PDF Operation & Maintenance Manual CAT Bucyrus CM220 Continuous Miner - 2 MB
The official Operation & Maintenance Manual for the CAT Continuous Miner CM220, formerly by Bucyrus.
This document is the primary guide for operators and maintenance personnel, covering safe operating procedures, machine controls, and scheduled maintenance tasks.
Adhering to the manufacturer's recommendations in this manual is crucial for maximizing the productivity, safety, and lifespan of this powerful mining machine.
It is an essential resource for any team operating a CM220.
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BI016882-03-EN
A6474X331
December 2014
Operation and
Maintenance
Manual
CM220 AC Continuous Miner
Serial Number GED00782
SAFETY.CAT.COM
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BI016882-03-EN
___________________________________________ Before starting to work
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. Possi-
ble 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 ma-
chine damage.
NOTICE!
Points in the text marked with this symbol draw attention to harm-
ful situations. Possible consequences are: damage to the ma-
chine 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.
______________________________________________________________
A6474X331 REV 03 1.5
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BI016882-03-EN
_______________________________________________Safety instructions
Installation and start-up
inclined face On inclined faces secure all component parts by chains, e.g. to the
support.
environmental acceptability When working with oils, greases and other chemical substances, ob-
serve the safety regulations applicable to the product.
Dispose of cleaning rags, etc. which have been soiled with oil, grease
or other chemical substances in an environmentally safe manner.
controls When starting up machine, do not operate any controls located inside
the operator’s compartment (optional) from outside the compartment.
starting procedures Follow the starting procedure instructions in the operations manual.
red zone Do not operate any levers, pedals or controls if anyone is in the red
zone. (See Red Zone in Chapter 5 of this manual)
Operation
training Operate the machine only if you have a profound knowledge of the
control elements and their functions. It is necessary that you have
been task trained on the respective Continuous Miner.
before start-up Before start-up, ensure that there are no persons or obstructions in
your line of travel or in the articulation area when steering the unit.
protective devices Check that all protective devices are installed on the machine and func-
tion properly.
operator’s compartment Clean the operator’s compartment at regular intervals. Ensure that the
(optional) operating symbols are legible in order to avoid any operator errors and
resulting accidents.
Never climb onto, or climb out of the machine while it is in motion.
Do not operate the machine with any part of your body outside of the
operator’s compartment in order to prevent body parts from being
crushed between the machine and outside objects .
traveling Use extreme caution when traveling in close quarters or in congested
or blind-travel areas.
passengers Never carry passengers. Passengers may be thrown off the machine
or crushed between the machine and outside objects.
safety rules Always follow all safety rules of each particular mine when operating
the machine.
problems and malfunctions If problems or malfunctions are encountered while operating the unit, it
must be properly shutdown and the problem corrected immediately.
______________________________________________________________
A6474X331 REV 03
2.9
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____________________________________ Overview of safety instructions
WARNING!
Warn “ALL CLEAR” before starting the conveyor. Failure to do so
may result in serious injury or death.
IMPORTANT!
The “CONV ON” key must be released before “SHIFT”. If “SHIFT”
is released first, the conveyor motors will shut off.
IMPORTANT!
The “FAN ON” key must be released before “SHIFT”. If “SHIFT” is
released first, the fan motor will shut off.
CAUTION!
Always ensure operator safety while operating the machine.
CAUTION!
Always be alert to hazardous conditions and take corrective ac-
tion as necessary.
IMPORTANT!
Care should be taken not to stall cutters on conveyor during cut-
ting operations. Severe damage to motors and gear boxes could
occur if cutters or conveyor are repeatedly stalled.
IMPORTANT!
Tram is limited in the forward direction while the cutters are run-
ning with the cutter head feedback circuit. As the cutters begin to
cut the material from the face the sump speed will automatically
slow the tram down to prevent over sumping the machine.
IMPORTANT!
Inspection of the bits and bit blocks before the start of each shift
will reduce later problems. Mining with dull, bent or broken bit
blocks increases dust and noise levels, as well as putting exces-
sive strain on both cutter and tram drives.
WARNING!
Failure to maintain the hydraulic system will result in damage to
its hydraulic components which will result in increased wear and
premature failure.
IMPORTANT!
Schematics may vary from one unit to the next. Consult the parts
book for the schematic for your machine.
IMPORTANT!
During disassembly of control valves, give particular attention to
identification of parts for reassembly. Spools are selectively fitted
to valve bodies and must be returned to the same bodies from
which they were removed. Spools are NOT interchangeable be-
tween valve bodies.
______________________________________________________________
A6474X331 REV 03
2.19
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____________________________________ Overview of safety instructions
WARNING!
Each stabilizer cylinder is extremely heavy. The next steps will
remove the cylinder from its tractor frame mounting. Be prepared
to support the weight from its tractor frame mounting. Be pre-
pared to support the weight of the cylinder when it becomes free
from the mounting.
