________________________________________________________ A6474X319 Rev 1 5.272

Troubleshooting ______________________________________________ Stabilizer Raise  Check the directional control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

Stabilizer Lower  Check the control valve for proper operation.  Check to see that hosing has not been crossed, especially if the problem occurs after maintenance or repair work.  Check the lubrication network for bound bushings.  Check for any mechanical bind or any obstruction blocking movement.  Check cylinder for bypassing.

General safety procedure for shutting down machine When shutting down the machine fore maintenance:  lower or mechanically secure (block) all suspended loads  exhaust any pressure locked in the system  drain down all accumulators  isolate the electrical control system  isolate the electrical power supply Follow all procedures listed in the Shutdown procedure in this chapter.

________________________________________________________________ 5.273 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 3: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

Cavitation

A

Coupling misaligned

C

Setting too low or too close to another valve setting

D

Air in fluid

B

Motor or coupling worn or damaged

E

Worn poppet and seat

E

Coupling misaligned

C

Pump worn or damaged

E

Remedies A. Any or all of the following:        

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature check fluid level

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal  replace pump C. All of the following:  align unit, ensure that mounting hardware is correct and tight  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

______________________________________________________________ A6474X319 Rev 1 5.274

Troubleshooting ______________________________________________ Table 4: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies A. Any or all of the following:      

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed overhaul or replace supercharge pump

F.  change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G.  clean cooler and/or strainer  replace cooler control valve  repair or replace cooler

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling  locate and correct mechanical binding  check for workload in excess of circuit design D.  install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings E.  overhaul or replace defective parts

________________________________________________________________ 5.275 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 5: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:    

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level

B. Any or all of the following:  tighten leaky inlet connections  bleed air from system

F. Any or all of the following  check position of manually operated controls  check electrical circuit on solenoid operated controls  repair or replace pilot pressure pump G.  reverse rotation H.  replace with correct unit

C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

______________________________________________________________ A6474X319 Rev 1 5.276

Troubleshooting ______________________________________________ Table 6: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

________________________________________________________________ 5.277 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 7: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  adjust, repair, or replace part D.  clean and adjust or replace part  check condition of system fluid and filters E.  overhaul or replace part F.  repair command console or interconnecting wires G.  lubricate H.  adjust, repair, or replace counterbalance valve

______________________________________________________________ A6474X319 Rev 1 5.278

Troubleshooting ______________________________________________ Table 8: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replacement?

No Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

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).

________________________________________________________________ 5.279 CM340 Continuous Miner

_____________________________________________ Troubleshooting Water system including circuits Table 9: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume (gpm) can-  not be maintained

Test, check and/or remedy

Dynamic water pressure (psi) is not being supplied to the recommended psi.



Change setting to the recommended psi.



Water supply hose is not the minimum diameter



Change hose to the recommended diameter size.



Incoming supply of water has a problem.



Check the water supply itself to see if there is an issue & fix.

Dirt in the system.



Remove the filter and clean it thoroughly; flush the system as necessary.



Change water filter frequently.



Remove the nozzles and clean thoroughly; flush the system as necessary.



Change water filter frequently.

Air in the system.



Check for leaks.

Pressure too high.



Adjust the pressure.

damaged or clogged filter, contaminates  in the water system

plugged water nozzles are restricting the  flow of water or pressure fluctuates

pressure fluctuates and there is extreme  noise in the system 

Dirt in the system.

water function will not shut “OFF” with Hydraulic pilot operated water valve radio transmitter stuck open.

Clean or replace.

Faulty solenoid.

Replace.

Radio transmitter toggle switch faulty.

Replace toggle switch.

no water pressure on the  pressure gauge 

Water filter plugged.



Replace or clean.

Main water ball valve “OFF”.



Close valve.



No incoming water.



Fix water supply issue.

Contaminated water supply



Clean or filter the incoming water supply to the miner.

water filter stopping up  frequently

______________________________________________________________ A6474X319 Rev 1 5.280

Troubleshooting ______________________________________________ Table 9 (continued): Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

jet pump not removing water from  Incorrect pressure reducing valve setting. sump Pressure reducing valve internal strainer dirty.

Test, check and/or remedy  Adjust psi. Check water volume gpm.

Jet pump nozzle plugged with dirt.

Remove strainer and clean.

Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.

Backflush pump, remove nozzle and clean.

Incorrect hose size from jet pump to manifold.

Adjust psi.

Manifold plugged. Remove restriction or tighten hose connection. Check for correct hose size. Clean.

________________________________________________________________ 5.281 CM340 Continuous Miner

_____________________________________________ Troubleshooting Electrical System Table 10: Electrical system troubleshooting Trouble, symptom or cause

Probable cause

motor contact chatter Low voltage

Test, check and/or remedy  Check supply voltage, especially during starting. Check coil voltage rating. Increase voltage or change coil rating as required.

 Poor contact in control circuit.

 Replace the contact or use holding-circuit interlock. (3-wire control)

 Loose wiring connections.

 Check wiring connections.

 Broken shading coil.

 Replace magnet and armature assemblies.

welding of motor contactor tips  Abnormal in rush current.

 Use the next larger size contactor or check for grounds, shorts or excessive motor current.

 Rapid jogging.

 Install larger device rated for jogging service.

 Insufficient contact pressure.

 Replace contacts and springs, check for contacts for abnormal wear or damage.

 Incorrect vacuum contactor gap.

 Use the over-travel gauge mounted on the front of the unit. When the gap on the bottle goes below 0.010 inches, the unit should be replaced.

 Low voltage preventing magnet from sealing.

 Check supply voltage to coil, especially for momentary voltage dip during starting.

 Foreign matter preventing contacts from closing.

 Clean contacts with Freon. Contacts used at low current and voltage levels should be cleaned with Freon.

 Vibration in starter mounting.

 Insulate starter from shock and vibration.

 Short circuit.

 Remove fault and check to be sure fuse or breaker size is correct.  For vacuum contactor: after a short circuit examine vacuum bottles, conductor bars, and cables for physical damage. Check over-travel on vacuum bottle.

short contact life or  Filing or dressing. overheating of motor contactor

 Do not file silver contacts. Rough spots or discoloration will not harm contacts or impair their efficiency.

 Interrupting excessively high currents.

 Install larger unit. Check for grounds, shorts or excessive motor currents.

 Excessive jogging.

 Install larger unit rated for jogging service.

 Weak contact pressure.

 Replace contacts and springs. Check contacts for abnormal wear or damage.

 Foreign matter on contact surface.

 Clean contacts with Freon. Take steps to reduce entry of foreign matter into enclosure.

______________________________________________________________ A6474X319 Rev 1 5.282

Troubleshooting ______________________________________________ Table 10 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

short contact life or  Short circuit or ground fault. overheating of motor contactor (continued)  Loose connections in power circuit.  Sustained overload. failure to pick-up and seal  Low voltage.

Test, check and/or remedy  Remove fault and check to be sure fuse or breaker size is correct.  Clean and tighten.  Check for excessive motor load current or install larger unit.  Check system voltage and voltage dips during starting.

 Wrong coil or wrong connection.

 Check coil marking and wiring.

 Mechanical obstruction.

 With power off, check for free movement of armature and contacts.

 Coil open or overheated.

 Replace.

failure to drop out  Sticky substance on pole faces.

 Clean pole faces with Toluol and seal with a drop of DC200 silicone fluid.

 Voltage not removed.

 Check coil circuit or length of leads from supply voltage to coil. May be excessive.

 Worn or rusted parts causing binding.

Replace unit.

 Contacts welded.

 See welding under contacts section.

open circuit  Mechanical damage. both cutter head motors do not start  Three phase power not present at contactors.

