PDF Operation & Maintenance Manual CAT CM340 Continuous Miner - 979 KB
This manual provides essential operation and maintenance instructions for the CAT CM340 Continuous Miner.
It covers critical safety procedures, control functions, and scheduled maintenance tasks to ensure reliable performance in demanding underground mining conditions.
This guide is vital for the safety of the crew and the productivity of the machine.
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EM021401 (BI001987)
A6474X319
March 2016
Operation and
Maintenance
Manual
CM340 Continuous Miner
Serial Number: GEZ00699, GEZ00722, GEZ00723, GEZ00724, GEZ00746,
GEZ00757, GEZ00758, GEZ00763, GEZ00764, GEZ00773, GEZ00781, GEZ00785,
GEZ00796, GEZ00797
SAFETY.CAT.COM
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EM021401 (BI001987)
___________________________________________ 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.
______________________________________________________________
A6474X319 REV 05 1.5
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EM021401 (BI001987)
_______________________________________________ Safety instructions
Stopping
parking Always park the unit on solid, level ground. If this is not possible, park
the unit at a right angle to the slope to prevent accidental movement of
the machine.
Use proper flags, warnings or barriers when parking in areas of traffic.
radio There is a unique code switch setup which permits each operator to
activate only his designated miner, allowing several remote-controlled
miners to operate in the same area without getting their radio signals
crossed. In addition, an improperly decoded radio signal will automati-
cally shut-off the miner. Follow the general safety notices and safety
recommendations listed in the remote control system guide.
Maintenance and repair
Be sure to observe the prescribed maintenance and inspection inter-
vals.
Inform the supervisory personnel and the face crew of any maintenance
and repair operations. Give them information on the intended opera-
tions and the anticipated duration.
trailing cable uncoupled Before attempting any repairs, a DANGER sign must be attached to the
and locked and tagged out appropriate circuit at the power distribution box. It is mandatory that the
trailing cable be uncoupled, tagged and locked-out from the power
source to provide visual evidence that the miner is de-energized. Fol-
low all applicable regulations regarding lockout/tagout.
securing Secure your working area over a wide range, in order to avoid endan-
gering other persons.
Disconnect the power from the machine to prevent unauthorized and
unintentional restarting.
Protect your work area against falling rocks.
Pass defective components removed on for servicing without delay in
order to prevent these parts being reinstalled elsewhere.
original parts Use only spare parts which satisfy the specified technical requirements.
This is only ensured with original spare parts. Please refer to the spare
parts lists or parts catalog for the order numbers.
methane monitoring Before attempting any repairs or maintenance, methane air monitoring
must be completed before and during the repair and maintenance.
______________________________________________________________
A6474X319 REV 05 2.9
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EM021401 (BI001987)
____________________________________________ Storage and transport
Transport
Load units: dimensions and weights
Observe the transport sheets for the machine and spare parts. They
contain information on:
■ dimensions,
■ weights,
■ lifting points, etc.
Additional information on the dimensions and weights can be found in
chapter 6 and in the lifting weight guide (Table 1) in this operating sec-
tion. Fig. 5 illustrates the position of lifting eyes on the miner.
WARNING!
Use only load handling devices complying with the technical and
legal regulations for the transport of loads. You could be serious-
ly injured or even killed by falling loads. Use only suitable load
handling devices.
Table 1: Lifting weights of Continuous Miner Assemblies
Description Approximate Weight
Complete Machine 160,370 lbs (72,742 kg)
Tractor Frame Assembly 75,000 lbs (34,019 kg)
Cutting Head Assembly 47,000 lbs (21,319 kg)
Gathering Head Assembly 19,300 lbs (8,754 kg)
Conveyor Assembly 15,800 lbs (7,167 kg)
Conveyor Chain Assembly 3,270 lbs (1,483 kg)
removal and installation of Whenever possible, all removals should be accomplished using an ad-
heavy components justable lifting beam. All supporting members (chains and cables) should
be parallel to each other and as nearly perpendicular as possible to the
top of the object being lifted.
