DOWNLOAD PDF : Cat CM445 Continuous Miner Operation and Maintenance Manual A6474X443

BI001576 A6474X443 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X443 (Mechanical - Traction)

SAFETY.CAT.COM

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

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

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

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

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

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

© CATERPILLAR 2012 ALL RIGHTS RESERVED

_________________________________________________Table of contents Table of contents

Safety Instructions ............................................................................. 4 Tram track adjustment....................................................................... 6 Tram motor ........................................................................................ 11 Tram drive gear case ........................................................................ 15 Crawler chain .................................................................................... 19 Crawler take-up roller ........................................................................ 23 Stabilizer cylinder .............................................................................. 27

________________________________________________________________ A6474X443

REV 0

Safety instructions _______________________________________________ Safety Precautions

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

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

!

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

!

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

!

WARNING 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.

IMPORTANT Machine power must be disconnected during installation of the current generator. Cut-

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

!

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

!

WARNING Stay clear of the blocked miner while the machine is energized. Failure to follow this warning may result in sever injury or death.

!

WARNING Observe the working load limits of chains. Overstressing the chains could cause the chain to break, resulting in serious injuries.

IMPORTANT If the miner and the gear case assembly are not both level and aligned correctly, install-

ing 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.

________________________________________________________________ 4 CM445 Mechanical - Traction

_______________________________________________ Safety instructions IMPORTANT Be sure that the grousers are in the correct direction before installing the chain into the

machine. Check the parts book for your machine to verify the correct direction.

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!

______________________________________________________________ A6474X443 REV 0 5

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.

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

Fig. 1: Tram track adjustment Bottom of tractor wear shoe

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

________________________________________________________________ 6 CM445 Mechanical - Traction

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

11. If the tram track tension is too tight, readjust the idler position using the following steps: a.

Pump grease into the take-up jack to extend the cylinder and remove pusher plate pressure on the idler shims.

b.

Remove one or more idler adjustment shims from the idler slide channel.

c.

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

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

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

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

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

!

WARNING 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.

______________________________________________________________ A6474X443 REV 0 7

Adjustment procedures ___________________________________________ Fig. 2: Tram track adjustment

Take-up cylinder

Idler assembly

Crawler chain take-up lubrication

Pressure relief valve

Shims

Crawler chain take-up lubrication

Pressure relief valve

________________________________________________________________ 8 CM445 Mechanical - Traction

___________________________________________ Adjustment procedures 13. If the tram track tension is still too loose when the entire 5 inch shim set is inserted into the idler slide channel, re-adjust the idler position after removing a tram track link using the following steps (reference Fig. 3): a. Pump grease into the take-up jack to extend the cylinder and remove the pusher plate pressure on the idler shims. b. Remove all of the idler adjustment shims from the idler slide channel. c.

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

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

Remove two (2) 3/8-16X1-1/4 flat socket head capscrews and two (2) 3/8-16 conelok nuts.

g. Using the hammer and punch, remove the tram track pins to disconnect the link from the track. Remove the disconnected link. h. Store the tram track link, one of the tram track pins and the bolts and nuts in a save place for reassembly. i.

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.

j.

Reinstall the two 3/8-16X1-1/4 flat socket head cap screws and two (2) 3/8-16 conelok nuts.

k.

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.

l.

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

m. 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. n. The idler adjustment shims will keep the idler stationary and the track tensioned. o.

Evaluate the resulting track tension and repeat until the track reaches proper tension.

______________________________________________________________ A6474X443 REV 0 9

Adjustment procedures ___________________________________________ Fig. 3: Tram track adjustment

Pin, bolt, and nut

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

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

18. Connect the trailing cable to energize the miner.

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

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

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

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

________________________________________________________________ 10 CM445 Mechanical - Traction

_____________________________________________________ Tram Motor Introduction

Tool Set Safety

!

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

Basic Tool Set Blocking When removing or installing a tram motor, observe the following safety precautions:

WARNING 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.

______________________________________________________________ A6474X443 REV 0 11

Tram Motor ______________________________________________________ Tram motor removal

To remove a tram motor (Fig. 4): 1. Position the miner so that there is adequate work space on the side from which the motor is being removed.

2. 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.

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

4. 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.

5. 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.

6. Remove the capscrews that secure the end cap on the motor.

7. Remove the snap ring inside the motor shaft.

8. Remove the shaft plug and o-ring, exposing the quill shaft.

9. Carefully remove the quill shaft and store in a safe place.

10. Remove the four (4) 1-8X6 socket head capscrews, four (4) 1 inch hardened steel washers, and one (1) spacer that secure the motor to the tram case.

