Hw300 Assemble

BI644125-00 (EN-US)
May 2016
Disassembly and Assembly
HW300 Highwall Miner

Field Assembly
Serial number HWM00184
SAFETY.CAT.COM
BI644125-00 (EN-US)
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the neces-
sary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER,
WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially pre-
sented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying your-
self that you have considered all safety rules and precautions applicable to the operation of the product
in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you start
any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this product

Caterpillar recommends using Caterpillar replacement
parts or parts with equivalent specifications including,
but not limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to premature

failures, product damage, personal injury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and systems
may be performed by any repair establishment or individual of the owners choosing.
BI644125-00 (EN-US) 3
Table of Contents
Disassembly and Assembly Section
Introduction ...........................................................4
General Information (Torque Specifications, Graph-
ic Color Description, and Graphic Symbol De-
scription).........................................................4
Base Frame - Install ........................................... 13
Front Super Beam - Install ................................. 18
Rear Super Beam - Install .................................. 22
Power Head - Install ........................................... 26
Base Power Module - Install ............................... 28
Front PTM Structure - Install .............................. 31
Rear PTM Structure - Install ............................... 34
Bridge - Install ..................................................... 37
Extended Discharge Boom - Install .................... 40
Transformer Frame - Install ................................ 44
Transformer - Install ........................................... 46
Base Power Module Catwalks - Install ............... 51
Cab - Install ........................................................ 62
Cab Ladders - Install .......................................... 64
Push Beam Plow - Install.................................... 69
PTM Transfer Cylinders and Catwalk - Install .... 72
Hose Reel - Install .............................................. 80
Drill and Anchor Masts - Install ........................... 84
Front Canopies - Install ...................................... 88
LH & RH Wing Catwalk Support - Install ............ 93
LH Wing Catwalk - Install ................................... 95
RH Wing Catwalk - Install ................................... 97
LH Hose Reel Catwalk - Install ........................... 99
RH Hose Reel Catwalk - Install .......................... 101
LH & RH Can Covers - Install ............................. 103
Hose Reel Guard - Install ................................... 105
PTM Tables - Install............................................ 107
Cab, Groundman Assembly - Install ................... 110
4 BI644125-00 (EN-US)
Disassembly and Assembly General Information

Section (Torque Specifications, Graphic Col-
or Description, and Graphic Symbol
Introduction Description)
Introduction Torque Specifications
This Field Assembly Manual contains the assembly
and installation procedures that are required to English (SAE) Fasteners
assemble the Highwall Miner.
The following table has the recommended standard
WARNING! torque values.
Table 1
Do not attempt to assemble this machine until
you read and understand the assembly instruc-
tions. Nuts and Bolts
Thread Size
Improper assembly procedures could result in Standard Torque
Inch
injury or death.
1/4 12 3 Nm (9 2 lb ft)
WARNING! 5/16 25 5 Nm (18 5 lb ft)

3/8 47 10 Nm (35 5 lb ft)
Personal injury or death can result from im-
proper lifting or blocking. 7/16 70 15 Nm (50 10 lb ft)
1/2 105 20 Nm (75 15 lb ft)
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure 9/16 160 30 Nm (120 20 lb ft)
the hoist or jack has the correct capacity to lift
a component. Install blocks or stands before 5/8 215 40 Nm (160 30 lb ft)
performance of any work under a heavy com- 3/4 370 50 Nm (275 37 lb ft)
ponent.
4/5 620 80 Nm (460 60 lb ft)
Approximate weights of the components are 1 900 100 Nm (660 75 lb ft)
shown.
1 1/8 1300 150 Nm (960 110 lb ft)
Clean all surfaces where parts are to be in-
1 1/4 1800 200 Nm (1320 150 lb ft)
stalled.
1 3/8 2400 300 Nm (1780 220 lb ft)
1 1/2 3100 350 Nm (2280 260 lb ft)
NOTICE
Do not allow any dirt or foreign material to get into
the hydraulic system during assembly, connection Metric (ISO) Fasteners
of lines, when component are filled with fluid, or
The following table has the recommended standard
during any maintenance operation.
torque values.
Do not perform any procedure in this publication or

order any parts until you understand the infor-
mation contained in this publication.
BI644125-00 (EN-US) 5
Table 2 1. Position the flanges parallel over the port.
Nuts and Bolts 2. Evenly install bolts hand-tight, keeping the gap
between flanges at a minimum.
Thread Size
Standard Torque
Inch
3. Put the hose in a position so that the hose
M6 12 3 Nm (9 2 lb ft) does not contact the machine or another hose.
M8 30 5 Nm (20 5 lb ft)
4. Tighten using one of the assembly torque val-
M10 55 10 Nm (40 5 lb ft) ues for bolts, using Illustration 1 for proper
M12 100 20 Nm (75 15 lb ft) torque sequence of various flange fittings.
M14 160 30 Nm (120 20 lb ft) Straight Thread O-Ring Fittings

M16 240 40 Nm (175 30 lb ft)
The following tables have the recommended stand-
M20 460 60 Nm (340 45 lb ft) ard torque values.
M24 800 100 Nm (590 75 lb ft)
Note: Straight Thread O-Ring Fittings for medium
M30 1600 200 Nm (1180 150 lb ft) pressure usage will have shorter threaded ends
M36 2700 300 Nm (2000 220 lb ft) than high-pressure fittings. The torque value for
medium pressure Straight Thread O-Ring Fittings
will be lower than the torque values that are re-
Hydraulic Four Bolt Flange quired for Straight Thread O-Ring Fittings for high-
pressure fittings.
Table 3
Ferrous Straight Thread O-Ring Fitting Tor-

