CAT EL 1000 Shearer Operation & Maintenance Manual SN LM210202 – PDF DOWNLOAD

Media-ID: EM028338-00-EN Doc.-No.: 4884994 BA 00 Jun. 2018

Operating and Maintenance Manual EL1000 Shearer

Part-No.:

4884994

Serial-No.:

LM210202

SAFETY.CAT.COM

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AMENDMENTS AND ALTERATIONS TO THIS PUBLICATION ARE NOT SUBJECT TO NOTIFICATION. CATERPILLAR RESERVES ALL RIGHTS TO THIS PUBLICATION. ITS CONTENT IS PROTECTED BY COPYRIGHT LAWS. NO PART OF THIS PUBLICATION MAY BE REPRODUCED OR TRANSFERRED IN ANY WAY OR FORM WITHOUT THE PRIOR WRITTEN APPROVAL OF CATERPILLAR. CATERPILLAR DECLINES ANY LIABILITY FOR DIRECT OR INDIRECT CONSEQUENCES OF PRINTING ERRORS. WE RESERVE THE RIGHT TO INTRDUCE MODIFICATIONS AS A RESULT OF TECHNICAL DEVELOPMENTS WITHOUT PREVIOUS NOTICE. © 2018 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of Contents

Table of Contents 1 About this manual ....................................................................................... 7 1.1 How to use this manual ........................................................................ 7 1.2 Signs and symbols used....................................................................... 8 2 Safety............................................................................................................ 9 2.1 Personnel.............................................................................................. 9 2.2 Operating Conditions ............................................................................ 9 2.2.1 Intended use .............................................................................. 9 2.2.2 Unauthorized use....................................................................... 9 2.2.3 Ambient conditions..................................................................... 9 2.2.4 Prerequisites for operation....................................................... 10 2.3 Operator requirements........................................................................ 10 Media-ID: EM028338-00-EN / Caterpillar Global Mining Europe GmbH 2018 ©

2.4 Using the machine and working on the machine ................................ 11 2.4.1 General principles .................................................................... 11 2.4.2 Storage and transport .............................................................. 12 2.4.3 Installation and commissioning ................................................ 12 2.4.4 Operation ................................................................................. 13 2.4.5 Maintenance and repair ........................................................... 14 2.5 Notes on the hydraulic system............................................................ 14 2.5.1 Recommended storage and use period................................... 16 3 Storage and transport ............................................................................... 17 3.1 Storage ............................................................................................... 17 3.1.1 Conditions for despatch ........................................................... 17 3.1.2 Storing the equipment.............................................................. 17 3.1.3 Storing used equipment ........................................................... 18 3.2 Transport ............................................................................................ 19 3.2.1 Load Units, Dimensions and Weights ...................................... 19 3.2.2 Before transport ....................................................................... 20 3.2.3 Transporting the components .................................................. 20 3.2.4 Dismantling of components...................................................... 21 3.2.5 Transporting the machine underground................................... 22 4 Assembly.................................................................................................... 23 4.1 Notes on installation ........................................................................... 23 4.2 Overview of EL1000 shearer .............................................................. 24 4.3 Installing the shearer .......................................................................... 25 4.4 Installing the shoe post and lifting cylinder on the mainframe ............ 26 4.5 Installing the downdrive on the mainframe ......................................... 32 4.6 Installing the ranging arm on the mainframe ...................................... 39 4.7 Installing the lifting cylinder on the ranging arm.................................. 47 4.8 Installing the spall guards ................................................................... 49 4.9 Installing the shearer drum on the ranging arm .................................. 50 4.10 Moving the shearer onto the conveyor ............................................... 54 4.11 Connecting the shearer ...................................................................... 59 4.11.1 Electrical connection ................................................................ 59 4.11.2 Water connection ..................................................................... 59