 Handle and store coils carefully. Check three phase input to contactors.

Contactor tips damaged.

Check contactor tips.

 Pump not running.

 Start pump.

 Low hydraulic level.

 Check oil level and level indicator light.

 Failed control relay contacts.

 Check contacts

Cutter head motor start and stop switches, conveyor start switch, or pump start switch not working properly.

 Check for faulty switches.

Control relay malfunction.

 Check coil and contacts.

 Overload relay.

 Check overload relays.

 Failed left cutter head motor contactor.

 Check contactor coil. Verify that contacts are free to move.

left cutter head motor starts but right Auxillary contacts not closing. cutter head motor does not

Check contactor auxillary contacts and wiring.

Time delay malfunction.

Check coil and timed closed contacts and wiring.

Load current relay problem.

Verify that normally closed load current relays are NOT open.and check wiring.

Failed contactor.

Check contactor coil and contact tips and wiring.

Overload relay problem.

Check overload relays and wiring.

________________________________________________________________ 5.283 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 10 (continued): Electrical system troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

both cutter head motors start but stop Problem with auxillary contacts. when pump start and cutter head start switches are released Overcurrent relays.

Check right cutter head motor contactor auxillary contacts and associated wiring.

conveyor starts forward operation but  Problem in holding circuit. stops when conveyor start switch is released

 Check normally open conveyor forward auxiliary contact and associated wiring.

conveyor will not start in forward or re-  Pump not running. verse. Contactor IS NOT pulling in contacts  Failed control relay contacts.

 Start pump.

Check overcurrent relays.

 Check contacts.

 Conveyor start and stop switches or con Check for faulty switches. veyor forward/reverse not working properly  Overload relay tripped/faulty/

 Check overload relays.

 Over current relay tripped/faulty.

 Check over current relay.

 Conveyor forward/reverse contactor failure.

 Check contactor coils. Verify that contacts are free to move.

conveyor will not start in forward or re-  Three phase power is not present at converse. Contactor IS pulling in contacts tactors.  Contactor tips are damaged. conveyor operates in forward only  Reverse switch.  Conveyor Forward auxiliary contacts.

conveyor operates in reverse only  Forward switch.  Conveyor Reverse auxiliary contacts.

 Check three phase power input to the contactors.  Check contactor tips.  Check that the Reverse switch is completing the circuit.  Verify that the conveyor forward auxiliary normally closed contacts have not failed to open.  Check that the Forward switch is completing the circuit.  Verify that the conveyor reverse auxiliary normally closed contacts have not failed to open.

______________________________________________________________ A6474X319 Rev 1 5.284

Troubleshooting ______________________________________________ Bearings Table 11: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing  Wrong type of grease or oil.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.

 Low oil level; loss of lubricant through seal; excessive grease.

 Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 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.

 Shaft out of line.

 Correct alignment and be sure shafts are coupled in a straight line.

noisy bearing  Insufficient clearance in bearing.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

 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.

 Shaft and other parts of bearing assembly distorted.

 Replace bearing, shaft and other parts as needed.

vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Foreign matter acting as abrasive.

 Clean bearing housing and replace worn seals.

 Unbalanced loading

 Check balance of rotating parts and rebalance as needed.

unsatisfactory performance  Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.

 Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

________________________________________________________________ 5.285 CM340 Continuous Miner

Troubleshooting ______________________________________________ Table 12: Remote control diagnostics Message

Meaning

Channel 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15

Operating on frequency displayed (Channel 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15)

SETUP MODE

The Setup mode has been engaged.

TEST MODE

The factory test mode has been engaged.

Powerdown

Powering down.

Stop

Radio stop activated.

Tilt

The remote control’s angle of inclination is beyond 45° relative to horizontal. The Radio STOP command is issued continuously until the unit is righted. The remote control will then power down.

Free Fall

The remote control detected a free fall drop fault event. It continuously sends Radio STOP command for two (2) seconds before powering down.

BatLow

The internal battery is low and the remote control should be recharged.

C.On

The internal battery is recharging.

CDone

The internal battery has been fully charged.

CErr

A fault condition has been detected during the internal battery recharging. Remove and then reinsert the charging connector.

Bad Key

This condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

No Activity

A user defined time has expired since the last key press activity. The expiration time is set in the User Setup option. The remote control will power down.

Service RF Fail

Indicating possible service requirements, a fault conditions has been detected. The remote control will power down.

TErr

If the Tilt or Free Fall option is enabled, this warning indicates a possible fault conditions was detected on the motion sensor accelerometer.

FErr

This warning indicates a possible fault condition was detected on its backup internal flash memory.

________________________________________________________________ 5.286 CM340 Continuous Miner

_____________________________________________ Troubleshooting The following is a complete list of all error messages in the control system.

Table 13: Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0001 SOL BOARD COMMS FAIL 0002 RELAY BOARD COMMS FAIL 0003 THERMISTOR MODULE FAILURE

0004 LEFT DRIVE COMMS BAD

0005 LEFT DRIVE WRONG SOFTWARE 0006 LEFT DRIVE INIT FAILURE 0007 RIGHT DRIVE COMMS FAILURE

0008 RIGHT DRIVE WRONG SOFTWARE 0009 RIGHT DRIVE INIT FAILURE 0010 RC HANDSET LOW BATTERY 0011 VOLTAGE TRANSDUCER FAILURE

______________________________________________________________ A6474X319 Rev 1 5.287

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0012 PUMP MOTOR MATE FAILURE PHASE A

0013 PUMP MOTOR MATE FAILURE PHASE B

0014 PUMP MOTOR MATE FAILURE PHASE C

0015 LEFT CUTTER MOTOR MATE FAILURE PHASE A

0016 LEFT CUTTER MOTOR MATE FAILURE PHASE B

________________________________________________________________ 5.288 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0017 LEFT CUTTER MOTOR MATE FAILURE PHASE C

0018 RIGHT CUTTER MOTOR MATE FAILURE PHASE A

0019 RIGHT CUTTER MOTOR MATE FAILURE PHASE B

0020 RIGHT CUTTER MOTOR MATE FAILURE PHASE C

0021 LEFT CONVEYOR MOTOR MATE FAILURE PHASE A

______________________________________________________________ A6474X319 Rev 1 5.289

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0022 LEFT CONVEYOR MOTOR MATE FAILURE PHASE B

0023 LEFT CONVEYOR MOTOR MATE FAILURE PHASE C

0024 RIGHT CONVEYOR MOTOR MATE FAILURE PHASE A

0025 RIGHT CONVEYOR MOTOR MATE FAILURE PHASE B

0026 RIGHT CONVEYOR MOTOR MATE FAILURE PHASE C

________________________________________________________________ 5.290 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0027 BLOWING SYSTEM MOTOR MATE FAILURE PHASE A

0028 BLOWING SYSTEM MOTOR MATE FAILURE PHASE B

0029 BLOWING SYSTEM MOTOR MATE FAILURE PHASE C

0030 LOW MACHINE VOLTAGE

0031 HIGH MACHINE VOLTAGE

0032 NO SOLENOID VOLTAGE 0033 SOLENOID UNDER VOLTAGE

______________________________________________________________ A6474X319 Rev 1 5.291

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0034 SOLENOID OVERVOLTAGE 0035 LOW OIL LEVEL WARNING 0036 LOCAL SELECT STUCK 0037 PUMP THERMAL OVERLOAD 0038 PUMP MOTOR OVER TEMPERATURE