ques for Mating with Ferrous Materials
Medium Pressure use Fittings
Nominal Outer
Thread Size Standard
Diameter of the
Inch Torque
Tube
3.18 mm 10 2 Nm
5/16-24
(.125 inch) (7 1 lb ft)
4.76 mm 17 3 Nm
3/8-24
(.188 inch) (13 2 lb ft)
6.35 mm 35 5 Nm
7/16-20
(.250 inch) (26 4 lb ft)
7.94 mm 45 7 Nm
1/2-20
(.312 inch) (33 5 lb ft)
9.52 mm 45 7 Nm
9/16-18
(.375 inch) (33 5 lb ft)
12.70 mm 80 12 Nm
3/4-16
(.500 inch) (59 9 lb ft)
15.88 mm 110 17 Nm
7/8-14
(.625 inch) (81 13 lb ft)
Illustration 1 (continued)
6 BI644125-00 (EN-US)
(Table 3, contd) (Table 4, contd)
Ferrous Straight Thread O-Ring Fitting Tor- Ferrous Straight Thread O-Ring Fitting Torques
ques for Mating with Ferrous Materials for Mating with Ferrous Materials
Medium Pressure use Fittings High Pressure use with O-Ring Face Seal Fit-
tings
Nominal Outer
Diameter of the Nominal Outer
Inch Torque Thread Size Standard
Tube Diameter of the
Inch Torque
Tube
19.05 mm 130 20 Nm
1 1/16-12
(.750 inch) (96 15 lb ft)
12.70 mm 110 17 Nm
3/4-16
22.22 mm 200 30 Nm (.500 inch) (81 13 lb ft)
1 3/16-12
(.875 inch) (148 22 lb ft)
15.88 mm 140 21 Nm
25.40 mm 220 33 Nm 7/8-14
1 5/16-12 (.625 inch) (103 15 lb ft)
(1.000 inch) (148 22 lb ft)
19.05 mm 220 33 Nm
31.75 mm 300 45 Nm 1 1/16-12
1 5/8-12 (.750 inch) (148 22 lb ft)
(1.250 inch) (221 33 lb ft)
22.22 mm 260 39 Nm
38.10 mm 350 53 Nm 1 3/16-12
1 7/8-12 (.875 inch) (192 29 lb ft)
(1.500 inch) (258 39 lb ft)
25.40 mm 350 53 Nm
50.80 mm 420 63 Nm 1 5/16-12
2 1/2-12 (1.000 inch) (258 39 lb ft)
(2.000 inch) (310 46 lb ft)
31.75 mm 400 60 Nm
1 5/8-12
(1.250 inch) (295 44 lb ft)
Note: Straight Thread O-Ring Fittings for high
pressure usage will have longer threaded ends 38.10 mm 420 63 Nm
1 7/8-12
than medium pressure fittings. The torque value (1.500 inch) (310 46 lb ft)
for high pressure Straight Thread O-Ring Fittings 50.80 mm 600 90 Nm
will be higher than the torque values required for 2 1/2-12
(2.000 inch) (443 66 lb ft)
Straight Thread O-Ring Fittings.
Table 5
Table 4
Ferrous Straight Thread O-Ring Fitting Tor- Metric Ferrous Straight Thread O-Ring Fitting
ques for Mating with Ferrous Materials Torques for Mating with Ferrous Materials
High Pressure use with O-Ring Face Seal Fit- Medium Pressure use with Fittings
tings
Nominal Outer
Nominal Outer Thread Size Standard
Thread Size Standard Diameter of the
Diameter of the Inch Torque
Inch Torque Tube
Tube
10 2 Nm
4.76 mm 25 4 Nm 4 mm M8 X 1
3/8-24 (7 1 lb ft)
(.188 inch) (18 3 lb ft)
17 3 Nm
6.35 mm 35 5 Nm 5 mm M10 X 1
7/16-20 (13 2 lb ft)
(.250 inch) (26 4 lb ft)
35 5 Nm
7.94 mm 50 8 Nm 6 mm M12 X 1.5
1/2-20 (26 4 lb ft)
(.312 inch) (37 6 lb ft)
45 7 Nm
9.52 mm 70 11 Nm 8 mm M14 X 1.5
9/16-18 (33 5 lb ft)
(.375 inch) (52 8 lb ft)
45 7 Nm
10 mm M16 X 1.5
(33 5 lb ft)
(continued)
BI644125-00 (EN-US) 7
Ferrous Straight Thread O-Ring Fitting Torques Ferrous Straight Thread O-Ring Fitting Torques
for Mating with Ferrous Materials for Mating with Ferrous Materials
High Pressure use with O-Ring Face Seal Fit- High Pressure use with O-Ring Face Seal Fit-
tings tings
Nominal Outer Nominal Outer
Thread Size Standard Thread Size Standard
Diameter of the Diameter of the
Inch Torque Inch Torque
Tube Tube
80 12 Nm 110 17 Nm
12 mm M18 X 1.5 12 mm M18 X 1.5
(59 9 lb ft) (81 13 lb ft)
110 17 Nm 140 21 Nm
16 mm M22 X 1.5 16 mm M22 X 1.5
(81 13 lb ft) (103 15 lb ft)
130 20 Nm 220 33 Nm
20 mm M27 X 2 20 mm M27 X 2
(96 15 lb ft) (148 22 lb ft)
200 30 Nm 260 39 Nm
22 mm M30 X 2 22 mm M30 X 2
(148 22 lb ft) (192 29 lb ft)
220 33 Nm 350 53 Nm
25 mm M33 X 2 25 mm M33 X 2
(148 22 lb ft) (258 39 lb ft)
300 45 Nm 400 60 Nm
30 mm M42X3 30 mm M42X3
(221 33 lb ft) (295 44 lb ft)
350 53 Nm 420 63 Nm
38 mm M48 X 2 38 mm M48 X 2
(258 39 lb ft) (310 46 lb ft)
420 63 Nm 600 90 Nm
50 mm M60 X 2 50 mm M60 X 2
(310 46 lb ft) (443 66 lb ft)
Table 6 O-Ring Face Seal Fittings