EL1000 Shearer

Table of Contents

4.12 Greases, oils and hydraulic fluids ....................................................... 59 4.13 Commissioning the shearer ................................................................ 60 4.13.1 Before commissioning.............................................................. 60 4.13.2 Commissioning the shearer ..................................................... 61 4.13.3 Retightening bolted connections.............................................. 61 4.13.4 Changing oils and hydraulic fluid ............................................. 61 4.14 Dismantling and removing the shearer ............................................... 61 4.14.1 Important instructions for dismantling ...................................... 61 5 Operation.................................................................................................... 63 5.1 Start of work........................................................................................ 63 5.2 Control elements................................................................................. 64 5.4 Wireless remote control ...................................................................... 67 5.4.1 General operating elements..................................................... 69 5.4.2 Switching the wireless remote control on/off............................ 70 5.4.3 General control buttons............................................................ 72 5.4.4 Shift keys ................................................................................. 73 5.4.5 Starting/stopping motors .......................................................... 74 5.4.6 Numeric keypad ....................................................................... 75 5.4.7 Setup Mode.............................................................................. 76 5.5 Starting the shearer ............................................................................ 77 5.6 What to observe during operation....................................................... 78 5.6.1 Operator's Report..................................................................... 78 5.6.2 Face conditions........................................................................ 78 5.7 Stopping the shearer .......................................................................... 79 5.8 Electrical isolation of the shearer........................................................ 79 5.9 Maintenance ....................................................................................... 80 5.9.1 Maintenance instructions ......................................................... 80 5.9.2 Important instructions............................................................... 80 5.9.3 Maintenance intervals (mechanical) ........................................ 81 5.9.4 Maintenance intervals (electrical) ............................................ 83 5.9.5 Oil and fluid analyses............................................................... 86 5.9.6 Maintenance of the ranging arms ............................................ 87 5.9.7 Maintenance of the cutting drums............................................ 95 5.9.8 Maintenance of the haulage units ............................................ 96 5.9.9 Maintenance of the power pack ............................................. 106 5.9.10 Maintenance of the downdrives ............................................. 108 5.9.11 Replacing wearing parts ........................................................ 109 6 Technical data.......................................................................................... 127 6.1 Main components of the shearer ...................................................... 127 6.2 Technical data sheet......................................................................... 127 6.3 Identification...................................................................................... 129 6.4 Mechanical components ................................................................... 131 6.4.1 RA0560 ranging arm.............................................................. 131 6.4.2 Haulage unit HU100............................................................... 133 6.4.3 Downdrive DD1-180............................................................... 135 6.5 Hydraulic components ...................................................................... 137 6.5.1 Hydraulic system.................................................................... 137 6.5.2 Powerpack PP2 ..................................................................... 139

EL1000 Shearer

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5.3 MMC/ Electrical Control Box............................................................... 65

Table of Contents

6.6 Electrical components....................................................................... 140 6.6.1 Electrical system .................................................................... 140 6.6.2 Pilot Power System................................................................ 140 6.6.3 Main power distribution system.............................................. 141 6.6.4 Power system for the control components............................. 143 6.6.5 Electrical control box ECB 2 .................................................. 144 6.6.6 Haulage transformer box HTB2 ............................................. 146 6.6.7 Cutter motors ......................................................................... 148 6.6.8 Haulage motors...................................................................... 149 6.6.9 Pump motor ........................................................................... 150 6.7 Water System ................................................................................... 151 6.7.1 Tasks ..................................................................................... 151 6.7.2 Cooling system ...................................................................... 151 6.7.3 Fire extinguishing system ...................................................... 152 6.7.4 Spray Boom ........................................................................... 153

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6.8 Permissible media ............................................................................ 154 6.8.1 Gear Oil.................................................................................. 154 6.8.2 Hydraulic Fluid ....................................................................... 155 6.8.3 Quill Shaft Grease.................................................................. 156 6.8.4 All Other Grease Applications................................................ 156 6.9 Tightening torques ............................................................................ 158 6.9.1 Screws and bolts with ISO metric thread .............................. 158

EL1000 Shearer

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Table of Contents

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EL1000 Shearer

About this manual

1

How to use this manual

1 About this manual This chapter contains important information that makes it easier for you to use this manual. You will also get information about the structure of the manual and the symbols, characters and abbreviations used and frequently used terms.

1.1 How to use this manual applicable operating manual

Using an operating manual that was not specifically written for the machine concerned can result in a safety hazard for yourself and others. Ensure that the data on the machine complies with the data given in the operating manual.

Category according to Atex di-

The machine is a device of Group I, Category M2 according to the European Directive 94/9/EC.

rective

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The operating manual must be accessible at all times to all persons working on or with the machine. It should always be available at the place of operation. new operating manual

service partner

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

Please contact your service partner for spare part requests or for the clarification of technical questions.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shearer. All persons working on the face, at the edge of the face or at the entry must read this operating manual.

This includes persons who: are in charge of transport, set up the rise heading, perform installation/removal work, operate the shearer, correct malfunctions, carry out daily routine work on the face or in the entry, carry out maintenance work, carry out repair work.

Supervisory personnel who: initiate the activities mentioned above and/or supervise them.

Purpose of this operating manual Efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all activities relating to the product.

Take the time to read this operating manual in its entirety. Pay particular attention to the respective safety instructions. Familiarize yourself well with the appearance and meaning of the safety and information symbols.

Safety

Carefully read through the chapter "Safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

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1

About this manual Signs and symbols used

1.2 Signs and symbols used DANGER The combination of the signal word DANGER and a corresponding symbol warns you of an immediate danger with a high personal risk.

If not observed, you or your coworkers will be seriously injured or killed.

