TA-1 Visual Inspection for Underground C

SMCS - Job Code - 540 Component Co

Cat dealer
Address
Contact

Customer: Mine Name:

Machine Model: Machine S/N:
Date: Inspector:
Tram (AC or DC): Radio System:
Hyd Schematic #: Elec Schematic #:
Pump Hours: Conveyor Hours:

Note: Review Machine & S·O·S History and check for Active Service Letters prior to in
nderground Continuous Miner

Component Code - 753S

Customer
Address
Contact

Section Number:
Mine Asset Number:
Mine Representative:
Methane Monitor:
Machine Tonnage:
Cutter Hours:

rvice Letters prior to inspection.

 Visual Inspection for Continuous Miners
Status Assessment OK - Normal M - Monitor A - Action NA - Not Applicable

1.0 Prepare Machine Inspection

No. Status Description Comments
1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection

1.3 Perform safety walk-around inspection

1.4 Check operating system for active faults

1.5 Check operating system fault log

Item No. Additional Comments

2.0 Control System Inspection

No. Status Description Comments
2.1 Radio remote
2.2 Text display
2.3 Graphics display
2.4 Emergency Stop buttons
2.5 Tram pendant
Item No. Additional Comments

3. 0 General Machine Inspection

No. Status Description Comments
3.1 Covers
3.2 Guards
3.3 Rub rails
3.4 Lights
3.5 Hydraulic hoses
3.6 Hydraulic pump
3.7 Hydraulic filters
3.8 Hydraulic gauges
3.9 Hydraulic cooling system
3.10 Electrical cables
3.11 Proximity detection generators
Item No. Additional Comments

4.0 Cutter Head Inspection

No. Status Description Comments
4.1 Cutter drums
4.2 Cutter gear case (LH and RH)
4.3 Cutter cylinder (LH and RH)
Cutter cylinder pin (top and bottom) (LH and
RH)
4.4
4.5 Cutter frame
4.6 Cutter head pivot pin (LH and RH)
4.7 Cutter motor (LH and RH)
Item No. Additional Comments

5.0 Conveyor/Gathering Pan Inspection

No. Status Description Comments
5.1 Gathering head cylinder (LH and RH)
Gathering head cylinder pin (top and bottom)
(LH and RH)
5.2
5.3 Gathering head gear case (LH and RH)
5.4 Gathering head motor (LH and RH)
5.5 Gathering pan
5.6 Conveyor foot shaft assembly
5.7 Conveyor tail roller
5.8 Conveyor chain
5.9 Conveyor swing cylinder (LH and RH)
5.10 Conveyor swing cylinder pin (front and back)
(left and right)
5.11 Conveyor chain take-up cylinder
5.12 Conveyor lift cylinder (LH and RH))
Conveyor lift cylinder pin (top and bottom) (LH
and RH)
5.13
5.14 Conveyor swivel pin
5.15 Centrifugal Loading Arm (CLA) (LH and RH)
5.16 Conveyor
Item No. Additional Comments

6.0 Tram Inspection

No. Status Description Comments
6.1 Crawler chain (LH and RH)
6.2 Drive sprocket (LH and RH)
6.3 Tram track front idler assembly (LH and RH)
Tram track front idler assembly grease take-up
cylinder (LH and RH)
6.4
6.5 Tram gear case (LH and RH)
6.6 Tram motor (LH and RH)
Item No. Additional Comments

7.0 Water/Dust Suppression System Inspection

No. Status Description Comments
7.1 Spray manifolds
7.2 Duct work
7.3 Crossover
7.4 Scrubber screen
7.5 Scrubber demister
7.6 Scrubber motor/blower
Item No. Additional Comments

8.0 Site Conditions

No. Status Description Comments
8.1 Ambient Temperature
NORMAL:
MONITOR:
Action:
8.2 Grade
NORMAL:
MONITOR:
Action:
8.3 Floor condition
8.4 Machine utilization
8.5 Overall seam height
8.6 Mined material seam height
8.7 Overburden seam height
8.8 Mined material
8.9 Maintenance practices
NORMAL: Excellent
MONITOR: Good
Action: Poor
Item No. Additional Comments
Dry
Wet
Muddy
Rolling
Hard
1 shift per day
2 shifts per day
3 shifts per day

