DOWNLOAD PDF : Cat CM445 Continuous Miner Operation and Maintenance Manual A6474X442

BI001575 A6474X442 August 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X442 (Mechanical - Gathering Head/Conveyor)

SAFETY.CAT.COM

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

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

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

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

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

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

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Instructions ............................................................................. 4 Preliminary Instructions ..................................................................... 6 Torque Values ................................................................................... 7 Component Weights .......................................................................... 9 Safety supports ................................................................................. 9 Foot Shaft .......................................................................................... 10 Gathering Head Motor Torque Shaft ................................................. 14 Gathering Head Drive Motor ............................................................. 17 Gathering Head Cylinder ................................................................... 21 Gathering Head Assembly ................................................................ 25 Gathering Head Control Arms ........................................................... 29 Gathering Head Gear Case .............................................................. 34 Centrifugal Loading Arm (CLA) ......................................................... 38 Conveyor Chain Adjustment Procedure ............................................ 41 Conveyor Chain................................................................................. 42 Tail Drive ........................................................................................... 46 Discharge Conveyor .......................................................................... 49 Conveyor Assembly .......................................................................... 53 Tail Shim Adjustment Procedure ....................................................... 57 Conveyor Lift Cylinder ....................................................................... 60 Conveyor Swing Cylinder .................................................................. 65

________________________________________________________________ A6474X442

REV 0

Safety Instructions _______________________________________________ Safety Precautions

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

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

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DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections except as allowed by applicable regulatory agencies. Contact with high voltage power supply will result in severe injury or death from electrocution.

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DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

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

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

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

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

________________________________________________________________ 4 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________________ Safety Instructions

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WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the conveyor. Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

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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.

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

______________________________________________________________ A6474X442 REV 0 5

Preliminary Instructions ___________________________________________ Introduction

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

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

Tools

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

Illustrations

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

Before Maintenance

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

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

Follow all applicable lockout/tagout procedures.

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

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

Important Notes

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

2. Use only original spare parts when replacing components.

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

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

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

________________________________________________________________ 6 CM445 Mechanical - Gathering Head and Conveyor

___________________________________________________ Torque Values Introduction

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

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

Use a calibrated torque wrench for accuracy.

Imperial Bolts

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

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

______________________________________________________________ A6474X442 REV 0 7

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

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

________________________________________________________________ 8 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Component Weights Component Weights

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

Component

Approximate Weight

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

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

Fig. 1: Conveyor safety supports

Conveyor safety support (storage location)

Conveyor safety support (installed location)

______________________________________________________________ A6474X442 REV 0 9

Foot Shaft _______________________________________________________ Introduction

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

Tool Set

Basic Tool Set Pry Bar

Safety

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

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WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

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

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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.

________________________________________________________________ 10 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________________ Foot Shaft Removal Procedure

To remove the foot shaft (Fig. 2): 1. Lower the gathering head assembly until it touches the floor.

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

3. Raise the cutter head assembly to its highest position and block.

4. 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.

5. Disconnect and lock out the electrical power to the miner. Follow all applicable lockout/tagout regulations and procedures.

6. Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.

7. Remove the two conveyor chain retaining pins from the closest connecting pin to the foot shaft and then remove the connecting pin.

8. Pull the top half of the conveyor chain away from the foot shaft sprocket (fold it back).

9. Remove the four (4) 3/4-10X2-1/2 socket head capscrews that secure the two foot shaft covers to the gathering head assembly and remove the covers.

10. Remove the four (4) 1/2-13X1-3/4socket head capscrews from the clamp rings (two capscrews on each clamp) on the foot shaft assembly and remove the clamp rings.

11. Slide both adapter shafts from the ends of the foot shaft toward the sprocket in the center. This will free the foot shaft from the gear case.

12. Remove the foot shaft from the gathering head.

______________________________________________________________ A6474X442 REV 0 11

Foot Shaft _______________________________________________________ Installation Procedure

To install the foot shaft (Fig. 2): 1. Position the CLAs as shown in Fig. 2.

2. Slide an adapter shaft onto each end of the foot shaft.

3. Slide the foot shaft into position between the two gathering head gear case bevel pinions. Note: Position the foot shaft so that it’s sprocket will engage the conveyor chain links when the chain is reconnected.

4. Align the foot shaft splines with the bevel pinion splines.

5. 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.

6. Place a collar onto each end of the foot shaft so that the adapter shaft is secured against the bevel gear case seal carriers.

7. Insert and tighten the four (4) 1/2-13X1-3/4 socket head capscrews (two for each collar) through both halves of the collars to secure the collars to the foot shaft. Torque to 118 ft-lb dry.

8. Replace the foot shaft covers and secure with the four (4) 3/4-10X2-1/2 socket head capscrews. Torque to 261 ft-lb dry.

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

10. Close the needle valve to the conveyor take-up cylinders.

11. Reconnect the trailing cable to energize the miner.

12. Start the pump so that the conveyor chain take-up cylinders are pressurized.

13. Turn on the gathering head motors to run the conveyor chain.

14. Elevate the conveyor full up and down and swing the discharge conveyor full left and right. Check that the conveyor chain is running smoothly.

15. Shutdown the machine and check the conveyor chain tension. If adjustment is necessary, see the Conveyor chain adjustment procedure.

________________________________________________________________ 12 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________________ Foot Shaft Fig. 2: Foot shaft removal and installation

Sprocket

Socket head capscrew (1/2-13x1-3/4) (2 each collar)

Adapter shaft (collar)

Socket head capscrew 3/4-10X2-1/2 (2 each cover)

Foot shaft cover

Foot shaft

______________________________________________________________ A6474X442 REV 0 13

Gathering Head Motor Torque Shaft _________________________________ Introduction

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

Tool Set

Basic Tool Set Pry Bar Retaining Ring Pliers

Damaged Torque Shaft Indicators

Following are conditions that may indicate one or both gathering head motor torque shafts are damaged or broken: 1. Both motors are operating but the gathering head is not moving. Both shafts may be broken.

