CAT EL3000 Shearer Operating & Maintenance Manual SN LSW30139 - PDF DOWNLOAD

Media-ID: EM029397-00-EN Doc.-No.: 4882700 BA 00 Oct. 2019

Operating and Maintenance Manual EL3000 Shearer

Serial-No.:

LSW30139

SAFETY.CAT.COM

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. © 2019 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 ....................................................................................... 6 1.1 How to use this manual ........................................................................ 6 1.2 Signs and symbols used....................................................................... 7 2 Safety............................................................................................................ 8 2.1 Personnel.............................................................................................. 8 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: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2.4 Using the machine and working on the machine ................................ 10 2.4.1 General principles .................................................................... 10 2.4.2 Storage and transport .............................................................. 12 2.4.3 Installation and commissioning ................................................ 13 2.4.4 Operation ................................................................................. 13 2.4.5 Maintenance and repair ........................................................... 14 2.5 Notes on the hydraulic system............................................................ 15 2.5.1 Recommended storage and use period................................... 16 3 Storage and transport ............................................................................... 18 3.1 Storage ............................................................................................... 18 3.1.1 Conditions for despatch ........................................................... 18 3.1.2 Storing the equipment.............................................................. 18 3.1.3 Storing used equipment ........................................................... 19 3.2 Transport ............................................................................................ 20 3.2.1 Load Units, Dimensions and Weights ...................................... 20 3.2.2 Before transport ....................................................................... 21 3.2.3 Transporting the components .................................................. 22 3.2.4 Dismantling of components...................................................... 22 3.2.5 Transporting the machine underground................................... 23 4 Assembly.................................................................................................... 24 4.1 Notes on installation ........................................................................... 24 4.2 Main components of the shearer ........................................................ 25 4.3 Installing the shearer .......................................................................... 25 4.4 Installing the shoe post on the mainframe .......................................... 26 4.5 Installing the lifting cylinders on the shoe post ................................... 40 4.6 Installing the downdrive on the mainframe ......................................... 42 4.7 Moving the shearer onto the conveyor ............................................... 49 4.8 Installing the ranging arm on the mainframe ...................................... 53 4.9 Installing the lifting cylinder on the ranging arm.................................. 61 4.10 Installing the shearer drum on the ranging arm .................................. 63 4.11 Connecting the shearer ...................................................................... 68 4.11.1 Electrical connection ................................................................ 68 4.11.2 Water connection ..................................................................... 68

EL3000 Shearer

Table of Contents

4.12 Greases, oils and hydraulic fluids ....................................................... 69 4.13 Commissioning the shearer ................................................................ 69 4.13.1 Before commissioning.............................................................. 69 4.13.2 Adjusting the cable arm ........................................................... 70 4.13.3 Commissioning the shearer ..................................................... 70 4.13.4 Retightening bolted connections.............................................. 70 4.13.5 Changing oils and hydraulic fluid ............................................. 70 4.14 Dismantling and removing the shearer ............................................... 71 4.14.1 Important instructions for dismantling ...................................... 71 5 Operation.................................................................................................... 72 5.1 Start of work........................................................................................ 72 5.2 Control elements................................................................................. 73 5.4 Wireless remote control ...................................................................... 76 5.4.1 General operating elements..................................................... 77 5.4.2 Switching the wireless remote control on/off............................ 79 5.4.3 General control buttons............................................................ 81 5.4.4 Shift keys ................................................................................. 82 5.4.5 Numeric keypad ....................................................................... 83 5.4.6 Starting/stopping motors .......................................................... 83 5.4.7 Setup Mode.............................................................................. 84 5.4.8 Shift keys ................................................................................. 87 5.5 Commissioning the shearer ................................................................ 87 5.6 What to observe during operation....................................................... 89 5.6.1 Operator's Report..................................................................... 89 5.6.2 Face conditions........................................................................ 89 5.7 Stopping the shearer .......................................................................... 89 5.8 Electrical isolation of the shearer........................................................ 90 5.9 Maintenance ....................................................................................... 90 5.9.1 Maintenance instructions ......................................................... 90 5.9.2 Important instructions............................................................... 91 5.9.3 Maintenance intervals (mechanical) ........................................ 91 5.9.4 Maintenance intervals (electrical) ............................................ 94 5.9.5 Oil and fluid analyses............................................................... 97 5.9.6 Filling oil and hydraulic fluid ..................................................... 98 5.9.7 Maintenance of the ranging arms .......................................... 101 5.9.8 Maintenance of the cutting drums.......................................... 112 5.9.9 Maintenance of the haulage units .......................................... 113 5.9.10 Maintenance of the power pack ............................................. 126 5.9.11 Maintenance of the downdrives ............................................. 128 5.9.12 Water spraying bar maintenance ........................................... 129 5.9.13 Replacing wearing parts ........................................................ 129 6 Technical data.......................................................................................... 143 6.1 Main components of the shearer ...................................................... 143 6.2 Technical data sheet......................................................................... 143 6.3 Identification...................................................................................... 144 6.4 Permissible media ............................................................................ 145 6.4.1 Gear Oil.................................................................................. 146 6.4.2 Hydraulic Fluid ....................................................................... 146