Coal
Potash
Trona
Salt
Gypsum
 Continuous Miner TA1 Inspection Reference
Inspection Benefits:
Minimizes downtime through scheduled maintenance
Locates potential problems
Identifies overlooked problems
Enables scheduled maintenance and repairs
Lowers owning and operating costs

1.0 Inspection Preparation

1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection
Be sure the area is free of personnel. Make sure no one is underneath the machine,
around the machine, or on the machine.

Be prepared to block the cutter head and the conveyor before performing any
inspections under either of these assemblies.

Be prepared to lock out the machine at the power source.

1.3 Perform safety inspections
1.4 Check the operating system for active faults
1.5 Check the operating system fault log
1.5 Check the operating system fault log

2.0 Control System Inspection

2.1 Radio remote

Check overall condition or radio remote - toggle switches, buttons, housing, etc.
2.2 Text Display
Visually inspect
2.3 Graphics Display
Visually inspect
2.4 Emergency Stop Buttons
Check that all Emergency Stop buttons are in place and are not damaged
2.5 Tram Pendant
Visually inspect

3.0 General Machine Inspection

3.1 Covers
Missing? Loose? Bent? Bolts missing?
3.2 Guards
In place? Secured?
3.3 Rub rails
Damaged? Missing pins?
3.4 Lights
Only verify that lights work. DO NOT perform permissibility checks.
 3.5 Hydraulic hoses
Checked for damaged or leaking hoses, hose routing, hoses rubbing sharp corners, etc.
3.6 Hydraulic pump
Check mounting bolts and pump fittings. Look for signs of leaks. Listen for unusual
noises. Excess noise could indicate:
Pump cavitation
Loose or failed bearing
3.7 Hydraulic filters
Check filter housings for signs of leaks or damage. Check to see if filter element needs
changed.
3.8 Hydraulic gauges
Verify that all gauges are in place, are not damaged, and are working
3.9 Hydraulic cooling system
Inspect system components for leaks, loose fittings and connections, damage
3.10 Electrical cables
Check general conduit routing, signs of damage, etc. DO NOT perform permissibility
checks.
3.11 Proximity detection generators
Check that generators are in place and that mounting is secure. DO NOT check
operational functionality of proximity system.

4.0 Cutter Head Inspection

Disconnect and lock out power before inspection. Never work beneath an unsupported cutter head;
insert adequate blocking. DO NOT rely on load locking valves to support the cutter head while
performing the inspection.

4.1 Cutter drums

Bit blocks (damaged, cracked welds, missing)
Bits (damaged, worn, missing)
4.2 Cutter gear case (LH and RH)
Oil level
Signs of leaks
4.3 Cutter cylinder (LH and RH)
Oil leaks indicated by dirt or oil buildup around the rod seal
Oil leaks at hose connections
Damaged or missing grease fittings (zerks)
Damage to cylinder rods (Refer to "Hydraulic Cylinder Inspection Guidelines")
Damage to mounting clevises: cracked welds, irregular pin bores
Loose or missing pin retainers
Damaged pins
4.4 Cutter cylinder pin (top and bottom) (LH and RH)
Irregular pin bores
Loose or missing pin retainers
4.5 Frame
Damage to frame
Structural cracks
Cracked welds
 4.6 Cutter head pivot pin (LH and RH)
Irregular pin bores
Loose or missing pin retainers
4.7 Cutter motor (left and right)
Mounting bolts
Clutch wear indicators