1. Follow the described instructions.

WARNING The combination of the signal word WARNING and a corresponding symbol warns you of a potential danger with a moderate personal risk.

1. Follow the described instructions.

CAUTION The combination of the signal word CAUTION and a corresponding symbol indicates a potential personal risk.

If not observed, you or your co-workers could suffer minor to moderate injuries.

1. Follow the described instructions.

NOTICE The combination of the signal word NOTICE and the adjacent symbol indicates a potential risk of damage to the machine.

If not observed, material damage might occur on the machine.

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

This information will help you become more familiar with the machine and allow you to prepare your work more exactly.

1. Observe the provided tips and information.

Important information The combination of the signal words IMPORTANT INFORMATION and the adjacent symbol indicates important information or other operating manuals which must be observed at this place.

1. Observe the information and read the specified operating manuals.

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If not observed, you or your co-workers might be seriously injured or killed.

Safety

2

Personnel

2 Safety 2.1 Personnel operation installation and repairs

The machine may only be operated by skilled or instructed personnel.

As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

The following parts may only be installed or repaired by service technicians authorized by Caterpillar or mining professionals as defined below: safety components (pressure relief valves, etc.) the electrical system (controls, signaling devices, etc.), hydraulic System

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qualification

An instructed person is someone who has been instructed with regard to the tasks assigned to him and the potential hazards which arise due to improper behavior, and, if applicable, has been trained/instructed concerning the necessary safety equipment and protective measures. The instructed person is able to work while looking ahead, recognize hazards and act accordingly.

A skilled worker is someone who, based on his special training and experience, has sufficient knowledge and is familiar with the relevant regulations.

A skilled worker can carry out the work assigned to him. He can recognize potential hazards and take the necessary measures to eliminate them. He also has the required repair and installation knowledge.

2.2 Operating Conditions 2.2.1 Intended use The shearer has been exclusively designed and manufactured for mining of minerals, preferably coal, using the longwall method. Employ the shearer only for its intended use!

Intended uses shall include: mining of minerals loading of the minerals onto the conveyor

2.2.2 Unauthorized use Applications not expressly listed as intended use represent unauthorized use and are not allowed with the shearer.

Unauthorized use includes the transport of persons.

Caterpillar will not accept any liability for damage resulting from any such unauthorized use.

2.2.3 Ambient conditions Suitable measures must be taken by the operator to combat explosion hazards due to firedamp and the ignition of dust which might occur in a mine (see DIN EN 1710).

That includes:

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2

Safety Operator requirements

adequate and consistent ventilation, water spraying systems.

The M2 equipment must be switched off if the firedamp concentration in the free cross-section of the parts of the face which are continuously ventilated reaches the lower explosion limit (LEL) defined by relevant national legislation.

It may only be restarted by an authorized person.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except those which are relevant for safety and suitable for use in explosive atmospheres.

The M2 equipment must be stopped immediately and secured against restarting if the firedamp protection systems are found to be damaged.

It is prohibited to start up the machine before it has been confirmed that the overall system in which the machine is installed complies with national regulations.

Since the equipment is only part of an overall system, the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. This must be labeled according to the legal provisions applicable at the time of its placement on the market.

The machine may be operated only if the safety requirements specified in national regulations are met. These include: equipment for preventing unauthorized startup, startup warning systems, water spraying systems in areas where there is a danger of explosion safe shutdown command systems, emergency stop systems, dust extraction systems, noise protection, warnings etc.

All electrical equipment required to operate the machine must be designated according to the legal provisions applicable at the time when it is placed on the market.

2.3 Operator requirements Operators are responsible for ensuring that the machine is always in a technically serviceable condition. This includes for example: Regularly maintenance and checking the machine in accordance with the provided schedule Ensuring sufficient supplies for operation such as electricity, water or hydraulic fluid Regularly checking all safety equipment (document the test results).

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2.2.4 Prerequisites for operation

Safety Using the machine and working on the machine

2

If any irregularities are noticed during operation, investigate them immediately and shut down the machine until any problems have been rectified Make sure that all of the signage on the machine is legible, and immediately replace any lost signs

2.4 Using the machine and working on the machine 2.4.1 General principles Always work with full concentration.

Become familiar with your working area.

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noise emissions

Always wear your personal protective equipment (PPE). This includes wearing suitable ear protection, since the noise emissions of the sharer sometimes can exceed a value of 85 dB (A) during operation.

Notify the responsible personnel of the following prior to working on the longwall: your exact location, the work you are carrying out how much time you will probably need

safety components

Start the shearer only if it is in good and safe condition and the safety components such as emergency-stop switch, cover plates, etc., are correctly installed.

Keep the signaling and lighting systems in good condition.

Pre-start warning and shutdown provisions have been installed for the safety of the personnel at the face. Never shut them off.