2. The gathering head starts to stall or goes on instant overload. One torque shaft is probably broken as indicated by the motor drawing the least current.

3. One motor coasts after power is removed; the motor probably has a broken shaft.

Safety

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

WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

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

________________________________________________________________ 14 CM445 Mechanical - Gathering Head and Conveyor

_________________________________ Gathering Head Motor Torque Shaft Removal Procedure

To remove a gathering head motor torque shaft (Fig. 3): 1. Lower the gathering head until the pan rests on the mine floor.

2. Raise the cutter head and block it securely.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

4. Remove the motor access cover on the side of the gathering head frame.

5. Remove the snap ring and plug from the end of the motor, exposing the torque shaft.

6. Remove the torque shaft.

Installation Procedure

To install a gathering head motor torque shaft (Fig. 3): 1. Insert the torque shaft into the motor.

2. Replace the plug and snap ring over the end of the torque shaft.

3. Replace the motor access cover on the side of the gathering head frame.

______________________________________________________________ A6474X442 REV 0 15

Gathering Head Motor Torque Shaft _________________________________ Fig. 3: Gathering head motor torque shaft removal and installation

1

5

2 4

1.

2.

3.

4.

5.

Motor access cover O-ring Snap ring Plug Motor torque shaft

3

________________________________________________________________ 16 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________ Gathering Head Drive Motor Introduction

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

Tool Set

Basic Tool Set Pry Bar

Safety

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

!

!

Blocking Retaining Ring Pliers

WARNING Do not rely on load holding valves when working under the cutter head. Always block the cutter head in the elevated position. Serious injury or death may occur if the cutter head is not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

______________________________________________________________ A6474X442 REV 0 17

Gathering Head Drive Motor ________________________________________ Removal Procedure

To remove a gathering head motor (Fig. 4): 1. Lower the gathering head until the pan rests on the mine floor.

2. Raise the cutter head and block it securely.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

4. Remove the motor access cover on the side of the gathering head frame.

5. Wash out compartment thoroughly.

6. Disconnect and tag the power cables to the gathering head motors.

7. Disconnect, tag, and cap the water hoses going to the gathering head motors.

8. Remove the snap ring and plug from the end of the motor, exposing the torque shaft.

9. Remove the torque shaft.

10. Securely block the motor to prevent it from falling when the mounting bolts are removed.

11. Remove the eight (8) hex head motor mounting bolts (four (4) 1-18X? and four (4) 1-1/8X6 and carefully back the motor out of the frame.

________________________________________________________________ 18 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________ Gathering Head Drive Motor Installation Procedure

To install a gathering head motor (Fig. 4): 1. Ensure mating surfaces of the frame and motor are clean and free of contaminants.

2. Carefully position the motor in the frame.

3. Insert the eight (8) hex head motor mounting bolts (four (4) 3/410X20 and four (4) 3/4-10X6) and torque to 242 - 261 ft-lbs.

4. Insert the torque shaft into the motor.

5. Replace the plug and snap ring over the end of the torque shaft.

6. Reconnect the water hoses to the motor.

7. Reconnect the power cable to the motor.

8. Replace the motor access cover on the side of the gathering head frame.

9. Replace the top cover over the input gear case.

______________________________________________________________ A6474X442 REV 0 19

Gathering Head Drive Motor ________________________________________ Fig. 4: Gathering head drive motor removal and installation

2

1 7

3 6

1.

2.

3.

4.

5.

6.

7.

Hex head bolt, 1-1/8X6 (4) Hex head bolt, 1-1/8X? (4) Gathering head motor Snap ring Plug Torque shaft Motor access cover

5

4

________________________________________________________________ 20 CM445 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder Introduction

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

Tool Set

Basic Tool Set Sling or Chain Slide Hammer

Safety

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

!

Blocking Pry Bar Puller Bolts

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

!

WARNING Never disconnect a pressurized hydraulic line. Bleed all hydraulic lines before disconnecting as serious injury could result.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

______________________________________________________________ A6474X442 REV 0 21

Gathering Head Cylinder __________________________________________ Removal Procedure

To remove a gathering head cylinder (Fig. 5): 1. Raise the gathering head off the ground by extending the cylinder and securely block.

2. Raise the cutter head and block it securely.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

4. Attach a lifting device around the cylinder and take up slack so that the weight of the cylinder is supported by the lifting chain/sling.

5. Remove the cotter pin from the upper cylinder mounting pin.

6. Remove the upper mounting pin.

7. Connect the trailing cable to energize the miner.

8. Slowly retract the cylinder until the rod eye is free of the gathering head clevis.

9. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

10. Verify that the cutter head and gathering head are still securely blocked.

11. Open the pan float valve to release hydraulic pressure.

12. Disconnect the hydraulic hoses from the cylinder. Plug the hoses and cylinder ports to protect them from dirt and damage.

13. Remove the two M16X45 hex head cap screws that secure the rod end pin retainer plate to the frame and remove the retainer plate.

14. Remove the rod end mounting pin.

15. The cylinder is now free to remove from the machine..

________________________________________________________________ 22 CM445 Mechanical - Gathering Head and Conveyor

__________________________________________ Gathering Head Cylinder Installation Procedure

To install a gathering head cylinder (Fig. 5): 1. Confirm that power is disconnected and locked/tagged out from the machine.

