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A6474X361 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X361 (Introduction - Operation)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information.

The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Instructions............................................................................. 4 Red Zones ......................................................................................... 6 General Description........................................................................... 11 Installation ......................................................................................... 12 Storage .............................................................................................. 17 Machine Mounted Controls ............................................................... 19 Remote Operation ............................................................................. 23 Operation........................................................................................... 24 Pre-Operational Checks............................................................ 24 Daily Checks ............................................................................. 24 Machine Shutdown Functions ........................................................... 25 Machine (Emergency) Stop Bypass.................................................. 25 Start-Up Procedure ........................................................................... 28 Shutdown Procedure......................................................................... 29 Hydraulic System .............................................................................. 30 Electrical System............................................................................... 32 Water System.................................................................................... 33

________________________________________________________________ A6474X361

REV 1

Safety Instructions _______________________________________________ Safety Precautions

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

Additional precautions may appear in each section of this book. All precautions listed, as well as all Federal, State, and Mine safety regulations must be followed at all times.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

!

DANGER

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

!

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

!

WARNING 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.

________________________________________________________________ 4 CM445 Continuous Miner

_______________________________________________ Safety Instructions

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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.

!

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

!

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

!

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

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

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Red Zones ______________________________________________________ Introduction

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

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

Red Zones (Danger Areas)

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

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

Fig. 1: Red zone designation

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

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

Fig. 2: Red zones

Tramming the miner red zone

Beginning 1st sump red zone

______________________________________________________________ A6474X361 REV 1 7

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

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

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

Fig. 3: Red zones

Sumping on the left hand side red zone

Repositioning miner for right hand cut red zone

Sumping in the right hand cut red zone

________________________________________________________________ 8 CM445 Continuous Miner

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

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

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

Fig. 4: Crosscut red zones

Beginning a right hand crosscut red zone

Right hand crosscut development

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

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

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

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

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

Fig. 5: Pillaring red zones

Pillaring in a left hand cut red zone

Pillaring in a end cut red zone

Pillaring in a right hand cut red zone

________________________________________________________________ 10 CM445 Continuous Miner

______________________________________________ General Description Introduction

The CM445 Continuous Miner is designed for harder cutting applications. The cutter head is powered by two 280 HP (one hour rating) cutting head motors mounted in the cutter head assembly. The motors tie together at a common drive shaft, allowing for the combined power of both motors at the cutter head.

Additionally, there are two 65 HP conveyor/gathering head motors, two 75HP AC traction motors controlled by Variable Frequency Drives (VFDs), and a 65 HP pump motor.

Fig. 6: General Arrangement

10 9

7 1

6 5

8 2 4 3

1.

2.

3.

4.

5.

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

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

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Installation ______________________________________________________ Introduction

The CM445 Continuous Miner can be shipped either as a complete machine or in component sections, depending on customer preference or transportation weight restrictions. The machine should only be unloaded by experienced personnel. Always refer to the Pre-Operational Checks and Start Up procedure before attempting to unload an assembled machine. If shipped in components, it is recommended that a representative assist in the reassembly.

Machine and Component Weights

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

Table 1: Component Weights

Description

Approximate Weight

Frame without bumper bars and louvers

25,506 lbs (11,569 kg)

Conveyor assembly with chain

28,750 lbs (13,041 kg)

Cutter head frame with covers

24,300 lbs (11,022 kg)

Cutter head drive assembly

21,900 lbs (9,934 kg)

Gathering head assembly

24,230 lbs (10,991 kg)

Crawler assembly

7,530 lbs (3,416 kg)

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

Lifting eye location

Lifting eye location

Lifting eye location (typical both sides)

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

Lifting eye

Lifting eye

Lifting eye

________________________________________________________________ 14 CM445 Continuous Miner

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

Lifting points

______________________________________________________________ A6474X361 REV 1 15

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

Lifting point Lifting point

Lifting point

Lifting point

________________________________________________________________ 16 CM445 Continuous Miner

_________________________________________________________Storage Storage

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

Corrosion Protection

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

Exposure to Sunlight

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

Dirt and Moisture

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

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

Short-term Storage

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

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

Long-term Storage

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

2. Completely fill the hydraulic oil tank with oil.

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

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

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

Machine Electrical Components

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

______________________________________________________________ A6474X361 REV 1 17

Storage _________________________________________________________ Traction Drives

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

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

Random Sample Inspection

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

Natural Aging

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

Long-term storage of spare components Hydraulic Components

Miscellaneous Components

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

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

Motors

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

Fan Assembly

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

Plastic Deformation

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

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________________________________________ Machine Mounted Controls Circuit Breakers

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

As soon as the main circuit breaker is closed, power is supplied to the pump motor, left and right conveyor/gathering head circuits, and the lighting and control circuits. When the cutter circuit breaker is closed, power is available to the left and right cutter circuits. Closing the tram circuit breaker will supply power to the tram motor circuit.

Fig. 8: Circuit Breaker

2 1

3

1. Main circuit breaker, main disconnect box Breaker Operation

Breaker 1. Main circuit

2. Cutter motor circuit breaker, controller case 3. Tram circuit breaker, controller case Function

Operation

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

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

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

2. Cutter motor

Isolates the cutter motor circuit.

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

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

3. Tram

Isolates the tram circuit.

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

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

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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.

______________________________________________________________ A6474X361 REV 1 19

Machine Mounted Controls ________________________________________ Control Switches

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There are control switches located on the front of the controller case that will function after the main circuit breaker is on (closed). The continuous miner is normally operated by radio remote. Manual operation via controls on the controller case is not permitted for production operation. Manual operation is for troubleshooting and maintenance under supported roof only.

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

Fig. 9: Control switches 1

1.

2.

3.

4.

5.

6.

7.

8.

Machine Stop Miner Operation Machine Lighting MCB1 MCB2 MCB3 MCB4 MCB5

2

9. MCB6 10. MCB7 11. MCB8 12. MCB9 13. MCB10 14. MCB11 15. MCB12 16. MCB13

3

4 - 11

12 - 19

20

21

17. MCB14 18. MCB15 19. MCB16 20. Conveyor Hour Meter 21. Cutter Head Hour Meter

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________________________________________ Machine Mounted Controls Control Switch Operation Switch

Function

Operation

Machine Stop

Removes power from the control circuit, Push the button to stop all motors. shutting down the machine.

Miner Operation

Determines mode of operation.

E-TRAM allows the miner to be trammed from the tram pendant.

REMOTE allows the miner to be operated from the radio remote.

GND CHK causes the mine power center to trip thereby shutting down the machine.

Machine Lighting

Controls the lights.

ALL OFF turns off all machine lights.

AREA LIGHTS ONLY turns on the machine’s area lights.

ALL ON turns on all machine lights.

MCB1

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

PULL to open.

MCB2

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

PUSH in to set/reset.

PULL to open.

MCB3

15A breaker for the 120VAC+ side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB4

15A breaker for the 120VAC- side of the area light circuit.

PUSH in to set/reset.

PULL to open.

MCB5

25A breaker for the 12VAC+ side of the PUSH in to set/reset. headlight circuit.

PULL to open.

MCB6

25A breaker for the 12VAC- side of the headlight circuit.

PUSH in to set/reset.

PULL to open.

MCB7

5A breaker for the 12VAC+ side of the RTD module circuit.

PUSH in to set/reset.

PULL to open.

MCB8

5A breaker for the 12VAC- side of the RTD module circuit.

PUSH in to set/reset.

PULL to open.

MCB9

5A breaker for the 120VAC+ side of the PUSH in to set/reset. contactor circuit.

PULL to open.

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Machine Mounted Controls ________________________________________ Control Switch Operation, continued Switch MCB10

Function 5A breaker on the 90VDC+ side of the solenoid circuit.

Operation PUSH in to set/reset.

PULL to open.

MCB11

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

PUSH in to set/reset.

PULL to open.

MCB12

5A breaker on the 24VDC+ side PLC power circuit.

PUSH in to set/reset.

PULL to open.

MCB13

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

PUSH in to set/reset.

PULL to open.

MCB14

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

MCB15

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

MCB16

5A breaker on the communications circuit.

PUSH in to set/reset.

PULL to open.

Conveyor Hour Meter

Displays hours of running time for the conveyor motor.

N/A

Cutter Head Hour Meter Displays hours of running time for the cutter head motors.

N/A

Left Side Machine Stop

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

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

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________________________________________ Remote Control Operation Radio Remote

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

Pendant Control

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

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

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

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

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

!

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

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Operation _______________________________________________________ Pre-Operational Checks

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

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

2. Check all hydraulic and lubricant fluid levels.

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

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

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

Daily Checks

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

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

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

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

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

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

6. Perform daily maintenance.

7. Check the conveyor and crawler chain tensions.

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

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

________________________________________________________________ 24 CM445 Continuous Miner

____________________________________________ Emergency Shutdown Emergency Shutdown Controls

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

The following controls can be used to shutdown the machine:

Control

Location

Action

Result

Main Circuit Breaker

Main Disconnect Box

Push to the right to Isolates the entire machine from power supplied via the turn OFF (open the trailing cable. breaker).

Machine Stop

Control Case

Push to activate.

Shuts down all motors on the machine.

Machine Left Side E- STOP

Radio Remote Push to activate.

Shuts down all motors on the machine. Note: The stop button is defaulted to function as a machine shutdown (power center trip). Once it is pressed, the remote transmits that message for several seconds before shutting itself down. The machine controller will energize the machine OE relay in order to trip the power center but will immediately shutdown the pump motor and other functions. Via the system menu, the function of this button can be set to shut down the pump motor only but default is power center trip.

Pump Off

Radio Remote Push toggle switch up to activate.

Shuts down all motors on the machine.

Machine Stop

Tram Pendant Push to activate.

Shuts down all motors on the machine.

Emergency Stop (Machine Stop) Bypass (optional)

!

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

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

Emergency Stop (Machine Stop) Bypass Procedure

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

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Emergency Shutdown_____________________________________________ Fig. 10: Bypass key Press key down

Press key up

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

Fig. 11: Bypass enable delay period timer

Five second timer

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

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

Fig. 12: Bypass active countdown timer

Thirty second timer

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Start-Up Procedure _______________________________________________ Introduction

!

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

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

Start-Up (Radio Remote)

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

2. Select the “REMOTE” position on the Miner switch on the front of the control case.

3. Turn the power switch on radio transmitter: press and hold the ON key until the remote control no longer displays the HOLD message. Once the remote control is initialized, it will display the channel selected and will then display ON. Note: If, during power up, any other key is pressed, the remote will begin a shutdown procedure and will display SERV, thinking there is a switch failure.

4. Press “SHIFT” and wait 1/4 second. Note: The “SHIFT” key has a two second timeout - if the motor start button is not pushed within two seconds, the “SHIFT” key must be released and pressed again.

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

6. Release the “PUMP ON” key.

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

7. Release the “SHIFT” key. Note: The shift key must be released before attempting to start another motor; it cannot be held down for more than one start procedure.

Start-Up (Tram Pendant)

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

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

3. Release both buttons.

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_____________________________________________ Shutdown Procedure Shutdown Procedure (Radio Remote)

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

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

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

4. Lower the cutter head to the floor.

5. Lower the conveyor and gathering head.

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

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

8. Release the “PUMP OFF” key.

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

11. Turn off the radio remote.

12. Shut off the main power supply.

13. Shut off the mine water supply.

______________________________________________________________ A6474X361 REV 1 29

Hydraulic System ________________________________________________ Introduction

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

A 65 HP pump motor drives a two-stage gear pump that delivers hydraulic oil to the hydraulic system. The 156 gallon (592 L) hydraulic oil tank is an integral part of the main frame. Only anti-wear hydraulic oil meeting Specification 100-1 should be used in the hydraulic system.

Load Holding (Load Lock) Valves

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

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

Shear Down (anti-chatter)/ Maintenance valve

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

System Pressure

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

Power Fill Function

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

________________________________________________________________ 30 CM445 Continuous Miner

________________________________________________ Hydraulic System Power Fill Operation

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

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

3. Open the ball valve.

4. Engage the conveyor down function.

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

6. Close the ball valve.

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

8. Stop the pump motor.

Filters

There are four hydraulic filters on the machine: 1. Pressure filter, bypassing 2. Pilot filter, bypassing 3. Pilot filter, non-bypassing 4. Power fill filter

______________________________________________________________ A6474X361 REV 1 31

Electrical System_________________________________________________ Introduction

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

Motors

This machine is powered by seven 995VAC electric motors: 1. One 55 hp pump motor 2. Two 335 hp cutter motors 3. Two 55 hp gathering head/conveyor motors 4. Two 75 hp traction motors

________________________________________________________________ 32 CM445 Continuous Miner

___________________________________________________ Water System Introduction

The minter is equipped with a water system used to cool the electric motors, the control case, the VFD case and for dust control. The mine water is normally connected on the right rear of the machine.

Water supply requirements are: Flow: 10 gpm for cooling Pressure: 250 psi (dynamic) minimum 500 psi maximum The water supply is connected to a ball valve, which must be manually opened before the cooling/dust suppression system can be activated. From the ball valve, water flows through a 150 micron by-passing water filter. Water pressure before and after the filter is monitored by gauges teed into the lines.

Activation

Maintenance

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

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

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

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

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

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

______________________________________________________________ A6474X361 REV 1 33

Water System____________________________________________________ Fig. 10: Water system layout 1

1 1

4

2 3

5

6

1. Dust Sprays 2. Cutter Motor, LH 3. Cutting Head Spray Water Manifold 4. Cutter Motor, RH 5. Gathering Head Motor, LH 6. Gathering Head Motor, RH 7. VFD Case 8. Pump Motor 9. Tram Motor, LH 10. Tram Motor, RH 11. Control Case 12. Relief Valve 13. Solenoid Valve (hydraulic) 14. Dust/Spray Solenoid Valve 15. Pressure Manifold 16. Flow Meter 17. Filter, By-Passing 18. Pressure Gauges 19. Ball Valve

8

7

10 9

11

12

13

14 16 15 17 18

19

________________________________________________________________ 34 CM445 Continuous Miner

A6474X362 February 2012

Operation and Maintenance Manual Super Simpson Control System Display A6474X362 (Super Simpson Control System Display)

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 Precautions........................................................................................... 4 Machine Control System.................................................................................. 5 Components .............................................................................................. 5 Radio Remote ........................................................................................... 6 Displays ..................................................................................................... 8 Main Screen........................................................................................ 8 System Menu .....................................................................................10 Diagnostics ........................................................................................12 Fault Log ............................................................................................17 Hour Meters .......................................................................................20 Setup Menu........................................................................................21

______________________________________________________________ A6474X362 REV 1 3

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

IMPORTANT

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

IMPORTANT

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

IMPORTANT

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

IMPORTANT

It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

IMPORTANT

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

IMPORTANT

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

________________________________________________________________ 4 Control system display

__________________________________________ Machine Control System Introduction

A multi-component system is used to control and monitor the functions of the machine. This system consists of the following main components: 1. Machine controller 2. Power supply 3. Input/output (I/O) modules 4. Radio remote 5. Graphics display This information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the continuous miner, training must be completed.

Machine Controller

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

Power Supply

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

Input/Output Modules

Input/output modules may be used to read data from and/or send commands to the following machine functions: 1. Cutter motors (left and right) 2. Gathering head motors (left and right) 3. Traction motors (left and right) 4. Pump motor 5. Hydraulic oil level 6. Methane monitoring (if applicable) 7. Fan motor (if applicable) Based on the parameter settings and the input received from different components, the control system has the ability to issue error messages, fault messages, and/or shutdown the machine.

_____________________________________________________________ A6474X362 REV 1 5

Machine Control System___________________________________________ Radio Remote

!

The radio remote (Fig. 1) is a battery powered remote used to control the continuous miner during normal operations.

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

Fig. 1: Radio remote (typical)

________________________________________________________________ 6 Control system display

__________________________________________ Machine Control System Radio Remote Charging

The radio remote contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be re-charged using the battery charger (Fig. 2). Recharge times for the unit are typically 1-4 hours, depending on the remaining charge in the battery.

Fig. 2: Radio remote battery charger (typical)

_____________________________________________________________ A6474X362 REV 1 7

Machine Control System___________________________________________ Displays

There are two displays located on the machine: a graphics display located at the operator’s case and a text display located near the back right hand side of the machine (Fig. 3). Both screens are used to display diagnostic information on the miner.

Fig. 3: Control system display locations (typical)

Text display

Graphics display

IMPORTANT

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

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

The text display, located above the operator’s case, has the same functions as the graphics display. If the control system loses power, the text display will remain powered through the battery back up.

Displays

There are different screens that can be displayed: production monitoring, function monitoring, diagnostic, motor hours, and fault pages. A system halt message can appear as a pop-up dialog box in the middle of any screen. A message will appear when a critical conditions has occurred that prevents continued operation of the machine in a safe manner.

The main screen (Fig. 4) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

________________________________________________________________ 8 Control system display

__________________________________________ Machine Control System Fig. 4: Main page, example

Graphics display

Text display

_____________________________________________________________ A6474X362 REV 1 9

Machine Control System___________________________________________ System Menu

The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 5). The system menu is accessed by using either display and a remote control handset.

To access and navigate the system menu using the radio remote: 1. Press the SHIFT and MENU key to access the system menu screen.

2. Press CONV UP or CONV DOWN to move the cursor up and down the list.

IMPORTANT

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

3. Press SHIFT and MENU to select the highlighted item 4. To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 5: System menu, example

Graphics display

________________________________________________________________ 10 Control system display

__________________________________________ Machine Control System Fig. 5: System menu, example, continued

Text display

_____________________________________________________________ A6474X362 REV 1 11

Machine Control System___________________________________________ Diagnostic Mode

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

To navigate through the screens, hold the SHIFT switch while pressing a conveyor switch. To return to the main menu, press SHIFT and MENU Graphics diagnostics may include the following pages: NOTE: Menu options may vary depending on machine configuration.

1. Main monitor 2. Production monitor 3. Pump monitor 4. Cutter monitor 5. Conveyor monitor 6. I/O monitor - relay outputs 7. I/O monitor - digital inputs 8. I/O monitor - analog outputs 9. Solenoids 10. Inverter right monitor 11. Inverter left monitor 12. Rectifier monitor 13. Thermistor monitor 14. Motor mate network monitor 15. CAN network monitor See Fig. 6 for example screen shots of various diagnostic pages.

________________________________________________________________ 12 Control system display

__________________________________________ Machine Control System Fig. 6: Graphics display diagnostic pages, examples

_____________________________________________________________ A6474X362 REV 1 13

Machine Control System___________________________________________ Fig. 6: Graphics display diagnostic pages, examples, continued

________________________________________________________________ 14 Control system display

__________________________________________ Machine Control System Text diagnostics includes the following pages: 1. Main monitor 2. Machine information 3. Pump diagnostics 4. Cutter diagnostics 5. Conveyor diagnostics 6. Fan diagnostics 7. Tram diagnostics 8. 24VDC digital input 9. I/O monitor - relay board 10. I/O monitor - solenoid board 11. I/O monitor - analog outputs 12. Solenoid board diagnostics 13. Relay board status 14. Power supply status 15. Thermistor module status To navigate the text display screens: 1. Enter menu - “SHIFT” + “MENU” 2. Exit menu - “SHIFT” + “REMOTE” 3. Move back one page - “SHIFT” + “CONV LEFT” 4. Move forward one page - “SHIFT” + “CONV RIGHT” 5. Move cursor down - “SHIFT” + “CONV UP” 6. Move cursor up - “SHIFT” + “CONV DOWN”

_____________________________________________________________ A6474X362 REV 1 15

Machine Control System___________________________________________ Fig. 7: Text display diagnostic pages, examples

________________________________________________________________ 16 Control system display

__________________________________________ Machine Control System Fault Log

The fault event log (Fig. 6) provides a list of recent faults. Individual faults (Fig. 6) can be selected from this screen to see more information regarding the fault.

To navigate through the screens: 1. Move browsing cursor up: “CONV UP” 2. Move down one page: “SHIFT” + “CONV DOWN” 3. Move up one page: “SHIFT” + “CONV UP” 4. Move browsing cursor down: “CONV DOWN” 5. Select a fault for more information: “SHIFT” + “MENU” 6. Go back up one level: “SHIFT” + “REMOTE”

IMPORTANT

It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

_____________________________________________________________ A6474X362 REV 1 17

Machine Control System___________________________________________ Fig 8: Fault log, example

Graphics display

Text display

________________________________________________________________ 18 Control system display

__________________________________________ Machine Control System Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 9).

Fig. 9: Fault detailed information, example

_____________________________________________________________ A6474X362 REV 1 19

Machine Control System___________________________________________ Hour Meters

Selecting hour meters (Fig. 10) from the Main Menu will display runtime for the following motors: pump, fan, left cutter, right cutter, and conveyor. Time is displayed in hours:minutes:seconds format. This runtime only reflects accumulated time since the machine controller has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

IMPORTANT

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

Fig. 10: Hour meters, examples

Graphics display

Text display

________________________________________________________________ 20 Control system display

__________________________________________ Machine Control System Setup Menu

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

_____________________________________________________________ A6474X362 REV 1 21

Machine Control System___________________________________________

________________________________________________________________ 22 Control system display

A6474X363 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X363 (Introduction - Maintenance)

SAFETY.CAT.COM

__________________________________________________________

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

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

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

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

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

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

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Precautions ............................................................................ 4 General Maintenance Instructions .................................................... 6 Lock Wiring Fasteners....................................................................... 8 Self-locking Screws ........................................................................... 8 Locknuts ............................................................................................ 8 Torque Values ................................................................................... 9 Lubrication and Maintenance Schedule ............................................ 11 Specific Lubrication and Maintenance Procedures ........................... 17 Every Shift................................................................................. 17 Daily .......................................................................................... 20 Weekly....................................................................................... 28 Crawler Chain Adjustment Procedure.................................. 30 Conveyor Chain Tension Adjustment Procedure................. 34 Monthly...................................................................................... 36 Every Three Months.................................................................. 42 Every Six Months ...................................................................... 47 Tail Shim Adjustment Procedure....................................................... 49 Lubricant Specifications ................................................................... 52

________________________________________________________________ A6474X363

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.

!

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.

!

DANGER

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

!

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

!

WARNING 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 Maintenance

_______________________________________________ Safety Instructions

!

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

!

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

!

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

!

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

______________________________________________________________ A6474X363 REV 0 5

General Maintenance Instructions___________________________________ Introduction

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

Tools

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

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

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

Maintenance Notes

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

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

3. Use only original spare parts when replacing components.

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

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

6. Shutdown the machine on level ground.

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

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

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

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

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

________________________________________________________________ 6 CM445 Maintenance

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

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

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

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

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

______________________________________________________________ A6474X363 REV 0 7

Special Fasteners ________________________________________________ Introduction

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

Locking Wire Fasteners

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

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

Fig. 1: Lock wire fasteners

Self-Locking Screws

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

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

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

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

Lock Nuts

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

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

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

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

________________________________________________________________ 8 CM445 Maintenance

___________________________________________________ Torque Values Introduction

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

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

Use a calibrated torque wrench for accuracy.