5.0 Conveyor/Gathering Pan Inspection

Disconnect and lock out power before inspection. Never enter conveyor chain area when power is on
the machine. Never work beneath an unsupported cutter head; insert appropriate blocking. DO NOT
rely on cylinder load locking valves to support the cutter head while performing the gathering pan
5.1
inspection. Gathering
Never workhead cylinder
beneath an(LH and RH) conveyor: insert appropriate blocking before
unsupported
Oil leaks
beginning inspection. DO NOTindicated
rely onbycylinder
dirt or oil
loadbuildup around
locking valvesthe rod seal the conveyor assembly.
to support
Oil leaks at hose connections
Damaged or missing grease fittings (zerks)
Damage to cylinder rods (Refer to "Hydraulic Cylinder Inspection Guidelines")
Damage to mounting clevises: cracked welds, irregular pin bores
Loose or missing pin retainers
5.2 Gathering head cylinder pin (LH and RH)
Irregular pin bores
Loose or missing pin retainers
5.3 Gathering head gear case (LH and RH)
Oil level (input and pot)
Signs of leaks
5.4 Gathering head motor (LH and RH)
Mounting bolts
Clutch wear indicators
5.5 Gathering pan
Slack in turn table
Damage to frame
Structural cracks
Cracked welds
5.6 Conveyor foot shaft sprocket
Wear
5.7 Conveyor tail roller
Wear
5.8 Conveyor chain
Condition of flights
Condition of connectors
Chain stretch (measure across six flights)
Chain tension (See OMM for Chain Tensioning procedure/correct chain tension)
5.9 Conveyor swing cylinder (LH and RH)
Oil leaks indicated by dirt or oil buildup around the rod seal
Oil leaks at hose connections
Damaged or missing grease fittings (zerks)
Damage to cylinder rods (Refer to "Hydraulic Cylinder Inspection Guidelines")
Damage to mounting clevises: cracked welds, irregular pin bores
 Loose or missing pin retainers
5.10 Conveyor swing cylinder pin (front and back) (LH and RH)
Irregular pin bores
Loose or missing pin retainers
5.11 Conveyor chain take-up cylinder (LH and RH)
Oil leaks indicated by dirt or oil buildup around the rod seal
Oil leaks at hose connections
Damaged or missing grease fittings (zerks)
Damage to cylinder rods (Refer to "Hydraulic Cylinder Inspection Guidelines")
Damage to mounting clevises: cracked welds, irregular pin bores
Loose or missing pin retainers
Damaged pins
5.12 Conveyor lift cylinder (LH and RH)
Oil leaks indicated by dirt or oil buildup around the rod seal
Oil leaks at hose connections
Damage to cylinder rods (Refer to "Hydraulic Cylinder Inspection Guidelines")
Damage to mounting clevises: cracked welds, irregular pin bores
Loose or missing pin retainers
Damaged pins
5.13 Conveyor lift cylinder pin (top and bottom) (LH and RH)
Irregular pin bores
Loose or missing pin retainers
5.14 Conveyor swivel pin (top and bottom)
Damaged or missing grease fittings (zerks)
Damaged or missing bolts
Damaged or missing center set screw
Damaged or missing pin retainer
Irregular pin bore
5.15 Gathering head centrifugal loading arm (CLA)
Damaged or missing removable tips
Mounting bolts
5.16 Conveyor
Condition of return chain guides
Damage to frame
Structural cracks
Cracked welds

6.0 Tram Inspection

Disconnect and lock out power before inspection.

6.1 Crawler chain (LH and RH)

Crawler chain tension (See OMM for correct tram track tension/tensioning procedure)
Chain stretch (measure pin to pin across 6 pads)
Wear on pads/cleats
Wear on bottom wear strips
6.2 Drive sprocket (LH and RH)
 Condition
6.3 Tram track front idler assembly (LH and RH)
Condition
6.4 Tram track front idler assembly grease take-up cylinder (LH and RH)
Condition
6.5 Tram gear case (LH and RH)
Oil level
Signs of leaks
6.6 Tram motor (LH and RH)
Mounting bolts

7.0 Water/Dust Suppression System Inspection

Disconnect and lock out power before inspection.