0039 LEFT CUTTER THERMAL OVERLOAD

0040 LEFT CUTTER MOTOR OVER TEMPERATURE

0041 RIGHT CUTTER THERMAL OVERLOAD 0042 RIGHT CUTTER MOTOR OVER TEMPERATURE

________________________________________________________________ 5.292 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0043 LEFT CONVEYOR THERMAL OVERLOAD 0044 LEFT CONVEYOR MOTOR OVER TEMPERATURE

0045 RIGHT CONVEYOR THERMAL OVERLOAD 0046 RIGHT CONVEYOR MOTOR OVER TEMPERATURE

0047 FAN THERMAL OVERLOAD

0048 FAN MOTOR OVER TEMPERATURE

0049 LEFT TRAM MOTOR OVERLOAD

0050 RIGHT TRAM MOTOR OVERLOAD

______________________________________________________________ A6474X319 Rev 1 5.293

Troubleshooting ______________________________________________

Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0051 METHANE SENSOR FAULT 0052 ILLEGAL PUMP FB CURR 0053 OPERATOR CASE MACHINE STOP PRESSED 0054 LEFT SIDE MACHINE STOP PRESSED 0055 MAIN AC SUPPLY LOST

0056 METHANE MONITOR RELAY OPEN 0057 MMR STATUS WIRE BROKEN 0058 RIGHT SIDE MACHINE STOP WIRE BROKEN 0059 LEFT SIDE MACHINE STOP WIRE BROKEN 0060 TRACTION COMMS FAILURE

________________________________________________________________ 5.294 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0061 PUMP TEMPERATURE WARNING

0062 LEFT CUTTER TEMPERATURE WARNING

0063 RIGHT CUTTER TEMPERATURE WARNING

0064 LEFT CONVEYOR TEMPERATURE WARNING

______________________________________________________________ A6474X319 Rev 1 5.295

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0065 RIGHT CONVEYOR TEMPERATURE WARNING

0066 PUMP PT100 SHORT CIRCUIT

0067 LEFT CUTTER PT100 SHORT CIRCUIT

0068 RIGHT CUTTER PT100 SHORT CIRCUIT

0069 LEFT CONVEYOR PT100 SHORT CIRCUIT

0070 RIGHT CONVEYOR PT100 SHORT CIRCUIT

0071 PUMP PT100 OPEN CIRCUIT

________________________________________________________________ 5.296 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0072 LEFT CUTTER PT100 OPEN CIRCUIT

0073 RIGHT CUTTER PT100 OPEN CIRCUIT

0074 LEFT CONVEYOR PT100 OPEN CIRCUIT

0075 RIGHT CONVEYOR PT100 OPEN CIRCUIT

0076 CUTTER BREAKER OPEN 0077 CB2 OPEN

0078 TRAM BREAKER OPEN

0079 LEFT TRAM MOTOR MATE FAILURE PHASE A

0080 LEFT TRAM MOTOR MATE FAILURE PHASE B

______________________________________________________________ A6474X319 Rev 1 5.297

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0081 LEFT TRAM MOTOR MATE FAILURE PHASE C

0082 RIGHT TRAM MOTOR MATE FAILURE PHASE A

0083 RIGHT TRAM MOTOR MATE FAILURE PHASE B

0084 RIGHT TRAM MOTOR MATE FAILURE PHASE C

0085 EXTERNAL PUMP OVERLOAD OPEN 0086 EXTERNAL LEFT TRAM OVERLOAD OPEN 0087 EXTERNAL RIGHT TRAM OVERLOAD OPEN 0088 LH VFD HEAT SINK WARNING 0089 LH VFD UNDER VOLTAGE

________________________________________________________________ 5.298 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0090 LH VHD HEAT SINK TRIP 0091 LH VFD SHORT CIRCUIT 0092 LH VFD OVER VOLTAGE 0093 LH VFD MOTOR OVER VOLTAGE 0094 LH VFD IGBT OVER TEMPERATURE 0095 LH VFD EXTERNAL INTERLOCK 0096 LH VFD INSTANT OVERLOAD 0097 LH VFD OVER VOLTAGE TRIP 0098 LH VFD MOTOR RTD TRIP 0099 LH VFD MOTOR TSTAT TRIP 0100 LH VFD OVER SPEED 0101 LH VFD PHASE LOSS 0102 LH VFD COMMS FAILURE 0103 RH VFD HEAT SINK WARNING

______________________________________________________________ A6474X319 Rev 1 5.299

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0104 RH VFD UNDER VOLTAGE 0105 RH VHD HEAT SINK TRIP 0106 RH VFD SHORT CIRCUIT 0107 RH VFD OVER VOLTAGE 0108 RH VFD MOTOR OVER VOLTAGE 0109 RH VFD IGBT OVER TEMPERATURE 0110 RH VFD EXTERNAL INTERLOCK 0111 RH VFD INSTANT OVERLOAD 0112 RH VFD OVER VOLTAGE TRIP 0113 RH VFD MOTOR RTD TRIP 0114 RH VFD MOTOR TSTAT TRIP 0115 RH VFD OVER SPEED 0116 RH VFD PHASE LOSS 0117 RH VFD COMMS FAILURE

________________________________________________________________ 5.300 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0118 RECTIFIER HEAT SINK WARNING 0119 RECTIFIER UNDER VOLTAGE 0120 RECTIFIER HEAT SINK TRIP 0121 RECTIFIER SHORT CIRCUIT 0122 RECTIFIER IGBT OVER TEMPERATURE 0123 BRAKE RESISTOR THERMAL 0124 RECTIFIER INPUT INSTANT OVERLOAD 0125 RECTIFIER PHASE SYNC LOSS 0126 RECTIFIER COMMS FAILURE 0127 ESR RELAY OPEN 0128 PILOT ILLEGAL VOLTAGE 0129 LH VFD ENCODERLESS OPERATION 0130 RH VFD ENCODERLESS OPERATON

______________________________________________________________ A6474X319 Rev 1 5.301

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0131 GROUND FAULT STATUS OPEN 0132 LEFT RMS INTERNAL COMMS LOSS 0133 RIGHT RMS INTERNAL COMMS LOSS 0134 LEFT RMS DRIVE IN ETRAM MODE 0135 RIGHT RMS DRIVE IN ETRAM MODE 0136 FAN PT100 SHORT CIRCUIT 0137 FAN PT100 OPEN CIRCUIT 0138 FAN MOTOR TEMPERATURE WARNING

0139 FAN MOTOR OVER TEMPERATURE

________________________________________________________________ 5.302 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0140 LEFT TRAM PT100 SHORT CIRCUIT

0141 LEFT TRAM PT100 OPEN CIRCUIT 0142 LEFT TRAM MOTOR TEMPERATURE WARNING

0143 LEFT TRAM MOTOR OVER TEMPERATURE

0144 RIGHT TRAM PT100 SHORT CIRCUIT 0145 RIGHT TRAM PT100 OPEN CIRCUIT

______________________________________________________________ A6474X319 Rev 1 5.303

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0146 RIGHT TRAM MOTOR TEMPERATURE WARNING

0147 RIGHT TRAM MOTOR OVER TEMPERATURE

0148 SOLENOID SHORT 0149 SOLENOID OPEN 0150 SOLENOID OVER CURRENT 0151 TRAM TRANSFORMER SHORT CIRCUIT 0152 TRAM TRANSFORMER OPEN CIRCUIT

________________________________________________________________ 5.304 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0153 TRAM TRANSFORMER TEMPERATURE WARNING