IMPORTANT!
To obtain maximum performance, the duocone seals must be in-
stalled accurately to insure uniform loading at the mating faces
and achieve a stable running position. Misalignment or cocking of
seal rings during assembly can produce non-uniform loading and
wobbling of the seals in their housings resulting in leakage due to
scoring and/or pumping of debris past the toric rings. Improper
installation can also result in breakage of the metal seal rings.
NOTICE!
Improper care and installation of duocone seals can result in im-
mediate leakage or reduced service life.
IMPORTANT!
The toric must lie uniformly in the seal with the sealing ring and
parallel to the seat face. Be sure that the toric is not twisted and
that it rests uniformly against the retaining lip or not deeper in one
side of the seat than the other.
IMPORTANT!
Do not get any oil onto the rubber torics!
IMPORTANT!
Even a small piece of lint can hold the faces apart and cause leak-
age!
IMPORTANT!
A mixture of marking compound and spindle oil is good lube for
the gears under light loads for 2-3 revolutions only. Check tooth
patterns all round to make sure the pattern/markings are uniform.
CAUTION!
Be careful not to set fire to any grease or lubricant when heating
bearings!
IMPORTANT!
Observe all applicable fire and safety regulations when heating
bearings!
______________________________________________________________
A6474X331 REV 03
2.29
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BI016882-03-EN
_______________________________________________________________
4 Installation
________________________________________________________________
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_______________________________________________________________
________________________________________________________________
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______________________________________________________ Operation
There are two displays located on the machine: a graphics display lo-
cated at the operator’s case and a text display located near the back
right hand side of the machine (Fig. 16). Both screens are used to dis-
play diagnostic information on the miner.
Fig. 16: Control system display locations (typical)
Text display
Graphics display
displays The graphics display, located on the operator’s case, is used to monitor
machine operating parameters, for diagnosing error and fault codes,
and for input of operating parameters.
The text display, located on the near the back right hand side of the
machine, has the same functions as the graphics display. If the control
system loses power, the text display will remain powered through the
battery back up.
NOTICE!
Information priority is given to the graphics display unless the
graphics display becomes unhealthy. The two monitors will not
necessarily display the same information at the same time.
There are different screens that can be displayed: production monitor-
ing, function monitoring, diagnostic, motor hours, and fault pages. A
system halt message can appear as a pop-up dialog box in the middle
of any screen. A message will appear when a critical conditions has
occurred that prevents continued operation of the machine in a safe
manner. The message box cannot be cleared and it is necessary to
recycle power to the control system to restore machine operation.
Normal display pages
The main diagnostic screen (Fig. 17) is displayed during normal remote
control operation of the machine. The screen presents real time diag-
nostic and performance information.
______________________________________________________________
A6474X331 REV 03
5.12
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BI016882-03-EN
______________________________________________________ Operation
Hour meters
Selecting hour meters (Fig. 23) from the Main Menu will display runtime
for the following motors: pump, fan, left cutter, right cutter, and convey-
or. Time is displayed in hours:minutes:seconds format. This runtime
only reflects accumulated time since the receiver has been installed or
since the counter was last reset. The hour meters can be cleared un-
der the Engineering Setup Menu, which is password protected.
IMPORTANT!
The hours meters should only be cleared when a motor is replaced
or when the receiver is installed. To keep an accurate log of a mo-
tor’s total hours, the information should be recorded anytime data
is cleared.
Fig. 23: Hour meters, examples
______________________________________________________________
A6474X331 REV 03
5.22
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______________________________________________________ Operation
Shutdown procedure
The Continuous Miner must be properly shutdown before leaving the
area or before performing any maintenance or service. Some mainte-
nance or service procedures may require additional steps to insure the
safety of the maintenance personnel working on or around the machine
and will be listed in the maintenance section of this guide.
Back the miner about one foot from the face providing sufficient
clearance and shut off the cutter head motors (see Cutter operation
in this section).
Tram the miner to an area of well supported roof. Park the machine
in its designated parking area out of traffic, on flat, solid ground. If it
is not possible to park the machine on flat ground, park the machine
at a right angle to the slope.
WARNING!
After turning off the power to the machine, never walk away and
leave the transmitter turned on. Failure to turn the transmitter off
could result in an accident causing serious injury or loss of life.
Reference Fig. 16.
Empty the conveyor and shut it off (see Conveyor operation in
this chapter).
Lower the cutter head to the floor.
Lower the conveyor and gathering head.
Press and hold the “PUMP OFF” key. The pump motor should
shutdown immediately.
Release the “PUMP OFF” key.
Turn off the water sprays.
Position all levers and controls to Neutral or Off.
Shut off the main power supply.