11. Replace the end cap on the motor and secure with the four capscrews.

12. Disconnect, tag, and cap the cooling water hoses from the cooling water fittings located on the right and left top corners of the motor.

13. Disconnect the power cable lugs from the motor.

14. Carefully remove the motor from the tram case, be careful not to damage the motor during removal.

!

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.

________________________________________________________________ 12 CM445 Mechanical - Traction

_____________________________________________________ Tram Motor Tram motor installation

To install the tram motor (Fig. 4): 1. Clean the motor and the motor cavity in the tram case thoroughly.

2. Install a new o-ring (lubricated) on the motor mounting flange (rear bell).

3. Oil the bore of the input planetary (in the motor cavity) to ease installation.

4. Carefully position the motor in the tram case, being careful not to damage the motor or the o-ring on the rear bell.

5. 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.

6. 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.

7. Install the shaft plug and o-ring and the snap ring on the end of the shaft.

8. Install the motor end cap and secure with capscrews. Tighten to the correct torque.

9. Install the spacer, four (4) 1 inch hardened steel washers, and four (4) 18X6 socket head capscrews to secure the motor to the tram case. Tighten to the 1,010 ft-lbs.

10. 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.

11. Reconnect the power cable to the motor.

12. Reconnect the cooling water lines to the motor.

13. Reconnect power to the miner and check for tram correct operation.

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

15. Replace the tram rub rail and secure with the two (2) pins.

16. Place the top cover onto the posts on the tram rub rail and secure with two (2) capscrews.

______________________________________________________________ A6474X443 REV 0 13

Tram Motor ______________________________________________________ Fig. 4: Tram motor removal and installation

8

1

7

2

3

6

4 7 9 6 1.

2.

3.

4.

5.

6.

7.

8.

9.

Top cover bolt (2) Top cover Rub rail pin (2) Rub rail Motor end cap Socket head cap screw, 1-8X6 (4) Washer, 1 inch hardened steel (4) Spacer Motor

5

________________________________________________________________ 14 CM445 Mechanical - Traction

_____________________________________________ Tram Drive Gear Case Introduction

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

Tool Set

Basic Tool Set Blocking

Safety When removing or installing a tram drive gear case, 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.

______________________________________________________________ A6474X443 REV 0 15

Tram Drive Gear Case _____________________________________________ Tram drive gear case removal

To remove a tram drive gear case (Fig. 5): 1. Position the miner so that there is adequate work space on the side from which the motor is being removed.

2. Block the miner so that the tram track is clear of the floor and free to turn.

Make sure the miner is level.

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

4. Remove the two (2) bolts and washers that secure the top cover to the tram rub rail and slide the top cover off of the tram rub rail.

5. 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.

6. Remove the two (2) pins that secure the electrical case rub rail and remove the rub rail.

7. 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.

8. Disconnect, tag, and cap all water and lubrication lines from the gear case.

9. The main gear case and final planetary gear case may be drained, if desired, but it is not necessary.

10. Disconnect and tag the power cable lugs from the motor.

11. Remove the fill tube and breather.

12. Remove the four (4) socket head cap screws and washers that secure the electrical case rub rail bracket to the frame and remove the bracket.

13. Remove the four (4) socket head cap screws and washers that secure the four (4) wedge blocks and remove the wedge blocks.

14. Remove the nine (9) socket head cap screws and washers from the mounting plate (four (4) on the rear/sprocket side and five (5) on the forward/ motor side).

15. Insert a screw into the four jacking holes and, using these holes, slowly jack the main case free of the frame.

16. 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.

17. Slowly maneuver the gear case and motor assembly clear of the machine and onto the loading device.

18. Cover the tram case compartment in the crawler assembly to keep out dirt

and debris. ________________________________________________________________ 16 CM445 Mechanical - Traction

_____________________________________________ Tram Drive Gear Case Tram drive gear case installation

To install the tram gear case (Fig. 5); 1. 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 paste to aid reinstallation.

2. Ensure that the mounting faces on both the tram drive gear case and the crawler frame are clean.

3. 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.

4. 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.

5. 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.