0154 TRAM TRANSFORMER OVER TEMPERATURE

0201 ILLEGAL PUMP CONTACTOR FEEDBACK DETECTED

0202 TBA 0203 TBA 0204 TBA 0205 TBA 0206 TBA 0207 ILLEGAL VOLTAGE ON PUMP RUN CIRCUIT

______________________________________________________________ A6474X319 Rev 1 5.305

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0208 ILLEGAL VOLTAGE ON LEFT CUTTER RUN CIRCUIT

0209 ILLEGAL VOLTAGE ON RIGHT CUTTER RUN CIRCUIT

0210 ILLEGAL VOLTAGE ON CONVEYOR FWD RUN CIRCUIT

0211 ILLEGAL VOLTAGE ON CONVEYOR REV RUN CIRCUIT

0212 ILLEGAL VOLTAGE ON FAN RUN CIRCUIT

0213 SOLENOID BOARD COMMS FAILURE

0214 SOLENOID BOARD COMMS FAILURE

________________________________________________________________ 5.306 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0215 THERMISTOR MODULE FAILURE

0216 LEFT TRACTION DRIVE COMMS FAILURE

0217 LEFT TRACTION DRIVE WRONG SOFTWARE VERSION 0218 LEFT TRACTION DRIVE INITIALIZATION FAILURE

0219 LEFT TRACTION DRIVE INTERNAL ERROR 0220 LEFT TRACTION DRIVE FATAL ERROR 0221 LEFT TRACTION DRIVE AC PHASE LOSS 0222 LEFT TRACTION DRIVE PHASE IMBALANCE

______________________________________________________________ A6474X319 Rev 1 5.307

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0223 LEFT TRACTION DRIVE INSTANTANEOUS OVERLOAD 0224 LEFT TRACTION DRIVE THERMAL OVERLOAD 0225 LEFT TRACTION MOTOR NO CURRENT

0226 RIGHT TRACTION DRIVE COMMS FAILURE

0227 RIGHT TRACTION DRIVE WRONG SOFTWARE VERSION 0228 RIGHT TRACTION DRIVE INITIALIZATION FAILURE 0229 RIGHT TRACTION DRIVE INTERNAL ERROR 0230 RIGHT TRACTION DRIVE FATAL ERROR 0231 RIGHT TRACTION DRIVE AC PHASE LOSS

________________________________________________________________ 5.308 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0232 RIGHT TRACTION DRIVE PHASE IMBALANCE 0233 RIGHT TRACTION DRIVE INSTANTANEOUS OVERLOAD 0234 RIGHT TRACTION DRIVE THERMAL OVERLOAD 0235 RIGHT TRACTION MOTOR NO CURRENT

0236 LOST RADIO CONTROL SIGNAL

0237 NO VOLTAGE AT PUMP RELAY OUTPUT

0238 TBD 0239 TBD 0240 TBD 0241 PUMP MOTOR MATE FAULTY

______________________________________________________________ A6474X319 Rev 1 5.309

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0242 PUMP NO LOAD CURRENT

0243 PUMP MOTOR PHASE LOSS

0244 PUMP MOTOR PHASE IMBALANCE

0245 PUMP MOTOR INSTANTANEOUS OVERLOAD 0246 PUMP MOTOR THERMAL OVERLOAD

0247 PUMP MOTOR OVER TEMPERATURE

0248 LOW HYDRAULIC OIL TRIP

________________________________________________________________ 5.310 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0249 NO VOLTAGE AT LEFT CUTTER RELAY OUTPUT

0250 NO VOLTAGE AT RIGHT CUTTER RELAY OUTPUT

0251 TBA 0252 TBA 0253 TBA 0254 TBA 0255 LEFT CUTTER MOTOR MATE FAULTY

0256 LEFT CUTTER NO LOAD

0257 LEFT CUTTER PHASE LOSS

______________________________________________________________ A6474X319 Rev 1 5.311

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0258 LEFT CUTTER PHASE IMBALANCE

0259 LEFT CUTTER MOTOR INSTANTANEOUS OVERLOAD

0260 LEFT CUTTER MOTOR THERMAL OVERLOAD

0261 LEFT CUTTER MOTOR OVER TEMPERATURE

0262 RIGHT CUTTER MOTOR MATE FAULTY

0263 RIGHT CUTTER MOTOR NO LOAD

________________________________________________________________ 5.312 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0264 RIGHT CUTTER PHASE LOSS

0265 RIGHT CUTTER PHASE IMBALANCE

0266 RIGHT CUTTER MOTOR INSTANTANEOUS OVERLOAD

0267 RIGHT CUTTER MOTOR THERMAL OVERLOAD

0268 RIGHT CUTTER MOTOR OVER TEMPERATURE

0269 NO VOLTAGE AT CONVEYOR FWD RELAY OUTPUT

______________________________________________________________ A6474X319 Rev 1 5.313

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0270 TBA 0271 TBA 0272 NO VOLTAGE AT CONVEYOR REV RELAY OUTPUT

0273 TBA 0274 TBA 0275 LEFT CONVEYOR MOTOR MATE FAULTY

0276 LEFT CONVEYOR NO LOAD CURRENT

0277 LEFT CONVEYOR MOTOR PHASE LOSS

0278 LEFT CONVEYOR MOTOR PHASE IMBALANCE

________________________________________________________________ 5.314 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0279 LEFT CONVEYOR MOTOR INSTANTANEOUS OVERLOAD 0280 LEFT CONVEYOR MOTOR THERMAL OVERLOAD

0281 LEFT CONVEYOR MOTOR OVER TEMPERATURE

0282 RIGHT CONVEYOR MOTOR MATE FAULTY

0283 RIGHT CONVEYOR NO LOAD CURRENT

0284 RIGHT CONVEYOR MOTOR PHASE LOSS

______________________________________________________________ A6474X319 Rev 1 5.315

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes ault

Explanation

Possible Cause

Checks to Carry Out

0285 RIGHT CONVEYOR MOTOR PHASE IMBALANCE

0286 RIGHT CONVEYOR MOTOR INSTANTANEOUS OVERLOAD 0287 RIGHT CONVEYOR MOTOR THERMAL OVERLOAD

0288 RIGHT CONVEYOR MOTOR OVER TEMPERATURE

0289 NO VOLTAGE AT FAN RELAY OUTPUT

0290 TBA 0291 TBA 0292 FAN MOTOR MATE FAULTY

________________________________________________________________ 5.316 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0293 FAN NO LOAD CURRENT

0294 FAN MOTOR PHASE LOSS

0295 FAN MOTOR PHASE IMBALANCE

0296 FAN MOTOR INSTANTANEOUS OVERLOAD

0297 FAN MOTOR THERMAL OVERLOAD

0298 FAN MOTOR OVER TEMPERATURE

0299 SOLENOID SHORT CIRCUIT

______________________________________________________________ A6474X319 Rev 1 5.317

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0300 SOLENOID OPEN CIRCUIT

0301 REMOTE CONSOLE PILOT TRIP KEY PRESSED 0302 REMOTE CONSOLE LOW BATTERY 0303 ADDCAR SEQUENCE OPEN

0304 PUMP MULTIPLE INSTANTANEOUS OVERLOADS

0305 LEFT CONVEYOR MULTIPLE INSTANTANEOUS OVERLOADS

0306 RIGHT CONVEYOR MULTIPLE INSTANTANEOUS OVERLOADS

________________________________________________________________ 5.318 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0307 LEFT CUTTER MULTIPLE INSTANTANEOUS OVERLOADS

0308 RIGHT CUTTER MULTIPLE INSTANTANEOUS OVERLOADS

0309 FAN MULTIPLE INSTANTANEOUS OVERLOADS

0310 METHANE SENSOR COMMS FAILURE

0311 HEAD METHANE SENSOR FAILURE 0312 REAR METHANE SENSOR COMMS FAILURE

0313 REAR METHANE SENSOR FAILURE

______________________________________________________________ A6474X319 Rev 1 5.319

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0314 METHANE MONITOR RELAY OPEN