2. Confirm that the gathering head and cutter head are securely blocked.

3. Confirm that the cylinder eye bushings are installed.

4. Using an appropriate lifting device, position the cylinder in the frame mounting clevis. Align the cylinder and mounting clevis pin bores and insert the cylinder mounting pin.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

5. Place the pin retainer plate over the pin and secure with two M16X45 socket head cap screws.

6. Connect they hydraulic lines to the cylinder.

7. Connect the trailing cable to energize the miner.

8. Make sure the pan float valve is closed.

9. Slowly extend the cylinder so that the rod end clevis cab be inserted into the gathering head assembly mounting clevis.

10. Disconnect and lock out electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

11. Insert the cotter pin through the cylinder mounting pin to secure..

12. Grease both cylinder pins with Spec. 100-3 grease.

13. Check the hydraulic fluid level in the tank; add fluid as necessary.

14. Restore electrical power to the machine.

15. Start the pump and extend and retract the cylinder to purge air from the hydraulic system.

16. Remove all blocking.

17. Test the machine for correct operation.

______________________________________________________________ A6474X442 REV 0 23

Gathering Head Cylinder __________________________________________ Fig. 5: Gathering head cylinder removal and installation

5

6

1 4 2

3 1.

2.

3.

4.

5.

6.

Gathering head cylinder Lower pin Socket head cap screw (2) Pin retainer Upper pin Cotter pin

________________________________________________________________ 24 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Gathering Head Assembly Introduction

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

Tool Set

Basic Tool Set Slide Hammer

Safety

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

!

Blocking Puller Bolts

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

______________________________________________________________ A6474X442 REV 0 25

Gathering Head Assembly _________________________________________ Removal Procedure

To remove the gathering head assembly (Fig. 6): 1. Position the machine so that the front of the crawlers are accessible, lower the gathering head until the pan rest on the mine floor, and raise the cutter head and block it securely.

2. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

3. Remove the motor access cover on the side of the gathering head frame and wash the motor compartment thoroughly for easier motor access and to prevent contamination of water system.

4. Disconnect and tag the gathering head motor power cables. Be sure to tape the power cables as power will be restored to the machine.

5. Disconnect, tag, and cap the gathering head motor cooling water hoses.

6. Repeat Steps 4 through 5 for the other motor.

7. Disconnect the conveyor chain. The chain does not have to be completely removed from the miner, however, 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.

8. Securely block the gathering head frame at the rear of the frame, as close to the pivot as possible, to prevent falling when the pivot pins are removed.

9. Open the pan float valve to relieve hydraulic pressure.

10. Support the rod end of the gathering head raise cylinders. Note: 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.

11. Remove the upper cylinder mounting pin keeper and remove the mounting pin.

12. Remove the hinge pin. 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.

Note: It may be helpful to only partially remove the first hinge pin, completely remove the second pin, and then go back and remove the first pin.

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.

13. Remove the cutter head blocking and slowly tram the miner away from the gathering head until the gathering head is clear and the conveyor chain is free.

14. Lower the cutting head to the floor and shutdown the machine.

15. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

________________________________________________________________ 26 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Gathering Head Assembly Installation Procedure

To install the gathering head assembly (Fig. 6): 1. Reconnect the trailing cable to energize the miner.

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.

IMPORTANT

2. 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.

3. 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.

4. Once the miner is aligned with the gathering head assembly, raise and block the cutter head.

5. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

6. Coat the pivot pins and their bushings with grease to aid in installation.

7. Be sure that the pivot bores in the gathering head and the main frame are aligned and install both the right and left hand pivot pins. Position each pivot pin so that it is flush with the main frame bushing. Take care not to damage the end of the pivot bushing during installation.

8. Verify that the pan float valve is closed.

9. Align the gathering hand frame clevises with the gathering head cylinder rod end clevises. Install the upper cylinder pins through the clevises and secure.

10. Grease all cylinder and pivot pins.

11. Install the conveyor chain.

12. Connect all water lines to both motors.

13. Connect the electrical leads to both motors.

14. Secure the motor access cover to the gathering head frame.

15. Check the oil levels in the gathering head pot cases and the gathering head input gear cases.

16. Restore power to the machine and test machine functions.

______________________________________________________________ A6474X442 REV 0 27

Gathering Head Assembly _________________________________________ Fig. 6: Gathering head assembly removal and installation

7

6

5

4

1

3 2 1.

2.

3.

4.

5.

6.

7.

Gathering head assembly Motor compartment (1 per side) Motor access cover (1 per side) Gathering head lift cylinder (1 per side) Cylinder mounting pin (1 per cylinder) Gathering head hinge pin (2) Hinge pin keeper

________________________________________________________________ 28 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________________ Control Arms Introduction

The following procedures are for the removal and installation of the gathering head left and right side control arms.

Tool Set

Basic Tool Set

Safety

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

!

Blocking

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

______________________________________________________________ A6474X442 REV 0 29

Control Arms ____________________________________________________ Removal Procedure - Right side Control Arm

To remove the right side gathering head control arm (Fig. 7): 1. Lower the gathering head assembly until it touches the floor.

2. Raise the cutter head assembly to its highest position and block.

3. Support the control arm and gathering head lift cylinder.

4. Disconnect grease line and fitting from gathering head side pin.

5. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

6. Remove two (2) M20 X 80 socket head capscews and remove the pin retainer.

7. Disconnect grease line and fitting from machine side pin.

8. Remove machine side pin and install M12 X1.75 bolt into end of pin to help in removal.

9. Remove anti-rotation pin from the gathering head side control arm pin.

10. Remove gathering head side pin.

11. Support control arm mount.

12. To remove the mount, remove the four (4) M24 X 140 socket head capscrews, flatwashers, lockwashers, lock nuts and two (2) frame backing plates.