Ferrous Straight Thread O-Ring Fitting Torques The following tables have the recommended stand-
for Mating with Ferrous Materials ard torque values.
High Pressure use with O-Ring Face Seal Fit-
tings Table 7
Nominal Outer Nuts and Bolts

Diameter of the
Inch Torque Thread Size
Tube Standard Torque
Inch
25 4 Nm
5 mm M10 X 1 9/16-18 30 5 Nm (22 4 lb ft)
(18 3 lb ft)
35 5 Nm 11/16-16 50 8 Nm (37 6 lb ft)
6 mm M12 X 1.5
(26 4 lb ft) 13/16-16 70 11 Nm (42 8 lb ft)
50 8 Nm 1-14 110 17 Nm (81 13 lb ft)
8 mm M14 X 1.5
(37 6 lb ft)
1 3/16-12 160 24 Nm (118 18 lb ft)
70 11 Nm
10 mm M16 X 1.5
(52 8 lb ft) 1 7/16-12 260 39 Nm (192 29 lb ft)
1 11/16-12 300 45 Nm (221 33 lb ft)
2-12 350 53 Nm (258 39 lb ft)
8 BI644125-00 (EN-US)
Table 9
Tapered Pipe Thread Fittings
The following tables have the recommended stand- Worm Drive Band Type Hose Clamps
ard torque values.
Width of Clamp Torque for New Hose
Table 8
7.5 mm (0.3 inch)
Tapered Pipe Thread Fittings 1.4 +0.3 Nm (12 3 lb in)
or smaller
12 mm (0.5 inch)
Standard Torque 4.5 +0.7 Nm (40 6 lb in)
or smaller
Diameter of the
Pip Thread 14 mm (0.6 inch)
Assembly 7.5 +1 Nm (66 9 lb in)
(inch) or smaller)
Turns after Torque
Hand Tight Width of Clamp Torque for Reused Hose (1)
10 +2 Nm 7.5 mm (0.3 inch)

1/16 3 0.8 +0.3 Nm (7 3 lb in)
(89 18 lb in) or smaller
20 3 Nm 12 mm (0.5 inch)
1/8 3 3.0 +0.5 Nm (27 4 lb in)
(177 27 lb in) or smaller
35 5 Nm 14 mm (0.6 inch)
1/4 3 4.5 +0.7 Nm (40 6 lb in)
(26 4 lb ft) or smaller)
60 9 Nm
3/8 3 (1)
Use this value when the hose is reused. The clamp may be
(44 7 lb ft)
new or reused.
80 12 Nm
1/2 2.5 Table 10
(60 9 lb ft)
100 15 Nm Constant Torque Hose Clamps
3/4 2.5
(74 11 lb ft) Belleveille Washer
120 18 Nm
1 2.5 Diameter of Clamp Standard Torque
(89 13 lb ft)
140 21 Nm Up to 50.8 mm (2 7.5 +1 Nm (65 10 lb
1 1/4 2.5
(103 15 lb ft) inch) in)
160 24 Nm Greater than 50.8
1 1/2 2.5 11 +1 Nm (95 6 10 in)
(118 18 lb ft) mm (2 inch)
180 27 Nm
2 2.5 Table 11
(130 20 lb ft)
Constant Torque Hose Clamps

Hose Clamps Tee Bolt and Spring
The following tables have the recommended stand- Diameter of

Standard Torque
Clamp
ard torque values.
All 7.5 +1 Nm (65 10 lb in)
BI644125-00 (EN-US) 9
Graphic Color Description

Table 12
The graphic color description table identifies what Assembly Preparation

the colors represent in each graphic.
Required Tools and Supplies
Graphic Symbol Description
Table 13
The graphic symbol description identifies what the
symbols represent in the graphic. Required Tools
Part
Description Qty
No.
208 L (55 US gal) barrels of hoist,
- converter, steering, and brake oil 6
(TDTO, TO-4)
227 L (60 US gal) of transmission/

drive train oil (TDTO). Ambient
temperatures that are extreme
- may require a different oil viscosi- 1
ty. Refer to Service Manual, SE-
BU6250, Caterpillar Machine Lub-
ricant Recommendations
Crane or suitable lifting device with

- lifting capacity of 54430 kg 1
(120000 lb)
Crane or suitable lifting device with
- lifting capacity of 36287 kg (80000 1
lb)
Lift truck with lifting capacity of
- 1
6810 kg (15000 lb)
Cables, lifting straps, and chains
- -
with adequate lifting capacity
(continued)
10 BI644125-00 (EN-US)
Required Tools Required Tools

Part No. Description Qty Part No. Description Qty
Shackles with lifting capacity of 386-6033 Lever Puller Hoist Gp 1
- 4
27240 kg (60050 lb)
176-6538 Spanner Wrench As 1
Portable air compressor with
385-7874 Hydraulic Wrench 1
capacity to operate two 25.4
- mm (1 inch) impact wrenches 1 Hydraulic Pump and Motor Gp,
(minimum capacity of 3 CM (100 385-8479 1
115 V
CFM)
Hydraulic Pump and Motor Gp,
Suitable cribbing: 914 mm (8 132-8231 1
220V
inch) Length X 203 mm (8.0
- 1 7X-1062 Ether Cylinder As 2
inch) Width X 102 mm (4 inch)
Height Tool Gp
399-0774 1
- Stepladder, 1.8 m (6 ft) 1 Reaction Arm
- Stepladder, 3.6 m (12 ft) 2 5P-5265 Forcing Bolts 4
Suitable rope: 94 m (308 ft) long 194-7586 Pneumatic Wrench Gp 1

