CAT CM210 Continuous Miner Operation and Maintenance Manual BI016890

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Operation and Maintenance Manual CM210 Continuous Miner SAFETY.CAT.COM BI016890-03-EN A6474X360 December 2014 Serial Number GEA000803, GEA000804

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This manual is intended to provide GENERAL product information for the Model CM210 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 set forth in the sales order specification.

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 Federal and State Mining 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.

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© CATERPILLAR 2013 ALL RIGHTS RESERVED

Table of contents

1. About this manual

2. Your safety

________________________________________________ Table of contents A6474X360 REV 03 BI016890-03-EN
About this manual...................................................................1.3 Before starting to work 1.3 Who is this operating manual intended for?.........................1.3 What is the purpose of this operating manual? 1.4 Characters and symbols ......................................................1.5
Your safety...............................................................................2.3 Personnel 2.4 Operation.........................................................................2.4 Installation and repair 2.4 Operating conditions 2.5 Intended use 2.5 Unauthorized use 2.5 Safety instructions 2.7 General rules: 2.7 Storage and transport 2.8 Pre-start inspection 2.8 Installation and start-up 2.9 Operation 2.9 Stopping 2.10 Maintenance and repair 2.10
Storage and transport.............................................................3.3 Storage 3.3 Storage of the machine and spare parts 3.3 Long-term storage of spare components 3.4 Transport 3.5 Load units: dimensions and weights...............................3.5 Transport environment 3.8 4. Installation Installation ...............................................................................4.3 Points to observe prior to installation...................................4.3 Who is allowed to carry out installation? 4.3 Which tools are required for installation?........................4.3 Notes on installation 4.4 Pre-installation check list.................................................4.5 Safety features 4.6
3. Storage and transport

5. Operation

Table of contents _________________________________________________ CM210 Continuous Miner BI016890-03-EN
Operation .................................................................................5.3 How to operate the Continuous Miner..................................5.3 Who is allowed to operate the Continuous Miner 5.3 When can operation be started?.....................................5.3 Machine description 5.4 Controls and indicators 5.4 Machine control system 5.14 Red zone 5.22 Safety precautions for underground operation 5.27 Tramming safety rules 5.27 Starting procedure in radio remote operation 5.29 Shutdown procedure in radio remote operation 5.31 Tramming the miner in radio remote operation 5.33 Cutter head operation in radio remote operation 5.35 Conveyor operation in radio remote operation 5.36 Scrubber motor operation in radio remote operation 5.38 Fire suppression in radio remote operation 5.39 Stabilizer cylinder raise/lower in radio remote operation 5.39 Shear up/down in radio remote operation 5.39 Gathering head raise/float in radio remote operation 5.39 Starting procedure from the operator’s pit.......................... 5.40 Shutdown procedure from the operator’s pit 5.42 Tramming the miner from the operator’s pit....................... 5.43 Cutter head operation from the operator’s pit 5.44 Conveyor operation from the operator’s pit........................ 5.45 Mechanical assemblies 5.46 Hydraulic system................................................................ 5.52 Water system 5.84 Electrical system ................................................................ 5.95 Instructions on the maintenance 5.125 Important notes ............................................................5.125 Before maintenance 5.125 Lubricants, fluids and capacities 5.127 Specific lubrication and maintenance instructions 5.131 Every shift 5.131 Every third shift (daily) 5.133 Weekly 5.138 Monthly 5.142 Every three months 5.148 Every six months 5.151 Adjustment procedures 5.157 Setting hydraulic pressures 5.157 Load holding valve 5.158 Pilot pump circuit relief 5.159 Main control valve 5.161 Port relief......................................................................5.162 Tram track 5.164 Tail shim.......................................................................5.169 Chain tension 5.172 Mechanical...........................................................5.172 Grease take-up 5.172 Cutter motor feedback..................................................5.176
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A6474X360 REV 03 BI016890-03-EN Instructions on replacement of wear parts........................5.179 Cutter head (boom) assembly 5.179 Boom pivot pin..............................................................5.183 Center cutter drum 5.188 End cutter drum............................................................5.192 Drum drive motor 5.194 Drum drive gear case...................................................5.200 Gathering head assembly 5.202 Gathering head drive motor..........................................5.208 Gathering head gear case 5.210 Gathering head foot shaft 5.219 CLA 5.222 CLA tip replacement 5.225 Tram motor 5.226 Tram primary planetary gear 5.231 Tram secondary planetary gear 5.234 Tram case 5.239 Tram reach gear set 5.244 Tram sprocket 5.252 Tram track front idler 5.259 Front idler take-up cylinder 5.263 Tram brake 5.265 Hydraulic pump 5.269 Hydraulic pump motor 5.272 Scrubber fan/motor 5.274 Stabilizer cylinder.........................................................5.279 Swivel pin assembly 5.280 Tail roller.......................................................................5.282 Conveyor chain replacement 5.283 Troubleshooting procedures ........................................5.283 Typical hydraulic problems 5.284 Contaminants in hydraulic systems..............................5.285 Specific hydraulic circuits 5.286 Multi-function failure.............................................5.286 Oil tank fill 5.287 Cutter head raise..................................................5.287 Cutter head lower 5.287 Gathering head raise 5.288 Gathering head float 5.288 Conveyor raise 5.288 Conveyor lower 5.291 Conveyor swing 5.291 Stabilizer raise 5.291 Stabilizer lower 5.291
Table of contents
Table of contents _________________________________________________ CM210 Continuous Miner BI016890-03-EN General safety procedure for shutdown ...................... 5.293 Excessive noise 5.293 Excessive heat............................................................. 5.294 Incorrect flow 5.295 Incorrect pressure........................................................ 5.296 Faulty operation 5.297 Restarting checklist...................................................... 5.298 Water system 5.299 Bearings....................................................................... 5.301 Electrical system 5.302 6. Technical data Technical data 6.3
_______________________________________________________________ 1 About this manual BI016890-03-EN
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applicable operating manual