Installation Procedure Right Side Control Arm

To install the right side gathering head control arm (Fig. 7): 1. Install the four (4) M24 X 140 socket head capscrews, flatwashers, lockwashers, locknuts and two (2) frame backing plates, and torque to 800 ft-lb (1084 N-m).

2. Install the gathering head side pin.

3. Install the anti-rotation pin from the gathering head side control arm or pin.

4. Install the machine side pin. Align marks on pin vertically for alignment with anti-rotation plate.

5. Install anti-rotation plate.

6. Install two (2) M20 X 80 socket head bolts and lockwashers, and torque to 370 lb-ft (500 N-m).

7. Connect the fitting and the grease line to both pins.

________________________________________________________________ 30 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________________ Control Arms Removal Procedure - Left side Control Arm

To remove the left side gathering head control arm (Fig. 8): 1. Lower the gathering head assembly until it touches the floor.

2. Raise the cutter head assembly to its highest position and block.

3. Support the control arm.

4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

5. Remove four (4) M20 X 80 socket head capscews and two (2) pin hold down caps.

5. Disconnect grease line and fitting from gathering head side pin.

6. Support gathering head lift cylinder 7. Remove two (2) M10 X 25 socket head capscrews and pin retainer plate.

8. Remove anti-rotation pin.

9. Remove gathering head side pin.

10. Remove arm.

Installation Procedure - Left Side Control Arm

To install the left side gathering head control arm (Fig. 8): 1. Install the gathering head side pin.

2. Install the anti-rotation pin.

3. Install the pin retainer plate, and two (2) M10 X 25 socket head capscrews.

Torque to 40.5 ft-lb (55 N-m).

4. Support the gathering head lift cylinder.

5. Connect the grease line and fitting from to the gathering head side pin.

6. Install four (4) M20 X 80 socket head capscrews and two (2) pin hold down caps.

______________________________________________________________ A6474X442 REV 0 31

Control Arms ____________________________________________________ Fig. 7: Gathering head right side control arm removal and installation

3

4

5

1 2

1.

2.

3.

4.

5.

M20 X 80 socket head capscrews (4) M20 lockwasher Pin retainer Control arm pin M12 X 1.75 socket head bolt (2)

________________________________________________________________ 32 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________________ Control Arms Fig. 8: Gathering head left side control arm removal and installation

1 6 7 3

4 5

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2.

3.

4.

5.

6.

7.

M20 X 80 socket head capscrews (4) Gathering head side pin Anti-rotation pin Control arm Pin retainer Pin retainer plate M10 X 24 socket head capscrews

______________________________________________________________ A6474X442 REV 0 33

Gathering Head Gear Case _________________________________________ Introduction

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

Tool Set

Basic Tool Set Torque Wrench

Safety

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

!

Blocking

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

________________________________________________________________ 34 CM445 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Removal Procedure

To remove a gathering head gear case and pot (Fig. 9): 1. Disconnect the conveyor chain (See Conveyor chain removal procedure in this chapter).

2. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

3. Remove the gathering head motor (see Gathering head motor removal procedure).

4. Securely block the input gear case in position to prevent the gear case from falling when the capscrews that secure it are removed.

5. Disconnect oil fill lines connected to the pot.

6. Attach a lifting device to the top surface of the pot and input gear case.

7. Remove the CLA (see CLA removal procedure).

8. Remove the top cover from over the gear case assembly by removing the twelve (12) 5/8-11X2-1/4 and four (4) 5/8-11X1-1/4 socket head cap screws that secure it to the frame.

9. Remove the cover from over the two wedge blocks by remove the four socket head cap screws that secure the cover.

10. Loosen the pot case attachment from the frame by removing the 7/8-9X21/2 socket head cap screws that secure the corners of the pot. Removing these screws will also remove the four wedge blocks which secure the pot in position.

11. Detach the foot shaft connector from output shaft on pot. a. Remove the foot shaft cover by removing the two cap screws that secure it to the gathering head frame. b. Remove the foot shaft locking collar and slide the splined coupling off the pot output shaft.

12. Lift the pot and input case from the gathering head frame.

______________________________________________________________ A6474X442 REV 0 35

Gathering Head Gear Case _________________________________________ Installation Procedure

To install a gathering head gear case and pot (Fig. 9): 1. Align the input gear case with the pot case (if separated) and secure with capscrews.

2. Ensure that mating surfaces on the gear case and gathering head frame are clean and free of all debris.

3. Attach a lifting device to the gear case assembly and position the gear case assembly in the gathering head frame.

4. Position the four wedge blocks which secure the pot in position.

5. Apply Loctite 242 to the 7/8-9X2-1/2 socket head cap screws that secure the wedge blocks and pot and torque to 420 ft-lbs.

6. Connect the oil fill lines to the pot.

7. Install the gathering head motor (see Gathering head motor installation procedure).

8. Reconnect foot shaft to output shaft on pot.

9. Replace the foot shaft cover and secure with the two (2) 3/4-10X2-1/2 socket head capscrews and torque to 261 ft-lb.

10. Replace the top cover and secure with ten (10) 5/8-11X2-1/4 and four (4) 5/8-11X1-1/4 socket head cap screws and torque to 172 ft-lbs.

11. Replace the cover over the two wedge blocks and secure with four socket head cap screws.

12. Install CLA (see CLA installation procedure).

________________________________________________________________ 36 CM445 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Fig. 9: Gathering head gear case removal and installation 3

2

1

4 5

8

6 7

1.

2.

3.

4.

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6.

7.

8.