6. Install the nine (9) socket head cap screws and washers and torque to 1,000 lb-ft (1,355 nm).

7. Install the wedge blocks and secure with cap screws and washers. Torque to 400 lb-ft (542 nm).

8. Install the fill tube and breather in the gear case.

9. Reconnect all water and lubrication lines to the gear case.

10. Reconnect the electrical leads to the motor.

11. Check the oil level in the gear case and add high demulsibility, extreme pressure gear oil as required.

12. Reconnect the crawler chain (see Crawler chain installation procedure in this chapter).

13. Connect the trailing cable to energize the miner.

14. Operate the tramming function on the side where the tram gear case assembly was installed. Check for correct operation.

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

16. Replace the electrical case rub rail, securing it with two (2) pins.

17. Replace the tram rub rail, securing it with the two (2) pins.

18. Position the top cover over the posts on the tram rub rail and secure with two (2) bolts and washers.

______________________________________________________________ A6474X443 REV 0 17

Tram Drive Gear Case _____________________________________________ Fig. 5: Tram case removal and installation 1 2

3 5 6

10 4 9

7 8 12

13

11 16 14

15

1. Rub rail pin, electrical case 2. Rub rail, electrical case 3. Rub rail pin, tram case 4. Rub rail, tram case 5. Top cover 6. Bolt (2) 7. Washer (2) 8. Socket head cap screw (4) 9. Washer (4) 10. Mounting bracket 11. Socket head cap screw (4) 12. Washer (4) 13. Wedge block (4) 14. Socket head cap screw (9) 15. Washer (9) 16. Tram case

________________________________________________________________ 18 CM445 Mechanical - Traction

___________________________________________________ Crawler Chain Introduction

Tool Set Safety

!

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

Basic Tool Set Blocking When removing or installing the crawler chain, 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 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.

______________________________________________________________ A6474X443 REV 0 19

Crawler Chain ___________________________________________________ Crawler chain removal

To remove the crawler chain (Fig. 6): 1. Position the miner so that there is sufficient clearance to work and enough space to pull the chain off.

2. Block the machine so that the crawler assembly is off of the mine floor. Do not place blocking under the crawler track.

3. Raise the gathering head assembly to its highest position and securely block it.

4. Lower the cutter head assembly so that it rests on the gathering head.

5. Lower the conveyor.

6. Disconnect and lock out the electrical power to the miner. Follow all applicable mine, State, and Federal regulations regarding lockout/tagout procedures.

7. 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.

8. 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.

9. Bleed off pressure in the grease take-up cylinder b opening the needle valve in the grease line. Be sure that the cylinder collapses to relieve tension in the crawler chain.

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

10. 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.

11. Lay out new chain behind machine with grousers on floor and chain fully assembled.

12. Back miner to new crawler chain as close as possible.

13. Block as instructed and relieve tensions at crawler take-up.

14. Break chain at bottom of drive sprocket.

15. Unblock the loose length of chain and lower it to the mine floor.

16. Attach new crawler to bottom portion of old crawler.

17. Attach top of old crawler to a pull vehicle.

18. Tram crawler in reverse as pull vehicle holds just enough tension to “tram” on new crawler chain.

19. Disconnect from old chain and pin new chain together.

________________________________________________________________ 20 CM445 Mechanical - Traction

___________________________________________________ Crawler Chain 20. 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.

21. Pull the crawler chain clear of the crawler frame and away from the machine.

Crawler chain installation

To install the crawler chain (Fig. 6): 1. Ensure that the miner is correctly cribbed.

2. 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 grousers are in the correct direction before installing the chain into the machine. Check the parts book for your machine to verify the correct direction.

3. Attach a pull cable to the rear of the crawler chain.

4. 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.

5. 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.

6. Block the bottom of the chain near the front.

7. Coat the connecting pins with EP#2 multi-purpose grease.

8. Remove the pull cable and mate the two ends of the chain using the two connecting pins.

9. Apply Loctite 271 to the bolts then secure the pins with the flat head socket capscrews and nuts.

10. Ensure that the needle valve on the grease take-up cylinder has been closed.

11. Pump grease into the take-up cylinder grease fitting until the proper chain sag is achieved (Fig. 7).

______________________________________________________________ A6474X443 REV 0 21

Crawler Chain ___________________________________________________ Fig. 6: Crawler chain removal and installation

Pin, bolt, and nut

Fig. 7: Crawler chain sag measurement Bottom of tractor wear shoe

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

________________________________________________________________ 22 CM445 Mechanical - Traction

_________________________________________________ Crawler Take-Up Introduction

The following procedure is for the removal and installation of the crawler takeup.