Imperial Bolts

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

______________________________________________________________ A6474X363 REV 0 9

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

________________________________________________________________ 10 CM445 Maintenance

____________________________________________Maintenance Schedule Introduction

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

Lubricant and Fluid Capacities

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

Location

Specification

Approximate capacity

Hydraulic oil tank GH Assembly CLA Primary

Spec. 100-1 Spec. 100-15

156 gals. (592 L) 1 gal (3.79 L)

GH Assembly CLA POT Tram Drive Assembly

Spec. 100-15 Spec. 100-15

2.5 gal (9.46 L) 3 gal (11.36 L)

Drum Drive Assembly, high speed (back) Drum Drive Assembly, low speed (front) Motor Lube Hoses

Spec. 100-15

0.5 gallon (1.89 L)

Spec. 100-15

5 gal (18.93 L)

Spec. 100-14

Variable

Notes

1

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

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

______________________________________________________________ A6474X363 REV 0 11

Maintenance Schedule ____________________________________________ Item

Description

Places

Lubricant

Specification

Every Shift 1

Cutter head lift cylinder pin, upper

2

Lithium based grease

Spec. 100-3

2

Cutter head lift cylinder pin, lower

2

Lithium based grease

Spec. 100-3

3

Conveyor swing cylinder pin, front

1

Lithium based grease

Spec. 100-3

4

Conveyor swing cylinder pin, rear

1

Lithium based grease

Spec. 100-3

5

Cutter head pivot pin

2

Lithium based grease

Spec. 100-3

6

Cutter head bits

Inspect

Daily 7

Tail roller

2

Lithium based grease

Spec. 100-3

8

Gathering head pivot pin

2

Lithium based grease

Spec. 100-3

9

Crawler idler roller

2

Lithium based grease

Spec. 100-3

10

Conveyor raise pivot pin

2

Lithium based grease

Spec. 100-3

11

Stabilizer shoe cylinder pin, upper

2

Lithium based grease

Spec. 100-3

12

Stabilizer shoe cylinder pin, lower

2

Lithium based grease

Spec. 100-3

13

Conveyor raise cylinder pin, upper

2

Lithium based grease

Spec. 100-3

14

Conveyor raise cylinder pin, lower

2

Lithium based grease

Spec. 100-3

15

Conveyor swing pivot pins

8

Lithium based grease

Spec. 100-3

16

Gathering head cylinder pin, upper

2

Lithium based grease

Spec. 100-3

17

Gathering head cylinder pin, lower

2

Lithium based grease

Spec. 100-3

18

CLA head pot assembly (Check)

2

High demulsibility EP gear oil

Spec. 100-15

19

CLA head transfer case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

20

Tram gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

21

Input cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

22

Main cutter head gear case (Check)

2

High demulsibility EP gear oil

Spec. 100-15

23

Hydraulic oil level (Check)

1

AW hydraulic oil

Spec. 100-1

24

Stab shoe pivot, frame

2

Lithium based grease

Spec. 100-3

25

Weekly Pressure filter

1

See Parts Book

26 27

Pilot pressure filter, non-bypassing Pilot pressure filter, bypassing

1 1

See Parts Book See Parts Book

28

Power fill filter

1

See Parts Book

29

Water filter

1

See Parts Book

30

Crawler chain

Inspect

31

Conveyor chain

Inspect

32

Fasteners (nuts, bolts, screws)

Inspect

33

Electrical cables, conduits, and glands

Inspect

34

Hydraulic/water hoses and connections

Inspect

35

Lighting

Inspect

36

Reflectors and warning tags

Inspect

37

Machine stop switch (Inspect)

2

________________________________________________________________ 12 CM445 Maintenance

____________________________________________Maintenance Schedule Item

Description

Places

Lubricant

Specification

Monthly 38 39

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

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

40 41

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

2 2

High demulsibility EP gear oil High demulsibility EP gear oil

Spec. 100-15 Spec. 100-15

42 43

CLAs Input cutter head gear case

Inspect 2

Sample

See Note 1

44 45

Main cutter head gear case CLA head pot assembly

2 2

Sample Sample

See Note 1 See Note 1

46 47 48

CLA head transfer case Tram gear case Main hydraulic tank

2 2 1

Sample Sample Sample

See Note 1 See Note 1 See Note 1

49

Every three months Cutter motor

4

Spec. 100-14

50

Gathering head motor

4

51

Pump motor

2

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

52

Every six months Tram gear case (Change)

2

High demulsibility EP gear oil

Spec. 100-15

53 54 55

Hydraulic oil (Change) Suction strainer, hydraulic oil tank (Change) Breathers

1 2 All

AW hydraulic oil

Spec. 100-1 See Parts Book See Parts Book

Spec. 100-14 Spec. 100-14

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

______________________________________________________________ A6474X363 REV 0 13

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

23, 48, 53, 54, 55

47, 52

47, 52

37

4

3

________________________________________________________________ 14 CM445 Maintenance

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

21, 40, 43

49 50 18, 38, 45 19, 39, 46

9

16

30 25, 26, 27 51

20

12 37 13 15

15

______________________________________________________________ A6474X363 REV 0 15

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

15

12 20

16

18, 38, 45

9

19, 39, 46 50

49

21, 40, 43

________________________________________________________________ 16 CM445 Maintenance

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

Lubricate the upper and lower cutter head cylinder pins (right and left). The upper pins are lubricated through the grease fittings located on each pin (Fig. 3). The lower cylinder pins are lubricated through a lubrication block mounted on each side of the machine (Fig. 3). Pump approximately 50 cubic cm (3 cubic inches) into each fitting.

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

Upper cutter head cylinder pin

Lower cutter head cylinder pin grease fitting

______________________________________________________________ A6474X363 REV 0 17

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

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

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

Cutter Head Pivot Pin (left and right)

Conveyor swing cylinder pin, front

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

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

________________________________________________________________ 18 CM445 Maintenance

__________________________________________Maintenance Instructions Cutter Head Bits

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

Fig. 6: Cutter head bits Bit holder

Bit

______________________________________________________________ A6474X363 REV 0 19

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

Lubricate the tail roller through the two (2) grease fittings located on the shaft (Fig. 7). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Fig. 7: Tail roller lubrication

Grease fittings (2)

________________________________________________________________ 20 CM445 Maintenance

__________________________________________Maintenance Instructions Gathering Head Pivot Pin (right and left)

Lubricate the left and right gathering head pivot pins through the grease fittings located on the left and right front lubrication blocks (Fig. 8). Pump approximately 3 cu. in. (50 cu. cm.) of grease into each fitting.

Crawler Idler Roller (right and left)

Lubricate the left and right crawler idler rollers (Fig. 8) through the grease fittings located on the outside face of the crawler idler roller.

Conveyor Raise Pivot (right and left)

Lubricate the conveyor raise pivot through the grease fitting located on the right and left front lubrications blocks (Fig. 8). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 8: Gathering head pivot pin, conveyor raise pivot, and crawler idler roller (typical both sides) Conveyor pivot pin lubrication

Gathering head pivot pin lubrication

Crawler idler roller

______________________________________________________________ A6474X363 REV 0 21

Maintenance Instructions __________________________________________ Upper Stabilizer Shoe Cylinder Pin (right and left)

Lubricate the upper stabilizer shoe cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Lower Conveyor Raise Cylinder Pin (right and left)

Lubricate the lower conveyor raise cylinder pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Stabilizer Shoe Pivot Pin (right and left)

Lubricate the stabilizer shoe pivot pins (right and left) through the two grease fittings located on the lubrication block on the left side of the machine (Fig. 9).

Pump approximately 3 cu. In (50 cu. Cm) of grease into each fitting.

Fig. 9: Lubrication block - stabilizer shoe and conveyor lift pin lubrication manifold

Lower Stabilizer Shoe Cylinder Pin (right and left)

Lubricate the lower stabilizer shoe cylinder pins (right and left) through the grease fittings located on the rod end of each cylinder (Fig. 10). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 10: Lower stabilizer shoe cylinder pin (typical both sides)

Lower stabilizer shoe cylinder pin

________________________________________________________________ 22 CM445 Maintenance

__________________________________________Maintenance Instructions Upper Conveyor Raise Cylinder Pin (left and right)

Lubricate the upper conveyor raise cylinder pins through the grease fittings located on the right side of the conveyor (Fig. 11). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 11: Upper conveyor raise cylinder pin lubrication

Upper conveyor raise cylinder pin grease fittings (2)

Conveyor Swing Pivot Pins

Lubricate the conveyor swing pivot pins through the four (4) grease fittings located each side of the conveyor (Fig. 12). Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 12: Conveyor swing pivot pin Conveyor swing pivot pin lubrication fittings (2) (typical both sides)

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

______________________________________________________________ A6474X363 REV 0 23

Maintenance Instructions __________________________________________ Gathering Head Raise Cylinder Pins

Lubricate the upper gathering head raise cylinder pins (Fig. 13) through the grease fittings located on each end of the cylinder. Pump approximately 3 cu. in (50 cu. cm) of grease into each fitting.

Fig. 13: Gathering head raise cylinder pins (typical both sides)

Gathering head raise cylinder pin (upper)

Gathering head raise cylinder pin (lower)

CLA Head Pot Assembly (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the pot assembly (Fig. 14). If oil is needed, add oil through the fill hole until oil comes out the breather.

CLA Head Transfer Case (right and left)

Level the miner and place the gathering head on grade before checking or adding lubricant. Check the oil level in the hydraulic transfer case (Fig. 14). If oil is needed, add oil through the fill hole until oil comes out the breather.

Fig. 14: CLA head pot assembly and transfer case lubrication Oil fill, pot assembly

Oil check, transfer case

Oil check, pot assembly

Oil fill, transfer case

________________________________________________________________ 24 CM445 Maintenance

__________________________________________Maintenance Instructions Tram Gear Case (right and left)

With the miner in a level position, check the oil level in both tram gear cases by looking at the sight glass located on the side of each gear case (Fig. 15). Oil should be visible in each sight glass. If oil level is low, add oil through either the fill pipe (accessed from the top of the machine) or the fill plug hole (accessed from the side of the machine).

Check that the breather is clean and free of debris.

Fig. 15: Tram gear case oil level (typical both sides) Oil fill plug

Breather (behind cover)

Oil check

______________________________________________________________ A6474X363 REV 0 25

Maintenance Instructions __________________________________________ Input Cutter Gear Case

Ensure fill areas are clean and free of debris. With the gathering head lowered to ground level and the cutter head boom level with ground, check the oil level in both of the input cutter gear cases by removing the check plug located on each side of the cutter head assembly (Fig. 16). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plugs located on each side of the gathering head.

Fig. 16: Input cutter gear case oil level (typical) Oil fill plug (one per side)

Oil check plug (one per side)

Main Cutter Gear Case

Ensure fill areas are clean and free of debris. With the cutter head boom level with ground, check the oil level in both of the main cutter head gear cases by removing the check plug located on the front of each gear case (Fig. 17). Oil should flow from check plug hole when plug (s) is removed. If oil level is low, add oil through the fill plug hole located on top of each gear case.

Fig. 17: Main cutter head gear case oil level (typical) Oil fill plug (one per side)

Oil check plug

(one per side) ________________________________________________________________ 26 CM445 Maintenance

__________________________________________Maintenance Instructions Hydraulic Oil Level

With all of the machine cylinders in the fully collapsed position, check the hydraulic oil level (Fig. 18). Remove dipstick from tank and wipe clean. Insert dipstick back into tank and remove. The oil should be level with the full line indicated on dipstick. If oil level is low, add oil until full level is met.

Fig. 18: Hydraulic oil tanks Hydraulic oil tank

Hydraulic oil tank

Dip stick location

______________________________________________________________ A6474X363 REV 0 27

Maintenance Instructions __________________________________________ Weekly The purpose of this section is to describe the following maintenance procedures, to be performed weekly: 1. Pressure filters (bypassing and non-bypassing), check and change as required 2. Return filter, check and change as required 3. Power fill filter, check and change as required 4. Water filter, check and change as required 5. Crawler chain, inspect 6. Conveyor chain, inspect 7. Inspect/check tightness/condition of all fasteners (nuts, bolts, screws, etc.)

8. Inspect electrical cables, conduits, and glands 9. Inspect hydraulic and water hoses and connections 10. Inspect lighting 11. Inspect reflectors and warning tags 12. Inspect/check the function of each machine stop switch Pressure Filter

Change the pressure filter elements (Fig. 19). If the element is extremely dirty, a more frequent change interval may be required.

Pilot Pressure Filters

Change the pilot pressure filter elements (bypassing and non-bypassing) (Fig. 19). If the elements are extremely dirty, a more frequent change interval may be required.

Power Fill Filter

Change the power fill filter element (Fig. 19). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 19: Hydraulic filter location Pilot pressure filter (non-bypassing)

Pressure filter

Pilot pressure filter (bypassing)

Power fill filter

________________________________________________________________ 28 CM445 Maintenance

__________________________________________Maintenance Instructions Water Filter

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

Fig. 20: Water filter location

Water filter

Crawler Chain Tension

Check the crawler chains for proper tension.

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

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

Fig. 21: Crawler track tension measurement

Bottom of tractor wear shoe

2 1/2” - 3 1/2” gap (64 - 89 mm)

Top of tram track

______________________________________________________________ A6474X363 REV 0 29

Maintenance Instructions __________________________________________ Crawler Chain Adjustment Introduction

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

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

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

Tool List

Standard tool set Grease gun

Procedure

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

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

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

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

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

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

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

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

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

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

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

________________________________________________________________ 30 CM445 Maintenance

__________________________________________Maintenance Instructions c.

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

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

12. If the tram track is too loose, readjust the idler position using the following steps: a. Pump grease into the idler take-up jack to extend the cylinder, move the idler assembly forward and tighten the tram track until it is at the correct location. The tram track is at the proper tension when it hangs 64 to 89 mm (2-1/2 to 3-1/2 inches) from the bottom wear shoes when the tractor frame is blocked off the floor. b. Insert shims (Fig. 22) into the idler slide channel until the space between the tractor frame and the pusher plate is filled. c.

Open the pressure release valve (Fig. 22) for the front idler take-up jack and allow the cylinder to contract. The idler adjustment shims will keep the idler stationary and the track tensioned.

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

CAUTION

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

IMPORTANT

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

!

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

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

______________________________________________________________ A6474X363 REV 0 31

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

Remove the four Conelok nuts and flat head screws that secure the crawler pins (Fig. 22).

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

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

i.

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

j.

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

k.

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

l.

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

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

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

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

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

17. Connect the trailing cable to energize the miner.

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

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

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

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

________________________________________________________________ 32 CM445 Maintenance

__________________________________________Maintenance Instructions Fig. 22: Tram track adjustment Crawler chain take-up lubrication

Pressure relief valve

Take-up cylinder

Shims Idler assembly

Pad

Cleat

Lock bolt Conelok nut

______________________________________________________________ A6474X363 REV 0 33

Maintenance Instructions __________________________________________ Conveyor Chain Tension

There are two different types of chain commonly used on the machine: Cincinnati chain (standard) or Joy chain (optional). To check the chain tension: Cincinnati chain: 1. Make sure the conveyor chain area is clean and free of any loose material.

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

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

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

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

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

Joy chain: 1. With the machine locked and tagged out, place a hand on each end of a chain flight near the end of the conveyor. the ends should be not more than 50 mm (2 inches) from center or 100 mm (4 inches) top to bottom. If the deflection is more than 100 mm (4 inches), the chain is too loose and needs tensioned. If the deflection is less than 50 mm (2 inches), the chain is too tight and needs loosened.

Conveyor chain tension adjustment The conveyor chain is tensioned with a hydraulic take-up cylinder. If the chain tension is not being maintained, then: 1. The conveyor chain take-up valve may need to be adjusted. See the Conveyor chain take-up valve adjustment procedure (Pilot/auxiliary pump circuit relief valve adjustments) in this section. If the valve adjustment is correct, then 2. The cylinder may be fully extended and, therefore, unable to take up any more chain slack. Remove a link from the chain or replace chain as necessary.

________________________________________________________________ 34 CM445 Maintenance

__________________________________________Maintenance Instructions Fasteners

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

Electrical Cables, Conduits, and Glands

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

Hoses and Fittings

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

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

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

! WARNING

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

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

Lighting

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

Reflectors and Warning Tags

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

Machine Stop Switches

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

______________________________________________________________ A6474X363 REV 0 35

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

Change the oil in both CLA head pot assemblies (Fig. 23).

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

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

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

4. Clean and reinstall drain plug.

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

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

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

8. Clean and reinstall the check and fill plugs.

CLA Head Transfer Case

Change the oil in both CLA head transfer cases (Fig. 23).

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

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

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

4. Clean and reinstall drain plug.

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

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

________________________________________________________________ 36 CM445 Maintenance

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

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

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

IMPORTANT

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

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

Fig. 23: CLA pot assembly and input transfer case Oil fill, pot assembly

Oil check, transfer case

Oil check, pot assembly

Oil fill, transfer case

______________________________________________________________ A6474X363 REV 0 37

Maintenance Instructions __________________________________________ Input Cutter Head Gear Case Change the oil in both input cutter head gear cases (Fig. 24).

1.

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

2.

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

3.

Clean and reinstall the drain plug.

4.

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

5.

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

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

7. Clean and reinstall the check and fill plugs.

Fig. 24: Input cutter head gear case (typical) Oil fill plug (one per side)

Oil check plug (one per side)

________________________________________________________________ 38 CM445 Maintenance

__________________________________________Maintenance Instructions Main Cutter Head Gear Case Change the oil in both main cutter head gear cases (Fig. 25).

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

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

3. Clean and reinstall the drain plug.

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

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

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

7. Clean and reinstall the check and fill plugs.

Fig. 25: Main cutter head gear case Oil fill plug (one per side)

Oil check plug (one per side)

______________________________________________________________ A6474X363 REV 0 39

Maintenance Instructions __________________________________________ CLAs

Inspect the CLAs (Fig. 26) for damage. If a CLA needs replaced, see CLA removal and installation procedure in the Mechanical section of this manual.

Fig. 26: CLAs CLA

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

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

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

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

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

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

IMPORTANT

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

________________________________________________________________ 40 CM445 Maintenance

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

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

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

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

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

Fig. 27: Oil sampling procedure Oil fill plug

Typical siphon pump and bottle

Oil level

Place end of siphon tube approximately half way into sump

Note: Hold sample pump and bottle below oil level

______________________________________________________________ A6474X363 REV 0 41

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

IMPORTANT

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

Cutter Motor Bearings

Lubricate the left and right cutter head motor bearings with high temperature lithium complex grease through the two grease fittings located on each side of the cutter head (Fig. 28) using the following procedure: 1. Open the cover (Fig. 28) to access the motor.

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

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

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

3. Replace the plugs in the ports.

! NOTICE

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

________________________________________________________________ 42 CM445 Maintenance

__________________________________________Maintenance Instructions Fig. 28: Cutter motor bearing lubrication (typical each side)

Motor located behind cover

Button type grease fitting

Cutter motor lubrication (2)

Spring loaded grease relief fitting

______________________________________________________________ A6474X363 REV 0 43

Maintenance Instructions __________________________________________ Gathering Head Motor Bearings

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

To lubricate the motors: 1. Open the cover (Fig. 29) to access the motor.

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

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

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

3. Replace the plugs in the ports.

________________________________________________________________ 44 CM445 Maintenance

__________________________________________Maintenance Instructions Fig. 29: Gathering head motor bearing lubrication (typical each side)

Gathering head motor lubrication

Motor located behind cover

Button type grease fitting

Spring loaded grease relief fitting

______________________________________________________________ A6474X363 REV 0 45

Maintenance Instructions __________________________________________ Pump Motor Bearings

Lubricate the pump motor (Fig. 30) with high temperature lithium complex grease (Spec. 100-14) through the two (2) grease fittings located the right side of the machine using the following procedure: 1. Open the cover (Fig. 30) to access the motor.

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

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

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

3. Replace the plugs in the ports.

Fig. 30: Pump motor bearings

Pump motor lubrication fitting (2)

Motor located behind cover

________________________________________________________________ 46 CM445 Maintenance

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

Change the oil in both tram gear cases (Fig. 31).

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

2. Clean and reinstall the drain plug.

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

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

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

6. Clean and reinstall the fill plug.

Fig. 31: Tram gear case Oil fill plug

Oil check

______________________________________________________________ A6474X363 REV 0 47

Maintenance Instructions __________________________________________ Hydraulic Oil, Suction Strainer, and Breather

Change the oil in the hydraulic oil tank (Fig. 32).

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

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

3. Remove and replace the suction strainer.

4. Clean and reinstall the drain plug.

5. Replace both breathers.

6. Add oil to the tank until the oil level is correct on the dipstick.

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

8. Recheck the oil level on the dipstick. Add more oil as needed.

Fig. 32: Hydraulic oil tank Hydraulic oil tank

Hydraulic oil tank

gear case breathers

Dip stick location

Change the breathers on the main and input cutter gear cases, the CLA head pot and transfer gear cases, and the tram gear cases. Reference drawings in the parts book for your machine for breather locations.

________________________________________________________________ 48 CM445 Maintenance

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

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

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

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

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

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

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

6. Loosen the socket head capscrews that secure the shims between the shim retainer and the conveyor lower pivot plate (Fig. 33).

Fig. 33: Shim removal Socket head capscrews

Shim retainer

Lower pivot plate

Shims

7. Connect the trailing cable to energize the miner.

______________________________________________________________ A6474X363 REV 0 49

Maintenance Instructions __________________________________________ !

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

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

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

10. Replace the removed shims (Fig. 33) 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. 34). If the sections are not horizontally aligned, then add or subtract shims as required.

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

17. Securely retighten the socket head capscrews.

Fig. 33: Tail shim adjustment Correct gap and alignment Conveyor tail section

Conveyor front section

Add shims Conveyor tail section

Conveyor front section

Remove shims Conveyor tail section

Conveyor front section

________________________________________________________________ 50 CM445 Maintenance

___________________________________________Lubricant Specifications Introduction

The following lubricants specifications are referenced throughout this manual.

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

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

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

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-29° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

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

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

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

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

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

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

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

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

______________________________________________________________ A6474X363 REV 0 51

Lubricant Specifications___________________________________________ Spec. 100-1: Anti-wear hydraulic oil approved suppliers 1 2 3 4

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

5 6 7 8 9 10 11 12

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

13

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

14 15 16 17 18

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

________________________________________________________________ 52 CM445 Maintenance

___________________________________________Lubricant Specifications Spec. 100-3: Extreme pressure motor bearing grease and hand grease specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

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

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

373° F 2.5

Rust Inhibitors

Required

Yes

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

Not more than 5% loss

Water Washout (ASTM D-1264)

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

Grease Mobility

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

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

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

31 200

4.25 4.00

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

1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

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

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

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

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

______________________________________________________________ A6474X363 REV 0 53

Lubricant Specifications___________________________________________ Spec. 100-14: Synthetic lithium complex grease for electric motor bearings Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

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

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

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

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

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

1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

________________________________________________________________ 54 CM445 Maintenance

___________________________________________Lubricant Specifications Spec. 100-15: High demulsibility extreme pressure gear oils specification Limit

Type

ISO VG

220

220

A.G.M.A. Grade

5EP

5EP

Viscosity Index (ASTM D-2270)

Min. 95

98

Flash Point (ASTM D-92)

Min. 450° F (232° C)

480° F (250° C)

Pour Point (ASTM D-97)

Max. 15° F (-9° C)

-27° F (-17° C)

Timken Test (ASTM D-2782)

Min. 65 lbs.

70 lbs.

FKOUR Ball EP Test (ASTM D-2783)

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

270 57

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

Not more than 6%

4.6%

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

Not less than 12th stage.

>12

SUS @ 100° F

950-1200

1119

SUS @ 210° F

85-110

95.5

CST @ 40° C

198-242

212

CST @ 100° C

15.24

18.7

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

0 ml. Emulsion Max.

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

Copper Corrosion (ASTM D-130)

1 or 1b

1b

Foam Test (ASTM D-892)

Pass

Pass

Rust Test (ASTM D-665)

Pass

Pass

Viscosity (ASTM D-445)

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

1

Supplier Conoco Inc.

Brand name GLW Gear Oil 220

______________________________________________________________ A6474X363 REV 0 55

_______________________________________________________________

________________________________________________________________ 56 CM445 Maintenance

A6474X364 February 2012

Operation and Maintenance Manual Super Simpson Radio Remote Operation A6474X364 (Super Simpson Radio Remote Operation)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information.

