CAT CM340 Continuous Miner Operation and Maintenance Manual EM021401 – PDF DOWNLOAD by www.heydownloads.com

Operation and Maintenance Manual

Serial Number: GEZ00699, GEZ00722, GEZ00723, GEZ00724, GEZ00746, GEZ00757, GEZ00758, GEZ00763, GEZ00764, GEZ00773, GEZ00781, GEZ00785, GEZ00796, GEZ00797

Continuous Miner SAFETY.CAT.COM

CM340

• 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 Model CM340 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.

__________________________________________________________ EM021401 (BI001987)

1. About this manual

2. Your

3. Storage and transport

________________________________________________ Table of contents ________________________________________________________________ A6474X319 REV 05 EM021401 (BI001987)

About this manual ................................................................... 1.2 Before starting to work.......................................................... 1.2 Who is this operating manual intended for? ......................... 1.2 What is the purpose of this operating manual? .................... 1.3 Characters and symbols ....................................................... 1.4

safety Your safety ............................................................................... 2.2 Personnel ............................................................................. 2.3 Operation ......................................................................... 2.3 Installation and repair ...................................................... 2.3 Operating conditions............................................................. 2.4 Intended use .................................................................... 2.4 Unauthorized use ............................................................ 2.4 Safety instructions ................................................................ 2.5 General rules ................................................................... 2.5 Storage and transport ...................................................... 2.6 Pre-start inspection .......................................................... 2.6 Installation and start-up ................................................... 2.7 Operation ......................................................................... 2.7 Stopping......................................................................... 2.8 Maintenance and repair ................................................. 2.8

Storage and transport ............................................................. 3.2 Storage ................................................................................. 3.2 Storage of the machine and spare parts ......................... 3.2 Long-term storage of spare components ........................ 3.3 Transport .............................................................................. 3.4 Lifting points..................................................................... 3.5 4. Installation Installation................................................................................ 4.2 Points to observe prior to installation ................................... 4.2 Who is allowed to carry out installation? ......................... 4.2 Which tools are required for installation? ........................ 4.2 Notes on installation ........................................................ 4.3 Pre-installation check list ................................................. 4.4 Safety features................................................................. 4.5

5. Operation

Table of contents _________________________________________________ ________________________________________________________________ CM340 Continuous Miner EM021401

(BI001987)

Operation .............................................................................. 5.2 How to operate the Continuous Miner............................... 5.2 Who is allowed to operate the Continuous Miner ............. 5.2 When can operation be started? ....................................... 5.2 Controls and indicators...................................................... 5.3 Machine control system .............................................. 5.11 Operating procedures........................................................ 5.25 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 Blowing system operation ........................................... 5.37 Conveyor operation .................................................... 5.38 Area and headlight operation...................................... 5.39 Fire suppression (optional) ......................................... 5.40 Shear up/down ............................................................ 5.41 Gathering head raise/float .......................................... 5.41 Stabilizer cylinder raise/lower ..................................... 5.41 Conveyor raise/lower and swing left/right ................... 5.42 Breaker “ON/OFF” in radio remote ............................. 5.43 Typical cutting sequence ............................................ 5.44 Mining operations ....................................................... 5.45 Mechanical assemblies ..................................................... 5.50 Hydraulic system ............................................................... 5.57 Water system .................................................................... 5.87 Electrical system ............................................................... 5.96 Instructions on the maintenance ....................................... 5.121 Important notes ............................................................ 5.121 Before maintenance ..................................................... 5.121 Torque values ............................................................... 5.123 Lubricants, fluids and capacities .................................. 5.124 Specific lubrication and maintenance instructions ............ 5.129 Every shift ..................................................................... 5.129 Every third shift (daily) .................................................. 5.133 Weekly .......................................................................... 5.142 Every 2 weeks .............................................................. 5.146 Monthly ......................................................................... 5.148 Every three months ...................................................... 5.154 Every six months .......................................................... 5.161 Instructions on the adjustment procedures ....................... 5.163 Pilot/auxiliary pump circuit relief ................................... 5.165 Main control valve ........................................................ 5.166 Tram track .................................................................... 5.170 Tail shim ....................................................................... 5.175 Conveyor chain tension ................................................ 5.178 Sump tramming ............................................................ 5.179