Top cover Socket head cap screw, 5/8-11x2-1/4 (10) Socket head cap screw, 5/8-11X1-1/4 (4) Wedge block (4) Socket head cap screw, 7/8-9X2-1/2 Foot shaft cover Gear case Cover over two wedge blocks

______________________________________________________________ A6474X442 REV 0 37

Centrifugal Loading Arm __________________________________________ Introduction

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

Tool Set

Basic Tool Set Torque Wrench

Safety

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

!

Blocking

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

________________________________________________________________ 38 CM445 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm Removal Procedure

To remove a centrifugal loading arm (CLA) (Fig. 10): 1. Lower the gathering head assembly until it touches the floor.

2. Raise the cutter head assembly to its highest position and block.

3. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

4. Remove the eight (8) 1-8X2-1/2 socket head capscrews from the CLA retainer plate and remove the retainer plate. There are two puller holes in the retainer plate to assist with it’s removal.

5. Remove the three (3) 3/4X4 hex head capscrews that secure the CLA to the hub. There are three puller holes, protected by 3/4-10X3/4 cup-point set screws, in the arm to assist with it’s removal.

6. Remove the three dowel pins, which position the CLA to the pot disc, and store in a safe place for use in installation.

7. The CLA is now free and can be removed.

Installation Procedure

To install a continuous loading arm (CLA) (Fig. 10): 1. Install the three dowel pins into the pot disc.

2. Position the CLA on the gathering head ensuring that CLAs are aligned as shown in the top view of Fig. 11.

3. Apply Loctite 262 to the three (3) 3/4X hex head capscrews that secure the arms to the hub and insert and tighten to 350 ft-lbs.

4. Insert the retainer cap into the center of the arm.

5. Apply Loctite 262 to the eight (8) 1-8X2-1/2 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 6. Reconnect the trailing cable and function test the machine to ensure the CLAs turn correctly.

______________________________________________________________ A6474X442 REV 0 39

Centrifugal Loading Arm __________________________________________ Fig. 10: CLA removal and installation

Required CLA mounting arrangement 2

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CLA CLA puller hole Retainer cap Cap screw, 1-8X2-1/2 (8) Retainer cap puller hole Cap screw, 3/4X4 (3)

________________________________________________________________ 40 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________ Conveyor Chain Adjustment Adjustment Procedure

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. 11).

Fig. 11: Conveyor chain tension measurement

Chain measurement area

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.

______________________________________________________________ A6474X442 REV 0 41

Conveyor Chain __________________________________________________ Introduction

The following procedure is for the removal and installation of the conveyor chain.

Tool Set

Basic Tool Set Pry Bar

Safety

When removing or installing the conveyor chain, observe the following safety precautions:

!

Blocking Puller Cable

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

________________________________________________________________ 42 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Removal Procedure

To remove the conveyor chain (Fig. 12): 1. 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.

2. Raise the cutter head and block it following all Mine and Federal regulations 3. Position the discharge conveyor in line with the intermediate conveyor and lower it to it’s lowest point.

4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

5. 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.

6. Using a pry bar, lift the chain off the conveyor deck several times to relieve tension in the chain.

7. Position new chain fully assembled behind miner (new chain should be upside down on mine floor) fully stretched out.

8. Break old chain at tail shaft.

9. Connect new chain to the bottom half of the old chain.

10. Hook puller cable to top half of old chain.

11. Using pull vehicle, pull old chain off the top as new chain pulls in on return deck.

12. Re-connect new chain approximately two feet in from tail shaft.

______________________________________________________________ A6474X442 REV 0 43

Conveyor Chain __________________________________________________ Installation Procedure

To install the conveyor chain (Fig. 12): 1. Ensure that the cutting head is adequately blocked.

2. Lay the new chain, uncoiled and upside down, behind the conveyor with the nearest end near the tail roller.

IMPORTANT

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.

3. Connect the pulling cable (attached to the old chain still in the machine) to the nearest end of the new conveyor chain.

4. Pull the conveyor chain under the tail roller and through the return deck, stopping when the chain reaches the foot shaft.

5. Pull the conveyor chain up over the foot shaft sprocket and lay it in the gathering pan.

6. 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.

7. 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.

8. Connect the chain using a connecting pin and two retaining pins. bend the retaining pins opposite the direction of conveyor chain travel.

9. 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.

10. Connect the trailing cable to energize the miner.

11. Start the pump motor.

12. Swing the discharge conveyor full right and left to ensure that the chain is clear.

13. Start 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.

________________________________________________________________ 44 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Fig. 12: Conveyor chain removal and installation

Connecting pin

Retaining pin

______________________________________________________________ A6474X442 REV 0 45

Tail Drive _______________________________________________________ Introduction

The following procedure is for the removal and installation of the tail drive.

Tool Set

Basic Tool Set Blocking

Safety

When removing or installing the tail drive, observe the following safety precautions:

!

Pry Bar Lifting Device

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

________________________________________________________________ 46 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________________________ Tail Drive Removal Procedure

To remove the tail drive (Fig. 13): 1. Position the machine so that the tail drive carriage 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 securely block.

4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

5. Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure).

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 feed chain from the drive sprocket.

10. Remove universal shaft from mating splines on both motors and gear case.

Remove yoke retainers.

11. Remove the ten (10) M20 X 50 hex head bots that secure the tail drive carriage to the frame.

12. Remove rear plates and M20 X 75 socket head capscrews.

13. The tail roller should now be free of the conveyor.

Installation Procedure

To install the tail drive (Fig. 13): 1. Install ten (10) M20 X 50 hex head bolts that secure the tail drive carriage to the frame, and torque to 314 ft-lbs (425 N-m).

2. Install the rear plates to the tail drive carriage with twelve (12) M20 X 75 socket head capscrews, and torque to 314 ft-lb (425 N-m). Install universal shafts.