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5.3 MMC/ Electrical Control Box............................................................... 74

Table of Contents

6.4.3 Grease Applications............................................................... 147

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6.5 Tightening torques ............................................................................ 148 6.5.1 Screws and bolts with ISO metric thread .............................. 148

EL3000 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 2014/34/EU.

rective

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 operating manual is intended for those persons who work with or on the Emotor. All persons working on the E-motor 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 conveyor, 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.

6 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

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.

About this manual

1

Signs and symbols used

safety

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

Observe the information given and follow the instructions.

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.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

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

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

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.

EL3000 Shearer

7 / 148

2

Safety Personnel

2 Safety This chapter provides important information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure are intended to help you avoid hazardous situations and perform the necessary work as safely as possible.

The shearer was developed on the basis of the latest technology and generally accepted safety regulations. Nevertheless, you and others may be exposed to dangerous situations, e.g,. from environmental factors, damage to the machine or or improper operation.

Do not make any modifications or carry out changes which could impair safety.

All modifications or conversions of the machine require the approval of the manufacturer.

Only use original Caterpillar spare parts. Please note that the use of spare parts from other manufacturers voids the warranty.

The European directives/standards referenced in this operating manual are binding for use of the shearer within the European Union (EU). When the machine is used outside the European Union, the directives and standards of the country where the machine is used must be observed.

Please also ensure that, in addition to this operating manual, the provisions and regulations regarding accident prevention in the country of use are observed.

Also observe the safety and accident prevention regulations of the following parties: the mine the mine inspectorate the mining supervisory authorities Also read the operating manuals of the other components needed for operation, e.g. electric motors, etc., carefully and attentively. Clarify any questions before starting work.

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

8 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

The electrical voltage and hydraulic pressure in the machine can injure you severely. It is the responsibility of the operator to ensure that how the machine is installed and operated complies with the requirements of health and safety regulations as well as applicable legislation of the country in which the machine is used.

Safety

2

Operating Conditions

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 Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

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: 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.

EL3000 Shearer

9 / 148

2

Safety Operator requirements

2.2.4 Prerequisites for operation 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,

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).

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.

10 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

startup warning systems,

Safety Using the machine and working on the machine

noise emissions

2

Always wear your personal protective clothing and 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.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

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 isolation

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" [} 90] 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.

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,

EL3000 Shearer

11 / 148

2

Safety Using the machine and working on the machine

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

Fig. 1: Maximum allowed angle of inclination

α Starting at a certain inclination towards the face side, the shearer can tip over if it is not restrained (e.g. by the rack bars of the conveyor of the coal face), especially when the cutting drums are mounted. As a result, you or others could be seriously injured or even killed. For this reason, always observe the specified maximum angle of inclination (α) for the machine. The maximum angle of inclination for this machine is 6°. Secure the machine against tipping whenever you perform work on the machine that requires raising the gob side.

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

12 / 148

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

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

risk of tipping over

Safety Using the machine and working on the machine

2

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.

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.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

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 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.

EL3000 Shearer

13 / 148

2

Safety Using the machine and working on the machine

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.

radio mode

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.

automation mode

Incorrect or lost information when the shearer is operated in automation mode might lead to unexpected machine movements or collisions with other parts of the longwall system. A risk assessment has to be carried out taking into account the conditions in the mine when the machine is to be operated in automation mode.

