CAT CM210 Continuous Miner Operation Manual BI016808 - PDF DOWNLOAD by www.heydownloads.com

and Maintenance Manual CM210 Continuous Miner SAFETY.CAT.COM BI016808-04 (EN-US) A6474X332 November 2014

Operation

Serial Number GEA00776

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This manual is intended to provide GENERAL product information for the 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 Caterpillar’s 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.

__________________________________________________________ BI016808-04 (EN-US)

1. About this manual

2. Your safety

3. Storage and transport

________________________________________________ Table of contents A6474X332 REV 4 BI016808-04 (EN-US)

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 Overview of the safety instructions 2.15 Chapter 3: Storage and transport 2.15 Chapter 4: Installation ................................................... 2.15 Chapter 5: Operation 2.16 Chapter 6: Technical data............................................. 2.31

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....................................................3.6

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

4. Installation

5. Operation

Table of contents _________________________________________________ CM210 Continuous Miner BI016808-04 (EN-US)

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 5.19 Red zone 5.26 Safety precautions for underground operation 5.31 Tramming safety rules 5.31 Starting procedure 5.32 Shutdown procedure 5.34 Tramming the miner 5.35 Cutter head operation 5.37 Conveyor operation 5.38 Scrubber motor operation 5.39 Area and headlight operation 5.32 Fire suppression in radio remote operation 5.40 Conveyor raise/lower/left/right in radio remote operation 5.40 Stabilizer cylinder raise/lower in radio remote operation 5.41 Shear up/down in radio remote operation.......................... 5.41 Gathering head raise/float in radio remote operation 5.41 Breaker on/off in radio remote operation ........................... 5.42 Typical cutting sequence 5.43 Mining operations............................................................... 5.45 Mechanical assemblies 5.50 Hydraulic system................................................................ 5.57 Water system 5.89 Electrical system ................................................................ 5.99 Instructions on the maintenance 5.135 Important notes ............................................................5.135 Before maintenance 5.135 Torque values 5.136 Lubricants, fluids and capacities 5.137 Specific lubrication and maintenance instructions 5.141 Every shift 5.141 Every third shift (daily) 5.143 Weekly 5.148 Monthly 5.152 Every three months 5.158 Every six months 5.161 Adjustment procedures 5.164 Setting hydraulic pressures 5.164 Load holding valve 5.165 Pilot pump circuit relief 5.166 Main control valve ........................................................5.168 Port relief 5.169 Tram track ....................................................................5.171 Tail shim 5.176 Chain tension................................................................5.179 Mechanical 5.179 Grease take-up.....................................................5.181 Cutter motor feedback 5.183

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A6474X332 REV 4 BI016808-04 (EN-US) Instructions on replacement of wear parts........................5.186 Cutter head (boom) assembly 5.186 Boom pivot pin..............................................................5.190 Center cutter drum 5.194 End cutter drum............................................................5.198 Drum drive motor 5.200 Drum drive gear case...................................................5.203 Gathering head assembly 5.208 Gathering head drive motor..........................................5.214 Gathering head gear case 5.219 Gathering head foot shaft 5.225 CLA 5.228 CLA tip replacement 5.231 Tram motor 5.232 Tram primary planetary gear 5.237 Tram secondary planetary gear 5.240 Tram case 5.245 Tram reach gear set 5.250 Tram sprocket 5.258 Tram track front idler 5.265 Front idler take-up cylinder 5.269 Hydraulic pump 5.272 Hydraulic pump motor 5.274 Scrubber fan/motor 5.277 Swivel pin assembly 5.280 Tail roller.......................................................................5.282 Conveyor chain replacement 5.284 Troubleshooting procedures .............................................5.285 Typical hydraulic problems 5.286 Contaminants in hydraulic systems..............................5.287 Specific hydraulic circuits 5.288 Multi-function failure.............................................5.288 Oil tank fill 5.289 Cutter head raise..................................................5.289 Cutter head lower 5.289 Gathering head raise............................................5.290 Gathering head float 5.290 Conveyor raise 5.291 Conveyor lower 5.291 Conveyor swing 5.291 Stabilizer raise 5.291 Stabilizer lower 5.291 General safety procedure for shutdown 5.320 Excessive noise 5.321 Excessive heat 5.322 Incorrect flow 5.323 Incorrect pressure 5.324 Faulty operation 5.325 Restarting checklist 5.326 Water system 5.327 Bearings .......................................................................5.329 Electrical system 5.330

Table of contents

Table of contents _________________________________________________ CM210 Continuous Miner BI016808-04 (EN-US)

_______________________________________________________________ 1 About this manual BI016808-04 (EN-US)

_______________________________________________________________ BI016808-04 (EN-US)

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 A6474X332 REV 4 1.3 BI016808-04 (EN-US)

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.

work____________________________________________ 1.4 CM210 Continuous Miner BI016808-04 (EN-US)

Before starting to

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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____________________________________________ 1.6 CM210 Continuous Miner BI016808-04 (EN-US)

Before starting to work

_______________________________________________________________ 2 Your

BI016808-04 (EN-US)

safety

_______________________________________________________________ BI016808-04 (EN-US)

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 Caterpillar 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 A6474X332 REV 4 2.3 BI016808-04 (EN-US)

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 BI016808-04 (EN-US)

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

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

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A6474X332 REV 4 2.5 BI016808-04 (EN-US)