When it is necessary to remove a component on an angle, remember that
the capacity of an eyebolt diminishes as the angle between the support-
ing members and the object increases. Eyebolts and brackets should
never be bent.
When an eyebolt is provided to lift a component, use it to lift only that
component.
WARNING!
You could be seriously injured or killed as a result of falling loads.
Do not use the eyebolt to lift the component and its related assem-
blies.
______________________________________________________________
A6474X319 REV 05 3.5
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EM021401 (BI001987)
_____________________________________________________ Installation
blowing system The Continuous Miner is equipped with an optional blowing system that
(optional) allows the Miner operator to apply fan induced air to the face during
operation. The fan draws the air from either intake located at the left
and right rear of the Miner. Air is then drawn from the rear intakes
through the fan and ductwork, to the crossover hood, which is located
on the cutter head support frame. The blowing system assembly is
located on the left hand side of the Miner.
guards and covers The machine is equipped with guards and covers to reduce the possi-
bility of personnel coming in contact with rotating or moving parts. All
guards and covers must be installed and securely fastened during op-
eration.
DANGER!
Do not operate the machine with any of the guards or covers re-
moved. You or other personnel could be seriously injured from
moving or rotating parts.
cutter boom safety supports There are two cutter boom safety supports, one on each side of the
cutter boom. The supports are used to block up the cutter boom during
maintenance operations.
conveyor safety supports There are two conveyor safety supports, one on each side of the con-
veyor. The supports are used to block up the conveyor during mainte-
nance operations.
methane monitor The machine is equipped with a methane monitor that detects the pres-
ence of methane in the mine atmosphere. When the miner is being
powered up, the monitor looks for methane before any other function is
energized. If the methane monitor detects a level of methane within a
preset tolerance, the methane monitor relay will close and power will be
supplied to the other functions on the machine. (The machine can have
optional dual sniffer heads or dual readouts.)
______________________________________________________________
A6474X319 REV 05 4.7
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EM021401 (BI001987)
______________________________________________________ Operation
“MACHINE STOP” The “MACHINE STOP” button (Fig. 9) is a large red push button locat-
ed on the left of the operator’s case. Pushing “MACHINE STOP” will
shut down the pump, causing the miner to shut down. To restart the
miner after pushing the “MACHINE STOP” button, follow the normal
start up procedure for the pump (see Start up procedures in this chap-
ter).
“MINER” operation The “MINER” operation selector switch (Fig. 9) is located to the right of
selector switch the “MACHINE STOP” button. The selector switch has three positions:
■ “E-TRAM” - Turning the switch to this position allows the miner to
be trammed from the pendant controls. “E-TRAM” is used in the
event that the operator loses his radio link with the miner.
■ “REMOTE” - During normal mining operations, the switch should
be in the “REMOTE” position. This allows the miner to be con-
trolled by the radio remote system.
■ “GND CHK” - Placing the operation switch in the ground check
position should cause the mine power center to trip, thereby shut-
ting down all power to the miner.
The “MACHINE LIGHTING” operation selector switch (Fig. 9) is located
“MACHINE LIGHTING” operation to the right of the “MINER” operation selector switch. The selector
selector switch switch has four positions:
■ “ALL ON” - Located at 3 o’clock, turning the switch to this position
allows all machine lighting to be turned on, including headlights and
area lights. (The headlights can be turned on or off from the trans-
mitter. The area lights are hard-wired and cannot be turned off by
the transmitter.)
■ “ALL OFF” - Located at 12 o’clock and 6 o’clock, turning the
switch to this position allows all machine lighting to be turned off.
■ “AREA LIGHTS ONLY” - Located at 9 o’clock, turning the switch
to this position allows only area lights to be turned on.