- 1
X 19 mm (0.75 inch) diameter 194-7886 Drive Extension 1
- Paint Spray Gun 1 4C-6723 Socket, 1 7/16 inch 1
Torque Wrench 4C-6724 Socket, 46 mm 1
8T-9293
54 to 342 Nm (40 to 252 lb ft)
208-8785 Plate 1
- T-size Nitrogen Bottles 20
175-5507 Nitrogen Charging Group 1 Required tools and supplies to perform the field
assembly.
9U-5617 Oil Refill Pump
6V-4040 Inflation Gp The required tools and supplies should be present
before assembly. If the required tools and supplies
Loctite Graphite 50 Anti-Seize are not present, assembly will be more difficult and
- -
Lubricant more time will be necessary to complete assembly.
- Loctite C5A Copper Anti-Seize -
Reference: Service Magazine, SEPD05313 July
- Loctite Low Breakloose PST - 2000, Fabric Slings and Protective Sleeves Are
Available for Lifting Truck Bodies
- Loctite 242 -
- Loctite 271 - Reference: Special Instruction, SMHS7867, Use
of 6V-4040 Inflation Group
8T-3087 Hand Tap: M10X1.5 1
Reference: Operation and Maintenance Manual,
8T3091 Tap: M12X1.75 1
SEBU5898, Cold Weather Recommendations for
4C-4968 Tap: M24X3.0 1 Caterpillar Machines
4C-4969 Tap: M30X3.5 1

4C-4970 Tap: M36X4 1
386-6031 Lever Puller Hoist Gp 4
(continued)
BI644125-00 (EN-US) 11
(Table 14, contd)

Shipping Weights
Component Approximate Weight
WARNING!
BPM/ECM Rear Catwalk 544 kg (1200 lb)
Personal injury or death can result from lifting
BPM/ECM Side Catwalk 544 kg (1200 lb)
a heavy assembly. The heavy assembly can
fall, if incorrect hoists are used to lift the load. BPM/ECM Front Catwalk 544 kg (1200 lb)
Be sure the hoist has the correct lift capacity. BPM/ECM RH Catwalk 181 kg (400 lb)
Approximate assembly weights are given be- BPM/ECM LH Catwalk 181 kg (400 lb)
low.
Cab 7250 kg (16000 lb)
Cab Ladders 227 kg (500 lb)
WARNING!
Super Beam Ladder 113 kg (250 lb)
Personal injury or death can result from im-
Push Beam Plow 1361 kg (3000 lb)
proper lifting or blocking.
Front Canopy 1361 kg (3000 lb)
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure Rock Guard 544 kg (1200 lb)
the hoist or jack has the correct capacity to lift PTM Transfer Cylinders
the component. Install blocks or stands before 5443 kg (12000 lb)
and Catwalk
performing any work under a heavy compo-
nent. Hose Reel 21772 kg (48000 lb)
Hose Reel Catwalk 227 kg (500 lb)
Approximate weights of the components are
shown. Hose Reel Guard 680 kg (1500 lb)
Clean all surfaces where parts are to be in- Anchor Drills 1497 kg (3300 lb)
stalled. PTM Tables 1678 kg (3700 lb)
Cab, Groundman As-
Table 14 2268 kg (5000 lb)
sembly
Approximate
Component
Weight
Base Frame 43772 kg (96500 lb)
Front Super Beam 32659 kg (72000 lb)
Rear Super Beam 32659 kg (72000 lb)
Power Head 29030 kg (64000 lb)
BPM/ECM 19051 kg (42000 lb)
Front PTM Structure 5897 kg (13000 lb)
Rear PTM Structure 6350 kg (14000 lb)
Bridge 363 kg (800 lb) each
Extended Discharge Boom 9120 kg (20000 lb)
Transformer Frame 4082 kg (9000 lb)
Transformer 12700 kg (28000 lb)
(continued)
12 BI644125-00 (EN-US)
Site Layout
Illustration 2
BI644125-00 (EN-US) 13
Typical Assembly Layout
The work area for the base frame and the compo-
nents should be flat, smooth, and drained. An area
of approximately 46 m (150 ft) by 29 m (95 ft) is
needed for the assembly of the machine.
The base frame should be located in the center of

the assembly area. Keep the assembly area
around the base frame clear. Also, the assembly
area should be left unobstructed in order for the
crane to lift the components.
Base Frame - Install

Parts and Specification Information
Illustration 3
Table 15
Base Frame
Item Qty Part Number Description Approximate Weight
1 1 4592663 Base Frame 43772 kg (96000 lb)

14 BI644125-00 (EN-US)
Installation Procedure
Illustration 4
1. Use an appropriate lifting device to set the

base frame (1) into position. The approximate
weight of the base frame is 43772 kg (965000
lb).
Illustration 5
Typical view of cribbing use to support the ma-

chine.
BI644125-00 (EN-US) 15
Illustration 6 View of level being used on the base frame from

side to side.
View of level being used on the base frame from
front to back. 2. Use 153 mm (6 inch) X 153 mm (6 inch) hard-
wood cribbing to position base frame (1). Po-
sition base frame (1) at least 610 mm (24 inch)
above ground level. Make sure the base
frame (1) is level from front to back and side to
side. Check level with 914.5 (36 inch) level.
Illustration 7
16 BI644125-00 (EN-US)
Illustration 8
3. Remove and discard the shipping brackets.

Retain the hardware.
BI644125-00 (EN-US) 17
Illustration 9
4. Fold the T-bar ends out and secure in place

using hardware retained from Step 3.
18 BI644125-00 (EN-US)
Front Super Beam - Install

Illustration 10
Table 16
Front Super Beam
1 1 4510739 Front Super Beam 32659 kg (72000 lb)

BI644125-00 (EN-US) 19
Illustration 11

front super beam (1) into position. The approx-
imate weight of the front super beam (1) is
32659 kg (72000 lb).
20 BI644125-00 (EN-US)
Illustration 12
2. Use a suitable tool to align the mounting holes of the front

super beam (1) with the mounting holes of the base frame.
BI644125-00 (EN-US) 21
Illustration 13
3. Secure the front super beam (1) to the base

frame using bolts, washers, and nuts.
22 BI644125-00 (EN-US)
Rear Super Beam - Install