0315 HEAD METHANE SENSOR FAULT F2 0316 HEAD METHANE SENSOR FAULT F3 0317 HEAD METHANE SENSOR FAULT F4 0318 HEAD METHANE SENSOR FAULT F6 0319 HEAD METHANE SENSOR FAULT F7 0320 HEAD METHANE SENSOR FAULT F8 0321 HEAD METHANE SENSOR FAULT F9 0322 REAR METHANE SENSOR FAULT F2 0323 REAR METHANE SENSOR FAULT F3 0324 REAR METHANE SENSOR FAULT F4 0325 REAR METHANE SENSOR FAULT F6 0326 REAR METHANE SENSOR FAULT F7

________________________________________________________________ 5.320 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0327 REAR METHANE SENSOR FAULT F8 0328 REAR METHANE SENSOR FAULT F9 0329 PUMP MOTOR OVER TEMP WARNING

0330 LEFT CUTTER MOTOR OVER TEMP WARNING

0331 RIGHT CUTTER MOTOR OVER TEMP WARNING

0332 LEFT CONVEYOR MOTOR OVER TEMP WARNING 0333 RIGHT CONVEYOR MOTOR OVER TEMP WARNING 0334 LOW HYDRAULIC OIL WARNING 0335 LEFT CONVEYOR TORQUE SHAFT OVERLOAD

______________________________________________________________ A6474X319 Rev 1 5.321

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0335 LEFT CONVEYOR TORQUE SHAFT OVERLOAD

0336 RIGHT CONVEYOR TORQUE SHAFT OVERLOAD

0337 RIGHT CUTTER TORQUE SHAFT OVERLOAD

0338 LEFT CUTTER TORQUE SHAFT OVERLOAD

0339 PUMP RUN CURRENT LOSS

0340 ILLEGAL PUMP CURRENT

0341 NO PUMP START CURRENT 0342 RIGHT MACHINE STOP PRESSED 0343 LEFT MACHINE STOP PRESSED

________________________________________________________________ 5.322 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0344 MAIN AC SUPPLY LOST

0345 TBA 0346 METHANE MONITOR STATUS WIRE 0347 RIGHT MACHINE STOP STATUS WIRE 0348 ILLEGAL LEFT CUTTER CURRENT

0349 ILLEGAL RIGHT CUTTER CURRENT

0350 TBA 0351 TBA 0352 LOST LEFT CUTTER CURRENT

0353 LOST RIGHT CUTTER CURRENT

0354 ILLEGAL LEFT CONVEYOR CURRENT

______________________________________________________________ A6474X319 Rev 1 5.323

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0355 ILLEGAL RIGHT CONVEYOR CURRENT

0356 TBA 0357 TBA 0358 LOST LEFT CONVEYOR CURRENT

0359 LOST RIGHT CONVEYOR CURRENT

0360 ILLEGAL FAN CURRENT

0361 TBA 0362 LOST FAN CURRENT

0363 LEFT TRACTION FROZEN INTERNAL 0364 LEFT TRACTION FROZEN EXTERNAL 0365 LEFT TRACTION OPEN INTERNAL 0366 LEFT TRACTION OPEN EXTERNAL

________________________________________________________________ 5.324 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0367 RIGHT TRACTION FROZEN INTERNAL 0368 RIGHT TRACTION FROZEN EXTERNAL 0369 RIGHT TRACTION OPEN INTERNAL 0370 RIGHT TRACTION OPEN EXTERNAL 0371 DEADMAN SWITCH OPEN 0372 DEADMAN SWITCH FROZEN 0373 TRACTION MODULE COMMS FAILURE

0374 LEFT TRACTION NO LOAD CURRENT

0375 LEFT TRACTION MULTIPLE INSTANT OVERLOAD 0376 RIGHT TRACTION NO LOAD CURRENT

0377 RIGHT TRACTION MULTIPLE INSTANT OVERLOAD

______________________________________________________________ A6474X319 Rev 1 5.325

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0378 ILLEGAL LEFT TRACTION CURRENT FEEDBACK 0379 ILLEGAL RIGHT TRACTION CURRENT FEEDBACK 0380 LEFT TRAM MOTOR MATE FAILURE

0381 LEFT TRAM MOTOR MATE FAILURE

0382 LEFT TRACTION CURRENT LOSS 0383 RIGHT TRACTION CURRENT LOSS 0384 CB2 OPEN

0385 CUTTER BREAKER OPEN

0386 TRAM BREAKER OPEN

0387 NO LEFT CUTTER START CURRENT

________________________________________________________________ 5.326 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0388 NO RIGHT CUTTER START CURRENT

0389 NO LEFT CONVEYOR START CURRENT

0390 NO RIGHT CONVEYOR START CURRENT

0391 NO FAN START CURRENT

0392 PUMP THERMISTOR SHORT CIRCUIT 0393 PUMP THERMISTOR OPEN CIRCUIT 0394 LEFT CUTTER THERMISTOR SHORT CIRCUIT 0395 LEFT CUTTER THERMISTOR OPEN CIRCUIT 0396 RIGHT CUTTER THERMISTOR SHORT CIRCUIT 0397 RIGHT CUTTER THERMISTOR OPEN CIRCUIT

______________________________________________________________ A6474X319 Rev 1 5.327

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0398 LEFT CONVEYOR THERMISTOR SHORT CIRCUIT 0399 LEFT CONVEYOR THERMISTOR OPEN CIRCUIT 0400 RIGHT CONVEYOR THERMISTOR SHORT CIRCUIT 0401 RIGHT CONVEYOR THERMISTOR OPEN CIRCUIT 0402 PUMP OVERLOAD RELAY OPEN

0403 LEFT TRAM OVERLOAD RELAY OPEN

0404 RIGHT TRAM OVERLOAD RELAY OPEN

0405 CB2 OPEN DURING FAN START

0406 FAN LOST AUXILIARY PUMP FEEDBACK 0407 CUTTER LOST AUXILIARY PUMP FEEDBACK

________________________________________________________________ 5.328 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0408 CONVEYOR LOST AUXILIARY PUMP FEEDBACK 409 CB2 OPEN AT LEFT CUTTER MOTOR START 410 CB2 OPEN AT RIGHT CUTTER MOTOR START 411 CB2 OPEN DURING FORWARD CONVEYOR START 412 CB2 OPEN DURING REVERSE CONVEYOR START 413 CB2 OPEN DURING PUMP MOTOR START 0414 LEFT VFD UNDER VOLTAGE

0415 LEFT VFD HEATSINK TRIP 0416 LEFT VFD SHORT CIRCUIT 0417 LEFT VFD OVER VOLTAGE 0418 LEFT VFD MOTOR OVERLOAD 0419 LEFT VFD IGBT OVER TEMPERATURE

______________________________________________________________ A6474X319 Rev 1 5.329

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0420 LEFT VFD IGBT EXTERNAL INTERLOCK 0421 LEFT VFD INSTANT OVERLOAD 0422 LEFT VFD THERMOSTAT TRIP 0423 LEFT VFD MOTOR OVER SPEED 0424 LEFT VFD PHASE LOSS 0425 LEFT VFD CAN COMMUNICATIONS FAILURE 0426 RIGHT VFD UNDER VOLTAGE

0427 RIGHT VFD HEATSINK TRIP 0428 RIGHT VFD SHORT CIRCUIT 0429 RIGHT VFD OVER VOLTAGE 0430 RIGHT VFD MOTOR OVERLOAD 0431 RIGHT VFD IGBT OVER TEMPERATURE 0432 RIGHT VFD IGBT EXTERNAL INTERLOCK