machine type

About this manual

This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for:

CM210 Continuous Miner

Serial No.: N/A

and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who:

■ are in charge of transport

■ perform assembly / disassembly work

■ operate the machine

■ eliminate faults

■ perform daily routine work on the face or in the entry

■ perform maintenance work

■ perform repair work

supervisory personnel who:

■ initiate and/or supervise the activities just indicated.

____________________________________________Before starting to work A6474X360 REV 03 1.3 BI016890-03-EN

safety

What is the purpose of this operating manual?

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

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Before starting to work
cost-effectiveness service

Characters and symbols used

The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER!

Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING!

These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION!

This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■ Items in lists are marked with bullets.

– Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations. Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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Before starting to work
_______________________________________________________________ 2 Your
BI016890-03-EN
safety
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further operating manuals

Your safety

This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. You and others can, nevertheless, be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by the manufacturer and any appropriate regulatory agency.

Use only original spare parts. Note that the use of parts from other manufacturers will void the warranty.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations

■ of the mine,

■ of the mine inspector, and

■ of the mining supervisory authorities.

Read the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, radio remotes, etc., carefully and thoroughly. Clarify any questions before starting work.

__________________________________________________ Personnel A6474X360 REV 03 2.3 BI016890-03-EN
state of the art

training

Personnel

Operation

The machine may only be operated by qualified, trained personnel. The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the

■ mechanics,

■ hydraulics, and

■ control engineering and must be able to prove this knowledge.

Installation and repair

As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on:

■ safety components (pressure relief valves, extinguishers, etc.)

■ the electrics (motors, controllers, etc.)

■ the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers or by specially qualified personnel of the mine.

Personnel _______________________________________________________ 2.4 CM210 Continuous Miner BI016890-03-EN

Operating conditions

Intended use

The Continuous Miner has been designed and manufactured for the extraction of coal, phosphate, potash, salt, trona and other medium hardness minerals.

Intended uses include:

■ extraction of coal, phosphate, potash, salt, trona and other medium hardness minerals

■ loading the materials listed above onto a haulage system or shuttle car, or dumping it onto the ground for loading at a later time

■ operation on grades of less than 10 degrees

Unauthorized use

Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■ the transport of persons

■ stone development or extraction

The manufacturer accepts no liability for any damage resulting from any such unauthorized use.

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A6474X360 REV 03 2.5 BI016890-03-EN
Operating conditions
Operating conditions _____________________________________________ 2.6 CM210 Continuous Miner BI016890-03-EN

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL

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