Illustration 14
Table 17
Rear Super Beam
1 1 4510739 Rear Super Beam 32659 kg (72000 lb)

BI644125-00 (EN-US) 23
Illustration 15
1. Use an appropriate lifting device to set the rear

super beam (1) into position. The approximate
weight of the rear super beam (1) is 32659 kg
(72000 lb).
24 BI644125-00 (EN-US)
Illustration 16
2. Use suitable tooling to align the mounting holes of the rear

super beam (1) with the mounting holes of the base frame.
BI644125-00 (EN-US) 25
Illustration 17
3. Secure the rear super beam (1) to the base

frame using bolts, washers, and nuts provided.
26 BI644125-00 (EN-US)
Power Head - Install

Illustration 18
Table18
Power Head
1 1 4592666 Power Head 29030 kg (64000 lb)

BI644125-00 (EN-US) 27
Illustration 19

power head (1) into position. The approximate
weight of the power head (1) is 29030 kg
(64000 lb).
2. Move the power head (1) into the base frame.
NOTICE
Make sure the conveyor chain and cables are out
of the way when pushing the power head (1) into
the base frame.
28 BI644125-00 (EN-US)
Base Power Module - Install

Illustration 20
Table 19
Base Power Module
1 1 4835971 Base Power Module 19051 kg (42000 lb)

BI644125-00 (EN-US) 29
Illustration 21

base power module (1) into positon. The ap-
proximate weight of the base power module (1)
is 19051 kg (42000 lb).
30 BI644125-00 (EN-US)
Illustration 22
2. Position the base power module (1) on the four

cone shaped cam locks located on the rear
super beam and the base frame.
Illustration 23
View of cam lock location
3. Turn the lever on the cam locks to secure base

power module 91) on the rear super beam and
on the base frame.
BI644125-00 (EN-US) 31
Front PTM Structure - Install

Illustration 24
Table 20
Front PTM Structure
1 1 4412288 Front PTM Structure 5897 kg (13000 lb)

32 BI644125-00 (EN-US)
Illustration 25

front PTM structure (1) into position. The ap-
proximate weight of the front PTM structure (1)
is 5897 kg (13000 lb).
BI644125-00 (EN-US) 33
Illustration 26
2. Secure the front PTM structure (1) with pins at

the locations shown. Raise and pin the sup-
port legs attached to the base frame to the
front PTM structure (1) at two locations.
34 BI644125-00 (EN-US)
Rear PTM Structure - Install

D
FW
Illustration 27
Table 21
Rear PTM Structure
1 1 4412287 Rear PTM Structure 6350 kg (14000 lb)

BI644125-00 (EN-US) 35
Illustration 28

PTM structure (1) into position. The approxi-
mate weight of the front PTM structure (1) is
6350 kg (14000 lb).
36 BI644125-00 (EN-US)
Illustration 29
2. Secure the rear PTM structure (1) with pins at

the locations shown. Raise and pin the sup-
port legs attached to the base frame to the rear
PTM structure (1) at two locations.
BI644125-00 (EN-US) 37
Bridge - Install
Illustration 30
Table 22
Bridge
1 2 4208239 Bridge 363 kg (800 lb)

38 BI644125-00 (EN-US)
Note: Install the following prior to installing the two

bridges:
PTM Tables
PTM Transfer Cylinders and Catwalk
Stagger Skid Catwalk
Illustration 31
BI644125-00 (EN-US) 39
Illustration 32
1. Use an appropriate lifting device to set each

bridge (1) into position. The approximate
weight of each bridge (1) is 363 kg (800 lb).
2. Secure the bridges (1) using two nuts on the

pins of each bridge (1). Use to 50.8 mm (2
inch) bolts and a washer with a nut on each
end.
40 BI644125-00 (EN-US)
Extended Discharge Boom - Install

Illustration 33
Table 23
Extended Discharge Boom
1 1 4509196 Extended Discharge Boom 9120 kg (20000 lb)

BI644125-00 (EN-US) 41
Illustration 34
1. Use an appropriate lifting device to set the ex-

tended discharge boom (1) into position. The
approximate weight of the extended discharge
boom (1) is 9120 kg (20100 lb).
42 BI644125-00 (EN-US)
Illustration 35
2. Secure the extended discharge boom (1) to the

base frame using two pins.
BI644125-00 (EN-US) 43
Illustration 36
3. Feed the conveyor chain around the sprocket

and assemble the chain with connecting links.
44 BI644125-00 (EN-US)
Transformer Frame - Install

Illustration 37
Table 24
Transformer Frame
1 1 4281682 Transformer Frame 4082 kg (9000 lb)

BI644125-00 (EN-US) 45
Illustration 38

transformer frame (1) into position. The ap-
proximate weight of the transformer frame (1)
is 4082 kg (9000 lb).
2. Secure the transformer frame (1) to the back of

the T-bar with eighteen bolts on each side.
46 BI644125-00 (EN-US)
Transformer - Install
Illustration 39
Table 25
Transformer
1 1 4830241 Transformer 12700 kg (28000 lb)

BI644125-00 (EN-US) 47
Illustration 40

transformer (1) into position. The approximate
weight of the transformer is 12700 kg (28000
lb).
48 BI644125-00 (EN-US)
Illustration 41
2. Secure the transformer (1) to the top of the

transformer frame with eight bolts on the front
and the rear of the transformer (1).
BI644125-00 (EN-US) 49
Illustration 42
Illustration 43
3. Secure the exhaust tubes to the exhaust

bracket with eight bolts, twelve washers, and
eight nuts.
4. Position the two exhaust tubes in the trans-

former (1).
50 BI644125-00 (EN-US)
Illustration 44
5. Secure the exhaust bracket to the transformer

(1) with six bolts and eighteen washers.
BI644125-00 (EN-US) 51
Base Power Module Catwalks - Install