________________________________________________________________ 5.330 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0433 RIGHT VFD INSTANT OVERLOAD 0434 RIGHT VFD THERMOSTAT TRIP 0435 RIGHT VFD MOTOR OVER SPEED 0436 RIGHT VFD PHASE LOSS 0437 RIGHT VFD CAN COMMUNICATIONS FAILURE 0438 RECTIFIER UNDER VOLTAGE

0439 RECTIFIER HEAT SINK TRIP 0440 RECTIFIER SHORT CIRCUIT 0441 BRAKE IGBT OVER TEMPERATURE 0442 BRAKE RESISTOR THERMAL TRIP 0443 RECTIFIER INPUT INSTANT OVERLOAD 0444 RECTIFIER CAN COMMUNICATIONS FAILURE 0445 LEFT VFD OVER VOLTAGE TRIP

______________________________________________________________ A6474X319 Rev 1 5.331

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0446 RIGHT VFD OVER VOLTAGE TRIP 0447 LEFT VFD MOTOR RTD TRIP 0448 RIGHT VFD MOTOR RTD TRIP 0449 ESR RELAY OPEN

0450 ILLEGAL VOLTAGE ON PILOT CIRCUIT 0451 LEFT RMS INTERNAL FAULT 0452 RIGHT RMS INTERNAL FAULT 0453 LEFT VFD ENCODER LOSS 0454 RIGHT VFD ENCODER LOSS 0455 LEFT RMS LOW LINE VOLTAGE 0456 LEFT RMS OVER TEMPERATURE 0457 LEFT RMS HIGH LINE VOLTAGE 0458 LEFT TRAM MOTOR THERMAL OVERLOAD 0459 LEFT TRAM MOTOR INSTANT OVERLOAD 0460 LEFT RMS OVER VOLTAGE

________________________________________________________________ 5.332 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0461 LEFT TRAM MOTOR RTD TRIP 0462 LEFT TRAM MOTOR THERMOSTAT TRIP 0463 LEFT RMS OVER SPEED 0464 LEFT RMS PHASE SYNC LOSS 0465 LEFT RMS LOST THREE PHASE SUPPLY 0466 LEFT RMS LOST CAN COMMUNICATIONS 0467 LEFT RMS UNPLANNED MOVEMENT 0468 LEFT RMS EMERGENCY TRAM MODE 0469 LEFT RMS NOT IN READY STATE 0470 RIGHT RMS LOW LINE VOLTAGE 0471 RIGHT RMS OVER TEMPERATURE 0472 RIGHT RMS HIGH LINE VOLTAGE 0473 RIGHT TRAM MOTOR THERMAL OVERLOAD 0474 RIGHT TRAM MOTOR INSTANT OVERLOAD

______________________________________________________________ A6474X319 Rev 1 5.333

Troubleshooting ______________________________________________ Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0475 RIGHT RMS OVER VOLTAGE 0476 RIGHT TRAM MOTOR RTD TRIP 0477 RIGHT TRAM MOTOR THERMOSTAT TRIP 0478 RIGHT RMS OVER SPEED 0479 RIGHT RMS PHASE SYNC LOSS 0480 RIGHT RMS LOST THREE PHASE SUPPLY 0481 RIGHT RMS LOST CAN COMMUNICATIONS 0482 RIGHT RMS UNPLANNED MOVEMENT 0483 RIGHT RMS EMERGENCY TRAM MODE 0484 RIGHT RMS NOT IN READY STATE 0485 VFD NOT SUPPORTED 0486 LEFT RMS NO FORWARD RESPONSE 0487 RIGHT RMS NO FORWARD RESPONSE 0488 LEFT RMS NO REVERSE RESPONSE

________________________________________________________________ 5.334 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 13 (continued): Control system fault codes Fault

Explanation

Possible Cause

Checks to Carry Out

0489 RIGHT RMS NO REVERSE RESPONSE 0490 GROUND FAULT RELAY STATUS

0491 FAN PT100 SHORT CIRCUIT

0492 FAN PT100 OPEN CIRCUIT

0494 TBA 0495 TBA

______________________________________________________________ A6474X319 Rev 1 5.335

Troubleshooting ______________________________________________ Table 14: Control system pin outs Super Simpson receiver control unit Connector X1 - 35 Burndy Female Pin No. Signal Name X1-A Output Relay 1 - Spare X1-B Output Relay 2 - Spare X1-C Output Relay 3 - AUX #1 Relay Output X1-D Relay 4 -MMR Status X1-E Relays Input (1 - 8) X1-F Output Relay 5 - AUX #2 Relay Output X1-G Output Relay 6 - Spare X1-H Output Relay 7 - Head Lights Output X1-J Output Relay 8 - Pump Run X1-L Output Relay 9 - Left Cutter Run X1-N Output Relay 11 - Conveyor Forward Run Output X1-P Output Relay 12 - conveyor Reverse Run Output X1-R Relays Input (9 - 16) X1-S Output Relay 13 - Right Cutter Run X1-T Digital Input 15 - CB2 Status X1-U Digital Input 16 - Cutter Breaker Feedback X1-V Digital Input 17 - Right E-Stop Feedback X1-W Neutral X1-X Digital Input 18 - Pump Feedback X1-Y Digital Input 19 - Pump External Overload X1-Z Output Relay 19 - L/R E-Stop Feedback X1-a Output Relay 20 - Main Supply Status X1-b Used as MOR Output Only X1-c Output Relay 21 - R Traction External Overload X1-d Input Relay - Ext Circuit Monitoring X1-e Input Relay - Ext Circuit Monitoring X1-f Input Relay - Ext Circuit Monitoring X1-g E-Stop Neutral X1-h E-Stop Input X1-l E-Stop Output

Signal Type 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Output 100 VAC Digital Input 100 VAC Digital Input 100 VAC Digital Input Neutral 110 VAC 100 VAC Digital Input 100 VAC Digital Input 110 VAC Input 110 VAC Input 110 VAC Output 110 VAC Output 110 VAC Input 110 VAC Input 110 VAC Input 110 VAC Neutral 110 VAC Input 110 VAC Output

________________________________________________________________ 5.336 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 14: Control system pin outs, continued Super Simpson receiver control unit Connector X2 - 19 Burndy Female Pin No. Signal Name X2-A Aux. Supply Output 24V+ X2-B Aux. Supply Output 0V

Signal Type 24V Output 0V Output

X2-C X2-D X2-E X2-F X2-G X2-H X2-J X2-K X2-L X2-M X2-N X2-P X2-R X2-S X2-T X2-U X2-V

24V Input 0V Input Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication Ext. Communication 24V Digital Input 24V Digital Input 24V Digital Input 24V Digital Input Ext. Communication 24VDC Output

Supply Input 24V+ Supply Input 0V Data Logging (Methane) RS485-A Data Logging (Methane) RS485-B Data Logging (Methane) RS485-Reference External Slaves RS485-A External Slaves RS485-B External Slaves RS485-Reference RS422 TX-P RS422 TX-N RS422 RX-P Frequency Selection #1 Frequency Selection #2 Frequency Selection #3 24V Input - Spare RS422 RX-N Supply Output

______________________________________________________________ A6474X319 Rev 1 5.337

Troubleshooting ______________________________________________ Table 14: Control system pin outs, continued Super Simpson receiver control unit Connector X3 - V35 Burndy (34 Pin Female) Pin No.