Fig. 9: “MACHINE STOP,” “MINER” and “MACHINE LIGHTING”
selector switches
“MACHINE
LIGHTING”
“MINER” selector selector
“MACHINE STOP” switch switch
______________________________________________________________
A6474X319 REV 05 5.5
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EM021401 (BI001987)
______________________________________________________ Operation
Fig. 18: Main page, example
Graphics display
Text display
______________________________________________________________
A6474X319 REV 05 5.15
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EM021401 (BI001987)
______________________________________________________ Operation
Tram pendant The machine can be operated using a pendant control (Fig. 25) con-
nected to the miner by an umbilical cable. This control is used in the
event that the operator loses radio link with the mine to safely recover
the miner from the face to an area under supported roof for trouble-
shooting and maintenance.
The pendant controller allows limited operation of the machine: tram-
ming and pump motor activation to provide hydraulic power to raise or
lower the cutting head.
In order to use the pendant, it must be connected to the machine via a
pigtail. After plugging in the umbilical cord, the “MACHINE” mode of
operation switch must be rotated to the “E-TRAM”.
IMPORTANT!
The pendant controller and its umbilical cord should be stored in a
protected location on the working section, away from the miner, to
prevent damage.
Fig. 25: Tram pendant
______________________________________________________________
A6474X319 REV 05 5.25
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EM021401 (BI001987)
______________________________________________________ Operation
Tramming the miner
Tramming requires cooling water to prevent damage.
NOTICE!
The Continuous Miner has skid type steering: it is capable of turn-
ing within its own limits.
WARNING!
Tramming requires cooling water to the tram motors. Failure to
cool the motors will result in motor damage and premature failure.
Ensure that the stabilizer shoe is away from the mine floor.
Raise cutter boom to best possible position to allow clearance from
roof, ribs, and floor.
Raise gathering head away from the mine floor.
Adjust conveyor boom to best possible position to allow clearance
from roof, walls, and floor.
WARNING!
Adjust conveyor boom to allow clearance from roof, walls, and
floor. Failure to do so will result in damage to the conveyor boom.
Ensure adequate clearance at all times while tramming machine.
Be award of people, equipment, and cables.
Remote control - tram enable
To enable machine tramming, press and release the “TRAM 2-3”
key.
Once enabled, the tram levers can be used to drive left and right
tramming tracks forwards and backwards. If the tram levers are
released for a continuous period of five (5) seconds, the tram be-
comes disabled.
To re-enable the tram function, press and release the “TRAM 2-3”
key.
Remote control - tram track console
Press the “LEFT FWD” tram key to turn the left tramming track for-
ward.
Press the “LEFT REV” tram key to turn the left tramming track
backwards.
Press the “RIGHT FWD” tram key to turn the right tramming track
forward.
Press the “RIGHT REV” tram key to turn the right tramming track
backwards.
______________________________________________________________
A6474X319 REV 05 5.35
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EM021401 (BI001987)
______________________________________________________ Operation
Shear down (lower cutter head). The shear down rate is controlled
by a shear down relief valve to limit the hydraulic pressure being
applied to the cylinders. This is an adjustable feature and can be
easily changed as mining conditions change.
To maintain smooth, level floor conditions, it may be necessary to
tram the machine backward approximately 36 in., thus trimming
ridges and smoothing the floor. This may or may not be necessary
each cut sequence depending on mine conditions.
Repeat this procedure to desired depth of cut.
Turning crosscuts is accomplished by making a series of partial
cuts (sumps) until the machine can be turned to the desired angle.
Relocating the miner
Ensure rear stabilizer is raised from the floor.
Position cutter boom so as to prevent it from hitting roof, ribs, or
floor.
Raise gathering head.
Lower conveyor boom down and position so it will not hit roof, ribs,
floor or any other equipment or obstacles.
Ensure that trailing cable out of the path of travel.
Ensure there is enough clearance when relocating to avoid damage
to machine and ensure operator safety.
Be alert to any people, obstacles, or other machines.
Know the position of fellow workers.
Engage tram in desired direction and speed.