The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© CATERPILLAR 2012 ALL RIGHTS RESERVED

________________________________________________ Table of Contents Table of contents

Safety Instructions.......................................................................................4 Remote Operation .......................................................................................7 Introductions .........................................................................................7 General Safety ......................................................................................7 Tramming Safety...................................................................................8 Radio Remote Power On/Off ................................................................10 Miner Starting Procedure......................................................................11 Miner Shutdown Procedure ..................................................................12 Tramming Operation .............................................................................13 Cutter Operation ...................................................................................15 Conveyor Operation..............................................................................16 Scrubber Fan Operation (if equipped) ..................................................17 Lights ....................................................................................................17 Fire Suppression Operation (if equipped).............................................18 Conveyor Boom Control .......................................................................18 Stabilizer Shoe Operation.....................................................................19 Shear Up/Down Operation....................................................................19 Gathering Head Raise/Lower Operation ..............................................19 Circuit Breaker On/Off ..........................................................................20 Emergency Shutdown Controls...................................................................21 Emergency Stop Bypass .............................................................................21 Tram Pendant..............................................................................................23

________________________________________________________________ A6474X364

REV 1

Safety Instructions _______________________________________________ Safety Precautions

!

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

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

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

IMPORTANT

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

!

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

!

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

!

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

!

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

!

WARNING Before starting the Continuous Miner, make sure that no one is in the red zone.

IMPORTANT

In extremely cold weather, allow motors and gear cases to idle. This will warm the hydraulic oils and lubricants. Still oils and greases could immobilize the machine.

IMPORTANT

A pump “growl” means not enough oil is reaching the pumps through the suction lines.

Ensure the pump gets primed before continuing operation. Always check the oil level.

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

!

DANGER

!

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

________________________________________________________________ 4 Super Simpson Radio Remote Operation

______________________________________________ Safety Instructions !

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

Manual operation generally is for troubleshooting and maintenance under roof support.

IMPORTANT

!

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

WARNING Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.

IMPORTANT

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

!

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

!

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

!

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

!

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

IMPORTANT

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

IMPORTANT

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

!

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

IMPORTANT

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

IMPORTANT

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

IMPORTANT

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

!

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

_____________________________________________________________ A6474X364 REV 1 5

Safety Instructions _______________________________________________ !

WARNING Always ensure operator safety while operating the machine.

!

WARNING Always be alert to hazardous conditions and take corrective action as necessary.

IMPORTANT

Care should be taken not to stall cutters on conveyor during cutting operations. Severe damage to motors and gear boxes could occur if cutters or conveyor are repeatedly stalled.

IMPORTANT

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

________________________________________________________________ 6 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Introduction

After reading and understanding the Operation Manual and completing training, the operator is ready to operate the miner. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

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

For complete maintenance procedures, see the Maintenance Manual.

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

General Safety

1. Communication is a key element in maintaining safety while operating the miner. Exact instructions and warnings should be given to, and thoroughly understood by, each person working with or around the miner. Good communications between the entire crew must be maintained throughout the shift.

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

3. This machine must be maintained in a permissible condition (if applicable), following the guidelines, procedures, and requirements as set forth in the sales order specification.

4. Make a visual check of the miner before energizing. Look for loose bolts, covers, locking devices, damaged parts, and cracked or broken lenses.

Any part of the machine which does not function properly is a hazard. Report it immediately to your immediate supervisor or their designee.

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

_______________________________________________________________ A6474X364 REV 1 7

Remote Operation ________________________________________________ Tramming Safety

1. Communicate your intentions to the employees affected by the movement of the machine.

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

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

4. Position the cutter and gathering head for tramming.

5. Position the stabilizer shoe for tramming.

6. Position yourself such that you are completely clear of the miner. If equipped, position your body completely inside the operator's compartment, facing the intended direction of travel.

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

________________________________________________________________ 8 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Fig. 1: Radio remote 1

7

8

2

9

3

10

4

5

11

12

6

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

1.

2.

3.

4.

5.

6.

Tram controls Machine stop Tram speed/water spray/control system menu Stabilizer controls/lights/machine stop bypass Gathering head float-up/circuit breaker on-off Shear up-down

7.

8.

9.

10.

11.

12.

Radio remote power/shift key Console display Pump on-off/cutter on-off Fan on-off Conveyor up-down/fire suppression Conveyor left-right

_______________________________________________________________ A6474X364 REV 1 9

Remote Operation ________________________________________________ Radio Remote Power

Radio remote - Power On To turn the radio remote (Fig 1) on: 1. Press and hold the ON key until the remote control no longer displays the HOLD message. Once the remote control is initialized, it will display the channel selected and will then display ON. Note: If, during power up, any other key is pressed, the remote will begin a shutdown procedure and will display SERV, thinking there is a switch failure.

2. The console display should read “HOLD”.

3. Release the key and the display should read “ON”.

Radio remote - Power Off To turn the radio remote (Fig 1) off: 1. Move the “ON/OFF” key to the “OFF” position.

2. The console display will show the “OFF” message for a moment and will then turn itself off.

Radio remote - Emergency Stop The Continuous Miner can be quickly shutdown at any time by using the red emergency “”STOP” button on the radio remote (Fig 1).

To quickly shutdown the miner in an emergency: 1. Press the “STOP” key down.

2. The console will send the stop command to shutdown all motors and functions on the miner and will then turn itself off. Note: The stop button is defaulted to function as a machine shutdown (power center trip). Once it is pressed, the remote transmits that message for several seconds before shutting itself down. The machine controller will energize the machine OE relay in order to trip the power center but will immediately shutdown the pump motor and other functions. Via the system menu, the function of this button can be set to shut down the pump motor only but default is power center trip.

3. To turn the console back on, the “STOP” key must be pulled out to return it to its original position.

________________________________________________________________ 10 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Miner Starting Procedure Improper position could result in injury or death to the operator by crushing him against the rib or roof supports. It may also cause him to run over the trailing cable or dislodge the roof supports.

!

DANGER

!

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

!

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

!

WARNING Before starting the continuous miner, make sure that no one is in the red zone.

IMPORTANT

In extremely cold weather, allow motors and gear cases to idle. This will warm the hydraulic oils and lubricants. Still oils and greases could immobilize the machine.

IMPORTANT

A pump “growl” means not enough oil is reaching the pumps through the suction lines.

Ensure the pump gets primed before continuing operation. Always check the oil level.

!

WARNING Visually check for other personnel and verbally shout a warning before starting this machine. Make sure all personnel are completely clear of the machine and it’s components and check that any loose material, tools, oil cans or other objects are clear from the area before starting the machine.

1. Turn the main circuit breaker to the “ON” position.

2. Select “REMOTE” on the mode of operation switch on the front of the control case.

3. Turn the radio remote on: a. Press and hold the ON key until the remote control no longer displays the HOLD message. Once the remote control is initialized, it will display the channel selected and will then display ON. Note: If, during power up, any other key is pressed, the remote will begin a shutdown procedure and will display SERV, thinking there is a switch failure.

4. Press and hold “SHIFT” for 1/4 second. Note: The “SHIFT” key has a two second timeout - if the motor start button is not pushed within two seconds, the “SHIFT” key must be released and pressed again. Continue to hold “SHIFT” and press “PUMP ON”. Hold both keys in until the pump starts.

5. Release the “PUMP ON” key 6. Release the “SHIFT” key and the pump should continue to run.

IMPORTANT

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

_______________________________________________________________ A6474X364 REV 1 11

Remote Operation ________________________________________________ Miner Shutdown Procedure

The machine must be properly shutdown before leaving the area or before performing any maintenance or service.

1. Back the miner about one foot from the face providing sufficient clearance and shut off the cutter head motors (see Cutter operation).

2. Tram the miner to an area of well supported roof. Park the machine in its designated parking area out of traffic, on flat, solid ground. If it is not possible to park the machine on flat ground, park the machine at a right angle to the slope.

3. Empty the conveyor and shut it off (see Conveyor operation).

4. Lower the cutter head to the floor.

5. Lower the conveyor and gathering head.

6. Press and hold the “PUMP OFF” key until the pump motor shuts off then release the key.

7. Turn off the water sprays (if equipped).

8. Turn off the radio remote.

9. Shut off the main power supply.

10. Shut off the mine water supply (if equipped).

________________________________________________________________ 12 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Tramming Operation

Note: Tramming requires cooling water to prevent damage.

1. Ensure that the stabilizer shoe is raised away from the mine floor.

2. Raise cutter boom to best possible position to allow clearance from roof, ribs, and floor.

3. Raise gathering head away from the mine floor.

4. Adjust conveyor boom to best possible position to allow clearance from roof, walls, and floor.

5. Ensure adequate clearance at all times while tramming machine. Be aware of people, equipment, and cables.

6. Press and release the “TRAM 2-3” key to enable tramming. Once enabled, the tram levers can be used to drive the left and right tramming tracks forward or reverse. If the tram levers are released for a continuous period of five (5) seconds, tramming will be disabled. Press and release the “TRAM 2-3” to re-enable tramming.

Tram Speed: The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2, and SPEED 3).

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

2. Once in SPEED 2, press the tram levers and “TRAM 2-3” together to move from SPEED 2 to SPEED 3.

Speed is limited by the control system.

_______________________________________________________________ A6474X364 REV 1 13

Remote Operation ________________________________________________ Cutter Operation

To start the cutter motors 1. Ensure that the cutter head is not in contact with anything. Cutter head motors must never be started under a load.

!

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

2. Warn ALL CLEAR before starting the cutter head.

!

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

3. Ensure that the pump motor is running. The cutter motors will not run if the pump motor is not running.

4. Press and hold “SHIFT” for 1/4 second. Continue to hold shift and press “CUTTER ON”. Continue to hold both keys in until the cutter motors turn on. Note: Both cutter motors do not start at the same time. There will be preset time delay between the left and right motors starting.

6. Release the “CUTTER ON” key.

7. Release the “SHIFT” key.

IMPORTANT

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

________________________________________________________________ 14 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Conveyor Operation !

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

To start the conveyor motors in forward 1. Place conveyor boom in desired position.

2. Warn ALL CLEAR before starting the conveyor.

3. Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.

4. Press and hold “SHIFT” for 1/4 second. Continue to hold “SHIFT” and press “CONV ON”. Continue to hold until the conveyor motors turn on and the conveyor starts to run in the forward direction.

5. Release the “CONV ON” key.

6. Release the “SHIFT” key.

IMPORTANT

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

To stop the conveyor motors when running in forward 1. Press and hold the “CONV OFF” key. The conveyor motors should shutdown immediately.

To start the conveyor motors in reverse (momentary only) 1. Place conveyor boom in desired position.

2. Warn “ALL CLEAR” before starting the conveyor.

3. Ensure that the pump motor is running. The conveyor motors will not start if the pump motor is not running.

4. Press and hold “SHIFT” for 1/4 second. While holding “SHIFT”, press “CONV REV”. Continue to hold until the conveyor motor turns on and the conveyor starts to run in reverse.

5. The conveyor will continue to run in reverse until the “CONV REV” or the “SHIFT” key is released.

_______________________________________________________________ A6474X364 REV 1 15

Remote Operation ________________________________________________ Scrubber Fan Operation (if equipped)

To start the scrubber fan motor 1. Ensure that the pump motor is running. The scrubber motor will not start if the pump motor is not running.

2. Press and hold the “SHIFT” key for 1/4 second. While holding “SHIFT”, press “FAN ON”. Continue to hold until the scrubber fan motor turns on.

3. Release the “FAN ON” key.

4. Release the “SHIFT” key.

IMPORTANT

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

To stop the scrubber fan motor 1. Press and hold the “FAN OFF” key. The fan motor will shutdown immediately.

2. Release the “FAN OFF” key.

Lights

To turn the headlights on or off 1. Press the “SHIFT” and “LIGHTS” keys together to turn the lights on.

2. Press the “SHIFT” and “LIGHTS” keys together to turn the lights off.

________________________________________________________________ 16 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Fire Suppression (if equipped)

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

When in “REMOTE” mode, the fire suppression can be activated from the radio remote as follows: 1. Press the “SHIFT” and “FIRE” keys at the same time and hold for five (5) full seconds.

2. After five seconds, the fire suppression system will activate. At this time, the “SHIFT” and “FIRE” keys can be released.

Conveyor Boom Control

The pump motor must be running in order to operate the conveyor raise, lower, and swing functions.

To position the conveyor: 1. Press the “CONVEYOR ” key to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.

2. Press the “CONVEYOR ” key to the right to swing the conveyor tail to the left. The solenoid controlling the right conveyor swing will remain energized until the key is released.

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

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

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

_______________________________________________________________ A6474X364 REV 1 17

Remote Operation ________________________________________________ Stabilizer Shoe Operation

The pump motor must be running in order to raise or lower the stabilizer cylinder.

1. Press “STAB UP” to raise the stabilizer cylinder. The stabilizer cylinder solenoid remains energized until the key is released.

2. Press “STAB DWN” to lower the stabilizer cylinder. The stabilizer cylinder down solenoid remains on until the key is released.

Shear Up/Down Operation

The pump motor must be running in order to raise or lower the cutter head.

1. Press “SHEAR UP” to move the cutter head up. The shear up solenoid remains energized until the key is released (unless height limiting is in force).

2. Press “SHEAR DWN” to move the cutter head down. The shear down solenoid remains energized until the key is released.

Gathering Head (Pan) Raise/Lower Operation

The pump motor must be running in order to raise or lower the gathering head (pan).

1. Press “PAN UP” to lift the gathering head. The pan up solenoid remains energized until the key is released.

2. Press “PAN FLOAT” to “float” the head down.

Note: The pan float solenoid output is configurable. The system defaults to pan assist active, which energizes the pan float solenoid from key press until the pump is shut off or the pan UP key is pressed. Via the system menu, pan assist can be turned off and then the solenoid output only energizes while the key is pressed.

________________________________________________________________ 18 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Circuit Breaker ON/OFF (optional)

The control system allows the machine circuit breaker “CB1” to be turned on and off with the radio remote. Normally, this requires that the control system power supply have a battery back-up.

To turn the circuit breaker off 1. Press and hold the “SHIFT” and “C.B. OFF” keys together for five (5) seconds. After five (5) seconds, the breaker off solenoid will energize, turning off the machine circuit breaker.

To turn the circuit breaker on It is essential that a battery backup version of the control system power supply be installed for this function to be available. Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power, a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged, then it will not be possible for the breaker to be turned on from the radio remote.

1. Press and hold the “SHIFT” and “C.B. ON” keys together until the breaker has engaged; this may take one (1) to two (2) seconds. After two (2) seconds, the breaker on solenoid will energize, turning on the machine circuit breaker.

IMPORTANT

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

_______________________________________________________________ A6474X364 REV 1 19

Remote Operation ________________________________________________ Emergency Shutdown Controls

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

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

Location

Action

Result

Main Circuit Breaker

Main Disconnect Box

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

Machine Stop

Control Case

Push to activate.

Shuts down all motors on the machine.

E- STOP

Radio Remote Push to activate.

Shuts down all motors on the machine.

Pump Off

Radio Remote Push toggle switch up to activate.

Shuts down all motors on the machine.

Machine Stop

Tram Pendant Push to activate.

Shuts down all motors on the machine.

Machine Left Side

Emergency Stop (Machine Stop) Bypass (optional)

!

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

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

Emergency Stop (Machine Stop) Bypass Procedure

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

________________________________________________________________ 20 Super Simpson Radio Remote Operation

_______________________________________________ Remote Operation Fig. 10: Bypass key Press key down

Press key up

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

Fig. 11: Bypass enable delay period timer

Five second timer

_______________________________________________________________ A6474X364 REV 1 21

Remote Operation ________________________________________________ 3. Once the five second delay has passed, the system enters bypass mode.

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

Fig. 12: Bypass active countdown timer

Thirty second timer

________________________________________________________________ 22 Super Simpson Radio Remote Operation

___________________________________________________ Tram Pendant Tram Pendant

The machine can be operated using a pendant control (Fig. 11) connected to the miner by an umbilical cable. This control is used in the event that the operator loses radio link with the mine to safely recover the miner from the face to an area under supported roof for troubleshooting and maintenance.

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

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

After plugging in the umbilical cord, the “MACHINE” mode of operation switch must be rotated to the “E-TRAM”.

IMPORTANT

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

Fig. 11: Tram pendant

_______________________________________________________________ A6474X364 REV 1 23

Tram Pendant____________________________________________________ Tram Pendant Functions

The tram pendant has the following functions:

“MACHINE STOP”

Depressing the “MACHINE STOP” button will immediately stop all motors.

“PUMP START/ENABLE”

The “PUMP START/ENABLE” button is used with the “PUMP ON” button to start the pump motor.

“PUMP ON”

The “PUMP ON” button is used to turn on and off the pump motor.

When pressed by itself, “PUMP ON” will turn off the pump motor.

When used in conjunction with “PUMP START ENABLE”, “PUMP ON” will start the pump motor: 1. Press and hold the “PUMP START/ENABLE” button.

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

3. Release the buttons.

“TRAM”

Press “TRAM” to activate the tramming function. Once “TRAM” is pressed, the “TRME” LED lights yellow for a preprogrammed number of seconds. If tram buttons are not used within this programmed time period, the LED extinguishes and tramming is disabled.

“TRAM FWD”

After pressing “TRAM ENABLE”, press the right “TRAM FWD” button to tram the right track forward, press the left “TRAM FWD” button to tram the left track forward, or press both “TRAM FWD” buttons together to tram both tracks forward.

“TRAM REV”

After pressing “TRAM ENABLE”, press the right “TRAM REV” button to tram the right track in reverse, press the left “TRAM REV” button to tram the left track in reverse, or press both “TRAM REV” buttons together to tram both tracks in reverse.

“CUTTER RAISE”

When pressed, the “CUTTER RAISE” button raises the cutter head.

The pump motor must be on for this button to be active.

“CUTTER LOWER”

When pressed, the “CUTTER LOWER” button lowers the cutter head.

The pump motor must be on for this button to be active.

LED lights

There are four (4) LED lights across the top of the pendant: “MODE”: LED blinks green when power is present, indicating the unit has power and is on.

“TRME”: Yellow LED indicates that tram action is enabled.

“TRML”: Red LED indicates that tram left command is being sent.

“TRMR”: Red LED indicates that tram right command is being sent.

________________________________________________________________ Super Simpson Radio Remote Operation

A6474X365 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X365 (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

________________________________________________________________ A6474X365

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!

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 REV 0 13

Tram Motor______________________________________________________ Fig. 4: Tram motor removal and installation 1 2

3

4 7 9 5

7 6

6 1.

2.

3.

4.

5.

6.

7.

8.

9.

8

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

________________________________________________________________ 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.

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 REV 0 17

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

6

3

7

4 2

11

9

8

12

10

13

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.

______________________________________________________________ A6474X365 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).

______________________________________________________________ A6474X365 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.

______________________________________________________________ A6474X365 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

______________________________________________________________ A6474X365 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.

!

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.

!

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.

______________________________________________________________ A6474X365 REV 0 27

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

1

2

3 4

1.

2.

3.

4.

5.

6.

7.

5

7 6

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

______________________________________________________________ A6474X365 REV 0 29

__________________________________________________________

A6474X366 April 2012

CM445 Continuous Miner A6474X366 (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 Foot Shaft.......................................................................................... 10 Gathering Head Motor Torque Shaft................................................. 14 Gathering Head Drive Motor ............................................................. 17 Gathering Head Cylinder................................................................... 21 Gathering Head Assembly ................................................................ 25 Gathering Head Gear Case .............................................................. 29 Centrifugal Loading Arm (CLA) ......................................................... 33 Conveyor Chain Adjustment Procedure............................................ 36 Conveyor Chain................................................................................. 37 Tail Roller .......................................................................................... 41 Discharge Conveyor.......................................................................... 45 Conveyor Assembly .......................................................................... 49 Tail Shim Adjustment Procedure....................................................... 53 Conveyor Lift Cylinder ....................................................................... 55 Conveyor Swing Cylinder .................................................................. 60

________________________________________________________________ A6474X366

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.

!

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.

!

DANGER

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

!

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

!

WARNING 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

!

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.

!

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.

______________________________________________________________ A6474X366 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 12 6 1/4 25 12 5/16 44 22 3/8 70 35 7/16 107 53 1/2 154 77 9/16 212 106 5/8 376 188 3/4 606 303 7/8 909 454 1 1287 644 1-1/8 1875 938 1-1/4 2382 1191 1-3/8 3161 1581 1-1/2 4988 2494 1-3/4 7500 3750 2 10969 5484 2-1/4 15000 7500 2-1/2 17794 8897 2-3/4 23507 11753 3 30286 15143 3-1/4 38266 19133 3-1/2 47545 23773 3-3/4 58100 29085 4

______________________________________________________________ A6474X366 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 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 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)

______________________________________________________________ A6474X366 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:

!

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.

!

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. 5): 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.

______________________________________________________________ A6474X366 REV 0 11

Foot Shaft_______________________________________________________ Installation Procedure

To install the foot shaft (Fig. 5): 1. Position the CLAs as shown in Fig. 5.

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. 5: 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

______________________________________________________________ A6474X366 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

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.

!

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. 6): 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. 6): 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.

______________________________________________________________ A6474X366 REV 0 15

Gathering Head Motor Torque Shaft _________________________________ Fig. 6: Gathering head motor torque shaft removal and installation

1 5 2

1.

2.

3.

4.

5.

3

4

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

________________________________________________________________ 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.

______________________________________________________________ A6474X366 REV 0 17

Gathering Head Drive Motor________________________________________ Removal Procedure

To remove a gathering head motor (Fig. 7): 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. 7): 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.

______________________________________________________________ A6474X366 REV 0 19

Gathering Head Drive Motor________________________________________ Fig. 7: Gathering head drive motor removal and installation

3

1

6 4 2

5 7

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

________________________________________________________________ 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.

______________________________________________________________ A6474X366 REV 0 21

Gathering Head Cylinder __________________________________________ Removal Procedure

To remove a gathering head cylinder (Fig. 8): 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. 8): 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.

______________________________________________________________ A6474X366 REV 0 23

Gathering Head Cylinder __________________________________________ Fig. 8: Gathering head cylinder removal and installation

6 5

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.

______________________________________________________________ A6474X366 REV 0 25

Gathering Head Assembly _________________________________________ Removal Procedure

To remove the gathering head assembly (Fig. 9): 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. 9): 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.

______________________________________________________________ A6474X366 REV 0 27

Gathering Head Assembly _________________________________________ Fig. 9: Gathering head assembly removal and installation

7

6

5

4 1 3

1.

2.

3.

4.

5.

6.

7.

2

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

________________________________________ 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.

______________________________________________________________ A6474X366 REV 0 29

Gathering Head Gear Case _________________________________________ Removal Procedure

To remove a gathering head gear case and pot (Fig. 10): 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.

________________________________________________________________ 30 CM445 Mechanical - Gathering Head and Conveyor

________________________________________ Gathering Head Gear Case Installation Procedure

To install a gathering head gear case and pot (Fig. 10): 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).

______________________________________________________________ A6474X366 REV 0 31

Gathering Head Gear Case _________________________________________ Fig. 10: Gathering head gear case removal and installation

3

1

2 4 5

9

7 4

1.

2.

3.

4.

5.

6.

7.

8.

9.

6 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 locking collar Foot shaft cover Gear case Cover over two wedge blocks

________________________________________________________________ 32 CM445 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm Introduction

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

Tool Set

Basic Tool Set Torque Wrench

Safety

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

Blocking

!

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.

______________________________________________________________ A6474X366 REV 0 33

Centrifugal Loading Arm __________________________________________ Removal Procedure

To remove a centrifugal loading arm (CLA) (Fig. 11): 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. 11): 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.