7.1 Spray manifolds

Condition
7.2 Duct work (left and/or right)
Condition
7.3 Crossover
Condition
7.4 Scrubber screen
Condition
7.5 Scrubber demister
Blade condition
7.6 Scrubber motor/blower
Mounting bolts

8.0 Site Conditions

8.1 Ambient Temperature

Record the average temperature in the mine
8.2 Grade
Record the normal operating grade for the machine
8.3 Floor Conditions
Choose a condition from the drop down box. Note anything unusual in the additional
comments section.
8.4 Machine utilization
Choose the number of shifts per day the machine is mining.

8.5 Overall seam height

Record seam height.
8.6 Mined material seam height
Record height
8.7 Overburden seam height
Record height
8.8 Mined material
 Choose the material being mined from the drop down list.
8.9 Maintenance practices
Note machine maintenance practices
corners, etc.
 Performance Checks for Continuous Miners
Status Assessment OK - Normal M - Monitor A - Action NA - Not Applicable/Not Performed (Add reason in comments)

1.0 Radio Remote Performance Check

No. Status Description Comments
1.1 Forced Potato Radio Remote
1.1.01 Power On
1.1.02 Power Of
1.1.03 Emergency Stop (E-Stop)
1.1.04 Fire Suppression
1.1.05 Pump Motor On/Of
1.1.06 Cutter Motors On/Of
1.1.07 Conveyor Motors On/Of
1.1.08 Fan Motor On/Of
1.1.09 Shear Up/Down
1.1.10 Pan Up/Float
1.1.11 Stab Up/Down
1.1.12 Conveyor Raise/Lower
1.1.13 Conveyor Left/Right
1.1.14 Water Sprays
1.1.15 Lights On/Of
1.1.16 Tram Enable
1.1.17 Left Tram Forward/Reverse
1.1.18 Right Tram Forward/Reverse
1.1.19 Tram Speed Control
1.1.20 Emergency Stop (E-Stop) Bypass
1.1.21 Breaker On/Of
1.1.22 Aux 1 Function
1.1.23 Aux 2 Functions
1.2 Cervis Radio Remote
1.2.01 TX Power On/Of
1.2.02 Battery/UMB Message LED
1.2.03 Error LED
1.2.04 Link Req/Shutdown LED
 1.2.05 Switch Active/Low Battery LED
1.2.06 Link Ack/Commanded Power Down LED
1.2.07 Cutter Start/Stop
1.2.08 Conveyor Start/Stop
1.2.09 Conveyor Reverse
1.2.10 Fire
1.2.11 Lights
1.2.12 Dust On/Of
1.2.13 Fan On/Of
1.2.14 Pump Start/Stop
1.2.15 Cutter Head Raise/Lower
1.2.16 Gathering Head Raise/Float
1.2.17 Conveyor Swing Left/Right
1.2.18 Conveyor Raise/Lower
1.2.19 Breaker Rest/On
1.2.20 Stab Lower/Raise
1.2.21 Tram Enable
1.2.22 Shift
1.2.23 Emergency Stop (E-STOP) Override
1.2.24 Tram High/Low
1.2.25 Left Tram Forward/Reverse
1.2.26 Right Tram Forward/Reverse
1.3 CST-110 Tram Pendant
1.3.01 Machine Stop
1.3.02 Pump Start/Enable
1.3.03 Pump On
1.3.04 Tram Enable
1.3.05 Tram Fwd
1.3.06 Tram Rev
1.3.07 Auger Raise
1.3.08 Auger Lower
1.3.09 WDG LED
1.3.10 TRME LED
1.3.11 TRML LED
 1.3.12 TRMR LED

2.0 Hydraulic Performance Checks

Recorded Movement
(distance/time)
No. Status Description (mm/sec) Comments
2.1 Cylinder Drift Test
2.1.01 Cutter Head Cylinder, Left
2.1.02 Cutter Head Cylinder, Right
2.1.03 Gathering Head Cylinder, Left
2.1.04 Gathering Head Cylinder, Right
2.1.05 Conveyor Lift Cylinder, Left
2.1.06 Conveyor Lift Cylinder, Right