Tool Set

Basic Tool Set Blocking

Safety When removing or installing the crawler take-up, 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 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.

______________________________________________________________ A6474X443 REV 0 23

Crawler Take-Up _________________________________________________ Crawler take-up roller removal

To remove the crawler take-up roller (Fig. 8): 1. Position the miner so that there is sufficient clearance to work.

2. Block the machine so that the crawler assembly is off of the mine floor.

Block under the crawler chain, just behind the crawler take-up roller.

3. Raise the gathering head assembly to its highest position and securely block it.

4. Lower the cutter head assembly so that it rests on the gathering head.

5. Lower the conveyor.

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

7. Separate the chain near bottom of roller and use a hoist to raise top of crawler off of roller.

8. Place a lifting device around both sides of the take-up roller and slide the roller forward until it clears the frame.

Crawler take-up roller installation

To install the crawler chain take-up idler roller (Fig. 8): 1. Apply a thin coating of grease to the top and bottom take-up slide areas of the crawler frame.

2. 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.

3. Position the crawler take-up assembly in front of the slide area of the crawler frame. Ensure that the key is still located in the keyway of the takeup cylinder.

4. Slide the assembly into the mainframe, making sure the key slot is oriented with the key in the take-up cylinder. Slide the assembly rearward until it sops against the piston of the take-up cylinder.

5. Ensure that the piston end of the take-up cylinder fits properly into the takeup plug in the roller assembly.

6. Reconnect the crawler chain.

7. Unblock the chain and check for proper tension. If necessary, adjust the shims until the required sag is achieved.

8. Connect the trailing cable to energize the miner.

9. Remove all blocking.

10. Check the crawler assembly for correct operation.

________________________________________________________________ 24 CM445 Mechanical - Traction

_________________________________________________ Crawler Take-Up Fig. 8: Crawler take-up roller removal and installation

Crawler take-up roller

______________________________________________________________ A6474X443 REV 0 25

Stabilizer (Foot) Cylinder __________________________________________ Introduction

The following procedure is for the removal and installation of the stabilizer (foot) cylinder.

Tool Set

Basic Tool Set Blocking

Safety When removing or installing a stabilizer (foot) 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.

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

________________________________________________________________ 26 CM445 Mechanical - Traction

__________________________________________ Stabilizer (Foot) Cylinder Stabilizer (foot) cylinder removal

To remove a stabilizer (foot) cylinder (Fig. 9): 1. Extend the stabilizer cylinder so that the foot is resting on the ground.

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

3. Block the miner so that it will not move when the stabilizer cylinder is removed.

4. Disconnect the grease line to the cylinder. pins 5. Remove the two (2) M16X40 hex head cap screws and the pin retainer that secure the rod end mounting pin.

6. Remove the mounting pin.

7. Restore power to the machine.

8. Retract the stabilizer cylinder to free the rod from the mounting clevis.

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

10. Disconnect, tag, and cap the hydraulic hoses to the cylinder.

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 two (2) M16X40 hex head cap screws and the pin retainer from the cylinder mounting pin.

13. Remove the mounting pin.

14. The cylinder can now be removed from the machine.

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Stabilizer (Foot) Cylinder __________________________________________ Stabilizer (foot) cylinder installation

To install a stabilizer cylinder (Fig. 9): 1. Verify that the machine is locked/tagged out.

2. Verify that the machine is adequately blocked.

3. Position the cylinder in the upper mounting clevis and align the clevises so that the pin can be inserted.

4. Insert the pin through the clevises.

5. Install the pin retainer and secure with the two (2) M16X40 hex head cap screws and torque to 224 ft-lbs.

6. Connect the hydraulic hoses to the cylinder.

7. Restore power to the machine.

8. Extend the stabilizer cylinder so that the rod end is aligned in the mounting clevis.

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

10. Insert the mounting pin.

11. Install the pin retainer and secure with the two (2) M16X40 hex head cap screws and torque to 224 ft-lbs.

12. Connect the grease line to the cylinder pins.

________________________________________________________________ 28 CM445 Mechanical - Traction

__________________________________________ Stabilizer (Foot) Cylinder Fig. 9: Stabilizer (foot) cylinder removal and installation

3

1

2

5 7

6 4

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2.

3.

4.

5.

6.

7.

Hex head cap screw, M16X40 (2) Pin retainer Pin Stabilizer cylinder Pin Pin retainer Hex head cap screw, M16X40 (2)

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