3. Make sure the valve is closed in the conveyor chain take-up circuit.

4. Reconnect the conveyor chain (see Conveyor chain installation procedure).

5. Connect the trailing cable to energize the miner.

6. Operate the conveyor and check for correct chain tension.

______________________________________________________________ A6474X442 REV 0 47

Tail Drive _______________________________________________________ Fig. 13: Tail drive removal and installation

5 4 1

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4.

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M20 X 75 socket head capscrews (12) M20 lockwashers (12) Rear plates Tail drive carriage M20 X 50 hex head bolts (10)

________________________________________________________________ 48 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Discharge Conveyor Introduction

Tool Set

Safety

!

The following procedure is for the removal and installation of the discharge conveyor.

Basic Tool Set Blocking

Lifting Device Grease Gun with Spec. 100-3 Grease

When removing or installing the discharge conveyor, observe the following safety precautions:

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

!

WARNING 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.

______________________________________________________________ A6474X442 REV 0 49

Discharge Conveyor ______________________________________________ Removal Procedure

To remove the conveyor discharge (Fig. 14): 1. 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.

2. Align the discharge conveyor straight with the centerline of the intermediate conveyor.

3. 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.

4. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

5. Relieve the pressure in the conveyor chain take-up circuit (see Conveyor chain removal procedure).

6. Attach lifting devices to the discharge conveyor and take up slack in the lifting device without raising the conveyor.

7. Disconnect the conveyor chain at a connecting pin close to the end of the discharge conveyor (see Conveyor chain removal procedure).

8. Disconnect, tag, and cap the hydraulic lines from the conveyor swing cylinders and cap the ports in the cylinders.

9. Remove the swing cylinder pin at the intermediate conveyor section.

10. Remove the three M12X35-4.6 carriage bolts and M12 lock nuts that attach the flexible sideboards to each side of the intermediate conveyor.

11. Slide each sideboard from its guide on the discharge conveyor. If the sideboards are not free to slide, remove the four M16X55-8.8 hex head cap screws and M16 lock washers from each flexible guide and remove the guides.

12. Remove the six M20X60-10.9 cap screws from the top pivot pin and remove the pin. Two puller holes, protected by M20X25-12.9 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. Note: There is a 1/2X1-1/2 anti-rotation dowel located on the top and bottom pivot pins.

Keep these dowels for use in reassembly.

13. 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.

14. Slowly and carefully maneuver the discharge conveyor away from the intermediate conveyor section.

________________________________________________________________ 50 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Discharge Conveyor Installation Procedure

To install the discharge conveyor (Fig. 14): 1. Ensure that the trailing cable is still disconnected and properly locked/ tagged out.

2. Ensure that the intermediate conveyor is still securely blocked.

3. Attach a lifting device to the discharge conveyor and slowly lift and maneuver it into the intermediate conveyor section.

4. 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.

5. Install the pivot retainer and top pivot pin and secure the with six M20X6010.9 cap screws. Torque to 430 ft-lb. Note: the pivot pin 1/2X1-1/2 antirotation dowel must be positioned in the slot in the top conveyor deck.

6. Repeat Step 5 for the bottom pivot pin and retainer.

7. 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.

8. Using the lifting device, swing the discharge conveyor fully to the left and right to make sure that it does not bind.

9. 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.

10. 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.

11. Connect the hydraulic lines to the cylinders.

12. With the discharge conveyor straight, reconnect the conveyor chain (see Conveyor chain installation procedure in this chapter).

13. If removed, install the flexible sideboard guides and secure each guide with four M16X55-8.8 hex head bolts and M16 lock washers.

14. Install a flexible sideboard on each side of the conveyor and secure with three M12X35-4.6 carriage bolts and M12 heavy elastic lock nuts.

15. Connect the trailing cable to energize the miner.

16. Raise the conveyor and remove the blocking.

17. Operate the conveyor raise, lower, swing left, and swing right functions and check for smooth operation.

______________________________________________________________ A6474X442 REV 0 51

Discharge Conveyor ______________________________________________ Fig. 14: Discharge conveyor removal and installation 2 3

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1. Discharge conveyor 2. Flexible sideboard (2) 3. Lock nut, M12 (6 - 3 each sideboard) 4. Carriage bolt, M12X35-4.6 (6 - 3 each sideboard) 5. Set screw, M20X25-12.9 (4 - 2 each pivot pin) 6. Cap screw, M20X60-10.9 (12 - 6 each pivot pin) 7. Pivot pin, top 8. Swing cylinder retaining pin 9. Intermediate conveyor 10. Anti-rotation dowel pin, 1/2X1-1/2 (2 - 1 each pivot pin) 11. Pivot pin, bottom 12. Pivot pin retainer, bottom 13. Pivot pin retainer, top 14. Guide, flexible sideboard 15. Hex head cap screw, M16X55-8.8 (8 - 4 each guide) 16. Lock washer, M16 (8 - 4 each guide)

________________________________________________________________ 52 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Conveyor Assembly Introduction

Tool Set

Safety

!

The following procedure is for the removal and installation of the conveyor assembly.

Basic Tool Set Blocking

Lifting Device Grease Gun with Spec. 100-3 Grease

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

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

!

WARNING 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.

______________________________________________________________ A6474X442 REV 0 53

Conveyor Assembly ______________________________________________ Removal Procedure

To remove the conveyor assembly (Fig. 15): 1. Raise the conveyor to an elevated position so at to provide access to the upper conveyor raise cylinder pins and block.

2. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

3. Attach lifting devices to both the intermediate and discharge conveyor sections. Take up slack in the lifting device without raising the conveyor.