________________________________________________________________ 34 CM445 Mechanical - Gathering Head and Conveyor

__________________________________________ Centrifugal Loading Arm Fig. 11: CLA removal and installation

Required CLA mounting arrangement

3

4

2

5

1 6

1.

2.

3.

4.

5.

6.

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

______________________________________________________________ A6474X366 REV 0 35

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. 12).

Fig. 12: 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.

________________________________________________________________ 36 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Introduction

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

Tool Set

Basic Tool Set Pry Bar

Safety

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

Blocking Puller Cable

!

WARNING 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.

______________________________________________________________ A6474X366 REV 0 37

Conveyor Chain __________________________________________________ Removal Procedure

To remove the conveyor chain (Fig. 13): 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.

________________________________________________________________ 38 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________________ Conveyor Chain Installation Procedure

To install the conveyor chain (Fig. 13): 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.

______________________________________________________________ A6474X366 REV 0 39

Conveyor Chain __________________________________________________ Fig. 13: Conveyor chain removal and installation

Connecting pin

Retaining pin

________________________________________________________________ 40 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________________________Tail Roller Introduction

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

Tool Set

Basic Tool Set Blocking

Safety

When removing or installing the tail roller, 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.

______________________________________________________________ A6474X366 REV 0 41

Tail Roller _______________________________________________________ Removal Procedure

To remove the tail roller (Fig. 14): 1. Position the machine so that the tail roller can be comfortably reached and there is enough room available for its removal.

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

3. Lower the conveyor to a comfortable working height and 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 cap from each end of the tail roller by removing the four (4) 1/2 -13X1-1/2 socket head capscrews.

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

Installation Procedure

To install the tail roller (Fig. 14): 1. Position the tail roller in the conveyor.

2. Install the cap over each end of the tail roller. Apply Loctite 242 to the four (4) 1/2-13X1-1/2 socket head capscrews and insert and torque to 118 ft-lb.

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.

________________________________________________________________ 42 CM445 Mechanical - Gathering Head and Conveyor

_______________________________________________________Tail Roller Fig. 14: Tail roller removal and installation

1

2

3

1. Tail roller 2. Cap (2) 3. Socket head cap screw, 1/2-13X1-1/2 (4 per cap)

______________________________________________________________ A6474X366 REV 0 43

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.

________________________________________________________________ 44 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Discharge Conveyor Removal Procedure

To remove the conveyor discharge (Fig. 15): 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.

______________________________________________________________ A6474X366 REV 0 45

Discharge Conveyor ______________________________________________ Installation Procedure

To install the discharge conveyor (Fig. 15): 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.

________________________________________________________________ 46 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Discharge Conveyor Fig. 15: Discharge conveyor removal and installation 2

1

3 4 5

6 7

8 9 15, 16

14

13 12

11

10

6

5

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)

______________________________________________________________ A6474X366 REV 0 47

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.

________________________________________________________________ 48 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Conveyor Assembly Removal Procedure

To remove the conveyor assembly (Fig. 16): 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.

______________________________________________________________ A6474X366 REV 0 49

Conveyor Assembly ______________________________________________ Installation Procedure

To install the conveyor assembly (Fig. 16): 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.

________________________________________________________________ 50 CM445 Mechanical - Gathering Head and Conveyor

______________________________________________ Conveyor Assembly Fig. 16: Conveyor assembly removal and installation

6 1

7

2

3 4

5

1.

2.

3.

4.

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

5.

6.

7.

8.

8

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

______________________________________________________________ A6474X366 REV 0 51

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.

________________________________________________________________ 52 CM445 Mechanical - Gathering Head and Conveyor

_____________________________________________ Tail Shim Adjustment Adjustment Procedure

Reference Fig. 17: 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. 18). 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.

______________________________________________________________ A6474X366 REV 0 53

Tail Shim Adjustment _____________________________________________ Fig. 17: Tail shim adjustment Socket head capscrew

Shim retainer

Lower pivot plate

Shims

Fig. 18: 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

________________________________________________________________ 54 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________ 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.

______________________________________________________________ A6474X366 REV 0 55

Conveyor Lift Cylinder ____________________________________________

Removal Procedure

To remove a conveyor lift cylinder (Fig. 20): 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. 19).

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.

________________________________________________________________ 56 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________ Conveyor Lift Cylinder Installation Procedure

To install a conveyor lift cylinder (Fig. 20): 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.

______________________________________________________________ A6474X366 REV 0 57

Conveyor Lift Cylinder ____________________________________________ Fig. 19: Conveyor safety support, installed

Conveyor safety support

________________________________________________________________ 58 CM445 Mechanical - Gathering Head and Conveyor

____________________________________________ Conveyor Lift Cylinder Fig. 20: Conveyor lift cylinder removal and installation

1

2

2 1

4

3

5 1.

2.

3.

4.

5.

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

______________________________________________________________ A6474X366 REV 0 59

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.

________________________________________________________________ 60 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Conveyor Swing Cylinder Removal Procedure

To remove the conveyor swing cylinder (Fig. 21): 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.

______________________________________________________________ A6474X366 REV 0 61

Conveyor Swing Cylinder __________________________________________ Installation Procedure

To install the conveyor swing cylinder (Fig. 21): 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.

________________________________________________________________ 62 CM445 Mechanical - Gathering Head and Conveyor

_________________________________________ Conveyor Swing Cylinder Fig. 21: Conveyor swing cylinder removal and installation

5

4

3

1

1.

2.

3.

4.

5.

2

Mounting pin Cotter pin Swing cylinder Cotter pin Mounting pin

______________________________________________________________ A6474X366 REV 0 63

__________________________________________________________

A6474X367 April 2012

CM445 Continuous Miner A6474X367 (Mechanical - Cutter)

SAFETY.CAT.COM

__________________________________________________________

This manual is intended to provide GENERAL product information for the CM445 Continuous Miner. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© CATERPILLAR 2012 ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Instructions............................................................................. 4 Torque Values ................................................................................... 7 Component Weights.......................................................................... 9 Cutter motor torque shaft .................................................................. 10 Cutter head (shear) cylinder.............................................................. 13 Cutter head (boom) assembly........................................................... 18 Cutter motor clutch ............................................................................ 23 Cutter motor ...................................................................................... 26 Cutter drum, end (left or right)........................................................... 30 Cutter drum, center ........................................................................... 34 Gear case.......................................................................................... 38

________________________________________________________________ A6474X367

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.

!

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.

!

DANGER

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

!

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

!

WARNING 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 Continuous Miner

_______________________________________________ Safety Instructions

!

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

!

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

!

WARNING Do not rely on load holding valves when working under the 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.

!

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.

______________________________________________________________ A6474X367 REV 0 5

Safety Instructions _______________________________________________ Introduction

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

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

Tools

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

Illustrations

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

Before Maintenance

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

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

Follow all applicable lockout/tagout procedures.

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

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

Important Notes

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

2. Use only original spare parts when replacing components.

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

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

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

________________________________________________________________ 6 CM445 Continuous Miner

___________________________________________________ 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 12 6 1/4 25 12 5/16 44 22 3/8 70 35 7/16 107 53 1/2 154 77 9/16 212 106 5/8 376 188 3/4 606 303 7/8 909 454 1 1287 644 1-1/8 1875 938 1-1/4 2382 1191 1-3/8 3161 1581 1-1/2 4988 2494 1-3/4 7500 3750 2 10969 5484 2-1/4 15000 7500 2-1/2 17794 8897 2-3/4 23507 11753 3 30286 15143 3-1/4 38266 19133 3-1/2 47545 23773 3-3/4 58100 29085 4

______________________________________________________________ A6474X367 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 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

________________________________________________________________ 8 CM445 Continuous Miner

______________________________________________ Component Weights Component Weights

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

Component

Approximate Weight

Cutter head (shear) cylinder Cutter head (boom) assembly Cutter motor Cutter drum, end (left or right) Cutter drum, center (half) Cutter drum, center (whole) Cutter head gear case

625 lbs (283 kg) 46,500 lbs (21,092 kg) 2,300 lbs (1,043 kg) 1,277 lbs (579 kg) 1,036 lbs (470 kg) 2,072 lbs (940 kg) 5,100 lbs (2,313 kg)

______________________________________________________________ A6474X367 REV 0 9

Cutter Motor Torque Shaft _________________________________________ Introduction

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

Tool Set

Basic Tool Set Slide Hammer Blocking

Safety

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

Cutter Head Safety Support Lifting Device

!

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.

!

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.

________________________________________________________________ 10 CM445 Continuous Miner

_________________________________________ Cutter Motor Torque Shaft Removal Procedure

To remove the cutter motor torque shaft (Fig. 5): 1. Raise the cutter head to a comfortable working height. Block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

3. Remove the two (2) M12X20-10.9 socket head cap screws that secure the end cap to the clutch cover and remove the end cap.

4. Remove the six (6) 5/16-18X1-1/4 hex head bolts and 5/16 lock washers that secure the seal cap and remove the cap to access the shaft.

5. Remove the internal snap ring from the torque limiter and remove shims.

6. Insert a 5/8-11 puller bolt into the end of the torque shaft and remove the shaft.

Installation Procedure

To install the cutter motor torque shaft (Fig. 5): 1. Verify that power is removed from the miner and that the miner is locked/ tagged out.

2. Verify that the cutter head is securely blocked.

3. Grease the torque shaft with NGLI No. 2.5 white lithium grease.

4. Insert the torque shaft in the motor, making sure that the splines are engaged and that the shaft is fully seated.

5. Replace shims and then the internal snap ring. Measure the gap between the shims and the internal snap ring. Add or remove shims as needed to achieve a gap of 0.091 to 0.115 inches.

6. Install seal cap and secure with six (6) 5/16-18X1-1/4 hex head cap screws and six (6) 5/16 lock washers. Torque to 25 ft-lbs (dry).

7. Replace the clutch cover end cap and secure with two (2) M12X20-10.9 socket head cap screws and torque to 93 ft-lbs.

______________________________________________________________ A6474X367 REV 0 11

Cutter Motor Torque Shaft _________________________________________ Fig. 5: Cutter motor torque shaft removal and installation

7

1 2

6 3

1.

2.

3.

4.

5.

6.

7.

4

5

M12X20-10-9 socket head cap screw (2) Clutch cover end cap 5/16-18X1-1/4 hex head cap screw (6) 5/16 lock washer (6) Seal cap Shims Torque shaft

________________________________________________________________ 12 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder Introduction

The following procedure is for the removal and installation of the cutter head (shear) cylinder.

Tool Set

Basic Tool Set Slide Hammer Lifting Device

Safety

When removing or installing a cutter head (shear) cylinder, observe the following safety precautions:

Cutter Head Safety Support Blocking Grease gun with Spec. 100-3 grease

!

WARNING 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.

!

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.

______________________________________________________________ A6474X367 REV 0 13

Cutter Head (Shear) Cylinder _______________________________________ Removal Procedure

Shear cylinder assembly removal and installation To remove a shear cylinder (Fig. 7): 1. Lower the gathering head until it touches the floor. Lower the conveyor tail section until it is even with the floor.

2. Raise the cutter head assembly and install the cutter boom safety supports (Fig. 6).

3. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

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

5. Cycle the shear cylinder control lever several times to release hydraulic pressure.

6. Remove the shear cylinder frame mounting pin: a. Open the front rub rail. b. Remove the four (4) M20 hex head cap screws that secure the two side covers and remove the covers to allow access to the rod mounting pin retainer plate. c.

Remove the two (2) M20X45-8.8 hex head cap screws and M20 lock washers that secure the pin keeper plate and remove the keeper plate.

d. Disconnect and cap the grease line going to the pin. e. Remove the grease fitting adapter from the end of the pin. f.

Insert a slide hammer into the treaded hole (M24X3.0) in the end of the pin and pull the pin.

8. Connect the trailing cable to energize the machine.

9. Start the pump motor.

10. Retract the shear cylinder to pull the rod bearing free from the mounting clevis.

11. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

12. Cycle the shear cylinder several time to release hydraulic pressure.

13. Disconnect, tag, and cap the hydraulic lines to the cylinder.

14. Block the cylinder so that it will not move when the boom clevis pin is removed.

________________________________________________________________ 14 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder 15. Remove the shear cylinder boom clevis pin. a. Remove the two (2) M20X60-8.8 screws and M20 lock washers that secure the cylinder pin keeper plate. b. Remove the grease fitting adapter from the end of the pin. c.

Installation Procedure

Insert a slide hammer into the treaded hole in the end of the pin and pull the pin.

To install a shear cylinder (Fig. 7): 1. Attach an appropriate lifting device to the shear cylinder and position the cylinder so that the cylinder clevis is aligned in the mounting clevis on the cutter head.

2. Install the boom clevis pin. a. Install the pin from the inside, toward the outside, of the machine with the threaded hole end of the pin toward the outside of the machine.

Note: The pin should be inserted so that it’s retaining channel remains outside the bushing. b. Insert the pin keeper plate and secure with two (2) M20X60-8.8 socket head cap screws and M20 lock washers. c.

Install the grease fitting into the end of the pin.

3. Attach the hydraulic hoses to the cylinder.

4. Connect the trailing cable to energize the machine.

5. Slowly extend the shear cylinder so that the rod clevis can be inserted into the frame mounting clevis.

6. Disconnect and lockout the trailing cable. Follow all applicable lockout/ tagout procedures.

7. Install the frame clevis pin. a. Install the pin from the inside, toward the outside, of the machine so that the threaded hole end is toward the outside of the machine. Note: The pin should be inserted so that it’s retaining channel remains outside the bushing. b. Insert the pin keeper plate and secure with two (2) socket head cap screws and lock washers. c.

Install the grease fitting into the end of the pin.

d. Attach the grease line to the grease fitting in the pin.

8. Close and secure the front covers.

______________________________________________________________ A6474X367 REV 0 15

Cutter Head (Shear) Cylinder _______________________________________ 9. Grease the pins with Spec. 100-3 grease.

10. Check the hydraulic oil level and add Spec. 100-1 oil as needed.

11. Connect the trailing cable to energize the machine.

12. Start the pump motor.

13. Remove the cutter head safety support and all blocking.

14. Raise and lower the cutter head to check for correct cylinder function.

________________________________________________________________ 16 CM445 Continuous Miner

_______________________________________ Cutter Head (Shear) Cylinder Fig. 7: Cutter head (shear) cylinder removal and installation

4 2

1

3

8 6

12

7 9

10

11

5

1. Cap screw (4) 2. Washer (4) 3. Frame mounting pin 4. Shear cylinder 5. Rub rail 6. Side cover 7. M20X45-8.8 hex head cap screw (2) 8. Pin keeper 9. M20X60-8.8 ?type screw (2) 10. M20 washer (2) 11. Pin keeper 12. Boom clevis mounting pin

______________________________________________________________ A6474X367 REV 0 17

Cutter Head (Boom) Assembly______________________________________ Introduction

The following procedure is for the removal and installation of the cutter head (boom) assembly.

Tool Set

Basic Tool Set Slide Hammer

Safety

When removing or installing the cutter head (boom) assembly, observe the following safety precautions:

Blocking Grease gun with Spec. 100-3 grease

!

WARNING 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.

!

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.

________________________________________________________________ 18 CM445 Continuous Miner

_____________________________________ Cutter Head (Boom) Assembly Removal Procedure

To remove the cutter head assembly (Fig. 8): 1. Lower the gathering head to the floor.

2. Raise the cutter head to allow access to the upper cutter head (shear) cylinder mounting pin. Securely block the cutter head.

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

4. Turn off the water supply to the machine.

5. Remove the motor access covers (left and right) by removing the bolts that secure the covers to the cutter head frame.

6. Disconnect and tag the power cables from both cutter motors. Be sure to tape the power cables as power will be restored to the machine.

7. Disconnect, tag, and cap the water hoses from both cutter motors 8. Disconnect the water hoses to the dust suppression sprays.

9. Remove the two (2) boom pivot pins. a. Remove the two (2) 5/8-11X2-1/2 socket head cap screws from the retaining plate on the right and left pivot pins and remove the retaining plate. b. On either side, force the main pivot pin inward from the outboard side, using the two (2) 1-8X1-1/2 puller holes, if necessary.

10. Connect electrical power to the machine.

11. Extend the shear cylinders to push the boom pivots out of their tractor frame clevises.

12. Block the boom and shear cylinders to keep them stationary during pin removal.

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

14. Remove the shear cylinder boom clevis pins. a. Remove the two (2) M20X60-8.8 cap screws and M20lock washers that secure the cylinder pin keeper plates on each side of the machine. b. Insert a slide hammer into the treaded hole in the end of the pin and remove the pin from each side of the machine.

15. Connect electrical power to the machine.

16. Retract the shear cylinders to pull their clevises free from the boom clevises.

17. Disconnect, tag, and cap the hydraulic lines from the shear cylinders and the boom.

______________________________________________________________ A6474X367 REV 0 19

Cutter Head (Boom) Assembly______________________________________ 18. Raise the rear of the boom assembly until it is above the top edge of the gathering head backboard.

19. Slowly tram the machine backwards until the cutter boom pivot points clear the front of the gathering head.

Installation Procedure

To install the cutter head (boom) assembly (Fig. 8): 1. Slowly tram the machine forward towards the raised end of the boom until the pivot pins clear the gathering head backboard.

2. Lower the boom pivot points until the shear cylinders can reach their clevises. Block the boom to keep it in a secure position.

3. Reconnect the hydraulic lines.

4. Extend the shear cylinders until the cylinder clevis can be inserted into the cutter boom clevises.

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

6. Align the boom clevis and the cylinder clevis and insert the shear cylinder boom clevis pin.

!

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

7. Insert the keeper plate and secure to the boom clevis with the two (2) M20X45-8.8 hex head cap screws and M20 lock washers.

8. Repeat steps 5 and 6 for the other shear cylinder.

9. Connect electrical power to the machine.

10. Once the shear cylinders are secured to the cutter boom remove the boom blocking to allow boom movement.

11. Retract the shear cylinders to pull the cutter boom pivot points into position in the tractor frame boom pivot clevises.

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

12. Install both cutter boom pivot pins. a. Insert the main pivot pin from the inside toward the outboard side of the clevis. b. Insert the retainer plate and secure with the two (2) 5/8-11X2-1/2 socket head cap screws.

________________________________________________________________ 20 CM445 Continuous Miner

_____________________________________ Cutter Head (Boom) Assembly 13. Disconnect and lock out the electrical power to the miner. Follow all applicable regulations regarding lockout/tagout procedures.

14. Connect the power cables and water cables to the cutter motors (see Cutter motor installation procedure in this chapter).

15. Connect the water hoses to the dust suppression sprays.

16. Connect all hydraulic and lubrication hoses.

17. Grease all pins with Spec. 100-3 grease.

18. Check the hydraulic oil level and add Spec. 100-1 oil as required.

19. Connect electrical power to the machine.

______________________________________________________________ A6474X367 REV 0 21

Cutter Head (Boom) Assembly______________________________________ Fig. 8: Cutter head (boom) assembly removal and installation 1 2 3

4

1.

2.

3.

4.

5.

6.

7.

8.

9.

5

6

7

8

9

Boom pivot pin (2) 5/8-11X2-1/2 (2 each pin) Pin retainer (2) M20X60-8.8 (2 each keeper) M20 lock washer (2 each keeper) Cylinder boom clevis pin (2) Pin keeper (2) Shear cylinder (2) Motor access cover (2)

________________________________________________________________ 22 CM445 Continuous Miner

______________________________________________ Cutter Motor Clutch Introduction

The following procedure is for the removal and installation cutter motor clutch.

Tool Set

Basic Tool Set Blocking Snap Ring Pliers

Safety

When removing or installing the cutter motor clutch, 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.

______________________________________________________________ A6474X367 REV 0 23

Cutter Motor Clutch_______________________________________________ Removal Procedure

To remove the cutter motor clutch (Fig. 9): 1. Raise the cutter head to a comfortable working height and block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/ tagout procedures.

3. Remove the eight (8) 5/8-11X1-3/4 hex head bolts and 5/8 washers that secure the clutch cover to the motor and remove clutch cover.

4. Remove the torque shaft (see Torque shaft removal procedure).

5. Split the clutch by removing the bolts.

6. Remove the clutch retaining nut.

7. Remove the rear half of the clutch.

Installation Procedure

To install the cutter motor clutch (Fig. 9): 1. Ensure that power is removed from the machine and that the trailing cable is locked out.

2. Ensure that the cutter head is securely blocked.

3. Install the rear half of the clutch.

4. Install the clutch retaining nut.

5. Install the bolts that secure the two halves of the clutch together. NOTE: You must follow the manufacturer’s torque specifications when installing these bolts. The instructions are supplied with each new clutch assembly.

6. Install the torque shaft (see Torque shaft installation procedure).

7. Install the clutch cover and secure with the eight (8) 5/8-11X1-3/4 hex head bolts and 5/8 washer..

________________________________________________________________ 24 CM445 Continuous Miner

______________________________________________ Cutter Motor Clutch Fig. 9: Cutter motor clutch removal and installation

5

6

4 3

1 2

10

13

12 8

9 7

16

14 15

11

1. M12X20-10.9 socket head cap screw (2) 2. Motor end cap 3. 5/8-11X1-3/4 hex head cap screw (8) 4. 5/8 lock washer (8) 5. Clutch cover 6. Seal 7. Shims 8. Clutch retaining nut 9. 5/16-18X1-1/4 socket head cap screw (6) 10. 5/16 lock washer (6) 11. Seal cap 12. Snap ring 13. Torque shaft 14. Socket head cap screw (6) 15. Clutch half 16. Clutch half

______________________________________________________________ A6474X367 REV 0 25

Cutter Motor _____________________________________________________ Introduction

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

Tool Set

Basic Tool Set Lifting Device

Safety

When removing or installing a cutter motor, 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.

________________________________________________________________ 26 CM445 Continuous Miner

____________________________________________________ Cutter Motor Removal Procedure

To remove the cutter drum drive motor (Fig. 10): 1. Raise the cutter head to a comfortable working height. Block it in this position under the support frame.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

3. Remove the hex head capscrews that secure the side motor cover and remove the cover to expose the side of the motor and the motor’s junction box.

4. Remove the hex head capscrews that secure the junction box cover and then remove the cover.

5. Locate the three (3) power lug connections and tag the lugs for correct reconnection. Remove the hex head capscrews that secure the three power cable lugs to the three motor lugs.

6. Remove the socket head capscrews that secure the global plug to the junction box.

7. Slide the global plug out of the junction box. At this point, the power cable should be completely disconnected from the motor.

!

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

8. To prevent damage to the motor power cable lugs and gland assembly, cover the power cable and secure it to the miner in a safe location.

9. Disconnect, tag, and cap the two (2) water hoses from the motor cooling water fittings. Remove the two water fittings from the motor and store for reuse during installation. Plug the motor cooling water ports to prevent contamination.

10. Disconnect, tag, and cap the motor bearing grease lines.

11. Securely block the motor so that it will not fall when the mounting bolts are removed.

12. Remove the torque shaft (see Torque shaft removal procedure).

13. Remove the four (4) 1-1/4-7X9 hex head cap screws and elastic lock nuts that secure the motor to the frame.

14. Carefully lower the motor out of the frame.

______________________________________________________________ A6474X367 REV 0 27

Cutter Motor _____________________________________________________ Installation Procedure

To install the cutter drum drive motor (Fig. 10):

!

WARNING MSHA requires that mining equipment electrical components be inspected by a certified electrician before the equipment can be operated.

!

WARNING This procedure involves attaching an electrical power cable to a motor. The trailing cable must be disconnected and locked and tagged out to safely perform this operation.

1. Block cutter motor in position against the rear of the boom so that the motor’s mounting holes align with the boom’s motor mounting holes.

2. Insert the four (4) 1-1/4-7X9 hex head mounting bolts and elastic lock nuts to secure the motor to the boom and torque to 1924 ft-lbs.

