Issuu

and Maintenance Manual CM220 Continuous Miner SAFETY.CAT.COM BI016907-02-EN A6474X307 December 2014

Operation

Serial Number GED00780

• 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

This manual is intended to provide GENERAL product information for the CM220 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 of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards

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.

__________________________________________________________

1. About this manual

2. Your safety

________________________________________________ Table of contents A6474X307 REV 02 BI016907-02-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 2.6 General rules: 2.6 Storage and transport 2.7 Pre-start inspection 2.7 Installation and start-up 2.8 Operation 2.8 Stopping 2.9 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 3.6 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 _________________________________________________ CM220 Continuous Miner BI016907-02-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 Controls and indicators.........................................................5.4 Machine control system 5.17 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 5.39 Scrubber motor operation 5.39 Area and headlight operation 5.39 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 Mechanical assemblies 5.43 Hydraulic system 5.49 Water system 5.81 Electrical system ................................................................ 5.91 Instructions on the maintenance 5.125 Important notes ............................................................5.125 Before maintenance 5.125 Torque values...............................................................5.126 Lubricants, fluids and capacities 5.127 Specific lubrication and maintenance instructions............5.128 Every shift 5.131 Every third shift (daily)..................................................5.133 Weekly 5.138 Monthly.........................................................................5.141 Every three months 5.148 Every six months..........................................................5.151 Adjustment procedures 5.153 Setting hydraulic pressures...........................................5.153 Load holding valve 5.154 Pilot pump circuit relief 5.155 Main control valve 5.156 Port relief 5.158 Tram track 5.160 Tail shim 5.165 Chain tension 5.167 Hydraulic 5.167

________________________________________________

A6474X307 REV 02 BI016907-02-EN Instructions on replacement of wear parts........................5.168 Cutter head (boom) assembly 5.168 Boom pivot pin..............................................................5.172 Center cutter drum 5.177 End cutter drum............................................................5.181 Drum drive motor 5.183 Drum drive gear case...................................................5.188 Gathering head assembly 5.190 Gathering head drive motor..........................................5.196 Gathering head gear case 5.201 Gathering head foot shaft 5.207 CLA 5.210 CLA tip replacement 5.213 Tram motor 5.214 Tram primary planetary gear 5.219 Tram secondary planetary gear 5.222 Tram case 5.227 Tram reach gear set 5.232 Tram sprocket 5.240 Tram track front idler 5.248 Front idler take-up cylinder 5.251 Hydraulic pump 5.253 Hydraulic pump motor 5.256 Scrubber fan/motor 5.259 Swivel pin assembly 5.262 Tail roller.......................................................................5.266 Conveyor chain replacement 5.268 Troubleshooting procedures.........................................5.269 Typical hydraulic problems 5.270 Contaminants in hydraulic systems..............................5.271 Specific hydraulic circuits 5.272 Multi-function failure.............................................5.272 Oil tank fill 5.273 Cutter head raise..................................................5.273 Cutter head lower 5.273 Gathering head raise............................................5.274 Gathering head float 5.274 Conveyor raise 5.274 Conveyor lower 5.275 Conveyor swing 5.275 Stabilizer raise 5.275 Stabilizer lower 5.275 General safety procedure for shutdown 5.276 Excessive noise 5.277 Excessive heat 5.278 Incorrect flow 5.279 Incorrect pressure 5.280 Faulty operation 5.281 Restarting checklist 5.282 Water system 5.283 Bearings .......................................................................5.285 Electrical system 5.288

Table of contents

Table of contents _________________________________________________ CM220 Continuous Miner BI016907-02-EN General safety procedure for shutdown ...................... 5.276 Excessive noise 5.277 Excessive heat............................................................. 5.278 Incorrect flow 5.279 Incorrect pressure........................................................ 5.280 Faulty operation 5.281 Restarting checklist...................................................... 5.282 Water system 5.283 Bearings....................................................................... 5.285 Electrical system 5.288

_______________________________________________________________ 1 About this manual BI016907-02-EN

_______________________________________________________________ BI016907-02-EN

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:

CM220 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 A6474X307 REV 02 1.3 BI016907-02-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.

Before

to work____________________________________________ 1.4 CM220 Continuous Miner BI016907-02-EN

starting

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.

___________________________________________ Before starting to work A6474X307 REV 02 1.5 BI016907-02-EN

____________________________________________ 1.6 CM220 Continuous Miner BI016907-02-EN

Before starting to work

_______________________________________________________________ 2 Your

BI016907-02-EN

safety

_______________________________________________________________ BI016907-02-EN

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 A6474X307 REV 02 2.3 BI016907-02-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 CM220 Continuous Miner BI016907-02-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.

_____________________________________________

A6474X307 REV 02 2.5 BI016907-02-EN

Operating conditions

general

Safety instructions

General rules:

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of

■ your exact location,

■ the work you are performing, and

■ the time that you will probably require.

safety equipment

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates

emergency stop

lock-out and tag-out

Observe the symbol plates on the machine.

Press the EMERGENCY STOP button immediately in the event of fault or irregularities in operation. Report any concerns to your superior so that necessary measures can be taken immediately.

Lock-out, tag-out and disconnect the power system while performing:

■ maintenance work

■ inspection work

■ repair work

cordon off working area

moving parts

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as:

■ chains, flights, and chain sprockets

■ pivot points

■ cutter head and loading head

■ crawler assemblies and conveyors

■ cutter and gathering head assemblies

_______________________________________________ 2.6 CM220 Continuous Miner BI016907-02-EN