2.4.5 Maintenance and repair Be sure to observe the intervals specified for maintenance and inspection.

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 You may only carry out work in the mining area if: the roof has been secured against falling rock, the coal face has been secured against collapsing and the mining equipment and conveyor have been shut down and secured against being switched back on. manual mode

14 / 148

When the shearer is in manual mode (e.g. for maintenance or repair) or the shearer is switched to manual mode motors might start and thus machine parts might move inadvertently. Beware of moving machine parts or flying rock from

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 2: Go/no-go zones

Safety Notes on the hydraulic system

2

unexpected cutting action. A risk assessment has to be carried out taking into account the conditions in the mine when the machine is to be operated in manual mode.

2.5 Notes on the hydraulic system hydraulic system protective devices

Note that when dismantling protective devices that include hydraulic components, those components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. It is therefore imperative that you depressurize the hydraulic components before dismantling the protective devices.

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace any defective protective caps immediately.

handling hydraulic fluids

Avoid direct skin contact with hydraulic fluids. Hydraulic fluid can penetrate the skin and cause dangerous infections.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids are very harmful to your health.

Only persons who have and can demonstrate special knowledge of hydraulics are allowed to work on the hydraulic system (technician).

Carry out a visual inspection of all hydraulic components at regular intervals. In particular, please observe the following: the hoses are not pinched. the hoses have no bubbles or blisters. the hoses or the outer sheaths of the hoses are not abnormally hard. the outer sheath of the hose is not damaged. the connectors are securely inserted into the coupling sockets. the connections are leak-tight.

Make sure that no dirt penetrates the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage to the entire system. Backflush the hydraulic lines thoroughly before installing them.

Before removing the staples for disconnecting the hose lines, turn the hose at the connector to check whether the line is still pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the hydraulic line.

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Do not fail to depressurize the hydraulic line.

Always secure the plug connectors of the hydraulic elements with the corresponding staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials.

Check all connectors and connections of the depressurized system for leaks after finishing repair work.

Never try to hold a hose line that is thrashing about. Depressurize the section in question immediately.

Never try to repair damaged hose lines.

Replace hose lines at the first suspicion of damage. permissible hose lines

Only use hose lines approved for the prevailing pressures.

Do not use any hose lines with damaged connectors or worn O-rings.

EL3000 Shearer

15 / 148

2

Safety Notes on the hydraulic system

Replace hose lines only with hose lines of the same or higher quality. installing hose lines

Lay the hose lines correctly behind the brackets and clips provided for them.

For more concise information, follow the "Technical information on hydraulic components".

Australia

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure in [bar] date of manufacture (YY, MM) Caterpillar ID Additional writing on the label: manufacturer ID material number

date of manufacture of the hose line, date of manufacture of the hose working pressure.

2.5.1 Recommended storage and use period The following recommendations apply to the use, storage and manufacture of hydraulic hoses and lines: hose storage period

length of storage time for hose lines

For the manufacture of a hose line, the used hose should not exceed a max. storage period of 4 years.

For hose lines, a maximum storage period of 2 years applies (starting from the time of manufacture).

To prevent signs of aging in hydraulic hoses and hose lines, aim for the following storage conditions: store in a dry, low-dust location in a lying position, the storage temperature should be between +15°C and +25°C at max. 65% relative humidity, avoid direct sunlight or exposure to UV radiation, do not use ozone-forming lights or electrical devices which form sparks in the direct vicinity, avoid contact with acids, bases or solvents, protect from nearby heat sources, when stored coiled up, the radius of the coils may not be smaller than the smallest bending radius indicated by the manufacturer.

service life/period of use of hose lines

The service life of hose lines must meet the requirements of DIN 20066. Hose lines must be checked for damage daily by the operator. The test criteria of DIN 20066 must be observed.

The period of use of hose lines should not exceed a period of 2 years.

