DOWNLOAD PDF : Cat CM445 Continuous Miner Reference Information Manual A6474X370

A6474X370 April 2012

Reference Information CM445 Continuous Miner A6474X370 (Reference Information)

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__________________________________________________________ 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

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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.

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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.

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___________________________________________________ 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

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______________________________________________ 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