and Maintenance Manual CM240 Continuous Miner SAFETY.CAT.COM BI016888-03-EN A6474X356 December 2014 Serial Number: GEW00763, GEW00772, GEW00798, GEW00802
Operation
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This manual is intended to provide GENERAL product information for the CM240 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
3. Storage and transport
________________________________________________ Table of contents A6474X356 REV 03 BI016888-03-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 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 Before transport...............................................................3.8
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 _________________________________________________ CM240 Continuous Miner BI016888-03-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 Red zone 5.25 Safety precautions for underground operation 5.30 Tramming safety rules 5.30 Starting procedure 5.31 Shutdown procedure 5.33 Tramming the miner 5.34 Cutter head operation 5.36 Conveyor operation............................................................ 5.37 Area and headlight operation 5.38 Fire suppression in radio remote operation ....................... 5.39 Shear up/down in radio remote operation 5.40 Gathering head raise/float in radio remote operation......... 5.40 Stabilizer cylinder raise/lower in radio remote operation 5.40 Breaker on/off in radio remote operation ........................... 5.42 Typical cutting sequence 5.43 Mining operations............................................................... 5.45 Mechanical assemblies 5.50 Hydraulic system................................................................ 5.56 Water system 5.90 Electrical system 5.101 Instructions on the maintenance 5.142 Important notes 5.142 Before maintenance 5.142 Lubricants, fluids and capacities 5.144 Specific lubrication and maintenance instructions 5.148 Every shift 5.148 Every third shift (daily) 5.150 Weekly 5.156 Monthly 5.159 Every three months 5.166 Every six months 5.170 Instructions on the adjustment procedures 5.173 Pilot/auxiliary pump circuit relief 5.175 Main control valve 5.177 Tram track ....................................................................5.180 Tail shim 5.185 Chain tension................................................................5.188 Mechanical 5.188 Grease take-up.....................................................5.190 Hydraulic 5.192 Cutter motor feedback..................................................5.193
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A6474X356 REV 03 BI016888-03-EN Replacement of wear parts 5.196 Cutter head (boom) assembly 5.196 Boom pivot pin 5.200 Center cutter drum .......................................................5.205 End cutter drum 5.209 Drum drive motor..........................................................5.213 Drum drive torque limiting clutch 5.219 Drum drive gear case...................................................5.224 Gathering head assembly 5.229 Gathering head drive motor..........................................5.234 Gathering head gear case 5.239 Gathering head foot shaft.............................................5.245 CLA 5.248 CLA tip replacement.....................................................5.251 Tram motor 5.252 Tram primary planetary gear........................................5.257 Tram secondary planetary gear 5.260 Tram case 5.265 Tram reach gear set 5.270 Tram sprocket 5.278 Tram track front idler 5.285 Front idler take-up cylinder 5.289 Hydraulic pump 5.291 Hydraulic pump motor 5.294 Fan motor removal/installation 5.297 Swivel pin assembly 5.300 Tail roller 5.302 Chain replacement 5.304 Superbolts 5.305 Troubleshooting procedures 5.309 Typical hydraulic problems...........................................5.310 Contaminants in hydraulic systems 5.311 Specific hydraulic circuits.............................................5.312 Multi-function failure 5.312 Oil tank fill.............................................................5.313 Cutter head raise 5.313 Cutter head lower.................................................5.313 Gathering head raise 5.314 Gathering head float.............................................5.314 Conveyor raise 5.315 Conveyor lower ....................................................5.315 Conveyor swing 5.315 Stabilizer up..........................................................5.315 Stabilizer down 5.315 General safety procedures for shutdown.....................5.316 Excessive noise 5.317 Excessive heat 5.318 Incorrect flow 5.319 Incorrect pressure 5.320 Faulty operation 5.321 Restarting checklist 5.322 Water system 5.323 Electrical system 5.325 Bearings 5.329
Table of contents
Table of contents _________________________________________________ CM240 Continuous Miner BI016888-03-EN
_______________________________________________________________ 1 About this manual BI016888-03-EN
_______________________________________________________________ BI016888-03-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:
CM240 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
■ find/fix 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 A6474X356 REV 03 1.3 BI016888-03-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.
____________________________________________ 1.4 CM240 Continuous Miner BI016888-03-EN
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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____________________________________________ 1.6 CM240 Continuous
BI016888-03-EN
Before starting to work
Miner
_______________________________________________________________ 2 Your
BI016888-03-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.
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 A6474X356 REV 03 2.3 BI016888-03-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 CM240 Continuous Miner BI016888-03-EN
Operating conditions
Intended use
The Continuous Miner has been designed and manufactured for specific uses. 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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A6474X356 REV 03 2.5 BI016888-03-EN
Operating conditions
Operating conditions _____________________________________________ 2.6 CM240 Continuous Miner BI016888-03-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
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