Illustration 45
Table 26
Base Power Module Catwalks
1 1 4510910 Rear Catwalk 544 kg (1200 lb)
2 1 4412241 LH Catwalk 544 kg (1200 lb)
3 1 4412239 Front Catwalk 544 kg (1200 lb)
4 1 4412240 RH Catwalk 544 kg (1200 lb)
5 1 4207996 RH Catwalk 181 kg (400 lb)
6 1 4207997 LH Catwalk 181 kg (400 lb)

52 BI644125-00 (EN-US)
Illustration 46
View of the location of the front catwalk (1).

BI644125-00 (EN-US) 53
Illustration 47
View of the mounting location for the front catwalk

(3).

front catwalk (3) into position. The approxi-
mate weight of the front catwalk (1) is 544 kg
(1200 lb).
2. Secure the front catwalk (3) to the rear super

beam with twelve bolts, twenty-four washers,
and twelve nuts.
54 BI644125-00 (EN-US)
Illustration 48
View of the locations of the RH catwalk (4) and the

LH catwalk (2).
BI644125-00 (EN-US) 55
Illustration 49
View of the mounting locations for the RH catwalk

(4).
56 BI644125-00 (EN-US)
Illustration 50 6. Secure the LH catwalk (2) and the RH catwalk

(4) to the rear super beam with four bolts, eight
View of the mounting location for the RH catwalk washers, and four nuts.
(4).
3. Use an appropriate lifting device to set the LH

catwalk (2) and RH catwalk (4) into position.
The approximate weight of the LH catwalk (2)
and the RH catwalk (4) is 544 kg (1200 lb).
4. Secure the LH catwalk (2) and the RH catwalk

(4) to the base frame with four bolts and eight
washers.
5. Secure the LH catwalk (2) and RH catwalk (4)

to the front catwalk (3) with four bolts, eight
washers, and four nuts.
BI644125-00 (EN-US) 57
Illustration 51
58 BI644125-00 (EN-US)
Illustration 52
View of the mounting bolt locations for the LH cat-

walk (6) and RH catwalk (5).
BI644125-00 (EN-US) 59
Illustration 53

catwalk (6) and RH catwalk (5) into position.
The approximate weight of the LH catwalk (6)
and the RH catwalk (5) is 181 kg (400 lb).
8. Secure the LH catwalk (6) and the RH catwalk

(5) to the LH and RH catwalks that were previ-
ously installed to the base frame with four
bolts, eight washers, and four nuts.
9. Secure the LH catwalk (6) and RH catwalk (5)

to the transformer frame with six bolts, twelve
washers, and six nuts.
60 BI644125-00 (EN-US)
Illustration 54
BI644125-00 (EN-US) 61
Illustration 55
Bolt locations on the LH side of the rear catwalk (1)

catwalk 91) into position. The approximate
weight of the rear catwalk 91) is 544 kg (1200
lb).
11. Secure the front catwalk (1) to the previously

installed catwalks with fourteen bolts, twenty-
eight washers, and fourteen nuts.
62 BI644125-00 (EN-US)
Cab - Install
Illustration 56
Table 27
Cab
1 1 4829476 Cab 7257 kg (16000 lb)

BI644125-00 (EN-US) 63
Illustration 57
1. Use an appropriate lifting device to set cab (1)

into position. The approximate weight of the
cab (1) is 7257 kg (16000 lb). Position the cab
(1) on the four cone shaped cam locks located
on the base power module.
2. Turn the lever on the cam locks to secure the

cab (1) to the base power module.
64 BI644125-00 (EN-US)
Cab Ladders - Install

Illustration 58
Table 28
Cab Ladders
1 1 4207928 RH Super Beam Ladder 113 kg (250 lb)
2 1 4207989 LH Rear Super Beam Ladder 113 kg (250 lb)
3 1 4207940 RH Cab Ladder 227 kg (500 lb)
4 1 4207941 LH Cab Ladder 227 kg (500 lb)

BI644125-00 (EN-US) 65
Illustration 59
1. Use an appropriate lifting device to set the RH

rear super beam ladder (1) and LH rear super
beam ladder (2) into position. The approxi-
mate weight of the RH rear super beam ladder
(1) and the LH rear super beam ladder (2) is
113 kg (250).
66 BI644125-00 (EN-US)
Illustration 60
2. Secure the RH rear super beam ladder (1) and

LH rear super beam ladders (2) using three bolts
and three washers for each ladder.
BI644125-00 (EN-US) 67
Illustration 61
View of RH cab ladder (3) and LH cab ladder (4).
3. Use appropriate lifting device to set the RH cab

ladder (3) and RH cab ladder (4) into position.
The approximate weight of the RH cab ladder
and the LH cab ladder (4) is 227 kg (500 lb).
68 BI644125-00 (EN-US)
Illustration 62
View of RH cab ladder (3)
4. Secure the RH cab ladder (3) and the LH cab

ladder (4) using five bolts and five washers for
each ladder.
BI644125-00 (EN-US) 69
Push Beam Plow - Install

Illustration 63
Table 29
Push Beam Plow
1 1 4207991 Push Beam Plow 1361 kg (3000 lb)

70 BI644125-00 (EN-US)
Illustration 64

push beam plow (1) into position. The approxi-
mate weight of the push beam plow (1) is 1361
kg (3000 lb).
BI644125-00 (EN-US) 71
Illustration 65
2. Secure the push beam plow (1) to the front

super beam using two pins.
3. Connect the cylinder.