3. Install the two motor cooling water fittings into the cooling water ports on the motor.

4. Attach the cooling water hoses to the fittings.

5. Remove the four (4) hex head capscrews that secure the junction box cover and remove the cover.

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

7. Tighten the two socket head capscrews to secure the gland to the junction box.

8. Inside the junction box, locate the three motor power lug connections.

Match the motor lugs with the corresponding power cable lugs.

9. Attach the first motor lug to its corresponding power cable lug by inserting a hex head capscrew through the motor lug, the power cable lug, a flat washer, and a lock washer. Secure the capscrew with a hex nut. Repeat for the other two lugs.

10. When all three connections have been secured, wrap each of the three connections with a layer of rubber tape, then a layer of black tape, and then a layer of glass tape.

11. Connect electrical power to the machine and verify correct phasing. If necessary, rewire to obtain correct rotation 12. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout.

13. Replace the junction box o-ring and cover and secure with the four hex head capscrews.

14. Attach the grease lines to the grease fittings on the motor.

15. Install the torque shaft (see Torque shaft installation procedure)..

________________________________________________________________ 28 CM445 Continuous Miner

____________________________________________________ Cutter Motor Fig. 10: Cutter motor removal and installation 13

12

11

1

10 2

3

4

5

6

7

8

9

1. MX12X20-10.9 socket head cap screw (2) 2. Clutch cover end cap 3. 1-1/4-7 elastic stop nut 94) 4. Motor 5. 5/16-18X1-1/4 socket head cap screw (6) 6. 5/16 lock washer (6) 7. Seal cap 8. Shims 9. Clutch retaining nut 10. Torque shaft 11. Junction box 12. Side cover 13. 1-1/4-7X9 hex head cap screw (4)

______________________________________________________________ A6474X367 REV 0 29

Cutter End Drum _________________________________________________ Introduction

Tool Set Safety

The following procedure is for the removal and installation of a cutter end drum.

The procedure is the same for the right and the left drums.

Basic Tool Set Torque Wrench

Blocking

When removing or installing a cutter end drum, observe the following safety precautions:

!

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

!

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

!

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

________________________________________________________________ 30 CM445 Continuous Miner

_________________________________________________ Cutter End Drum Removal Procedure

To remove an end drum (Fig. 11): 1. Place the miner so that the cutting head is easily accessible and there is side clearance to pull the end drum off of the cutting head.

2. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

3. There may be an optional cap on the end of the drum. If the end cap is present, remove the eight (8) 7/8-9X2-1/2 socket head cap screws that secure it to the drum. Apply heat as necessary to liquify Loctite used when the cap screws were installed.

4. Using the four puller holes in the end cap and four of the eight socket head screw just removed, remove the end cap. Note: If the assembly is seized, it may be necessary to pry on the edges. Care must be taken not to damage the o-ring or its seal land.

5. Attach a lifting device to the end drum and apply tension so that the weight of the drum is supported by the lifting device.

6. Loosen the eighteen (18) 1-8X2-3/4 socket head cap screws that secure the drum to the cutting head hub.

7. Match mark both the end drum and the cutting head hub so that the cutting bit arrangement is not disturbed upon reassembly.

8. Remove the weld securing each key to the end drum and remove the keys.

9. Slowly pull the end drum off of the main assembly, maneuvering it away from the miner.

______________________________________________________________ A6474X367 REV 0 31

Cutter End Drum _________________________________________________ Installation Procedure

To install an end drum (Fig. 11) 1. Verify that power is disconnected and that the trailing cable is properly locked and tagged out. Follow all Mine, State, and Federal lockout/tagout procedures.

2. Attach a lifting device to the end drum.

3. Using the match marks made when the end drum was removed, align the end drum and the cutting head hub.

4. Install the two (2) keys and weld keys to end drum (reference drawing 397038).

5. Install the eighteen (18) 1-8X2-3/4 socket head cap screws to secure the drum to the cutting head hub and torque to 595ft-lbs.

6. Coat the threads of the eight (8) 7/8-9X2-1/2 socket head cap screws with Loctite 242 (blue) and install the eight socket head cap screws to secure the end cap and torque to 490 ft-lbs.

________________________________________________________________ 32 CM445 Continuous Miner

_________________________________________________ Cutter End Drum Fig. 11: Cutter end drum removal and installation

6

7

5 4

3 1

1.

2.

3.

4.

5.

6.

7.

2

Socket head cap screw, 7/8-9X2-1/2 (8) End cap O-ring Cap screw, 1-8X2-3/4 (18) End drum Key (2) 3/4-10X1 cup point set screw (2 per key)

______________________________________________________________ A6474X367 REV 0 33

Cutter Center Drum _______________________________________________ Introduction

The following procedure is for the removal and installation of the cutter center drum.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter center drum, observe the following safety precautions:

!

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

!

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

!

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

________________________________________________________________ 34 CM445 Continuous Miner

_______________________________________________Cutter Center Drum Removal Procedure

To remove the center cutter drum (Fig. 13): 1. Lower the gathering head assembly to the floor.

2. Slowly rotate the cutter head until on of the center drum seams appears directly in front and one appears directly in the rear of the cutter head.

3. Lower the cutter head assembly until it is resting on the floor.

4. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

5. Remove the twenty-four (24) 1-8X6-1/2 hex head bolts that secure the two halves of the center drum to each other. Make sure to collect the bolts, the forty-eight (48) flat washers, and the twenty-four 1-8 lock nuts for use in reassembly.

6. Attach a lifting device to the top half of the center drum and lift the it off of the assembly. It may be necessary to use a pry bar or other force to break the seal between the top and bottom halves of the center drum before the top half can be lifted off.

7. Remove the four (4) alignment keys from the bottom half of the center drum and store for use in reassembly.

8. Connect the trailing cable to energize the machine.

9. Slowly raise the cutter head assembly until it is clear of the bottom half of the center drum.

10. Slowly tram the miner backwards away from the bottom half of the center drum.

______________________________________________________________ A6474X367 REV 0 35

Cutter Center Drum _______________________________________________ Installation Procedure

To install the center cutter drum (Fig. 13): 1. Place the four (4) alignment keys into the keyway slots around the outer edges of the bottom half of the center drum.

2. Slowly tram the miner into position so that the cutter head assembly is position over the bottom half of the center drum.

3. Slowly rotate the cutter head until the center drum drive keys are positioned directly on top and bottom of the cutter head assembly.

4. Slowly lower the cutter head assembly onto the bottom half of the center drum.

5. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

6. Attach a lifting device to the upper half of the center drum.

7. Lower the upper half of the center drum onto the cutter head assembly, making sure that the keyways align with the keys on the bottom half.

8. Check that the upper half of the center drum is fully seated on the bottom half. Using a rod, check the bolt holes for alignment. Adjust the position of the upper half of the center drum as necessary to align the bolt holes.

9. Install the twenty-four (24) 1-8X6/12 hex head bolts that secure the two halves of the center drum to each other, placing a flat washer under the head of the bolt and between the bolt and the nut. Install the bolt heads in the direction of rotation, if lacing permits.

10. Torque the bolts to 595 ft-lbs using the pattern shown in Fig. 12.

Fig. 12: Center drum bolt torque pattern

________________________________________________________________ 36 CM445 Continuous Miner

_______________________________________________Cutter Center Drum Fig. 13: Cutter center drum removal and installation

1

2

3 1.

2.

3.

4.

Lock nut, 1-8 (24) Alignment key (4) Hex head bolt, 1-8X6/12 (24) Flat washer, 1 inch (48) (not shown)

______________________________________________________________ A6474X367 REV 0 37

Cutter Gear Case _________________________________________________ Introduction

The following procedure is for the removal and installation of the cutter gear case. The cutter head gear case may be removed with cutter drum installed but it is easier with it removed.

Tool Set

Basic Tool Set Torque Wrench

Safety

When removing or installing the cutter 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.

________________________________________________________________ 38 CM445 Continuous Miner

_________________________________________________Cutter Gear Case Removal Procedure To remove the cutter drum drive gear case (Fig. 14): 1. Remove the cutter head center drum (see Cutter center drum removal procedure in this manual).

2. Remove the cutter head end drums (see Cutter end drum removal procedure in this chapter).

3. Ensure that the cutter head assembly is adequately blocked.

4. Securely block the cutter head gear case so that it will not fall when it is unbolted from the frame.

!

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

5. Carefully loosen and remove the forty (40) 1-1/4 hex head cap screws that secure the cutter head gear case to the cutter head support frame.

6. Connect the trailing cable to energize the miner.

7. Slowly tram the miner away from the gear case.

!

CAUTION Use care when tramming the miner away from the gear case. While each cutter motor is supported by a bracket at the rear of the motor, excessive bumping could cause the motor to fall.

______________________________________________________________ A6474X367 REV 0 39

Cutter Gear Case _________________________________________________ Installation Procedure

To install the cutter drum drive gear case (Fig. 14): 1. Ensure that the gear case is securely blocked so that the miner can be trammed into position behind it.

2. Slowly tram the miner into position behind the gear box.

3. Disconnect and lockout the trailing cable. Follow all applicable regulations regarding lockout/tagout procedures.

4. Using a metal rod, check for alignment between the mounting holes on the miner and the mounting holes in the gear case.

5. Install the forty 1-1/4 hex head cap screws that secure the gear case to the miner. Torque to 1924 ft-lbs.

6. Install the end drums (see Cutter end drum installation procedure in this manual).

7. Install the center drum (see Cutter center drum installation procedure in this manual).

________________________________________________________________ 40 CM445 Continuous Miner

_________________________________________________Cutter Gear Case Fig. 14: Cutter gear case removal and installation

Spray block location

Washer (40)

Bolt (40)

______________________________________________________________ A6474X367 REV 0 41

_______________________________________________________________

________________________________________________________________ 42 CM445 Continuous Miner

A6474X368 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X368 (Electrical)

SAFETY.CAT.COM

___________________________________________________________

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

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

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

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

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

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

© CATERPILLAR 2012 ALL RIGHTS RESERVED

_______________________________________________________________

Table of contents Safety Instructions ............................................................................. 4 Introduction........................................................................................ 6 Electrical Component Locator ........................................................... 7 Electrical Block Diagram ................................................................... 8 Specifications .................................................................................... 9 Circuits............................................................................................... 10 Power ........................................................................................ 10 Power Center Trip ..................................................................... 11 Control and Lighting .................................................................. 13 Emergency Stop........................................................................ 15 Emergency Stop Bypass ........................................................... 16 Pump ......................................................................................... 18 Cutter......................................................................................... 22 Conveyor ................................................................................... 25 Tram .......................................................................................... 31 Emergency Tram....................................................................... 34 Hydraulic Control....................................................................... 35 Controller Case.................................................................................. 36 Right Wall .................................................................................. 37 Left Wall .................................................................................... 37 Rear Wall................................................................................... 39 Swing Panel .............................................................................. 40

________________________________________________________________ A6474X368

REV 1

Safety Instructions _______________________________________________ Safety Precautions

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

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

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

!

DANGER

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

!

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

!

WARNING 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 Electrical

_______________________________________________ Safety Instructions

!

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

!

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

!

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

!

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

______________________________________________________________ A6474X368 REV 1 5

Introduction _____________________________________________________ Introduction

The purpose of this manual is to give an overview the electrical circuits of the CM445 Continuous Miner. This manual is only intended to familiarize the user with the electrical system. All electrical maintenance must be performed by a qualified person.

Electrical Overview

950VAC, 3-phase power is supplied to the machine via a trailing cable. During normal mining operations, the machine is operated by a radio remote. If required, and under certain circumstances, the control system allows limited functions to be operated from controls located on the machine or from an tram pendant.

Control System Overview

The control system consists of a machine controller, a power supply, input/ output modules, the radio remote, a text display, and an optional graphics display.

The control system monitors machine operating parameters and has the ability to prevent motors from starting or to shut down motors based upon preset parameter values. It will also issue faults, warnings, and alarms based on these parameters. Note: For more information on the control system, see the Graphics Display and Control System manuals in this book.

VFD Overview

The variable frequency drive (VFD) system used 3-phase, 950 VAC motors for tramming. The motors respond to changes in frequency from the control system to tram the machine at infinitely variable speeds.

________________________________________________________________ 6 CM445 Electrical

_____________________________________________________ Introduction Fig. 1: Electrical component locator

1

10

9 8 7 6 2

1.

2.

3.

4.

5.

Tram case Text display Controller case Programming port Main breaker case

3

4

5

6. Tram motor (2) 7. Pump motor 8. CLA junction box 9. Gathering head motor (2) 10. Cuter motor (2)

______________________________________________________________ A6474X368 REV 0 7

Introduction _____________________________________________________ Fig. 2: Electrical block diagram 1

2

3 4 5

7

6

8

21 20

10

11

9 12 13

18

14

25 19

24

15 17

23

16

22

1. Left emergency stop 2. Area light 3. Head light 4. Head light 5. Left CLA motor 6. Left cutter motor 7. Left tram motor 8. Hydraulic oil level switch 9. Right cutter motor 10. CLA junction box 11. Solenoid junction box 12. Head light 13. Pump motor

14. Right CLA motor 15. Head light 16. Head light 17. Area light 18. Right tram motor 19. Main breaker case 20. Dust spray 21. Programming port 22. Emergency tram pendant 23. Transmitter pendant 24. Antenna 25. Miniature text display

________________________________________________________________ 8 CM445 Electrical

______________________________________________________ Installation Specifications

Specifications for the CM445 are as follows: Nominal Line Power ......................................... 950VAC, 60 hz Control Transformer ......................................... 950 VAC to 120VAC and 12VAC Pump Motor Power........................................... 55 hp/41 KW Left Cutter Motor Power ................................... 335 hp/166 KW Right Cutter Motor Power ................................. 335 hp/166 KW Left Gathering Head/Conveyor Motor Power ... 55 hp/41 KW Right Gathering Head/Conveyor Motor Power. 55 hp/41 KW Left Traction Motor Power ................................ 75 hp/42.6 KW Right Traction Motor Power.............................. 75 hp/42.6 KW

______________________________________________________________ A6474X368 REV 1 9

Electrical Circuits ________________________________________________ Power Circuit

All machine motors operate on 995VAC power which is supplied to the machine via the trailing cable. The trailing cable is energized when connected to the power center and the four power center trip contactors are closed.

The machine is protected by a 600 amp main circuit breaker, CB1, set to instantaneously trip at 1500 amps. Once CB1 is closed, the machine is energized.

Power is active in the lighting and control circuits, as well as the pump and conveyor motor circuits. The pump and conveyor motors are further protected by overloads located on each phase of the incoming power to each motor.

The cutter motor circuit is protected by a 600 amp circuit breaker, CB2, set to instantaneously trip at 1200 amps. When CB2 is closed, power is active in the cutter motor circuit. Each cutter motor is further protected by overloads located on each phase of the incoming power to each motor.

The tram circuit is protected by a 400 amp circuit breaker, CB3, instantaneously set to trip at 300 amps. When CB3 is closed, power is active in the tram circuit.

Each motor has a contactor that opens and closes in response to an ON/OFF command. No motor can be started until the pump motor is started (contactor P is closed).

!

WARNING The schematics in this manual are typical and are for reference only. Do not use these schematics to troubleshoot or perform maintenance on the machine. Always refer to the schematic in the parts book for your machine.

________________________________________________________________ 10 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 3: Power circuit

______________________________________________________________ A6474X368 REV 0 11

Electrical Circuits ________________________________________________ Power Center Trip (Pilot Circuit)

Before power is applied to the trailing cable, all four power center trip contacts, PCT, must be closed. If any one set of contacts is open, the pilot circuit is interrupted and the trailing cable will not be energized. To close the PCT, reset the source power (mine power center).

The control system contains a relay for controlling the power center trip. A message can be sent to the power supply at any time to drive the pilot relay output and trip the main power supply to the machine. If this happens, the source power must be reset.

Fig. 4: Power Center Trip

Ground Pilot

________________________________________________________________ 12 CM445 Electrical

________________________________________________ Electrical Circuits Control and Lighting Circuits

The control and lighting circuits are supplied by transformer, T1. The 995VAC incoming power is stepped down through the transformer to 120VAC and 12VAC circuits.

120VAC

The 120VAC circuit supplies power to control system, including the PLC, the battery backup, and the displays, as well as the area lights. It is also the power source for the emergency tram module, the VFD system, and the ground fault monitoring system.

Individual 120VAC circuits are protected by circuit breakers as follows: 1. The main 120VAC supply lines are protected by two 15A circuit breakers, MCB1 and MCB2.

2. Area lights are protected by two 15A circuit breakers, MCB3 and MCB4.

3. The LCD display is protected by two 5A circuit breakers, MCB12 and MCB13.

4. The solenoids are protected by two 5A circuit breakers, MCB10 and MCB11.

5. The 120VAC feed into the PLC is protected by a 5A circuit breaker, MCB9.

12VAC

The 12VAC circuit supplies power to the headlights and the thermistor module.

The individual 12VAC circuits are protected by circuit breakers as follows: 1. The headlights are protected two 25A circuit breakers, MCB5 and MCB6.

2. The thermistor module is protected by two 5A circuit breakers, MCB7 and MCB8.

Headlights

The headlights can be turned on using the light switch on the front of the controller case or the radio remote. When the rotary light switch on the front of the control case is rotated to the “ALL ON” position, the headlight relay, L, signals the normally open contacts, L, in lines 703 and 704 to close, turning on the headlights. Note: the area lights will also be turned on.

When the headlight switch on the radio remote is activated, the control system sends a digital output (X1-H) to energize the headlight relay, L, which signals the normally open contacts, L, in lines 703 and 704 to close, turning on the headlights

Area Lights

The area lights are turned on using the light switch on the front of the controller case. Turning the switch to “ALL ON” or “AREA LIGHTS ONLY” position closes the area lights contacts, LS, located in lines 701, 702, 803, and 804, turning on the area lights. Note: When the switch is in the “ALL ON” position, the head lights will also turn on.

______________________________________________________________ A6474X368 REV 0 13

Electrical Circuits ________________________________________________ Fig. 5: Headlights and Area Lights Circuits

________________________________________________________________ 14 CM445 Electrical

________________________________________________ Electrical Circuits Emergency Stop Circuit

Power to the motor control circuits is isolated by an emergency stop relay, ESR. Relay ESR is controlled by two machine stop switches, one located on the right side of the machine on the front of the control case and the other on the left rear corner of the machine. Pressing either switch interrupts power to the motor relay, stopping all machine functions.

Fig. 6: Emergency Stop Circuit

______________________________________________________________ A6474X368 REV 0 15

Electrical Circuits ________________________________________________ Emergency Stop Bypass Circuit

There is an emergency stop bypass function available from the radio remote that allows the operator to temporarily override an activated emergency stop button.

Pressing SHIFT and BYPASS on the radio remote activated the bypass function (see the Introduction-Operation Manual for Emergency Stop Bypass Operation Procedure). Activating the emergency stop bypass causes the control system to issue a digital output t X1-G that is sent to he emergency stop relay bridge rectifier, BRE, causing the emergency stop relay, ESR, to close. A digital output at X1-J will close the pump contactor and an output at X1-H will close the headlights contactor. Once the pump has started, the trams drives will be energized, allowing the machine to be trammed.

Note: This feature is only for use under supported roof to temporarily bypass an accidentally pushed emergency stop switch.

________________________________________________________________ 16 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 7: Emergency Stop Bypass Circuit

Neutral AC DC

______________________________________________________________ A6474X368 REV 0 17

Electrical Circuits ________________________________________________ Pump Control Circuit

When the main circuit breaker, CB1, and all emergency stop relays, ESR, are closed, the operator can start the pump. When the pump start button is pushed, the control system sends a signal from location X1-J to the pump relay, P, to close the pump contacts, P. A thermistor module monitors the pump RTD at inputs A16-M and A16-N. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming pump power supply, send a signal to the control system at inputs X4-T, X4-U, AND X4-V. If the values received from the thermistor module or the current transducer exceed preset values, the control system will de-energize the relay, P, opening contacts P and shutting down the pump motor.

________________________________________________________________ 18 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 8: Pump Control Circuit

Neutral AC

______________________________________________________________ A6474X368 REV 0 19

Electrical Circuits ________________________________________________ Pump Power Circuit

When the normally open pump contactor, P, is energized, the contactor closes.

The pump contactor supplies 950VAC power to the pump motor through lines 5T1, 5T2, and 5T3. The pump is protected by a current transducer, CT5, that monitors the current draw of the pump during operation. The transducer provides current overload protection while the machine is running. The pump is also equipped with an RTD to provide thermal overload protection. If the control system reads an overload condition, contactor P is opened and the pump is shut down.

Note: There are three pump thermal overloads, CT7A, CT7B, and CT7C, located on each leg of incoming pump power. These thermal overloads protect the pump motor during emergency tramming operations with the remote tram.

________________________________________________________________ 20 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 9: Pump Power Circuit

Ground AC Pilot

______________________________________________________________ A6474X368 REV 0 21

Electrical Circuits ________________________________________________ Cutter Control Circuit

When the main circuit breaker, CB1, all emergency stop relays, ESR, and the cutter circuit breaker, CB2 are closed, and the pump motor is running, the operator can start the cutter motors. The control system issues a command at X1L and X1-S to energize the left and right cutter motor relays, A and B, closing contacts A and B and starting the cutter motors.

A thermistor module monitors the cutter motor RTDs at inputs A16-C, A16-D, A16-E, and A16-F. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs X4-L, X4-M, and X4-N for the left cutter motor and at inputs X4-P, X4-R, and A4-S for the right cutter motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relays, A and B, opening contacts A and B, and shutting down the left and right cutter motors.

________________________________________________________________ 22 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 10: Cutter Control Circuit

Neutral AC

______________________________________________________________ A6474X368 REV 0 23

Electrical Circuits ________________________________________________ Cutter Power Circuit

When the pump motor is running and the normally open circuit breaker, CB2, is closed, the cutter motor contactors, A and B, are energized and close. 995VAC power is supplied to the left cutter motor through lines 1T1, 1T2, and 1T3 and to the right cutter motor through lines 2T1, 2T2, and 2T3. The left cutter motor is protected by current transducer CT1 and the right cutter motor by current transducer CT2. The transducers provide current overload protection while the cutter motors are running. Each motor is also equipped with an RTD to provide thermal overload protection. If the control system reads an overload condition during operation, contactors A and B are opened and the motors are shut down.

Fig. 10: Cutter Power Circuit

Ground AC Pilot

________________________________________________________________ 24 CM445 Electrical

________________________________________________ Electrical Circuits Conveyor Forward Control Circuit

When the pump motor is running, the operator can start the gathering head/ conveyor motors in either forward or reverse direction. When started in the forward direction, the control system issues a command at X1-N to energize the left and right conveyor forward motor relay, CF, closing contact CF and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-LF. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs X4-H, X4-J, and X4-K for the left conveyor motor and at inputs X4-A, X4-B, and A4-C for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CF, opening contact CF, and shutting down the left and right conveyor motors.

______________________________________________________________ A6474X368 REV 0 25

Electrical Circuits ________________________________________________ Fig. 11: Conveyor Forward Control Circuit

Neutral AC

________________________________________________________________ 26 CM445 Electrical

________________________________________________ Electrical Circuits Conveyor Forward Power Circuit

When the pump motor is running, the conveyor motors can be started. When the control circuit energizes the forward contactor, CF, the contactor closes.

995VAC power is supplied to the left conveyor motor through lines CT1, CT2, and CT3 and to the right motor through lines 4T1, 4T2, and 4T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT3 on the left motor and CT4 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor CF, shutting down the conveyor motors.

Fig. 13: Conveyor Forward Power Circuit

______________________________________________________________ A6474X368 REV 0 27

Electrical Circuits ________________________________________________ Conveyor Reverse Control Circuit

When the pump motor is running, the operator can start the gathering head/ conveyor motors in either forward or reverse direction. When started in the reverse direction, the control system issues a command at X1-P to energize the left and right conveyor reverse motor relay, CR, closing contact CR and starting the conveyor motors.