The integrity of intrinsically safe systems must be checked and maintained in original condition.

Observe the warning signs on the machine.

emergency stop switch

Actuate the emergency-stop switch immediately in the event of serious faults or irregularities during operation. Inform your supervisor of any unusual situations so that the necessary measures can be initiated without delay.

Actuate the emergency-stop switch immediately if safety components such as firedamp protection devices suddenly no longer function.

electrical trips

Shut off the shearer completely for: maintenance work inspection work repair work Never carry out work on the shearer or walk on the conveyor if the shearer and conveyor have not been shut off. For information on the shutdown procedure for the shearer, see "Electrical isolation of the shearer" [} 79] If it is necessary to supply power to the shearer for the above-mentioned work, the operator must carry out a risk assessment that considers the individual risks in the mine. The manual operating mode must be activated when performing work while power is switched on in order to prevent unintentional activation of functions via the remote control that could endanger the personnel working on the machine.

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2

Safety Using the machine and working on the machine

Never reach into or enter areas between machine components which can move. automatic mode

danger of explosion

In automatic mode, the shield units of a face are controlled by an automatic program without any human intervention. When traveling along the face you should therefore always bear in mind that the shield units may move automatically.

Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals emitted by the control unit in the shield unit currently operated.

Make sure to observe the intervals specified for shearer maintenance and inspection, since hot surfaces might cause explosive atmospheres (fulmination) and dust to ignite.

Observe the separate operating manuals for the components used.

You may only carry out work in the mining area if: the roof has been secured against falling rock,

the mining equipment and conveyor have been shut down and secured against being switched back on.

2.4.2 Storage and transport Observe the specified storage times and requirements for storage.

Do not store any materials or components in the travel way or in your working area.

Inform the persons concerned about the intended transport route and the probable duration of transport. transport safety device

Make sure that the transport safety devices have been correctly fitted.

Secure all moving parts.

Never walk or stay under unsecured components or suspended loads.

means of attachment

Only hook the lifting tackle into the lifting points provided for this purpose. Pay attention to the different load limits of the lifting points. Also observe the instructions on the transport sheets. Never attach lifting tackle to brackets and cylinder connections.

Only use means of attachment that are in perfect condition and have been designed for the loads that occur.

For round components use transport straps only. Never use chains or steel cables for this purpose.

Do not damage any finished or polished surfaces, such as shaft surfaces, sealing surfaces, etc.

mobile handling systems

When using floor conveying devices for transport make sure that the center of gravity is as low as possible.

2.4.3 Installation and commissioning Secure the installed electric motors against unauthorized or unintentional startup during the installation Heed the safety data sheets and safety instructions when working with oils, lubricants and other chemical substances.

Dispose of auxiliary materials contaminated with oil, lubricants or other chemical substances in an environmentally compatible manner.

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the coal face has been secured against collapsing and

Safety Using the machine and working on the machine

2

In case the shearer is to be driven onto the conveyor with the help of an external hydraulic motor, the operator must prepare a Safe Work Practice/Procedure (SWP) that considers possible dangers in the mine in order to ensure correct and safe operation.

Every oil filling procedure using an onboard pump requires that the operator prepare a Safe Work Practice/Procedure (SWP) that considers the local regulations for working on a machine under power and the special conditions in the mine. cutting drums

Before installing the cutting drums, check whether the machine's center of gravity has changed. The shearer can tip over if the cutting drums are heavy enough. Assess the risk of possible hazards and take appropriate safety precautions if there is a risk that the machine could tip over.

2.4.4 Operation Media-ID: EM028338-00-EN / Caterpillar Global Mining Europe GmbH 2018 ©

You may operate the control system only if you have detailed knowledge of the operating controls and their method of operation. You need to have been instructed on the control system concerned.

Before applying power to the shearer, make sure that no one is on the conveyor.

Check that all protective devices are installed on the shearer and are in working order.

Clean the control components regularly. Ensure that the operating symbols are clearly recognizable in order to avoid any operator errors and accidents that may result.

As the shearer moves forward flying rock from the cutting action can cause severe damage and shields advance behind the shearer. Beware of flying rock, moving shields and other moving machine parts when you follow the shearer along the face or are working in the face. A risk assessment has to be carried out that clearly defines safe standing and no-go zones for the mine.

Fig. 1: Go/no-go zones

radio mode

EL1000 Shearer

When operating the shearer in radio mode or switching the shearer from manual to radio mode motors might start and thus machine parts might move inadvertently. Beware of moving machine parts or flying rock from unexpected cutting action. When operating with two transmitters (A and B) special care has to be taken as unexpected control commands of one operator might cause machine movement that the other operator is not expecting. A risk assessment has to be carried out taking into account the conditions in the mine when the machine is to be operated in radio mode.

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