______________________________________________________________
A6474X319 REV 05 5.45
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EM021401 (BI001987)
_______________________________________________________ Hydraulic
Hydraulic system schematics
Abbreviations and Symbols
Troubleshooting is easier when you can readily read and understand
the diagrams and blueprints of a hydraulic network. To do this, you
need to know hydraulic symbols.
Graphic symbols denote the type of function a component performs
but do not necessarily sh ow its s hap e or c ons tr uction . T hes e
schematic symbols are used to trace the system flow from the reser-
voir to the actual work being performed and then back to the reservoir.
The symbols used are shown individually with a functional description
where needed. The study of these symbols helps in understanding
the system and thereby aids in troubleshooting the system.
In a hydraulic schematic, components are represented on a schematic
diagram by symbols. Using the hydraulic symbols to trace a circuit will
help to define the relationships of the components and circuits. The
component symbols are linked together by lines, which represent the
hydraulic hoses and pipes on the miner.
A schematic diagram is an illustration which shows the hydraulic rela-
tionship of the various components in the circuits. A schematic diagram
does not show the physical location of the components.
IMPORTANT!
Schematics may vary from one unit to the next. Consult the parts
manual for the correct schematic for your machine.
_____________________________________________________________
A6474X319 REV 05 5.55
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EM021401 (BI001987)
_______________________________________________________ Hydraulic
Fig. 48: Valve hydraulic symbols
Check valve
Flow control
valve Flow control valve with
internal check
Ball valve
Pressure reducing/
relieving valve
Multipurpose valve
Shuttle
valve
Relief valve
Water valve,
Solenoid valve hydraulically piloted,
2-unit detented
Water valve,
hydraulically piloted
_____________________________________________________________
A6474X319 REV 05 5.65
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EM021401 (BI001987)
_______________________________________________________ Hydraulic
Fig. 55: Conveyor raise/lower
_____________________________________________________________
A6474X319 REV 05 5.75
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EM021401 (BI001987)
__________________________________________________________ Water
Fig. 61: Dust-cooling component locations
CH front spray manifold CH front spray manifold CH front spray manifold
LH cutter side spray
manifold
CH bottom spray
CH bottom spray manifold
manifold
GH spray manifold GH spray manifold
Washdown manifold
Atmospheric relief
Cleaning spray manifold Washdown manifold
______________________________________________________________
A6474X319 REV 05 5.85
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EM021401 (BI001987)
_______________________________________________________ Electrical
Fig. 69: Electrical component layout
1. Left cutter motor 15. Area lights
2. Right cutter motor 16. Graphic display
3. Left CLA motor 17. Text display
4. Right CLA motor 18. Emergency tram pendant
5. Pump motor 19. Antenna
6. Blowing system motor 20. Solenoid junction box
7. Tram transformer case 21. Dust Spray
8. Left tram motor 22. Fire spray
9. Right tram motor 23. Methane displays
10. Left emergency stop 24. Methane sensors
11. Hydraulic oil level switch 25. Methane warning light
12. Headlights
13. Headlights
14. Area lights
_____________________________________________________________
A6474X319 REV 05 5.95
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EM021401 (BI001987)
_______________________________________________________ Electrical
Controller case - front wall
Mounted on the front wall of the controller case (Fig. 76) are an e-stop
button, the “MINER” mode of operation selector switch, control break-
ers, conveyor and cutter motor hour meters, and the tram circuit break-
er.
main rotary switch “RS1” The main rotary switch, “RS1”, is the mode of operation selector switch.
The machine can be operated in “REMOTE”, which means it is con-
trolled by the remote transmitter, “ETRAM”, which means it can only be
operated by the emergency tram pendant and that there are limited
functions available or “GND CHECK”, which is used to perform a con-
trol voltage ground check of the machine.
e-stop The control case e-stop button, “CASE ES”, can be used to quickly shut
“CASE ES” down the machine. Depressing the button will shut the pump motor
down, thereby shutting down all machine functions.
lighting rotary switch “LS1” The lighting rotary switch, “LS1”, can be used to turn all lights on, all
lights off, or can be set to turn on area lights only.
cutter hour meter “HM1” The cutter hour meter, “HM1”, records the total number of running
hours for the cutter motors.
conveyor hour meter “HM2” The conveyor hour meter, “HM2”, records the total number of running
hours for the conveyor motors.