A thermistor module monitors the conveyor motor RTDs at inputs A16-H, A16-J, A16-K, and A16-LF. The values are transmitted to the Input/Output system communication port of the control system over an A2 molded cable. The current transducers, located on each leg of the incoming cutter motor power supply, send a signal to the control system at inputs X4-H, X4-J, and X4-K for the left conveyor motor and at inputs X4-A, X4-B, and A4-C for the right conveyor motor. If the values received from the thermistor module or the current transducers exceed preset values, the control system will de-energize the relay, CR, opening contact CF, and shutting down the left and right conveyor motors.

________________________________________________________________ 28 CM445 Electrical

________________________________________________ Electrical Circuits Fig. 12: Conveyor Reverse Control Circuit

Neutral AC

______________________________________________________________ A6474X368 REV 0 29

Electrical Circuits ________________________________________________ Conveyor Reverse Power Circuit

When the pump motor is running, the conveyor motors can be started. When the control circuit energizes the reverse contactor, CR, the contactor closes.

995VAC power is supplied to the left conveyor motor through lines CT1, CT2, and CT3 and to the right motor through lines 4T1, 4T2, and 4T3.

Each leg of power going into the left and right conveyor motors is monitored by a current transducer: CT3 on the left motor and CT4 on the right. The transducers provide current overload current protection while the motors are running.

Each motor is also equipped with an RTD to provide thermal overload protection. If the control system detects an overload condition, it will open contactor CR, shutting down the conveyor motors.

Fig. 14: Conveyor Reverse Power Circuit

________________________________________________________________ 30 CM445 Electrical

________________________________________________ Electrical Circuits Tram Control Circuit

The tram control circuit uses two three-phase, 995VAC tram motors that respond to change in frequency from the controls to tram in forward or reverse at varying speeds.

The machine control system provides tram control through CAN communication. The drives are equipped with software that has built in protection for the drive itself, allows communication with the control system, and displays information on the graphics display.

Tram speed is limited by the control system based on the following: Cutters not Running

Tramming Operation

Speed Limitation

Both remote control levers forward or reverse

Tram speed selected (1,2, or 3)

One lever forward, one reverse (split track tramming)

Both motors limited to 1st speed

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

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

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

Speed Limitation

Both remote control levers forward

FWD CLEANUP speed regardless of speed selected

Both remote control levers reverse

Tram speed selected (1,2, or 3)

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

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

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

FWD CLEANUP speed regardless of speed selected

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

REV SLEW speed regardless of speed selected

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

Speed Limitation

Both remote control levers forward

Speed limited by control system

Both remote control levers reverse

Tram speed selected (1,2, or 3)

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

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

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

Speed is limited by control system

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

REV SLEW speed regardless of speed selected

______________________________________________________________ A6474X368 REV 0 31

Electrical Circuits ________________________________________________ Fig. 14: Tram Control Circuit

________________________________________________________________ 32 CM445 Electrical

________________________________________________ Electrical Circuits Tram Power Circuit

When the pump motor is running and the traction breaker, CB3, is closed, the control system can operate the traction system. 995VAC power is fed to the VFD components, located in the tram case enclosure and out to the left and right tram motors. Power is supplied to the left tram motor through lines 9T1, 9T2, and 9T3 and to the right tram motor through lines 10T1, 10T2, and 10T3.

Fig. 15: Tram Power Circuit AC DC

______________________________________________________________ A6474X368 REV 0 33

Electrical Circuits ________________________________________________ Emergency Tram Control Circuit

In the event that the machine cannot be trammed using the remote control, an emergency tram pendant, connected to the machine through and umbilical cord, can be used to start the pump and perform tramming operations.

When the machine mode of operation switch, RS1, located on the front of the controller is turned to the “E-TRAM” position, the emergency tram relay, ETR, is energized and the emergency tram and lighting contactors, ETR and L, are closed. Pushing the “PUMP START ENABLE” and “PUMP ON” buttons on the tram pendant will energize the pump relay, P, closing contactors P, and starting the pump motor. Once the pump motor is started, the tram pendant can be used to tram the miner forward or in reverse.

Fig. 15: E-Tram Control Circuit

________________________________________________________________ 34 CM445 Electrical

________________________________________________ Electrical Circuits Hydraulic Control Circuit

The PLC controls hydraulic functions through a solenoid module. When the operator engages a hydraulic function on the radio remote, the solenoid shifts, directing pilot oil to shift the main hydraulic valve.

Fig. 16: Hydraulic Control Circuit

______________________________________________________________ A6474X368 REV 0 35

Controller Case __________________________________________________ Introduction

The controller case (Fig. 17) is typically located on the right rear side of the machine and houses the major electrical control components. These components are mounted on the right, left, and rear walls, as well as on the front and back of a swing panel.

Fig. 17: Controller case

________________________________________________________________ 36 CM445 Electrical

__________________________________________________ Controller Case Controller - Right Wall

The following components are mounted on the controller right wall (Fig. 18): CB2 - 600 amp cutter motor circuit breaker set to instantaneously trip at 1200 amps.

CB3 - 400 amp tram circuit breaker set to instantaneously trip at 300 amps.

Fig. 18: Controller - right wall

CB2

CB3

______________________________________________________________ A6474X368 REV 1 37

Controller Case __________________________________________________ Controller - Left Wall

The following components are mounted on the controller left wall (Fig. 19): CF - Forward contactor for the gathering head motors (left and right) CR - Reverse contactor for the gathering head motors (left and right) P - Pump motor contactor CT3 - Left gathering head motor current transducer CT4 - Right gathering head motor current transducer CT5 - Pump motor current transducer Fig. 19: Controller - left wall

P CR

CF

CT5

CT4

CT3

________________________________________________________________ 38 CM445 Electrical

__________________________________________________ Controller Case Controller - Rear Wall

The following components are mounted on the controller rear wall (Fig. 20): A - Contactor for the left cutter motor B - Contactor for the right cutter motor CT1 - Left cutter motor current transducer CT2 - Right cutter motor current transducer Fig. 20: Controller - rear wall

B

A

CT2 CT1

______________________________________________________________ A6474X368 REV 1 39

Controller Case __________________________________________________ Controller - Swing Panel (front)

The following components are mounted on the front of the controller swing panel (Fig. 21): GFM - Ground fault monitor relay. If a ground is detected on either leg of the 120VAC circuit, the normally closed terminals 11 and 12 on the relay will open and a signal will be sent to the PLC that a fault exists.

MCB19 and MCB20 - 5 amp circuit breakers for the graphics display L - Contactor for the headlights.

ESR - Emergency stop relay. This contactor will open when an emergency stop button is pushed and the pump motor will shut down.

PTOL - Pump thermal overload, active only when the machine in operating in ETRAM mode. If the PTOL detects an overload during emergency tramming operations, the relay will open and the pump motor will shut down.

ETR - Emergency tram relay. This relay is normally open and is closed when the machine mode of operation switch is set to ETRAM. When this relay is closed, the tram pendant is active.

PCT - Power center trip relay. Used to open the pilot core of the trailing cable and trip the power center.

BRE - Bridge rectifier used to convert the AC input from the emergency stop push button circuit to a DC output used to pull in the emergency stop relay, ESR. TPI - Tram pendant interface. Communication interface between the tram pendant and the control system when the miner mode of operation switch isn in ETRAM mode.

Fig. 21: Controller - swing panel (front)

TPI

GFM MCB19 MCB20 BRE

Spares L Spare

PCT

ESR PTOL

ETR ________________________________________________________________ 40 CM445 Electrical

__________________________________________________ Controller Case Controller - Swing Panel (back)

The following components are mounted on the back of the controller swing panel (Fig. 22): Power supply - Power supply, with battery back-up, for the machine controller.

Machine controller - Houses the control system software.

Thermistor module - Communicates the RTD/thermistor inputs to the machine controller.

BR90- Bridge rectifier. Converts the 120VAC supply to 90VDC for the power supply and the solenoids.

Fig. 22: Controller - swing panel (rear) Power supply

Machine controller

Thermistor module

BR90

______________________________________________________________ A6474X368 REV 1 41

___________________________________________________________

A6474X369 April 2012

Operation and Maintenance Manual CM445 Continuous Miner A6474X369 (Hydraulic)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information .

The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

_________________________________________________Table of contents

Table of contents Safety Instructions............................................................................. 4 Introduction........................................................................................ 6 Cylinder locations .............................................................................. 7 Component locations......................................................................... 8 Main control valve ............................................................................. 10 Hydraulic schematics ........................................................................ 11 Hydraulic pump ......................................................................... 11 Main flow/primary pressure ....................................................... 12 Pilot pressure ............................................................................ 13 Cutter head ............................................................................... 14 Conveyor raise/lower ................................................................ 17 Conveyor swing......................................................................... 19 Gathering head ......................................................................... 21 Stabilizer shoe........................................................................... 24 Conveyor chain take-up ............................................................ 26 Reduced MCV pilot pressure/radio function MCV .................... 27 Dust sprays ............................................................................... 28 Water schematics.............................................................................. 29 Water supply circuit................................................................... 30 Water component location ........................................................ 31 Dust-cooling right hand chassis ................................................ 32 Dust-cooling left hand chassis .................................................. 33 Adjustment procedures ..................................................................... 34 Troubleshooting................................................................................. 41

________________________________________________________________ A6474X369

REV 0

Safety instructions _______________________________________________ Safety Precautions

!

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

IMPORTANT

!

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

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

WARNING

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

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

IMPORTANT

The two inch locking ball valve between the pump and main control valve must be locked open in normal operation.

!

DANGER

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

!

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

!

DANGER

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

!

DANGER

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

!

WARNING

!

WARNING Use extreme caution when performing test procedures and making adjustments. Unless noted in the procedures, all controls are to be in the neutral position.

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

IMPORTANT

Always use the proper tools when adjusting valve cartridges.

IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

________________________________________________________________ 4 CM445 Hydraulics

______________________________________________ Safety instructions IMPORTANT

!

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

IMPORTANT

!

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

Before making any further adjustments, verify that the hydraulic oil is at operating temperature.

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

IMPORTANT

The main relief is set higher than the port reliefs and will only relieve if a spike occurs in the system or if the port relief does not function properly. This provides protection of the main pump section.

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

IMPORTANT

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

!

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

!

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

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

______________________________________________________________ A6474X369 REV 0 5

Hydraulic _______________________________________________________ Introduction

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

Fig. 1 gives an overview of hydraulic cylinders located on the CM445 Continuous Miner. Fig. 2 shows the location of other hydraulic components.

Schematics

This section gives general descriptions of the hydraulic components used on the miner along with typical schematics for hydraulic functions. The schematics in this section are general; always refer to the hydraulic schematic in your parts manual supplied with your machine.

Hydraulic maintenance

In order for a hydraulic system to function correctly, it must be properly maintained. Maintenance of the hydraulic system includes: 1. maintaining atmospheric pressure in the tank by keeping the breather clean and free of obstructions; 2. maintaining a sufficient oil level in the tank; 3. maintaining tight, leak-proof pump suction lines to prohibit air being pumped through the system; and 4. changing filters and fluids at prescribed intervals.

For complete maintenance procedures, see the Maintenance Manual.

!

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

________________________________________________________________ 6 CM445 Hydraulics

_______________________________________________________Hydraulic Fig. 1: Cylinder locations

1

1

2

7

2 1

3

4

4

3

3

4

5 5

6

1. Cutter head raise cylinder 2. Gathering head raise cylinder 3. Conveyor lift cylinder

6

6

4. Stabilizer shoe cylinder 5. Conveyor swing cylinder 6. Conveyor chain take-up cylinder

______________________________________________________________ A6474X369 REV 0 7

Hydraulic _______________________________________________________ Fig. 2: Hydraulic component location

4 1

9

2

7

1

6

3 10 8 11 5

12

1.

2.

3.

4.

5.

6.

Breather Tank magnet Oil level switch Gathering head float valve Conveyor chain take-up valve Relief valve, pilot pressure

7. Pilot pressure filter 8. Main pressure gauge 9. Hydraulic pump 10. Valve bank 11. Anti-chatter/maintenance valve 12. Dust cooling solenoid valve

________________________________________________________________ 8 CM445 Hydraulics

_______________________________________________________Hydraulic Main control valve

The Main Control Valve (MCV) (Fig. 3), typically located on the right side of the machine, consists of a series of directional control valves assembled in a row.

Typically, there are (5) five working sections. The MCV directs fluid flow to perform a specific function of work that transforms hydraulic energy into mechanical energy. Control may be initiated manually or electrically (through the solenoid pilot valve).

If the valve sections are separated for any reason, make sure that all reassembled parts are in their proper location and that all mating surfaces are free of burrs and foreign items (paint, dirt, etc.). Assembly stud nuts or screws should be tightened to specified torques.

IMPORTANT

!

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

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

______________________________________________________________ A6474X369 REV 0 9

Hydraulic _______________________________________________________ Fig. 3: Main control valve

2

1

3

8

9

10

11

12 7

6

4

1.

2.

3.

4.

Main inlet relief Pressure supply Tank return “A” port relief (typical)

5.

6.

7.

8.

“B” port relief (typical) “B” pressure solenoid (5 places) “A” pressure solenoid (5 places) Stabilizer shoe section

5

9. Conveyor swing section 10. Conveyor raise section 11. Gathering head section 12. Cutter raise section

________________________________________________________________ 10 CM445 Hydraulics

_______________________________________________________Hydraulic Hydraulic pump assembly

Hydraulic power for all of the hydraulically actuated functions originates with the pump assembly (Fig. 4). Always be sure the shut-off valve (if equipped) is turned to open and the locking device is replaced before starting the machine.

Hydraulic pump on circuit

This pump utilizes two working sections: main flow and pilot flow. Oil is supplied from the oil reservoir through a suction line to the pump inlet ports. The main flow is monitored by a pressure gauge and moves through a bypass filter set at 50 psi and before entering the main control valve. After leaving the pump, the pilot flow enters a bypass filter set at 40 psi. Before continuing on to a non-bypassing filter and the conveyor take-up circuit, dust spray circuit, gathering head circuit and main control valve, pilot oil passes through a relief valve set at 500 psi (34 bar). The flow relief is monitored by a pressure gauge.

IMPORTANT

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

Fig. 4: Hydraulic pump circuit

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 11

Hydraulic _______________________________________________________ Main flow primary pressure circuit

The main flow-primary pressure circuit is powered by the hydraulic pump.

From the pump, oil enters a 10 micron by-passing pressure filter and continues to the main control valve, whose relief is set at 3,000 psi (204 bar). The main control valve operates all cylinder functions.

The auxiliary pressure circuit is powered by the hydraulic pump. Oil from both the primary and auxiliary circuits exits the main control valve and passes to the oil reservoir.

Fig. 5: Main flow-primary pressure circuit (pump running)

Pressure Return Suction

________________________________________________________________ 12 CM445 Hydraulics

_______________________________________________________Hydraulic Pilot pressure circuit

The pilot hydraulic section is a closed-center system powered by the hydraulic pump. It supplies oil flow to the following: 1. hydraulic tension conveyor chain take-up 2. gathering head float circuit, and 3. all solenoid valves, which control the dust sprays, and all main control valve functions.

From the pump, oil flows through a 10 micron bypass filter, a relief valve set at 500 psi (34 bar) and a 3 micron non-bypassing filter before being distributed to the conveyor take-up, gathering head, and main control valve. Pilot pressure oil also flows on to the solenoid valves and the gathering head float circuit.

Fig. 6: Pilot pressure circuit (pump running)

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 13

Hydraulic _______________________________________________________ !

DANGER

The area under and around the raised cutter head is dangerous. Securely block the head before performing maintenance on or below it. Failure to block the raised cutter head could result in serious injury or even death.

Cutter head cylinder

Oil is supplied from the hydraulic pump through a 10-micron bypassing pressure filter to the cutter head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the cutter head cylinder circuit.

Circuit operation - raise

Reference Fig. 8: To manually raise the cutter head (extend cylinders), pull the valve’s handle. Remote operation is achieved by energizing the cutter head raise solenoid (CHU). Oil goes to port “P2” and continues to the extend port of the cylinders, free flowing through the check valve of the load holding cartridge to extend the cylinders. The cutter head raise circuit is protected by a port relief that is set at 3,000 psi (207 bar).

Circuit operation - lower

Reference Fig. 9: To manually lower the cutter head (retract cylinders), push the valve’s handle. Remote operation is achieved by energizing the cutter head lower (CHD) solenoid. Oil goes to the retract port of the cylinders and also pilots open the load holding cartridge, allowing oil to exit through the extend ports on the cylinders. The extend port oil continues to the anti-chatter/maintenance valve block, where it passes through a counterbalance valve, which is set to relieve at 1,200 psi (83 bar), then through the main control valve and into the oil tank. The cutter head lower circuit is protected by a port relief that is set at 2,800 psi (193 bar).

!

DANGER

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

!

DANGER

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

!

WARNING

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

________________________________________________________________ 14 CM445 Hydraulics

_______________________________________________________Hydraulic Fig. 8: Cutter head raise circuit

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 15

Hydraulic _______________________________________________________ Fig. 9: Cutter head lower circuit

Pressure Return Suction

________________________________________________________________ 16 CM445 Hydraulics

_______________________________________________________Hydraulic conveyor raise/lower circuit

Oil is supplied by the hydraulic pump through a 10-micron bypassing pressure filter to the conveyor raise/lower working section of the main valve control. By manual or remote solenoid control, the valve spool allows oil to enter the conveyor raise/lower cylinder circuit

Circuit operation - raise (extend)

Reference Fig. 10: To manually raise the conveyor (extend the cylinders), pull the valve’s handle. Remote operation is achieved by energizing the conveyor raise (CU) solenoid. Oil free flows through pilot operated check valves to the extend port of the cylinders. The conveyor raise circuit is protected by a port relief that is set at 1,800 psi (124 bar).

Circuit operation - lower (retract)

Reference Fig. 11: To manually lower the conveyor (retract the cylinders), push the valve’s handle. Remote operation is achieved by energizing the conveyor lower (CD) solenoid. Oil is directed to the pilot port on the pilot operated check valve on the cylinders. This “pilots” the check valve open and allows oil to exit the cylinders through the main control valve and return to tank. The conveyor lower circuit is protected by a port relief that is set at 1,400 psi (97 bar).

Oil tank fill

The oil tank fill operates from the conveyor lower circuit. Oil goes to lower the conveyor and tees off to a ball valve that is closed. With the conveyor in the down position, the ball valve is manually opened. By remote solenoid control, the spool allows oil to enter the conveyor lower cylinder circuit and runs the oil tank fill. Oil passes thru the ball valve to a jet pump, which creates a venturi (vacuum) effect, pulling oil from the clean oil reservoir through a check valve joining the return oil.

Fig. 10: Conveyor raise

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 17

Hydraulic _______________________________________________________ Fig. 11: Conveyor lower

Pressure Return Suction

________________________________________________________________ 18 CM445 Hydraulics

_______________________________________________________Hydraulic Conveyor swing cylinder circuit

Oil is supplied by hydraulic pump to the conveyor swing working section on the main control valve. By manual or remote solenoid control, the spool allows oil to enter the swing circuit. The range on the cylinder will allow the conveyor tail to move 45 degrees off the centerline of machine in both directions.

Circuit operation right (extend)

Reference Fig. 12: To manually move the conveyor to the right (extend the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the conveyor swing left (CSL) solenoid. Oil free flows to the extend port of the cylinder. The conveyor swing right circuit is protected by a port relief that is set at 1,800 psi (25 bar).

Circuit operation left (retract)

Reference Fig. 13: To manually move the conveyor to the left (retract the cylinder, push the valve’s handle. Remote operation is achieved by energizing the conveyor swing right (CSR) solenoid. Oil free flows to the retract port of the cylinder. The conveyor swing left circuit is protected by a port relief that is set at 1,800 psi (125 bar).

Fig. 12: Conveyor swing cylinder circuit - left

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 19

Hydraulic _______________________________________________________ Fig. 13: Conveyor swing cylinder circuit - right

Pressure Return Suction

________________________________________________________________ 20 CM445 Hydraulics

_______________________________________________________Hydraulic Gathering head raise/ hold/float/lower circuit

Circuit operation Raise (extend)

Circuit operation Lower (retract)

Oil is supplied by the hydraulic pump to the gathering head working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the gathering head raise circuit.

Reference Fig. 14: To manually raise the gathering head pan (extend the cylinder), pull the valve’s handle. Remote operation is achieved by energizing the gathering head up solenoid (GHU). Oil free flows through the check valve in counterbalance valve designated “VR” in the gathering head float valve block and is directed to both cylinder extend ports. At any time while raising the gathering head, the operator can stop the gathering head pan by centering the handle on the valve (or de-energizing the solenoid) and the pan will hold in position. The gathering head raise circuit is protected by a port relief that is set at 1,700 psi (117 bar).

Reference Fig. 15: To put the gathering head pan in the lower mode, push the valve’s handle. Remote operation is achieved by energizing the gathering head down (GHD) solenoid. This vents the port labeled “V” on the gathering head float valve block to tank and allows control of the gathering head lower via the valves in the block. The counterbalance valve “VR” is set to relieve at 1,200 psi to allow the gathering head to drift down at a controlled rate of speed. This valve is adjustable and the rate of retract speed for the cylinders can be increased by decreasing the pressure setting of the valve.

Conversely, the retract speed for the cylinders can be decreased by increasing the pressure setting of the valve. When in the float condition, the cylinders carry some of the gathering head pan weight to prevent the gathering head leading edge from digging into the soft bottom of the mine and moves the machine’s center of gravity forward when mining. The gathering head lower circuit is protected by a port relief that is set at 1,700 psi (117 bar).

The counterbalance valve that is designated “CR” is set to relieve at 1,800 psi (124 bar). This setting will relieve pressure directly to the tank in the event of a forced movement of the gathering head.

The pilot pressure supply for the gathering head float comes from the hydraulic pump through a 10 micron bypass filter and a 3 micron non by-pass filter, to the gathering head float valve. The pilot pump provides make up oil for the gathering head cylinders. When the pan goes over uneven terrain, it may raise quickly and extend the gathering head cylinders at a rapid rate. This temporary condition can create high demand for pilot oil supply. In extreme cases, the pilot pressure may decrease to the point where the main control valve may not have sufficient pilot pressure to shift when the solenoids are engaged. It is, therefore, possible to experience a momentary loss of radio control of the machine.

To minimize the chance of the occurrence, a restrictor orifice is installed in the pilot supply for the valve block. This orifice is protected from contamination by an upstream filter. A downstream check valve keeps system pressure from entering the pilot pressure lines. An adjustable needle valve allows for the bleeding off of pressure for maintenance. This needle valve is to remain closed except for performing maintenance. A gauge is incorporated into the valve block for maintenance and troubleshooting.

______________________________________________________________ A6474X369 REV 0 21

Hydraulic _______________________________________________________ Fig. 14: Gathering head raise circuit

Pressure Return Suction

________________________________________________________________ 22 CM445 Hydraulics

_______________________________________________________Hydraulic Fig. 15: Gathering head lower circuit

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 23

Hydraulic _______________________________________________________ Stabilizer shoe cylinders

Oil is supplied by the hydraulic pump to the stabilizer shoe working section of the main control valve. By manual or remote solenoid control, the valve spool allows oil to enter the stabilizer shoe circuit.

Circuit operation - raise (retract)

Reference Fig. 16: To manually raise the stabilizer shoe (retract the cylinder), pull the valve’s handle. Oil also pilots open the load holding cartridge, allowing oil to exit the extend port of the cylinders. The stabilizer raise circuit is protected by a port relief that is set at 1,150 psi (79 bar).