Signal Name

Signal Type

X3-A X3-B X3-C X3-D X3-E X3-F X3-H X3-J X3-K

Solenoid 1 - Gathering Head Up Solenoid 3 - Shear Up 100+ VDC for Solenoid Drivers Solenoid 4- Shear Down Solenoid 2 - Gathering Head Down Solenoid 5 - Conveyor Up 0V for 110 VDC Solenoid Drivers Solenoid 6 - Conveyor Down 0V for 110 VDC Solenoid Drivers

Solenoid 0VDC O/P Solenoid 0VDC O/P 100 VDC + Input Solenoid 0VDC O/P Solenoid 0VDC O/P Solenoid 0VDC O/P 0V - Input Solenoid 0VDC O/P 0V - Input

X3-L X3-M X3-N X3-P X3-R X3-S X3-T X3-U X3-V X3-W X3-X X3-Y X3-Z X3-AA X3-BB X3-CC X3-EE X3-FF X3-HH X3-JJ X3-KK X3-LL X3-MM X3-NN

Solenoid 7 - Conveyor Left Digital Input 1 - Spare Solenoid 8 - Conveyor Right Digital Input 2 - Spare Solenoid 9 - Stabilizer Up Digital Input 3 - Spare Solenoid 10 - Stabilizer Down Digital Input 4 - LH Traction External Overload Solenoid 11 - Fire Suppression Digital Input 5 - Tram Breaker Solenoid 12 - Breaker OFF Digital Input 6 - Low Oil Level Solenoid 13 - Breaker ON Digital Input 7 - Reserved Solenoid 14 - Cutter Water Spray Digital Input 8 - Reserved Digital Input 9 - Spare Solenoid 16 - Methane Override Enable Digital Input 10 - Spare Digital Input 11 - Miner Model Select Digital Input Digital Input 12 - Miner Model Select Digital Input 13 - Miner Model Select Digital Input 14 - Miner Model Select

Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input 100VAC Digital Input Solenoid 0VDC O/P 100VAC Digital Input 100VAC Digital Input Neutral 100VAC I/P 100VAC Digital Input 100VAC Digital Input 100VAC Digital Input

________________________________________________________________ 5.338 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 14: Control system pin outs, continued Super Simpson receiver control unit Connector X4 - GAPL26 26 Pin Female Pin No.

Signal Name

Signal Type

X4-A X4-B X4-C X4-D X4-E X4-F X4-H X4-J X4-K X4-L X4-M X4-N X4-P X4-R X4-S X4-T X4-U X4-V X4-W X4-X X4-Y X4-Z

Right Conveyor Motor Phase A Right Conveyor Motor Phase B Right Conveyor Motor Phase C Blowing System Motor Phase A Blowing System Motor Phase B Blowing System Motor Phase C Left Conveyor Motor Phase A Left Conveyor Motor Phase B Left Conveyor Motor Phase C Left Cutter Motor Phase A Left Cutter Motor Phase B Left Cutter Motor Phase C Right Cutter Motor Phase A Right Cutter Motor Phase B Right Cutter Motor Phase C Pump Motor Phase A Pump Motor Phase B Pump Motor Phase C Left Tram Motor Phase A Left Tram Motor Phase B Left Tram Motor Phase C Right Tram Motor Phase A

4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA 4-20mA

X4-AA X4-BB X4-CC X4-DD

Right Tram Motor Phase B Right Tram Motor Phase C +24 VDC Active 0VDC Neutral

4-20mA 4-20mA +24VDC 0VDC

Super Simpson Battery Backup Power Supply Connector X5 - 8 Pin Burndy Female Pin No.

Signal Name

Signal Type

X5-A

Door Switch Input

Link

X5-B X5-C X5-D X5-E X5-F X5-G X5-H

Door Switch Output Main Supply O/P 24V+ Main Supply O/P 0V N/C RS458 - A RS458 - B RS458 - Reference

Link 24V+ Output 0V Output Communication Communication Communication

______________________________________________________________ A6474X319 Rev 1 5.339

Troubleshooting ______________________________________________ Table 14: Control system pin outs, continued Super Simpson Battery Backup Power Supply Connector X6 - 8 Pin Burndy Male Pin No. X6-A X6-B X6-C X6-D X6-E X6-F X6-G X6-H

Signal Name 100VAC Neutral Earth 100VAC Line N/C 0VDC 100VDC + N/C N/C

Signal Type Supply Input Supply Earth Connection Supply Input Output 110VDC Output 110VDC

Super Simpson Receiver Control Unit Connector X7 - RS-422 Graphics Display Pin No. X7-A X7-B X7-C X7-D

Signal Name RS-422 RS-422 RS-422 RS-422

Signal Type RxRx+ TxTx+

Super Simpson Receiver Control Unit Connector X8 - RS-422 Data Logger Pin No. X8-A X8-B X8-C X8-D X8-E X8-F

Signal Name +24VDC Active 0VDC Neutral RS-422 RS-422 RS-422 RS-422

Signal Type +24VDC Output 0VDC RS-422 RxRx+ TxTx+

Super Simpson Display Unit (4X20 “Lil’ Blue”) Terminal Connections J3, J4 Pin No. 24V+ 0V A B COM

Signal Name Auxiliary Supply I/P 24V+ Auxiliary Supply I/P 0V Display RS485 - A Display RS485 - B Display RS485 - Reference

Signal Type 24V Input 0V Input External Communications External Communications External Communications

________________________________________________________________ 5.340 CM340 Continuous Miner

_____________________________________________ Troubleshooting Table 14: Control system pin outs, continued Super Simpson Programming A1 Pin No. X1-A X1-B X1-C X1-D

Signal Name Rx Tx 0V -

Signal Type Rx Tx 0V -

Super Simpson Thermistor Module A2 CAN Pin No. X2-A +24VDC Active X2-B 0VDC X2-C CAN H X2-D CAN H X2-E CAN L X2-F CAN L X2-G Thermistor T1 X2-H Thermistor T2

Signal Name

Signal Type 24VDC 0VDC CAN H CAN H CAN L CAN L T1 T2

Super Simpson Traction Unit Connector X10 - GAPL26 26 Pin Male Pin No.

Signal Name

Signal Type

X10-A X10-B X10-C X10-D X10-E X10-F X10-H X10-J X10-K

External Supply (GND) External Supply (GND) Spare Left Hand Forward (LHFWD) External Supply (GND) External Supply (GND) Deadman Right Hand Reverse (RHREV) External Supply (GND)

+13V GND (Ext.) +13V GND (Ext.)

X10-L X10-M X10-N X10-R X10-T X10-U X10-V X10-X X10-Y X10-Z X10-AA X10-BB X10-CC X10-DD

External Supply (GND) Left Hand Reverse (LH REV) Right Hand Forward (RHFWD) External Supply (13VDC) External Supply (13VDC) Data A 0V FP 0V FP Data B Right Hand Proportional Output System Supply (+24VDC Active) Left Hand Proportional Output System Supply (24VDC GND) Data Communications

+13V GND (Ext.) +13V ON/OFF Output +13V ON/OFF Output +13V Supply +13V Supply RS-485 Signal A 12V GND 12V GND RS-485 Signal B 0-10V Prop. Output +24V Supply (System) 0-10V Prop. Output +24V GND (System) RS-485 Reference

+13V ON/OFF Output +13V GND (Ext.) +13V GND (Ext.) +13V ON/OFF Output +13V ON/OFF Output +13V GND (Ext.)