There are sixteen (16) circuit breakers mounted with their shafts
through the wall so that they can be reset from the front of the controller
case.
circuit breaker “MCB1” “MCB1” is a 15A breaker for the 120VAC+ side of the control power
circuit.
circuit breaker “MCB2” “MCB2” is a 15A breaker for the 120VAC- side of the control power cir-
cuit.
circuit breaker “MCB3” “MCB3” is a 15A breaker for the 120VAC+ side of the area light circuit.
circuit breaker “MCB4” “MCB4” is a 15A breaker for the 120VAC- side of the area light circuit.
circuit breaker “MCB5” “MCB5” is a 25A breaker for the 12VAC+ side of the head light circuit.
circuit breaker “MCB6” “MCB6” is a 25A breaker for the 12VAC- side of the head light circuit.
circuit breaker “MCB7” “MCB7” is a 5A breaker for the 12VAC+ side of the RTD module circuit.
circuit breaker “MCB8” “MCB8” is a 5A breaker for the 12VAC- side of the RTD module circuit.
circuit breaker “MCB9” “MCB9” is a 5A breaker for the 120VAC+ side of the contactor circuit.
circuit breaker “MCB10” “MCB10” is a 5A breaker on the 90VDC+ side of the solenoid circuit.
circuit breaker “MCB11” “MCB11” is a 5A breaker on the 0VDC- side of the solenoid circuit.
_____________________________________________________________
A6474X319 REV 05 5.105
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EM021401 (BI001987)
_______________________________________________________ Electrical
Headlights and area lights
The area lights on the machine are energized and will turn on as soon
as power is applied to the machine and the main circuit breaker is
closed.
The headlights are energized when power is applied to the machine
and the main circuit breaker is closed. The remote control transmitter
can then be used to turn the headlights on or off.
Fig. 85 is a typical light schematic. Always refer to the schematic in the
parts book for your machine.
Fig. 85: Headlights and area lights
_____________________________________________________________
A6474X319 REV 05 5.115
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EM021401 (BI001987)
____________________________________________________ Maintenance
Specific lubrication and maintenance procedures
Every shift
cutter head lift cylinder pins Lubricate the upper and lower cutter head cylinder pins (right and left).
(upper and lower) The upper pins are lubricated through the grease fittings located on
each pin (Fig. 88). The lower cylinder pins are lubricated through a
lubrication block mounted on each side of the machine (Fig. 88). Pump
approximately 50 cubic cm (3 cubic inches) into each fitting.
Fig. 88: Cutter head cylinder pins (typical both sides)
Cutter head lift
cylinder pin, upper (2)
Cutter head lift
cylinder pin, lower (2)
______________________________________________________________
A6474X319 REV 05 5.125
--- Page 20 ---
EM021401 (BI001987)
____________________________________________________ Maintenance
hydraulic oil level With all of the machine cylinders in the fully collapsed position, check
the hydraulic oil level (Fig. 104). Remove dipstick from tank and wipe
clean. Insert dipstick back into tank and remove. The oil should be
level with the full line indicated on dipstick. If oil level is low, add oil
until full level is met.
Fig. 104: Hydraulic oil tank level
Hydraulic oil tank
Hydraulic oil tank Dip stick location
stabilizer shoe pivot pins Lubricate the stabilizer shoe pivot pins through the two (2) grease fit-
tings located on left rear lubrication block (Fig. 105). Pump approxi-
mately 3 cu. in (50 cu. cm) of grease into each fitting.
Fig. 105: Stabilizer shoe pivot pin lubrication