Shut off the mine water supply.
______________________________________________________________
A6474X331 REV 03
5.32
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Operation _______________________________________________________
Stabilizer (stab) cylinder raise/lower in radio remote
The pump motor must be running in order to raise or lower the
stabilizer cylinder.
Reference Fig. 16.
Press “STAB UP” to raise the stabilizer cylinder. The stabilizer
cylinder solenoid remains energized until the key is released.
Press “STAB DOWN” to lower the stabilizer cylinder. The stabilizer
cylinder down solenoid remains on until the key is released.
See the operation manual for the radio remote that shipped with your
machine for options.
Shear up/down in radio remote
The pump motor must be running in order to raise or lower the cutter
head.
Reference Fig. 16.
Press “SHEAR UP” to move the cutter head up. The shear up
solenoid remains energized until the key is released (unless height
limiting is in force).
Press “SHEAR DOWN” to move the cutter head down. The shear
down solenoid remains energized until the key is released.
See the operation manual for the radio remote that shipped with your
machine for options.
Gathering head raise/float in radio remote
The pump motor must be running in order to raise or lower the
gathering head.
Reference Fig. 16.
Press “PAN UP” to lift the gathering head. The pan up solenoid
remains energized until the key is released.
Press “PAN FLOAT” to “float” the head down.
See the operation manual for the radio remote that shipped with your
machine for options.
________________________________________________________________
5.42 CM220 Continuous Miner
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BI016882-03-EN
Mechanical assemblies ____________________________________________
Carbide bits and bit blocks
The carbide-tipped cutter bits are mounted into holders called bit blocks
(Fig. 37). While a variety of bit and bit block designs are available to
meet light, tough, or average mining conditions, all are designed to ab-
sorb vibration to maintain cutter efficiency. The conical bits also rotate
as they cut to produce a self-sharpening effect. The bits and blocks
may be deployed around the drum in different bit lacing patterns to give
the best performance under different conditions.
IMPORTANT!
Inspection of the bits and bit blocks before the start of each shift
will reduce later problems. Mining with dull, bent or broken bit
blocks increases dust and noise levels, as well as putting exces-
sive strain on both cutter and tram drives.
Fig. 37: Cutter bit and bit blocks
Cutter bit
Bit block
Conveyor chain
The miner is equipped with a conveyor chain assembly that runs
through the center of the miner and transports the mined material from
the gathering head to the rear of the miner for haulage at a high loading
rate compatible with the miner’s cutting output. The conveyor chain
(Fig. 38) is made up of one basic chain assembly which repeats
sequentially along the entire chain loop (see Maintenance section in
this chapter for Conveyor chain maintenance).
Fig. 38: Conveyor chain
Conveyor
chain
________________________________________________________________
5.52 CM220 Continuous Miner
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BI016882-03-EN
______________________________________________________ Hydraulic
Micron: 1/1000th of a millimeter (0.00003937 inches). The meas-
ure used to determine the particle size of contaminants in a fluid sys-
tem.
Micron rating: The size, in microns, of particles a filter will re-
move.
PSI (psi): Pounds per square inch (unit of pressure).
Open center circuit: A circuit in which flow through the system
and back to the oil tank reservoir is open in neutral. Example: the main
flow-primary pressure circuit.
Viscosity: A measure of the internal friction, or resistance to flow,
of a fluid.
Reading a hydraulic schematic
All valves are shown in the neutral position on the hydraulic schematics.
Fig. 46: Oil flow through a spool
______________________________________________________________
A6474X331 REV 03
5.62
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BI016882-03-EN
______________________________________________________ Hydraulic
Hydraulic pump assembly circuit
Hydraulic power for all of the hydraulically actuated functions originates
with the pump assembly (Fig. 52). This pump assembly is made up of
single-stage pump with a piggy-back hydraulic pump (2-section
tandem pump). The pump outlets are designated A1 (main flow) and
A2 (pilot flow). The pump assembly is typically mounted on the left side
of the machine frame. Oil is supplied from the oil tank reservoir to the
suction side of pump through a 2” suction line.
Fig. 52: Hydraulic pump circuit
TO PRESSURE MANIFOLD
TO MAIN CONTROL VALVE
______________________________________________________________
A6474X331 REV 03
5.72
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______________________________________________________ Hydraulic
Cutter head cylinder circuit
DANGER!
The area under and around the raised cutter head is dangerous.
Securely block the head before performing maintenance on or
below it. Failure to block the raised cutter head could result in
serious injury or even death.
Oil is supplied by hydraulic pump section A1 to the cutter head working
section on the main control valve. By manual or remote solenoid con-
trol, the spool allows oil to enter the cutter head cylinder circuit. The
cutter head cylinder is a double-acting cylinder with load holding car-
tridge. There are two (2) cutter head cylinders, one on each side of the
machine.