______________________________________________________________ A6474X319 Rev 1 5.341

Troubleshooting ______________________________________________ Table 15: RTD Corresponding Temperature Values Resistance (Ohms)

Temperature (°C)

Resistance (Ohms)

Temperature (°C)

100

0.0

170

178.6

101

2.6

171

181.1

102

5.1

172

183.7

103

7.7

173

186.2

104

10.2

174

188.8

105

12.8

175

191.3

106

15.3

176

193.9

107

17.9

177

196.4

108

20.4

178

199.0

109

23.0

178.4

200.0

110

25.5

179

201.5

111

28.1

112

30.96

113

33.2

114

35.7

115

38.3

116

40.8

117

43.4

118

45.9

119

48.5

120

51.0

121

53.6

122

56.1

123

58.7

124

61.2

125

63.8

126

66.3

127

68.9

128

71.4

129

74.0

130

76.5

131

79.1

132

81.6

133

84.2

134

86.7

________________________________________________________________ 5.342 CM340 Continuous Miner

_______________________________________________________________

6

Technical data

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the CM340 Continuous Miner. Further data can be found in the spare parts lists.

At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully, and pay particular attention to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Components of the CM340 Continuous Miner Technical data sheet Note: All dimensions and rates are for a Miner with a 9 inch ground clearance and a 44 inch diameter cutting drum. operating dimensions

Recommended mining range ...............................approx. 66 to 156 in (3,962 mm) Minimum height over cutter boom assembly .......approx. 49 in (1,245 mm) Maximum mining height .......................................approx. 158 in (4 m) Minimum mining height (Zero Cut).......................approx. 54 in (1.4 m) Maximum reach....................................................approx. 158 in (4 m) Ground clearance.................................................approx. 9 - 12 in (.23 - .30 m) Length (bumper to face) .......................................approx. 16 ft 6 in (4.9 m)

transport dimensions

Width (outside of rub rails) ...................................approx. 10 ft 2 in (3.09 m) Overall length .......................................................approx. 37 ft (11.3 m) Height (cover line) ................................................approx. 54 in (1372 mm) Weight (total) ........................................................approx. 160,000 lbs (72,575 kg)

cutter unit

Cutter drum diameter ...........................................approx. 44 in (1,119 mm) Cutter drum width .................................................approx. 11 ft 9 in (3.6 m) Cutter head speed................................................approx. 720 fpm (62 rpm) (3.54 m/sec) Cutter motors (continuous rating).........................2X280 HP/209 kW

______________________________________________________________ A6474X319 Rev 1 6.3

Technical data________________________________________________ loading unit

Loading method....................................................... 3 finger CLA Conveyor width........................................................ approx. 38 in (965 mm) Conveyor speed ...................................................... approx. 483 fpm (147 m/min) Conveyor depth ....................................................... 8 in (203 mm) Loading capacity ..................................................... 15 to 39 TPM (14 to 35 tonnes/min) Horse Power on Conveyor through CLAs ............... 2X65 HP/48 kW (one-hour rating)

traction unit

Crawler chain width ................................................. 22 in (559 mm) Crawler assembly length ......................................... 9 ft 2 in (2,794 mm) Ground pressure (average) ..................................... < 32 psi (221 kPa) Crawler speed ......................................................... 0 - 85 fpm (0 - 26 m/min) Traction horse power............................................... 2X75 hp/60 kW DC (one-hour rating)

electrical system

Machine voltage (no load) ....................................... IEC, 1140 VAC Machine voltage (under load).................................. 1000 VAC Control system ........................................................ Processor based/ radio remote control

hydraulic system

Hydraulic pump unit, triple gear pump ................. 2,200 psi (152 bar) Working pressure Horse Power on Hydraulic Pump .........................1X65 HP (48 kW) (one-hour rating)

total installed horse power

Continuous rating (without blowing system)............ 765 HP (570 kW) One hour rating (without blowing system)............... 905 HP (675 kW)

________________________________________________________________ 6.4 CM340 Continuous Miner

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy!

Table 12: Hex head bolts, Grade 8 (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

______________________________________________________________ A6474X319 Rev 1 6.5

Tightening torques ____________________________________________

________________________________________________________________ 6.6 CM340 Continuous Miner

___________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only approved lubrication fluids and greases! These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! The approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be stored and disposed of per your local EPA standards.

______________________________________________________________ A6474X319 Rev 1 6.7

Permissible media ____________________________________________ Approved suppliers: Table 13: Anti-wear hydraulic oil (Spec 100-1) 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century (Fuchs) Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

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

Table 14: Extreme pressure gear oils (Spec. 100-2) 1 2 3

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil company Century (Fuchs)

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

Brand name Amoco Permagear EP 460 EP Lubricant HD 460 Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460 Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

________________________________________________________________ 6.8 CM340 Continuous Miner

___________________________________________ Permissible media Table 15: Extreme pressure motor bearing grease (Spec. 100-3)

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

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 15 16

Hydrotex Phillips Atlantic Richfield

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 Replex2, 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 Philube EP Grease Litholine H EP-2 Grease

Table 16: Semi-fluid grease (Spec. 100-4) 1 2 3 4 5 6

Supplier Texaco Lubricants Company Century (Fuchs) Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid Grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

______________________________________________________________ A6474X319 Rev 1 6.9

Permissible media ____________________________________________ Table 17: Invert emulsion hydraulic fluid (Spec. 100-5)

10 11

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company Cincinnati – Vulcon Company Cities Service Oil company Century (Fuchs) Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century (Fuchs) Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

22 23 24 25

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company Wynn Oil Company Lubrication Engineers

26

Hydrotex

1 2 3 4 5 6 7 8 9

19 20 21

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion Fire Resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant Hydraulic Fluid HY-Guard

Table 18: Extreme pressure gear oil, SAE 90 (Spec. 100-6) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century (Fuchs) Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc. Hydrotex Phillips Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil Gear 632 Chevron Gear Compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

________________________________________________________________ 6.10 CM340 Continuous Miner

___________________________________________ Permissible media Table 19: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) 1 2 3 4

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

5 6

Sun Oil Company Unocal 76

7 8 9 10 11 12 13

Shell Oil Company Century (Fuchs) Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16 17 18

Hydrotex Atlantic Richfield Cities Service Miner Oil Texaco, Lubricants Company

Brand name American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68 Centraulic R&O 68 Regal Oil R&O N-68 Tresstic 68 Pennzbell RO 68 6120 Monolec Turbine Oil Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68 Duro 5.315 Citgo Pacemaker A/W68 Hydraulic Oil AW68 TDH 1893

Table 20: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8)

1 2 3 4

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

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil Company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

9 10 11 12 13 14 15 16 17 18

Brand name American Industrial oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150 Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

______________________________________________________________ A6474X319 Rev 1 6.11

Permissible media ____________________________________________ Table 21: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) 1 2 3 4 5 6 7 8 9 10 11

Supplier Amoco Oil Company Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Century (Fuchs) Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Brand name Cylinder oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

Table 22: Light gear oil, SAE 40 motor oil (Spec. 100-10) 1 2 3 4 5 6 7

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century (Fuchs) Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 23: Synthetic EP gear lubricants (Spec. 100-11) 1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 24: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4 5 6 7

Supplier Exxon / Mobil Century (Fuchs) Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

________________________________________________________________ 6.12 CM340 Continuous Miner

___________________________________________ Permissible media Table 25: Extreme pressure gear oil (Spec. 100-13) 1

Supplier Century Lubricants

Brand name Powergear H680

Table 26: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 27: High demulsibility EP gear oil (Spec. 100-15) 1

Supplier Conoco

Brand name GLW Gear Oil 220

______________________________________________________________ A6474X319 Rev 1 6.13

Permissible media ____________________________________________

________________________________________________________________ 6.14 CM340 Continuous Miner

_______________________________________________________________

7

For your information

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

______________________________________________________________ A6474X319 Rev 1 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

________________________________________________________________ 7.4 CM340 Continuous Miner