BI644125-00 (EN-US) 72
PTM II Lift Mechanism - Install

Illustration 66
73 BI644125-00 (EN-US)
Illustration 67
Table 30
PTM II Lift Mechanism
1 1 4412284 PTM II Lift Mechanism 5443 kg (12000 lb)

BI644125-00 (EN-US) 74
Illustration 68
1. Use an appropriate lifting device to position the

PTM II lift mechanism (1) into position. The
approximate weight of the rear PTM structure
(1) is 5443 kg (12000). Support the PTM II lift
mechanism (1) with appropriate cribbing for
assembly.
75 BI644125-00 (EN-US)
Illustration 69
2. Secure the two beams and two cylinders to the

PTM II lift mechanism (1) with sixteen bolts,
sixteen washers, sixteen lock washers, and
sixteen nuts.
BI644125-00 (EN-US) 76
Illustration 70
77 BI644125-00 (EN-US)
Illustration 71
3. Use an appropriate lifting device to set the cat-

walk and handrail into position. The approxi-
mate weight of the catwalk and handrail is 182
kg (400 lb).
4. Secure the catwalk and handrail PTM structure

(1) using four bolts, four flat washers, four lock
washers, and four nuts.
BI644125-00 (EN-US) 78
Illustration 72

PTM II lift mechanism (1) into position. The
approximate weight of the rear PTM structure
(1) is 5443 kg (12000 lb). Lift the PTM II lift
mechanism (1) by the top bracket and slide the
rollers onto the I-beam (catwalk facing the RH
side).
79 BI644125-00 (EN-US)
Illustration 73
6. Use an appropriate lifting device to set the end

bracket into position. The approximate weight
of the end bracket is 182 kg (400 lb).
7. The end bracket can be bolted to the I-beam in

one of two locations, depending on which side
from which the push beams will be loaded.
After determining the location, secure the end
bracket to the I-beam with four bolts, four lock
washers, and four nuts on each side.
BI644125-00 (EN-US) 80
Hose Reel - Install

Illustration 83
Table 33
Base Frame
1 1 4835743 Hose Reel 21772 kg (48000 lb)

81 BI644125-00 (EN-US)
Illustration 84
View of hose reel (1) as shipped.

BI644125-00 (EN-US) 82
Illustration 85 4. Assemble the temporary stand for the tempo-

rary hose reel and set next to the machine
1. Remove all beams that are assembled with hose reel. Straighten cables and hoses and,
bolts in the hose reel shipping frame. using the required hose chain, permanently
connect the two spools of hose chain.
2. Using an oxygen/acetylene torch, cut through
the lifting plate and bottom beam on both sides 5. Using the highwall miner hydraulic power, or
of the frame to create a base for the hose reel an alternate hydraulic power source, apply hy-
to stand upright on. draulic power to the hose reel motor.
3. Using four shackles and 9.1 m (30 ft) cables, 6. Reel the hose chain from the temporary hose
lift the hose reel 91) and set in front of the reel to the machine hose reel.
highwall miner in the upright position. The ap-
proximate weight of the hose reel (1) is 21772
kg (48000 lb).
83 BI644125-00 (EN-US)
Illustration 86
7. Clean the hose reel mounting pads.
8. Once all hose chain has been transferred to

the machine hose reel (1), set it in place on the
front super beam.
9. Secure the hose reel (1) with ten bolts on each

side.
BI644125-00 (EN-US) 84
Drill and Anchor Masts - Install

Illustration 74
Table 31
Drill and Anchor Masts
1 1 4207740 RH Drill and Anchor Mast 1497 kg (3300 lb)
2 1 4281509 LH Drill and Anchor Mast 1497 kg (3300 lb)

85 BI644125-00 (EN-US)
Illustration 75
View of the mounting locations on the RH drill and

anchor mast (1).
BI644125-00 (EN-US) 86
Illustration 76
View of the mounting locations on the LH drill and

anchor mast (2).
87 BI644125-00 (EN-US)
1
2
Illustration 77 3. Secure the LH drill and anchor mast (1) using

eight bolts on the top mounting plate and ten
1. Use an appropriate lifting device to set the RH bolts on the bottom mounting plate. Take care
drill and anchor mast (1) and the LH drill and to avoid damaging wiring and hoses.
anchor mast (2) into position. The approxi-
mate weight of the RH drill and anchor mast
(1) and the LH drill and anchor mast (2) is
1497 kg (3300 lb).
2. Secure the RH drill and anchor mast (1) using

eight bolts on the top mounting plate and ten
bolts on the bottom mounting plate. Take care
to avoid damaging wiring and hoses.
88 BI644125-00 (EN-US)
Front Canopies - Install

Illustration 78
Table 32
Front Canopies
1 1 4613952 Front Canopy 1075 kg (2370 lb)
2 1 4281683 Blast Shield 544 kg (1200 lb)

BI644125-00 (EN-US) 89
Illustration 79
View of the front canopy sitting in position on the

front supports.

front canopy (1) into position.. The approxi-
mate weight of the front canopy (1) is 1075 kg
(2370 lb).
90 BI644125-00 (EN-US)
Illustration 80
2. Secure the front canopy (1) to the front super

beam using four pins.
BI644125-00 (EN-US) 91
Illustration 81
92 BI644125-00 (EN-US)
Illustration 82
3. Use an appropriate lifting device to position the

rock guard (2) into position. The approximate
weight of the rock guard (2) is 544 kg (1200
lb).
4. Secure the rock guard (2) to the front canopy

(1) using three pins.
5. Connect the cylinder.

BI644125-00 (EN-US) 93
LH & RH Wing Catwalk Support - Install

Illustration 87
Table 34
Hose Reel Catwalk
1 2 4614020 Wing Support, RH and LH 65 kg (30 lb)

94 BI644125-00 (EN-US)
3 2
1 2
3 1
Illustration 88
1. Position the LH wing catwalk support (1) and

the RH wing catwalk support (2) and secure
with bolts (2) and washers (3). The approxi-
mate weight of the LH wing catwalk support (1)
and RH wing catwalk support (2) is 65 kg (30
lb).
BI644125-00 (EN-US) 95
LH Wing Catwalk - Install

Illustration 89
Table 35
LH Wing Catwalk
1 1 4613996 LH Wing Catwalk 280 kg (620 lb)

96 BI644125-00 (EN-US)
Illustration 90

wing catwalk (1) into position. The approxi-
mate weight of the LH wing catwalk (1) is 280
kg (620 lb).
2. Secure with bolts, nuts, and washers.