There are two (2) port reliefs in the working section of the main control
valve. Both port reliefs are set at 2,800 psi. To raise the cutter head
(extend cylinders), pull the handle. Oil goes to port “P2” of the anti-
chatter/maintenance valve free flowing thru the check valve out of port
“P1” and continues to the retract port of the cylinders free flowing thru
the check valve of the load holding cartridge to retract the cylinders.
To lower the cutter head (retract cylinders), push the handle. Oil goes
to the extension port of the cylinders and also pilots open the load hold-
ing cartridge allowing oil to exit the retract ports on the cylinders. The
oil continues to the anti-chatter/maintenance valve block where it pass-
es through a counterbalance valve which is set to relieve at 1,200 psi,
then through the main control valve and a 10-micron bypassing return
filter into the oil tank.
The shear down/anti chatter manifold has three primary functions:
shear down/maintenance valve
(anti-chatter) 1. It provides back pressure against the shear cylinder pistons when
shearing down to prevent the machine form climbing the face
(raising the machine off of the ground).
2. It provides back pressure against the shear cylinder pistons when
lowering the cutter head without shearing. This allows for a smooth
downward motion without allowing the load for the cutter head to
run uncontrollably.
3. It allows for bypassing of the counterbalance valve to eliminate the
back pressure against the shear cylinder pistons. This provides the
maximum pressure differential between the two sides of the shear
cylinders which allows the machine to be raised off the ground
(jack-knifed). To jack-knife the miner, the stabilizer shoe is first
lowered and then the cutter head is lowered with the bypass
opened. At this point, the machine can be inspected, adjustments
can be made to the crawler tracks.
4. This counterbalance valve is set at 1,200 psi.
______________________________________________________________
A6474X331 REV 03
5.82
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__________________________________________________________ Water
Continuous Miner water system overview
Water is supplied to the continuous miner for the following purposes:
■ deluge water fire protection
■ cooling water for motors, transformers, etc.
■ cooling water for dust suppression
■ air cleaning via the scrubber system
■ washdown hoses
The water supplied by the mine must meet the following requirements:
■ flow rate of 10 gpm minimum for cooling
■ total flow rate: based on customer dust plan
■ pressure of 250 psi (dynamic) minimum, 500 psi maximum
The manufacturer offers straight, left hand, right hand, or bi-directional
cutter head spray manifolds. This section describes bi-direction
sprays.
The schematics in this section are for reference only. Always refer to
the schematic in the parts book for your machine.
______________________________________________________________
A6474X331 REV 03
5.92
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BI016882-03-EN
Electrical _______________________________________________________
Related components share the same designation and when tracing a
particular circuit, it may be helpful to think of the flow of electricity as
being similar to the flow of water through a hose. When a set of con-
tacts are open, the current cannot flow across them, and when contacts
are closed, the current can flow. When three (3) lines are connected in
a tee, the current will flow in whatever direction that it can. Like water or
hydraulic fluid, an electrical current will also tend to follow the path of
least resistance through a circuit. Finally, for a circuit to work, the elec-
trical current must make a complete loop, similar to hydraulic fluid go-
ing through a circuit and returning to a tank.
Fig. 72: Standard electrical symbols
________________________________________________________________
5.102 CM220 Continuous Miner
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BI016882-03-EN
Electrical _______________________________________________________
Methane monitor circuit
The methane monitor detects methane gas when the continuous miner
is powered up. Before any motor or function occurs, the methane moni-
tor checks for methane gas. If the methane level is below the preset
value, the methane monitor relay will close. The methane monitor is
powered from the control transformer.
The schematic shown in Fig. 75 is a typical methane monitor circuit.
Always refer to the schematic in the parts book for your machine.
Fig. 75: Methane monitor circuit
________________________________________________________________
5.112 CM220 Continuous Miner
--- Page 21 ---
BI016882-03-EN
Electrical _______________________________________________________
Fig. 81: Scrubber motor circuit with control (cont.)
________________________________________________________________
5.122 CM220 Continuous Miner
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____________________________________________________ Maintenance
Specific lubrication and maintenance procedures
Every shift
cutter head lift cylinder pins Lubricate the right and left cylinder pins (upper and lower) through the
grease fittings and remote lube block located on each cylinder (Fig.
85). Pump approximately 3 cu. in. (50 cu. cm.) into each fitting.
Fig. 85: Cutter head cylinder pin location
Cutter head cylinder
pin (upper) (2)
Cutter head cylinder pin
(lower) (2) (remote lube block)
conveyor swing cylinder pin Lubricate the front and rear conveyor swing cylinder pins through the
(front and rear) grease fittings located on each end of the cylinder (Fig. 86). Pump ap-
proximately 3 cu. in. (50 cu. cm.) into each fitting.