Circuit operation - lower (extend)

Reference Fig. 17: To manually lower the stabilizer shoe (extend the cylinders), push the valve’s handle. The stabilizer lower circuit is protected by a port relief that is set at 2,450 psi (169 bar).

Fig. 16: Stabilizer shoe circuit - raise (retract)

Pressure Return Suction

________________________________________________________________ 24 CM445 Hydraulics

_______________________________________________________Hydraulic Fig. 17: Stabilizer shoe circuit - lower (extend)

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 25

Hydraulic _______________________________________________________ Conveyor chain take-up circuit (optional)

Reference Fig. 18: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil provides hydraulic power to the hydraulic tension conveyor chain take-up and to the three pilot pressure circuits.

The oil continues to the conveyor chain take-up valve where it passes thru a free flow check valve cartridge out to (2) two conveyor chain take-up cylinder assemblies. The conveyor chain take-up valve consist of a check valve to hold pressure in the circuit, a pressure reducing/relieving cartridge to reduce the pilot pressure to 200 psi for conveyor chain tension and relieves pressure build up above 200 psi. A needle valve cartridge relieves pressure from the circuit for maintenance.

!

DANGER

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

Fig. 18: Conveyor chain take-up circuit

Pressure Return Suction

________________________________________________________________ 26 CM445 Hydraulics

_______________________________________________________Hydraulic Reduced MCV pilot pressure circuit - radio function main control valve

Reference Fig. 19: The pilot pressure circuit is powered by the hydraulic pump.

From the pump, the pilot pressure oil passes through a 10 micron bypassing filter and a 3 micron non-bypassing filter. The pilot pressure is controlled by a pressure relief valve that is normally set to 500 psi (34 bar). When the non bypassing 3 micron filter element starts clogging with trapped particles, the radio system/solenoid functions will slow down, indicating that it is time to change the filter element. For filter element maintenance and changing schedules, see the Maintenance manual.

Oil continues through a pressure reducing valve set a 350 psi to the pilot port of the main control valve. A gauge monitors pressure entering the main control valve. The reduced pressure is required to prevent damage to the main control valve. This supplies oil pressure, which allows the small solenoid pilot valve to shift the spools in the working sections of the main control valve.

Fig. 19: Reduced MCV pilot pressure circuit - radio function main control valve circuit

Pressure Return Suction

______________________________________________________________ A6474X369 REV 0 27

Hydraulic _______________________________________________________ Dust sprays hydraulic circuit

Reference Fig. 20: The pilot-auxiliary hydraulic pressure circuit is powered by the hydraulic pump. From the pump, oil passes through a 10 micron bypassing filter and a 3 micron non-bypassing filter, and is controlled by a pressure relief valve that is normally set to 500 psi (34 bar). The oil continues to a solenoid manifold which has a normally closed cartridge which is used for the dust spray system .

When the D/S coil is energized, it shifts the spool allowing oil to travel to pilot operated normally closed water valve, shifting its spool to allow water to pass through it to the dust spray water circuit.

When the solenoid cell is de-energized, the spool in the hydraulic pilot valve shifts back to its neutral position, venting the hydraulic pilot pressure on the water control valve. This venting allows the water control valves to return to their normally closed positions.

Fig. 20: Dust sprays hydraulic circuit

Pump running

Pump running, pilot operated water valve on

Pressure Return Suction

________________________________________________________________ 28 CM445 Hydraulics

__________________________________________________________ Water Introduction

A water supply to the continuous miner is required for the following purposes: 1. cooling water for all motors, control case and the VFD case 2. spray water for dust suppression The water supplied by the mine must meet the following requirements: 1. minimum flow rate of 25 gpm for cooling 2. total flow rate: based on customer dust plan 3. minimum pressure of 250 psi (dynamic), 500 psi maximum

Schematics

The water system circuits described below are for a typical CM445 miner. The circuit for your machine may vary depending on your dust plan and unique requirements. Always refer to the schematic in the parts book for your machine.

______________________________________________________________ A6474X369 REV 0 29

Water___________________________________________________________ Water supply circuit

Mine water is supplied to the miner from a connection located on the right side of the miner (typical). The water supply to the miner is controlled through a 2 position, manually-operated ball valve.

Water then flows through a water filter and a 75 GPM flow meter to a pilot operated valve for dust sprays. Gauges measure the pressure of the mine water.

The water is directed to a 2-unit pressure manifold, where it supplies water to the left and right hand chassis, and cutter head spray cooling circuits.

Fig. 21: Water supply circuit

________________________________________________________________ 30 CM445 Hydraulics

__________________________________________________________ Water Fig. 22: Dust-cooling component locations 1

1

1

2 2

3

4

5

8,9 6 7

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cutter head front spray manifold Cutter head side spray manifold Right hand chassis side spray manifold Relief valve 0-400 psi pressure gauges (2) Atmospheric relief Ball valve 2-unit pressure manifold 2-way pilot operated valve

______________________________________________________________ A6474X369 REV 0 31

Water___________________________________________________________ Dust-cooling right hand chassis circuit

From the dust-cooling pressure manifold, water is supplied to the right hand chassis spray cooling circuit (Fig. 18) where it supplies spray/cooling water to the following components: control case, RH tram motor, pump motor, and RH and LH CLA motors.

Fig. 23: Dust-cooling right hand chassis circuit

________________________________________________________________ 32 CM445 Hydraulics

__________________________________________________________ Water Dust cooling left hand chassis/cutter head spray cooling circuit

From the dust-cooling pressure manifold, water is supplied to the left hand chassis spray cooling circuit (Fig 19) where it supplies spray/cooling water to the following components: LH tram motor, VFD case, LH and RH cutter head motors, cutting head spray bar manifold, and LH, RH and center cutter head sprays.

Fig. 24: Dust cooling left hand chassis/ cutter head spray cooling circuit

______________________________________________________________ A6474X369 REV 0 33

Adjustment procedures ___________________________________________ Introduction

1. Always refer to the hydraulic schematic in the parts book supplied with your miner.

2. Most relief valves are set to factory specifications and should require no further adjustment.

3. Generally speaking, when adjusting relief valves, turning the adjusting screw in (clockwise) will increase the pressure setting.

4. If the valve pressure setting is unknown, always adjust the valve fully counterclockwise prior to initiating any action that will create flow and prove the potential for pressure.

!

WARNING Use extreme caution when performing test procedures and making adjustments.

Unless noted in the procedures, all controls are to be in the neutral position.

Gauges

The miner is equipped with six (6) hydraulic pressure gauges to aid in setting relief pressures. The gauges measure the following pressures: 1. main pressure (all functions of the MCV) 2. pilot pressure 3. conveyor chain take-up pressure 4. anti-chatter/maintenance (shear down) pressure 5. gathering head float/relief pressure 6. cylinder load pressure

Setting relief valves

Setting relief valve pressure is necessary when a relief valve is replaced with a new unit or when an existing relief valve needs to be adjusted. To properly adjust a relief valve, the circuit must be “dead-headed”.

Setting hydraulic pressures

The adjustment procedure should start with the pilot pressure circuit. This system will build pressure as soon as the pump is started. The main relief valve on the main control valve (MCV) and high speed cutter head raise control valve, as well as the pilot pressure relief and brake cooling circuit pressure reducing valve, should all be adjusted to their lowest setting prior to initial start up and adjustment. Reference circuit descriptions, abbreviations, and terms in the Hydraulic Components section of this chapter.

________________________________________________________________ 34 CM445 Hydraulics

___________________________________________ Adjustment procedures IMPORTANT

Do not start any motors - CLA, cutter head, pump, or traction motors - until all pressures are set. Start the pump motor as directed.

Load holding valve adjustment IMPORTANT

The load holding valve is factory preset and should not be field adjusted.

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

Adjustment procedure should start with the pilot/auxiliary pressure circuit, which will build pressure as soon as the pump is started.

Pilot/auxiliary pump circuit relief valve adjustments !

The following procedure is for start up of new and rebuilt machines:

WARNING Two people are required to adjust pressure settings. One person will make the adjustments while the second person must remain at the machine stop at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

1. Pilot pressure circuit 1: Loosen the nut on the relief valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit. Remove the hose and cap or plug the outlet port of the relief valve. Take care to prevent dirt from entering the system.

2. Sequence valve for Accumulator/Brake circuit: Loosen the nut on the sequence valve cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on the circuit.

3. Pilot pressure circuit 2: Loosen the nut on the relief cartridge and turn the screw out (counter-clockwise) using an Allen wrench to prevent over pressuring the gauge on this circuit.

4. Conveyor chain take-up circuit: Open the needle valve by turning the knob counter-clockwise, opening flow to tank.

5. Start the pump motor (see startup procedure in this manual) and adjust the pilot pressure 2 relief valve. a. Turn the cartridge in until the pressure reading is 2,800 psi (193 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut. c.

Stop the pump motor and reconnect the hose to the pilot pressure 1 relief outlet.

______________________________________________________________ A6474X369 REV 0 35

Adjustment procedures ___________________________________________

IMPORTANT Before making any further adjustments, verify that the hydraulic oil is at operating

temperature.

6. Start the pump motor (See startup procedure in this manual) and adjust the pilot pressure 2 relief valve. a. Turn the cartridge in until the pressure reading is 500 psi (34 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.

7. Adjust the conveyor chain take-up pressure reducing valve (optional). a. Close the needle valve by turning the knob clockwise, opening flow to the take-up cylinders. The pressure reading should be 200 psi (14 bar). b. If adjustment is required, remove the hex socket head plug to adjust the inner spool. Using an Allen wrench, turn the screw in (clockwise) to increase pressure or out (counter-clockwise) to decrease pressure. c.

Replace the hex socket head plug.

8. Adjust the sequence valve for the Accumulator/Brake circuit. a. Turn the cartridge clockwise until the pressure reading on the accumulator circuit reads 2,500 psi (172 bar). b. While holding the cartridge in place, tighten the nut to lock the spool in place. Double check the pressure reading to ensure that the cartridge was not turned while tightening the nut.

9. Re-adjust the pilot pressure 2 relief valve, if necessary, to 500 psi (34 bar).

________________________________________________________________ 36 CM445 Hydraulics

___________________________________________ Adjustment procedures Set the pilot relief to 500 psi (34 bar), per step 3 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure that the conveyor chain take-up knob is closed (turn clockwise to close).

Pilot relief valve replacement Conveyor chain take-up valve replacement:

Main control valve working port relief adjustment

Set the pilot relief to 200 psi (14 bar), per step 4 of the Pilot/auxiliary pump circuit relief valve adjustments procedure, making sure the conveyor chain takeup needle valve is closed (turn clockwise to close).

Each valve bank section, with the exception of the gathering head, has two (2) working port reliefs (Fig 25). When the handle is pulled (spool in), oil is directed to the work port and relief closest to the handle; this is “A” port. When the handle is pushed in (spool out), oil is directed to the work port and relief farthest from the handle; this is ‘B” port.

Fig. 25: Main control valve Port reliefs

“A” port relief

!

“B” port relief

WARNING Always allow cylinder functions to bottom out (stop moving) before adjusting any pressure. Pressure adjustments will only be accurate when the cylinder is in this condition.

IMPORTANT The main relief is set higher than the port reliefs and will only relieve if a spike occurs in

the system or if the port relief does not function properly. This provides protection of the main pump section.

!

DANGER

Do not adjust the main relief over 3,000 psi (207 bar). Destruction of the valve bank and the main pump could result.

!

DANGER

Always be alert for any unintended machine movement.

IMPORTANT Reference the Hydraulic section in this chapter for individual circuit information. Al-

ways refer to the hydraulic schematic in your parts manual for your miner.

Always allow cylinder Two people functions are required to bottom to adjust out (stop pressure moving) settings. before adjusting One person anywill pressure. make the Pressure adjustWARNING ! ! WARNING ments adjustments while the will second only be person accurate must when remain the at cylinder the machine is in this stop condition. at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

______________________________________________________________ A6474X369 REV 0 37

Adjustment procedures ___________________________________________ Main control valve adjustment

To properly adjust any relief valve, the hydraulic system must be “dead headed”. Dead heading is achieved by actuating a cylinder function and allowing it to travel to its full stroke position (either extended or retracted). To set the main system relief, it is recommended that the stabilizer shoe cylinder be extended until it is dead headed. Since the stabilizer section of the main control valve is equipped with a port relief in the extend circuit, the port relief must be temporarily adjusted to a pressure setting higher than the main relief. This procedure is described in detail below.

1. During the adjustment procedure, pump output pressure and flow will be relieved past either the main relief or the stabilizer extend port relief which will cause rapid heating of the hydraulic oil. Preparation should be made to perform the adjustment procedure efficiently and in a relatively short period off time. It may be necessary to wait several minutes between adjustment periods.

2. It is critical that the stabilizer extend port relief valve be adjusted back to its proper setting after the main relief is adjusted.

Main relief adjustment

1. Remove the protective cap on the rear port relief of the stabilizer working section and loosen the nut on the adjusting screw. Turn the adjusting screw in all the way.

2. Loosen the nut on the main relief cartridge. Turn the main relief adjusting screw two turns clockwise.

3. Start the pump (see Startup procedure in this chapter) and activate the stabilizer shoe down function. This will raise the back portion of the machine off the ground.

4. With the stabilizer shoe down function bottomed out, turn the main relief cartridge adjusting screw in (clockwise) until a pressure of 2,450 psi (169 bar) is obtained.

!

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

5

With the stabilizer shoe function in the neutral position, hold the main relief cartridge screw in place and tighten the nut to lock the screw in place.

Check the pressure setting to verify that the screw was not moved while tightening the nut.

6. Adjust the stabilizer shoe down port relief (see Port relief adjustment procedure in this chapter).

7. Replace the protective cap.

________________________________________________________________ 38 CM445 Hydraulics

___________________________________________ Adjustment procedures Port relief valve adjustment

If the correct pressure reading is not obtained as noted in Items 1 through 5 below, the port relief (Fig 26) for that function must be adjusted. The port reliefs shown are typical for each section of the valve. The adjustment procedure for each port relief is the same and is: 1. Remove the protective cap on the port relief and loosen the nut on the adjusting screw.

2. Turn the port relief screw in (clockwise) to increase pressure and out (counter-clockwise) to decrease pressure.

3. Once the correct pressure reading is obtained, return the function to the neutral position, hold the screw in place, and tighten the lock nut. Check the pressure reading to ensure that the screw did not turn while the lock nut was being tightened.

Fig. 26: Main control valve - port reliefs

“A” port relief

“B” port relief

Stabilizer Conveyor swing Conveyor raise Gathering head

Cutter raise

______________________________________________________________ A6474X369 REV 0 39

Adjustment procedures ___________________________________________ Pressure readings 1. Cutter head

1. Activate the cutter head raise circuit to fully raise the cutter head. The main control pressure gauge should read 2,800 psi (193 bar).

2. Activate the cutter head lower circuit to fully lower the cutter head and raise the front of the machine off the ground. The main control pressure gauge should read 2,800 psi (193 bar).

2. Conveyor raise/lower

1. Activate the conveyor raise circuit to fully raise the conveyor. The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor lower circuit to fully lower the conveyor. The main control valve pressure gauge should read 1,400 psi (96 bar).

Note: Be sure that the ball valve is closed on the tank oil fill part of this circuit.

3. Conveyor swing

1. Activate the conveyor swing left circuit to fully swing the conveyor to the left.

The main control valve pressure gauge should read 1,800 psi (124 bar).

2. Activate the conveyor swing right circuit to fully swing the conveyor to the right. The main control valve pressure gauge should read 1,800 psi (124 bar).

4. Gathering head

1. Activate the gathering head raise circuit to fully raise the gathering head.

The main control valve pressure gauge should read 1,700 psi (117 bar).

2. If 1,700 psi (117 bar) is not obtainable, check that the relief in the gathering head float valve that is stamped “CR” is set to 1,800 psi (124 bar) (see Gathering head raise/hold/float-lower circuit in the Hydraulic section of this chapter).

5. Stabilizer shoe

1. Activate the stabilizer shoe raise circuit to fully raise the stabilizer shoe.

The main control valve pressure gauge should read 1,150 psi (79 bar).

2. Activate the stabilizer shoe lower circuit allow to fully lower the stabilizer shoe. The main control valve pressure gauge should read 2,450 psi (169 bar).

________________________________________________________________ 40 CM445 Hydraulics

_________________________________________________Troubleshooting Introduction

!

The following section lists possible problems encountered when servicing the Continuous Miner and can aid in locating and correcting these problems. This section covers basic components, with each listed in a trouble-cause-remedy format.

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

Hydraulic troubleshooting procedures

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: 1. Before removing the controller covers, remove power from the system by disconnecting the trailing cable.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: 1. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the “POWER OFF” button must be pushed.

2. Use insulated gloves and tools where possible.

3. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

______________________________________________________________ A6474X369 REV 0 41

Troubleshooting _________________________________________________ Typical hydraulic problems

The most common causes for improper function are: 1.

contaminated oil or poor oil quality;

2.

low or insufficient oil in the system;

3. using the wrong type of oil or wrong viscosity grade; 4. air in the hydraulic system; 5. internal or external leakage of the hydraulic system; 6. improper mechanical adjustments, such as reliefs; 7. mechanical or structural damage leading to component failure; and 8. components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, and other costly, critical components.

The construction and operating characteristics of each of these components should be clearly understood before attempting to troubleshoot the machine.

Please familiarize yourself with the operational descriptions of the hydraulic circuits given in the Hydraulics section of this chapter.

Each component in the system has a maximum rated speed, flow, torque, or pressure. The correct operating pressures of a system must be known and must always be checked and set with a pressure gauge.

________________________________________________________________ 42 CM445 Hydraulics

_________________________________________________Troubleshooting The ability to recognize trouble indicators in a specific system is usually acquired with experience. the gaining of this experience can be greatly enhanced by developing a logical sequence for determining the cause of a hydraulic problem and implementing the proper remedy. Refer to the general troubleshooting charts in this section that illustrate the logical sequence for shutdown, troubleshooting, and restarting the machine. The charts cover: 1.

general safety procedure for shutting down the machine;

2.

troubleshooting excessive noise;

3.

troubleshooting excessive heat;

4.

troubleshooting incorrect flow;

5.

troubleshooting incorrect pressure;

6.

troubleshooting faulty movement/operation; and

7.

general restart checklist and procedure

This general information is intended to enhance the understanding of basic hydraulic principles which will lead to the development of a logical troubleshooting procedure. Specific troubleshooting checklists for each hydraulic circuit are given directly after the very important “Contaminants in hydraulic systems” section.

Contamination

Cleanliness must be a high priority when servicing the hydraulic system. Ensure that bulk oils are at acceptable cleanliness levels.

Areas where customers have made improvements in the past include: 1.

implementing ISO Cleanliness Code standards for bulk hydraulic oils;

2.

evaluating bulk oil shipments for cleanliness by conducting particle counts and maintain records;

3.

minimizing drum usage by utilizing tote tanks and five gallon pails;

4.

utilizing plastic versus steel storage tanks, if possible;

5.

installing desiccant breathers on all bulk tanks;

6.

using sealed plastic containers for adding oil to small sumps;

7.

locating bulk tanks near equipment and pump directly to reservoirs;

______________________________________________________________ A6474X369 REV 0 43

Troubleshooting _________________________________________________ Cutter head raise failure troubleshooting

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the raise pilot cylinder on the cutter head directional control valve when the remote control valve is in the Raise position.

3

Check the directional control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check that the "in-line" counterbalance holding valve is piloted and shifting to direct retract port cylinder oil flow back to tank.

6. Check to see that there is no mechanical bind.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder’s holding valves. Also check that the valves are shifting to send oil back to the tank. (Note: cylinder removal will be required to safely achieve this)

Cutter head lower failure troubleshooting

1. Check pilot supply pressure at remote control valves.

2. Check pilot pressure at the Lower pilot cylinder on the cutter head directional control valve when the remote control valve is in the Lower position.

3. Check the direction control valve for proper operation.

4. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

5. Check to see that there is no mechanical bind or hydraulic block.

6. Check flow control valve cartridge.

7. Check cylinders for bypassing.

8. Check for pilot pressure on the cutter head cylinder's holding valves. Also check that the valves are shifting to send (extend port) oil back to the tank.

Note: cylinder removal will be required to safely achieve this.

________________________________________________________________ 44 CM445 Hydraulics

_________________________________________________Troubleshooting 8.

utilizing filter carts to maintain oil cleanliness standards;

9.

properly training personnel on the importance of clean oil and best practices for storage and handling; and

10.

monitoring the program closely and looking for continuous improvement.

Eliminate contamination source through “clean” maintenance practices best achieved by maintenance and troubleshooting given below:

Multi-function failure

1.

always clean the area around the component that is to be removed and inspected;

2.

store components in a plastic bag after inspection and prior to replacement on machine;

3.

cap off all open hoses/fittings;

4.

never touch a filter with bare hands when installing it back onto the machine; and

5.

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame.

If more than one function fails to operate on the machine, check the output of the pumps. Since this is an “open center” circuit, the normal pressure (with all directional control valves in the center position) should be less than 100 psi.

This pressure reading illustrates the necessary pressure to circulate the oil through the system. If the pressure reading under these conditions is significantly greater than 100 psi, it is likely that one of the control valves is trying to direct oil to one (or more) of the circuits on the machine.

The next step in troubleshooting a multi-function failure is to check the pilot pressure on the main control valve manifold. This pressure should be between 400 500 psi. If the pilot pressure is significantly below 350 psi, start with the General Troubleshooting Flow Chart IV - Incorrect Pressure. Another step to resolve multifunction failure is to have an electrician check for power to the solenoid circuits.

Check for correct pump rotation if electrical work has been performed (such as trailing cable replacement).

______________________________________________________________ A6474X369 REV 0 45

Troubleshooting _________________________________________________

Gathering head raise failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing.

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check in-line counterbalance valve for proper operation or blockage.

Gathering head float failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check to see that there is no mechanical bind.

4. Check cylinders for bypassing (they will leak out the top).

5. Check needle valve on pilot circuit to verify that it is not open or leaking off.

6. Check counterbalance valve for proper operation (see the schematic in the parts book supplied with your machine for the proper setting).

1. Check the directional control valve for proper operation.

Conveyor raise failure

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Be sure that the built-in atmospheric-vented reliefs on the cylinders are not dumping oil.

4. Check to see that there is no mechanical bind.

5. Verify that cylinders are not bypassing.

________________________________________________________________ 46 CM445 Hydraulics

_________________________________________________Troubleshooting Conveyor lower failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Verify that pilot pressure is being applied to open the piloted built-in checks.

4. Verify that cylinders are not bypassing.

Conveyor swing failure

1. Check the directional control valve for proper operation.

2. Check for any mechanical bind or any obstruction blocking movement, either to the cylinder itself, the main pivot area, or to some point along or under the discharge conveyor itself. Also check to ensure that the pivot bushings have not frozen up from lack of lubrication.

3. Verify that the cylinder is not bypassing.

Stabilizer raise failure

1. Check the directional control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

Stabilizer lower failure

1. Check the control valve for proper operation.

2. Check to see that piping has not been crossed, especially if the problem occurs after maintenance or repair work.

3. Check the lubrication network for bound bushings.

4. Check for any mechanical bind or any obstruction blocking movement.

5. Check cylinder for bypassing.

______________________________________________________________ A6474X369 REV 0 47

Troubleshooting _________________________________________________ Table 3: Flow chart I for troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

Cavitation

A

Coupling misaligned

C

Setting too low or too close to another valve setting

D

Air in fluid

B

Motor or coupling worn or damaged

E

Worn poppet and seat

E

Coupling misaligned

C

Pump worn or damaged

E

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

6.

7.

8.