________________________________________________ Table of contents ________________________________________________________________ A6474X319 REV 05

Replacement of wear parts ...............................................5.177 Cutter head (boom) assembly ......................................5.177 Cutter head assembly removal/installation ..............5.177 Center cutter drum ...................................................5.182 End cutter drum .......................................................5.185 Drum drive motor .....................................................5.188 Drum drive gear case ..............................................5.194 Gathering head assembly.............................................5.197 Gathering head assembly removal/installation ........5.198 Gathering head drive motor .....................................5.203 Gathering head gear case .......................................5.206 Gathering head foot shaft ........................................5.211 CLA ..........................................................................5.214 CLA tip replacement ................................................5.216 Crawler assembly .........................................................5.217 Tram motor ..............................................................5.218 Tram case ................................................................5.223 Crawler chain ...........................................................5.228 Tram track front idler 5.234 Conveyor assembly ......................................................5.235 Conveyor chain ........................................................5.236 Conveyor assembly removal/installation .................5.240 Discharge conveyor .................................................5.244 Tail roller ..................................................................5.249 Troubleshooting procedures ..............................................5.253 Typical hydraulic problems ...........................................5.254 Contaminants in hydraulic systems ..............................5.255 Specific hydraulic circuits .............................................5.256 General safety procedures for shutdown .....................5.260 Excessive noise ............................................................5.261 Excessive heat..............................................................5.262 Incorrect flow ................................................................5.263 Incorrect pressure .........................................................5.264 Faulty operation ............................................................5.265 Restarting checklist ......................................................5.266 Water system ................................................................5.267 Electrical system ...........................................................5.269 Bearings 5.272 Control system ..............................................................5.274 Fault codes ..............................................................5.274

EM021401 (BI001987)

Table of contents _________________________________________________ ________________________________________________________________ CM340 Continuous Miner EM021401 (BI001987) 6. Technical data Technical data .......................................................................... 6.3 Tightening torques ................................................................ 6.5 Permissible data ................................................................... 6.7 Lubrication fluids and greases ......................................... 6.7

_______________________________________________________________ ________________________________________________________________ 1 About this manual EM021401 (BI001987)

__________________________________________________________ EM021401 (BI001987)

applicable operating manual

machine type

About this manual

This chapter provides important information making it easier for you to use this manual. It contains 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:

Model CM340 Continuous Miner

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:

■ operate the machine

■ are in charge of transport

■ perform assembly/disassembly work

■ find/fix faults

■ perform daily routine work at 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 ______________________________________________________________ A6474X319 REV 05 1.3 EM021401 (BI001987)

service 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 CM340 Continuous Miner EM021401 (BI001987)

starting

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 ______________________________________________________________ A6474X319 REV 05 1.5 EM021401 (BI001987)

__________________________________________________________ EM021401 (BI001987)

_______________________________________________________________ ________________________________________________________________ 2 Your safety EM021401 (BI001987)

__________________________________________________________ EM021401 (BI001987)

alterations

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.

This machine has been manufactured in accordance with 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 safe operation and maintainability of the machine. All modifications and changes must be approved by the manufacturer and all appropriate regulatory agencies.

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’s inspectors, and

■ of the mining supervisory authorities.

further operating manuals

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 ______________________________________________________________ A6474X319 REV 05 2.3 EM021401 (BI001987)

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 CM340 Continuous Miner EM021401 (BI001987)

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.

_____________________________________________

______________________________________________________________ A6474X319 REV 05 2.5 EM021401 (BI001987)

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, machine stop buttons, 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

Observe the symbol plates on the machine.

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

Disconnect, lockout, and tag the power system while performing:

■ maintenance

■ inspection

■ repair work

Follow all applicable regulations regarding lockout/tag out procedures.

Cordon off your working area widely for the machine.

cordon off working area

moving parts

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

■ chains, flights, and chain sprockets

■ pivot points

■ crawler assemblies and conveyors

■ cutter and gathering head assemblies

Safety instructions _______________________________________________ ________________________________________________________________ 2.6 CM340 Continuous Miner EM021401 (BI001987)

• 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