4. Disconnect the conveyor chain (see Conveyor chain removal procedure) and remove it from the machine.

5. Block each conveyor raise cylinder so that they will not move when they are unpinned from the conveyor.

6. Remove the cotter pins from each conveyor cylinder upper mounting pin and remove the mounting pins.

7. Appropriately secure the conveyor assembly laterally to prevent it from swinging when the hydraulic lines to the swing cylinders are removed.

8. Relieve pressure from the swing cylinder hydraulic lines.

9. Disconnect, tag, and cap the hydraulic lines going to the swing cylinder.

10. Cap the ports on the swing cylinder to prevent contamination.

11. Disconnect, tag, and cap the lubrication lines going to the right and left pivot pins.

12. Release any pressure that might exist between the lateral sway guides and the guide discs by backing out the set screw on each side.

13. Remove the six M20X50-10.9 hex head cap screws from the conveyor pivot pin retainer and remove the retainer.

Note: It may be helpful to only partially drive out the first pin, remove the second pin, and then go back and remove the first pin.

14. Push the conveyor pivot pins toward the center until they are free. Note: 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.

15. With the lifting device, slowly maneuver the conveyor assembly away from the machine.

________________________________________________________________ 54 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Conveyor Assembly Installation Procedure

To install the conveyor assembly (Fig. 15): 1. Verify that the trailing cable is disconnected and locked/tagged out.

2. Attach a lifting device to the conveyor assembly and slowly maneuver it onto the machine.

3. With the conveyor pivot in position, grease the conveyor pivot pins to ease installation and then drive the pins into the pivot bores.

4. Install the pivot pin retainer and secure with six M20X50-10.9 hex head cap screws and torque to 196 ft-lb dry.

5. Reconnect the grease lines to each pivot pin.

6. Using the lifting device, pivot the conveyor into an elevated position and securely block the conveyor.

7. Connect the hydraulic lines to the swing cylinders.

8. Attach the conveyor raise cylinders to the clevises on the underside of the conveyor by installing the conveyor raise cylinder pins and secure with cotter pins.

9. Reconnect the grease lines to the cylinder pings.

10. Reconnect the conveyor chain (see Conveyor chain installation procedure).

11. Apply nominal pressure of the guide discs to the lateral sway guides.

!

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.

12. Connect the trailing cable to energize the miner.

13. Start the pump motor.

14. Start the gathering head motors to run the conveyor chain.

15. 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.

______________________________________________________________ A6474X442 REV 0 55

Conveyor Assembly ______________________________________________ Fig. 15: Conveyor assembly removal and installation

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Cotter pin location (2) Conveyor lift cylinder upper mounting pin (2) Upper mounting pin grease fitting (2) Conveyor lift cylinder (2)

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Conveyor assembly Pin retainer Hex head cap screw, M20X50-10.9 (6) Conveyor pivot pin (2)

________________________________________________________________ 56 CM445 Mechanical - Gathering Head and Conveyor

_____________________________________________ Tail Shim Adjustment Introduction

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.

Tool Set

Basic Tool Set Blocking

Safety

When shimming the conveyor, observe the following safety precautions:

!

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

______________________________________________________________ A6474X442 REV 0 57

Tail Shim Adjustment _____________________________________________ Adjustment Procedure

Reference Fig. 16: 1. Lower the cutter head and gathering head assemblies until they touch the floor.

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

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

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

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

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

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

7. Connect the trailing cable to energize the miner.

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 applicable lockout/tagout regulations.

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

11. Tighten the socket head capscrews.

12. Connect the trailing cable to energize the miner.

13. Raise the conveyor tail from the blocking.

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

15. Check the gap and alignment at the juncture of the conveyor front and tail sections for alignment (Fig. 17). If the sections are not horizontally aligned, then add or subtract shims as required.

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

17. Securely retighten the socket head capscrews.

________________________________________________________________ 58 CM445 Mechanical - Gathering Head and Conveyor

_____________________________________________ Tail Shim Adjustment Fig. 16: Tail shim adjustment Socket head capscrew

Shim retainer

Lower pivot plate

Shims

Fig. 17: Front and tail section alignment

Correct gap and alignment

Gap and alignment area of detail

Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

______________________________________________________________ A6474X442 REV 0 59

Conveyor Lift Cylinder ____________________________________________ Introduction

Tool Set

Safety

!

The following procedure is for the removal and installation of a conveyor lift cylinder.

Basic Tool Set Blocking

Lifting Device Grease Gun with Spec. 100-3 Grease

When removing or installing a conveyor lift cylinder, observe the following safety precautions:

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

!

WARNING 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.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

________________________________________________________________ 60 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________ Conveyor Lift Cylinder Removal Procedure

To remove a conveyor lift cylinder (Fig. 19): 1. Raise the conveyor as high as possible and block securely.

2. Disconnect the trailing cable to de-energize the miner. Follow all applicable lockout/tagout regulations.

3. Insert the conveyor safety support (Fig. 18).

4. Relieve the hydraulic pressure to the conveyor lift cylinders.

5. Attach a lifting device to the cylinder and take up slack in the lifting device so that the weight of the cylinder is supported by the lifting device.

6. Disconnect and cap the grease line to the rod end mounting pin.

7. Remove the cotter pin from the rod end cylinder mounting pin.

8. Remove the rod end mounting pin taking care not to damage the grease fitting.

9. Connect the trailing cable to energize the miner.

10. Start the pump motor.

11. Slowly retract the conveyor lift cylinder to pull the rod eye out of the mounting clevis.

12. Disconnect the trailing cable to de-energize the miner. Follow all applicable lockout/tagout regulations 13. Disconnect, tag, and cap the hydraulic lines to the cylinder. Plug the ports on the cylinder to prevent contamination.