BI644125-00 (EN-US) 97
RH Wing Catwalk - Install

Illustration 91
Table 36
RH Wing Catwalk
1 1 4614654 RH Wing Catwalk 480 kg (1060 lb)

98 BI644125-00 (EN-US)
Illustration 92

wing catwalk (1) into position. The approxi-
mate weight of the RH wing catwalk (1) is 480
kg (1060 lb).

BI644125-00 (EN-US) 99
LH Hose Reel Catwalk - Install

Illustration 93
Table 37
LH Hose Reel Catwalk
1 1 4614622 LH Hose Reel Catwalk 625 kg (1380 lb)

100 BI644125-00 (EN-US)
Illustration 94

hose reel catwalk (1) into position. The ap-
proximate weight of the LH hose reel catwalk
(1) is 625 kg (1380 lb).

BI644125-00 (EN-US) 101
RH Hose Reel Catwalk - Install

Illustration 95
Table 38
RH Hose Reel Catwalk
1 1 4614654 RH Hose Reel Catwalk 480 kg (1060 lb)

102 BI644125-00 (EN-US)
Illustration 96

hose reel catwalk (1) into position. The ap-
proximate weight of the RH hose reel catwalk
(1) is 480 kg (1060 lb).

BI644125-00 (EN-US) 103
LH and RH Can Cover - Install

Illustration 97
Table 39
RH Hose Reel Catwalk
1 2 4509748 Can Cover 10 kg (20 lb)

104 BI644125-00 (EN-US)
Illustration 98
and LH can covers (1) into position. The ap-
proximate weight of the RH hose reel catwalk
(1) is 10 kg (20 lb).
BI644125-00 (EN-US) 105
Hose Reel Guard - Install

Illustration 99
Table 40
Hose Reel Guard
1 1 4208087 Hose Reel Guard 680 kg (1500 lb)

106 BI644125-00 (EN-US)
Illustration 100

hose reel guard (1) into position. The approxi-
mate weight of the hose reel guard 91) is 680
kg (1500 lb).
2. Secure the hose reel guard (1) to the hose reel

with four bolts on each side.
BI644125-00 (EN-US) 107
PTM Tables - Install

Illustration 101
Table 41
PTM Tables
1 2 4512184 PTM Tables 1678 kg (3700 lb)

108 BI644125-00 (EN-US)
Illustration 102
View of the mounting location of the PTM tables

(1).
BI644125-00 (EN-US) 109
Illustration 103

PTM tables (1) into position. The approximate
weight of the PTM tables (1) is 1678 kg (3700
lb).
2. Secure the PTM tables (1) to the front and rear

super beams with four cables and four turn
buckles.
110 BI644125-00 (EN-US)
Cab , Groundman Assembly - Install

Illustration 104
Table 42
Cab, Groundman Assembly
1 1 4830242 Cab, Groundman Assembly 2268 kg (5000 lb)

BI644125-00 (EN-US) 111
Illustration 105
Illustration 106 2. Install the cab, groundman assembly (1) on the

opposite side of where the beams will be load-
1. Use an appropriate lifting device to set the cab, ed.
groundman assembly (1) into position. The
approximate weight of the cab, groundman Note: The cab, groundman assembly (1) sets in
assembly (1) is 2268 kg (5000 lb). the table with no need for any attachment.

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BI644125-00 (EN-US)

Disassembly and Assembly

HW300 Highwall Miner

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this product

Failure to heed this warning can lead to premature

Disassembly and Assembly General Information

WARNING! 5/16 25 5 Nm (18 5 lb ft)

Do not perform any procedure in this publication or

Table 2 1. Position the flanges parallel over the port.

M14 160 30 Nm (120 20 lb ft) Straight Thread O-Ring Fittings

Ferrous Straight Thread O-Ring Fitting Tor-

(Table 3, contd) (Table 4, contd)

(Table 5, contd) (Table 6, contd)

Table 6 O-Ring Face Seal Fittings

Nominal Outer Nuts and Bolts

10 +2 Nm 7.5 mm (0.3 inch)

Constant Torque Hose Clamps

The following tables have the recommended stand- Diameter of

Graphic Color Description

The graphic color description table identifies what Assembly Preparation

227 L (60 US gal) of transmission/

Crane or suitable lifting device with

(Table 13, contd) (Table 13, contd)

Required Tools Required Tools

- Stepladder, 3.6 m (12 ft) 2 5P-5265 Forcing Bolts 4

Suitable rope: 94 m (308 ft) long 194-7586 Pneumatic Wrench Gp 1

4C-4969 Tap: M30X3.5 1

(Table 14, contd)

Typical Assembly Layout

The base frame should be located in the center of

Base Frame - Install

Item Qty Part Number Description Approximate Weight

1 1 4592663 Base Frame 43772 kg (96000 lb)

1. Use an appropriate lifting device to set the

Typical view of cribbing use to support the ma-

Illustration 6 View of level being used on the base frame from

3. Remove and discard the shipping brackets.

4. Fold the T-bar ends out and secure in place

Front Super Beam - Install

Front Super Beam

Item Qty Part Number Description Approximate Weight

1 1 4510739 Front Super Beam 32659 kg (72000 lb)

1. Use an appropriate lifting device to set the

2. Use a suitable tool to align the mounting holes of the front

3. Secure the front super beam (1) to the base

Rear Super Beam - Install

Rear Super Beam

Item Qty Part Number Description Approximate Weight

1 1 4510739 Rear Super Beam 32659 kg (72000 lb)

1. Use an appropriate lifting device to set the rear

2. Use suitable tooling to align the mounting holes of the rear

3. Secure the rear super beam (1) to the base

Power Head - Install

Item Qty Part Number Description Approximate Weight

1 1 4592666 Power Head 29030 kg (64000 lb)

1. Use an appropriate lifting device to set the

2. Move the power head (1) into the base frame.