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature check fluid level

B. Any or all of the following: 1. tighten leaky inlet connections 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir 3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal 5. replace pump C. All of the following: 1. align unit, ensure that mounting hardware is correct and tight 2. check condition of seals, bearings, and coupling D. 1. install and/or adjust pressure gauge E. 1. overhaul or replace defective parts

________________________________________________________________ 48 CM445 Hydraulics

_________________________________________________Troubleshooting Table 4: Flow chart II for troubleshooting excessive heat Pump Heated

Motor Heated Cause

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Cavitation

A

Relief or unloading valve set too high

D

Valve setting incorrect

D

Unloading valve set too high

D

Air in fluid

B

Excessive load

C

Worn or damaged valve

E

Fluid dirty or low supply

F

Relief or unloading valve set too high

D

Worn or damaged motor

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve motor, cylinder, or other component

E

Fluid heated

Remedy

Relief Valve Heated

See Fluid Heated

Fluid heated

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

6.

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed overhaul or replace supercharge pump

F. 1. change filters 2. check system fluid viscosity; change if necessary 3. fill reservoir to proper level G. 1. clean cooler and/or strainer 2. replace cooler control valve 3. repair or replace cooler

B. Any or all of the following: 1. tighten leaky inlet connections 2. fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir 3. bleed air from system 4. replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: 1. align unit 2. check condition of seals, bearings, and coupling 3. locate and correct mechanical binding 4. check for workload in excess of circuit design D. 1. install and/or adjust pressure gauge; keep at least 125 psi difference between valve settings E. 1. overhaul or replace defective parts

______________________________________________________________ A6474X369 REV 0 49

Troubleshooting _________________________________________________ Table 5: Flow chart III for troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following: 1.

2.

3.

4.

5.

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level overhaul or replace supercharge pump

F. Any or all of the following 1. check position of manually operated controls 2. check electrical circuit on solenoid operated controls 3. repair or replace pilot pressure pump G. 1. reverse rotation

B. Any or all of the following: H. 1. replace with correct unit 1. tighten leaky inlet connections 2. bleed air from system C. All of the following: 1. check for damaged pump or pump drive 2. replace and align coupling D. 1. adjust setting on valve E. 1. overhaul or replace part

________________________________________________________________ 50 CM445 Hydraulics

_________________________________________________Troubleshooting Table 6: Flow chart IV for troubleshooting incorrect pressure No Pressure

Low Pressure

Erratic Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Pressure reducing valve set too low

Cause

Excessive Pressure

Remedy

Cause

Remedy

Air in fluid

B

Pressure reducing, relief, or unloading valve misadjusted

D

D

Worn relief valve

E

Pressure recuing, relief, or unloading valve worn or damaged

E

Pressure reducing valve damaged

E

Contamination in fluid

A

Damaged pump, motor, or cylinder

E

Accumulator defective or has lost charge

C

Worn pump, motor, or cylinder

E

Remedies A. 1. replace dirty filters and system fluid B. 1. tighten leaky connections 2. fill reservoir to proper level and bleed air from system C. 1. gas valve for leakage 2. charge to correct pressure 3. overhaul if defective D. 1. adjust valve E. 1. overhaul or replace part

______________________________________________________________ A6474X369 REV 0 51

Troubleshooting _________________________________________________ Table 7: Flow chart V for troubleshooting faulty operation No Movement Cause No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement Remedy

Excessive Speed or Movement

Remedy

Cause

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Feedback 3 transducer malfunctioning

E

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

E

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

G

Misadjusted or malfunctioning valve amplifier

C

No command signal to valve or amplifier

F

No lubrication of machine ways or linkage

G

Erratic command signal

F

Overriding work load

H

Inoperative or misadjusted valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Misadjusted or malfunctioning valve amplifier

C

Inoperative solenoid or proportional valve

E

Sticking valve

D

Malfunctioning feedback transducer

E

Worn or damaged cylinder or motor

E

Worn or damaged cylinder or motor

E

Sticking valve

D

Pilot filter clogged

See Table 5

Worn or damaged cylinder or motor

E

Remedies A. 1. check fluid temperature 2. check system fluid viscosity; change if necessary B. 1. locate bind and repair C. 1. adjust, repair, or replace part D. 1. clean and adjust or replace part 2. check condition of system fluid and filters E. 1. overhaul or replace part F. 1. repair command console or interconnecting wires G. 1. lubricate H. 1. adjust, repair, or replace counterbalance valve

________________________________________________________________ 52 CM445 Hydraulics

_________________________________________________Troubleshooting Table 8: Restarting checklist Has the cause of the failure been remedied?

No

Carry out further investigation.

Yes

Clean or flush the system as required.

Yes Can dirt have entered the system by the unit failure or during replaceNo Is the unit the correct one?

No

Modify or replace with correct unit.

No

Remedy installation.

No

Remedy installation.

Yes

Is the unit adjusted to a safe condition for start up?

Yes Are all hydraulic connections correct?

Yes Are all electrical connections correct?

Yes Is the unit adjustable?

No

Adjust to a safe condition.

Yes No Have the cases of pumps and motors been filled?

No

Fill case.

Yes

Bleed or prime as necessary.

No

Remove safety interlocks.

No

Sound alarm or inform personnel.

Yes Will the system require bleeding or priming?

No Have all safety interlocks been removed Yes Are all personnel aware the machine is restarting?

Yes Start machine (see Startup procedure in this chapter).

______________________________________________________________ A6474X369 REV 0 53

Troubleshooting _________________________________________________ Water system including circuits Table 9: Water system troubleshooting including circuits Trouble, symptom or cause

Probable cause

recommended water volume (gpm) can- 1. not be maintained

Dynamic water pressure (psi) is not being supplied to the recommended psi.

Test, check and/or remedy 1.

Change setting to the recommended psi.

2.

Change hose to the recommended diameter size.

3.

Check the water supply itself to see if there is an issue & fix.

1.

Remove the filter and clean it thoroughly; flush the system as necessary.

2.

Change water filter frequently.

1.

Remove the nozzles and clean thoroughly; flush the system as necessary.

2.

Change water filter frequently.

Air in the system.

1.

Check for leaks.

Pressure too high.

2.

Adjust the pressure.

Hydraulic pilot operated water valve stuck open.

1.

Clean or replace.

2.

Faulty solenoid.

2.

Replace.

3.

Radio transmitter toggle switch faulty.

3.

Replace toggle switch.

no water pressure on the 1. pressure gauge 2.

Water filter plugged.

1.

Replace or clean.

Main water ball valve “OFF”.

2.

Close valve.

3.

No incoming water.

3.

Fix water supply issue.

Contaminated water supply

1.

Clean or filter the incoming water supply to the miner.

Incorrect pressure reducing valve setting.

1.

Adjust psi.

2.

Check water volume gpm.

3.

Remove strainer and clean.

4.

Backflush pump, remove nozzle and clean.

5.

Adjust psi.

2.

Water supply hose is not the minimum diameter

3.

Incoming supply of water has a problem.

damaged or clogged filter, contaminates 1. in the water system

plugged water nozzles are restricting the 1. flow of water or pressure fluctuates

pressure fluctuates and there is extreme 1. noise in the system 2. water function will not shut “OFF” with 1. radio transmitter

water filter stopping up 1. frequently jet pump not removing water from sump 1.

2.

Dirt in the system.

Dirt in the system.

Pressure reducing valve internal strainer dirty.

3.

Jet pump nozzle plugged with dirt.

4.

Suction hose from sump to jet pump plugged with sludge or hose has a loose connection.

5.

Incorrect hose size from jet pump to manifold.

6.

Remove restriction or tighten hose connection.

6.

Manifold plugged.

7.

Check for correct hose size.

8.

Clean.

________________________________________________________________ 54 CM445 Hydraulics

A6474X370 April 2012

Reference Information CM445 Continuous Miner A6474X370 (Reference Information)

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 local and national 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 nontransferable. 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 Special Fasteners.............................................................................. 4 Metal Face Seals............................................................................... 5 Bearing .............................................................................................. 7 Torque Values ................................................................................... 13 Fraction to Decimal Equivalents........................................................ 15 Conversion Factors ........................................................................... 16

________________________________________________________________ A6474X370

REV 0

Special Fasteners ________________________________________________ Introduction

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

Locking Wire Fasteners

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

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

Fig. 1: Lock wire fasteners

Self-Locking Screws

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

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

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

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

Lock Nuts

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

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

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

________________________________________________________________ 4 Reference

_________________________________________________ Metal Face Seals Introduction

There are two types of metal face seals commonly used on the miner: Caterpillar® type seals and Chicago Rawhide (CR)® type seals. This section gives a general installation procedure for metal face seals.

Installation procedure

Follow these procedures to install a metal face seal (Fig. 1): 1. Verify that matching seals are being installed. Never install mismatched seals - one new, one used or two used seals that have never run together.

2. Using a lint-free wipe and a non-petroleum based solvent, remove all foreign material (oil, grease, dirt, metal chips, dust, lint, etc.) from the housing components that contact the rubber sealing ring. Dry with a clean, lint free wipe.

3. Using a lint free wipe, remove all foreign material from the rubber sealing rings. Dry with a clean wipe.

4. Place the rubber sealing ring on the metal seal ring at the bottom of the seal ring ramp and against the retaining lip. Make sure the rubber sealing ring is straight on the seal ring and is not twisted.

5. Lightly coat the lower half of the rubber sealing ring with the appropriate assembly lubricant (isopropyl alcohol or other approved lubricant). Lubricant can be applied with a lint free wipe, clean foam brush, etc.

6. With the lower half of the rubber sealing ring still wet, use the installation tool to position the seal ring and the rubber sealing ring squarely against the application housing.

7. Apply even pressure with an installer tool to force the rubber sealing ring under the seal retaining lip. Note: Never coat the rubber sealing ring with oil to aid in installation. Never use a screwdriver or pointed object to install the rubber sealing ring as seal damage and leaks may occur.

8. Check the assembled height variation, A (Fig. 2), in at least four places, 90° apart. Use a caliper or other calibrated measuring tool. The difference in height may not be more than 1.0 mm. If adjustments are necessary, do not push or pull directly on the seal ring. Use the installation tool to push down or, by hand, pull up uniformly on the rubber seal ring and seal ring.

Note: The rubber seal ring can twist if it is not wet all around during installation or if there are burrs on the retaining lip of the housing.

Twists, misalignment, or bulges of the toric will result in seal failure. If correct installation is not obvious, remove the seal from the housing and repeat the process.

9. Wipe the face of each seal ring using a lint free wipe. No foreign material of any kind can be left on the sealing surface.

10. Coat both metal seal faces with light oil before assembling the machine components. Do not get oil on the toric ring or in t he seal seat or retaining lip.

______________________________________________________________ A6474X370 REV 0 5

Metal Face Seals _________________________________________________ Fig. 1: Metal face seal (Caterpillar® seal shown) 1-Seal Ring 2-Rubber Toric 3-Housing Retainer Lip 4-Housing Ramp 5-Seal Ring Housing 6-Seal Ring Face 7-Seal Ring Ramp 8-Seal Ring Retaining Lip 9-Installation Tool

1 2 3

4

5 6 9 7

8

Fig. 2: Assembled seal height measurement

________________________________________________________________ 6 Reference

________________________________________________________Bearings Bearings The most important single factor in obtaining good service and long life from bearings is to keep dirt and foreign particles out of the bearing.

■

Use only clean grease/oil from clean containers.

■

Keep the grease/oil containers closed.

■

Handle the grease/oil so as to keep it clean.

■

Clean all dirt from adjacent surfaces before opening a bearing housing.

■

Always protect an exposed bearing with a lint free protective cover.

Try to prevent chips or dirt from getting between the bearing face and the shaft or housing shoulder. Contamination keeps the bearing from seating properly.

The dirt may then work out and cause the bearing to work back against the shoulder, resulting in the bearing adjustment being excessively loose. Chips or dirt on one side of the shoulder could cock the bearing on the shaft, causing a misaligned condition similar to an off square shoulder.

Bearings are originally packed in cardboard cartons, tubes or spiral wrapping at the factory to give the proper protection against dirt and moisture. Leave bearings in these containers and store in a clean, dry place until ready to be used.

Bearings should not be removed from cartons and left in open trays, pans or in open cabinets exposed to dirt, dust or moisture. Keep bearings clean and dry!

It is not necessary to wash new bearings to remove the slushing grease put on at the factory for rust protection. This grease has little lubricating value, but it will not harm to the lubricant used in the bearings.

In special cases, it is necessary to wash bearings before assembly because they become dirty. Use a clean solution; kerosene is recommended. Cover bearings with a lubricant as soon as possible after washing to prevent rust.

When bearings are removed, examine each one for wear. If the bearing is in good condition, it should be cleaned with a suitable cleaner and then dried.

When drying a bearing that has just been cleaned, never rotate the bearing at high speed; there is no lubricant in the bearing to protect it. Id the bearing is being dried with an air hose, direct the airstream so that rotation does not occur. After the bearings have been cleaned and dried, they should be coated immediately with light oil and covered with a lint-free cloth.

Note: A mixture of marking compound and spindle oil is good lube for the gears under light loads for 2-3 revolutions only. Check tooth patterns all round to make sure the pattern/markings are uniform.

______________________________________________________________ A6474X370 REV 0 7

Bearings ________________________________________________________ Bearing Assembly Bearing cones and cups can be assembled in many ways. Smaller bearings can be pressed onto shaft or into housings. Bearing cones can be heated and shrunk onto shafts. Cups can be frozen and contracted to slip into housings easier. Proper bearing operation hinges upon correct mounting. With any method used, a number of factors should be considered.

Mount in a relatively clean environment. Dirt and debris affect internal clearances and fits. Dust can keep two mating surfaces from being tight, causing out -of -round bores. Dirt on a shaft contact area can cause seal wear. Debris mixing with gear oil forms a lapping compound that wears the bearing. Keep the bearing in its container until ready to mount it.

■

Do not drop or roughly handle the bearings.

■

Do not subject bearings to sudden, large temperature changes. This could cause condensation onto the bearing surfaces.

■

Do not handle the bearings more than necessary. Finger prints can be a starting point for rust.

■

When installing, be sure the cone or cup is solidly seated against its shoulder. After the part has been pressed, shrunk, or cooled on, check with a thickness gauge to make sure it is properly seated.

■

Be sure the bearing being installed is Original Equipment Manufacturer (OEM) . This ensures that an exact duplicate is put on. Bearings and shafts are designed for each other, and changes can cause failure, loss of warranty, and extended downtime.

■

Be sure the bearing fit is not too loose or too tight. A loose bearing will creep, slip and cause it to overheat and be subjected to abrasive wear on the bore or shaft.

■ On a tight bearing, the inner ring of the cup will be stretched to where there is no room for the rollers or balls to revolve freely.

■ The bearing should be supported properly and pressure should be applied to the correct ring of the bearing.

There are generally three basic methods to mounting bearings: cold mounting, temperature mounting, and hydraulic mounting.

Bearings up to 4" (102 mm) in diameter can be cold mounted, using a sleeve and a hammer or press. Soft-metal hammers, while less likely to cause damage, have a tendency to chip and send metal flying into the bearing.

The end faces of a driving sleeve should be flat, parallel, and free of burrs.

The bearing seating on the shaft and in the housing should be lightly smeared with thin oil.

________________________________________________________________ 8 Reference

________________________________________________________Bearings Micronized graphite can be used on shafts, cone seats, and in the cone bores to facilitate the assembly and removal of bearing cones on the shaft. Considerably less pressure is needed to press on a cone if micronized graphite is used. Removal is easier too, since it reduces or eliminates oxidizing on the cone seat (fretting corrosion).

Drivers should be used wherever possible to assemble cups and cones. They save time, ease installation by driving/pressing cups onto cones straight, prevent damage to bearing cages and nicks in bearing parts, and in general assure better assembly.

Do not damage the cage of the bearing cone by pressing or driving against it.

This will distort and loosen it. Distortion causes skewing of the rollers and early failure of the bearings. Loosening the cage will cause cage and rollers to fall off the cone.

Drivers can be hardened for longer life. If they are not available, mild steel bars can be used, although they are not preferred. Use mild steel, not hardened drifts or brass bars. Hardened bars damage the bearing. Brass will chip easily and get into the bearing or behind the bearing face, preventing it from becoming seated against the shoulder.

When bars are used as drivers, take care to see that they are tapered to clear the bearing cage, and hit only against the bearing race. Drivers should be used wherever possible as they save time.

Heating bearings Temperature mounting is done by one of three ways: ■ ■ ■

Heating one part Cooling one part Heating one and cooling another

Heating is recommended for larger bearings. Cooling is suitable for any size, straight or tapered, although if temperature mounting is to be done to smaller assemblies, cooling is preferred. Be absolutely sure that no bearings are ever heated over 135° - 150° C (275° - 300°F). If they are, they will begin to draw, or soften.

Heating bearings in oil is common. Before heating, the oil and the container should be clean. Quenching oils with a minimum flash point of 150° C (300° F) should be used. The oil quantity should be large in relationship to the bearing being heated. A smaller volume heats and cools too rapidly. Where oil is heated in a pan or metal container over an open flame, there should be a screen on which the bearings will rest. It should be raised an inch from the bottom of the pan.

The bearing must not rest on the bottom, since heat would be transferred directly from the flame through the pan to the bearing. This temperature will be very high and will draw the bearing. A wire rack can be installed about 3 inches (75 mm) from the bottom. This will keep the bearing away from the direct heat, and also out of contamination. Another method is to suspend the bearing in the bath.

______________________________________________________________ A6474X370 REV 0 9

Bearings ________________________________________________________ Once the bearing is heated, wipe the bore clean, place the assembly immediately on the shaft, and lock it in place. If there is no locking device, use a mounting tool to hold the inner ring in place until it has cooled. Oil baths are not recommended for sealed bearings.

Induction heating is not recommended. Surface temperatures will get too high and will draw the bearings.

Note: When bearings are heated for assembly, the part heated should be checked after cooling to see that it is seated properly against the shoulder. Bearings have a tendency to pull away from the shoulder .

Where cups are to be assembled in housings with a press fit, they can be shrunk in a deep freeze unit or an alcohol bath cooled with dry ice. In some cases, you must also heat the housing to get the cup to slip into place readily.

The accurate location and mating of rotating parts depends on the internal running clearance and stability of the support bearings. Running clearance of tapered roller bearings can be readily adjusted to meet a variety of operation conditions. This is through the axial adjustment of either the cone (inner race) or cup (outer race).

Proper initial adjustment should compensate for thermal changes and/or deflections produced by normal operation. Tapered roller bearings operate well over a relatively wide adjustment range. The optimum initial bearing adjustment results in an operating adjustment of almost "metal to metal", or no appreciable end play within the bearings.

Though the surface hardness of bearings resists abrasion, dirt in the lubricant accelerates wear. After extended periods of operation, this wear results in the loss of the original adjustment and increases running clearance or end play.

The adjustable feature of a tapered assembly allows readjustment to compensate for this condition. This readjustment increases life to bearings, seals, gears, and other rotating parts.

These general recommendations for adjusting tapered roller bearings cover most applications.

Thermal expansion reduces end play. As a bearing rotates, heat is generated, causing successive thermal expansions. Usually the cone and roller assembly expands first, followed by the cup. When the cup is in a rigid housing with a tight fit, it cannot expand until the housing itself heats and expands.

In a typical gear drive or transmission, the operating temperature of the cup is lower than the cone and roller assembly. This is due to the cooling effect of the housing, since normally it can more effectively dissipate heat than can the shaft on which the cone is mounted.

Under operating conditions, the component parts of the bearing do not expand uniformly. When a single-row tapered roller bearing is used at each end of a shaft, consider the axial expansion of the shaft and housing in determining the proper initial bearing adjustment.

________________________________________________________________ 10 Reference

________________________________________________________Bearings Lubrication is important in the thermal characteristics. Bearings rotating at high speed partially or completely submerged in oil may cause a high degree of heat from their churning action of bearings in the lubricant.

Bearings usually are first adjusted with slight running clearance or end play. On applications such as gear cases, initial end play will be about 0.001 to 0.003 inches (0.025 - 0.076 mm) on the small sizes and proportionately greater as the bearings size increases. Generally, running bearings at higher speeds and temperatures increases the amount of initial end play or running clearance required.

The following recommended procedure for adjusting tapered roller bearings is used in most applications. Pull up on the end cap or bearing cup carrier, or end plate, without shims in place, until bearings bind slightly in rotation. Then the gap between the cap flange and housing or the end of the shaft, can be measured with a thickness gauge. The measured gap plus the end play desired will give the total shim pack required.

Another good way is to put a lead wire where the shims go and then pull up until all end play is taken up. The wire, which has to be larger than the original gap, is then flattened and can be measured with micrometers and the shim pack made up in the same manner as when thickness gauges are used. The shaft should then be tapped with a hammer so that the adjusted bearing member (cup or cone) is likewise backed off and seated against the adjusting device.

Where large tapered roller bearings are adjusted, it may be hard to manually feel when a "metal to metal" setting is reached. In such cases, a simple torque measuring device is commonly used. With this method, as the bearings are being adjusted, an increase in bearing torque can be detected which indicates that a close setting has been reached.

Do not confuse this torque with torque generated by gears and seals. When bearings are being set for desired initial end play, check the axial movement of the shaft as the bearings rotate. Rotating bearings ensures that the rollers will align and seat against the cone rib, resulting in a true end play measurement.

After the bearings have been installed and the machine reassembled, it should be tested. Running the machine without a load or a short time will ensure that all components are installed correctly.

Check the bearings for noise, excessive heat and vibration. Any of these signs could indicate damage which may have occurred during the installation procedure. Interference or overload will produce a high-pitched whine. Bearing misalignment will cause a medium or low-pitched noise and poor shaft finish or outof-round housings will create a rumbling noise. Excessive heat is frequently caused by the presence of too much lubricant.

______________________________________________________________ A6474X370 REV 0 11

Bearings ________________________________________________________ If the bearing is designed to be installed with an arbor press, then use an arbor press to remove the bearing. If the bearing or shaft is too long to fit in a press, use a bearing puller.

If the bearing does not come off the shaft easily, a different approach must be tried. One possible method is to heat the bearing with a torch, thereby increasing the clearance between the shaft and the bearing. Make sure the heating torch is the proper type and that it is set for heating, not cutting or burning. Remember to provide proper support for the bearing and shaft during disassembly.

________________________________________________________________ 12 Reference

___________________________________________________ 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

______________________________________________________________ A6474X370 REV 0 13

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

________________________________________________________________ 14 Reference

______________________________________________ General Information Introduction

Fraction to Decimal Equivalents

This section provides general information.

Fraction

Decimal Equivalent

1/32

0.03125

3/32

0.09375

1/16

0.0625

1/8

0.125

3/16

0.1875

5/32

0.15625

7/32

0.21875

1/4

0.25

9/32

0.28125

5/16

0.3125

3/8

0.375

7/16

0.4375

9/16

0.5625

1/2

0.50

5/8

0.625

11/16

0.6875

3/4

0.75

13/16

0.8215

15/16

0.9375

7/8

0.875

______________________________________________________________ A6474X370 REV 0 15

General Information ______________________________________________ Common Conversion Factors

To Convert From

To

°F

°C

(°F - 32) ÷ 1.8

°C

°F

(°C + 32) x 1.8

inches

mm

inches x 25.4

mm

inches

mm x 0.039

feet

meters (m)

ft x 0.305

meters (m)

feet

m x 3.28

yards

meters

yd x 0.914

meters

yard

m x 1.09

ounces

grams

oz x 28.35

grams

ounces

g x 0.035

pounds

kilograms

lbs x 0.454

kilograms

pounds

kg x 2.202

pound-force

newtons (N)

lbf x 4.45

newtons

pound-force

N x 0.225

pound-force per square inch

kilopascals (kPa)

lbf/in2 x 6.89

kilopascals

pound-force per square inch

kPa x 0.145

________________________________________________________________ 16 Reference