14. Lower the cylinder onto blocking. Leave the lifting device attached and ensure that the cylinder will not move.

15. Remove the three (3) M24X50 socket head bolts that secure the cylinder pin cap and remove the cap.

16. Lift the cylinder from the machine.

______________________________________________________________ A6474X442 REV 0 61

Conveyor Lift Cylinder ____________________________________________ Installation Procedure

To install a conveyor lift cylinder (Fig. 19): 1. Verify that the trailing cable is disconnected and locked/tagged out.

2. Verify that the conveyor is securely blocked.

3. Verify that bushing are installed in the cylinder mounting clevises.

4. Verify that the cylinder end pin is installed in the cylinder mounting clevis.

5. Attach a lifting device to the cylinder and position the cylinder in the machine.

6. Replace the cylinder pin cap and secure with three (3) M24X50 socket head cap screws. Torque the cap screws to 734 ft-lb (995 N-m) dry.

7. Using the lifting device, raise the cylinder into position so that the rod end clevis is aligned for mounting.

8. Securely block the cylinder so that it will not move.

9. Attach the hydraulic lines to the cylinder.

10. Connect the trailing cable to energize the miner.

11. Start the pump motor.

12. Slowly extend the cylinder until the rod end clevis is aligned in the conveyor mounting clevis.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

13. Insert the cylinder mounting pin through the clevis and secure with a 3/8X31/2 cotter pin.

14. Connect the grease line to the rod mounting pin.

15. Grease the rod mounting pin with Spec. 100-3.

16. Check the hydraulic fluid level and fill as necessary.

17. Connect the trailing cable to energize the machine.

18. Start the pump motor.

19. Remove the conveyor safety support and all blocking.

20. Raise and lower the conveyor several times to purge are from the system and to check for correct operation.

________________________________________________________________ 62 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________ Conveyor Lift Cylinder Fig. 18: Conveyor safety support, installed

Conveyor safety support

______________________________________________________________ A6474X442 REV 0 63

Conveyor Lift Cylinder ____________________________________________ Fig. 19: Conveyor lift cylinder removal and installation

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Cotter pin, 3/8X3-1/2 Upper mounting pin Socket head cap screw, M24X50-10.9 (3) Cylinder pin cap Cylinder pin

________________________________________________________________ 64 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Conveyor Swing Cylinder Introduction

Tool Set

Safety

!

The following procedure is for the removal and installation of a conveyor swing cylinder.

Basic Tool Set Blocking

Lifting Device Grease Gun with Spec. 100-3 Grease

When removing or installing the conveyor swing cylinder, observe the following safety precautions:

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support the machine or component or lower the component to ground level.

!

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

!

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

!

WARNING 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.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

______________________________________________________________ A6474X442 REV 0 65

Conveyor Swing Cylinder __________________________________________ Removal Procedure

To remove the conveyor swing cylinder (Fig. 20): 1. Lower the conveyor as far as possible and block appropriately.

2. Swing the conveyor tail section as far as possible to one side to fully extend the cylinder.

3. Disconnect the trailing cable to de-energize the miner. Follow all applicable lockout/tagout regulations.

4. Remove the cotter pin from the rod end mounting pin.

5. Remove the rod end cylinder mounting pin.

6. Restore power to the miner.

7. Retract the cylinder.

8. Disconnect the trailing cable to de-energize the miner. Follow all applicable lockout/tagout regulations.

9. Manually actuate the conveyor swing cylinder to relieve any pressure in the hydraulic lines.

10. Disconnect and cap the cylinder hydraulic hoses and plug the ports on the cylinder to prevent contamination.

11. Attach a lifting device to the cylinder and take up any slack so that the weight of the cylinder is supported by the lifting device.

12. Remove the cotter pin from the cylinder end mounting pin.

13. Remove the cylinder end mounting pin.

14. Pull the cylinder away from the conveyor, taking care to not hit the cylinder ports on the guards as the cylinder is removed.

________________________________________________________________ 66 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Conveyor Swing Cylinder Installation Procedure

To install the conveyor swing cylinder (Fig. 20): 1. Verify that the trailing cable is disconnected and that the machine is locked/ tagged out.

2. Verify that the conveyor is securely blocked.

3. Attach a lifting device to the cylinder. Note: At this point, the cylinder should be fully collapsed.

4. Insert the cylinder into position within the cylinder guard.

5. Align the cylinder rod end clevis in the mounting clevis.

!

WARNING Never use fingers to check the alignment of pin bores. If the components shift, pinched, broken, or amputated fingers may result.

6. Insert the mounting pin and secure with a 1/4X2 cotter pin.

7. Connect the hydraulic hoses to the cylinder.

8. Connect the trailing cable to energize the machine.

9. Start the pump motor.

10. Manually extend the cylinder to align the cylinder end clevis in the mounting clevis.

11. Disconnect the trailing cable to de-energize the miner. Follow all applicable lockout/tagout regulations.

12. Install the cylinder end mounting pin and secure with a 1/4X2 cotter pin.

13. Grease both cylinder pins.

14. Check the hydraulic oil tank level and fill as necessary.

15. Remove all blocking.

16. Connect the trailing cable to energize the machine.

17. Start the pump motor.

18. Test the cylinder for correct operation. Note: Make sure the conveyor swings in the correct direction. If it does not, the hydraulic hoses are connected backwards to the cylinder.

______________________________________________________________ A6474X442 REV 0 67

Conveyor Swing Cylinder __________________________________________ Fig. 20: Conveyor swing cylinder removal and installation

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Mounting pin Cotter pin Swing cylinder Cotter pin Mounting pin

________________________________________________________________ 68 CM445 Mechanical - Gathering Head and Conveyor