16 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

number of the test record,

Safety Notes on the hydraulic system

2

Guide values for service life Tab. 1: Service life Hose line

Storage period

Storage period

Service life

max. 4 years (calculated from date of manufacture)

max. 2 years (calculated from date of manufacture)

max. 2 years

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Hydraulic hose

EL3000 Shearer

17 / 148

3

Storage and transport Storage

3 Storage and transport This chapter contains important information on correct storage and transport.

Following the instructions and notes will increase the life cycle and service life.

You will be able to carry out transport work more safely and quickly. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

3.1 Storage 3.1.1 Conditions for despatch

gearbox

Gearboxes are filled with oil to maximum capacity. Gearbox breathers are removed and plugged off. Advisory labels in the language of the country destination are attached to the gearbox to instruct the end user on procedures for oil checking, refit of breathers and removal of anti-freeze fluid before the unit is put into service.

In many regions, transporting a machine was liquids is not allowed. In these cases, a preservative coating is applied to the inside of the gearboxes prior to shipment. On receipt of the machines the units with the preservative coating are preserved for 9 months before requiring further preservative measures. Contact Caterpillar for further information if the storage of gearboxes with preservative coating will exceed a period of 9 months.

hydraulic components

Before delivery, the hydraulically operated equipment is operated with a test medium which is drained as far as possible prior to shipment. The medium remaining in the equipment also protects all the internal parts against corrosion for at least six months.

3.1.2 Storing the equipment corrosion protection

avoid direct exposure to sunlight

dirt and moisture

Components coated with temporary corrosion protection are protected for about six months.

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15oC to 25oC. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. by using tarpaulins.

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic plug-type connections and the connections of the electrical cables with the caps and plugs supplied.

18 / 148

short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be specially protected against excessive temperatures, dirt and moisture.

long-term storage

For long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Before despatch the shearer units are prepared for long-term-storage. All motors, coolers and cooling water tubes in control boxes are filled with an antifreeze fluid.

Storage and transport Storage

3

After a storage period of approximately two years, an inspection must be performed to determine whether the measures taken and the method of storage have prevented damage. This inspection can be carried out by our service technicians upon request. frost protection for oil cooler

hydraulic Components

Before storing gearboxes with an oil cooler, when ambient temperatures are below freezing, the oil cooler must be flushed with an anti-freeze agent.

If storage exceeds a period of six months, the hydraulic components must be filled completely with a corrosion inhibitor. This fluid must have anticorrosive and frost-proof properties, such as MinetechTMProtection Fluid.

Fill the hollow areas of hydraulic components (e.g. the piston chambers and annuli of cylinders) in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

storage of motors

natural aging

In order to prevent damage to the motor, drain all cooling water off the motor stator winding gallery and replace the water with an antifreeze fluid. The motor drive shaft should be physically rotated once per month during storage to ensure that the bearings and seals are maintained in good condition before use up to a maximum of 2 years.

Even with proper storage, seals and hoses are subject to natural aging. Do not use these: sip they have been stored more than two years.

Tip When storing and removing machines and machine parts from storage with a limited service life, make sure to use old deliveries first.

3.1.3 Storing used equipment The points mentioned above also apply to storing used hydraulic components, except for the anticorrosive.

If the hydraulic system is to be taken out of operation for a period of time, the hydraulic system must first be flushed and then filled with a suitable anticorrosive (e.g. MinetechTM Protection Fluid). If this is not done, the hydraulic components can suffer considerable damage in a short period of time, since the condition of the hydraulic fluid can degrade very quickly, e.g. due to the action of bacteria.

The following water-conducting parts must be emptied completely for storage and then filled with a suitable antifreeze fluid: ranging arms cooler haulage unit cooler power pack cooler haulage transformer box (HTB) cooler electric motors coal sizer motor (if installed) coal sizer gearbox (if installed) water spraying bar (if installed)

EL3000 Shearer

19 / 148

3

Storage and transport Transport

NOTICE Escaping antifreeze Make sure that the outlets of the components filled with antifreeze fluid are closed by means of plugs.

3.2 Transport 3.2.1 Load Units, Dimensions and Weights Make sure to pay attention to the transport sheet. It includes information on: Dimensions Weight

Centers of gravity The load units are provided with suitable lifting points for transport and installation as far as technically possible.

Notice on work safety Transport weights It may be necessary to divide the transport units differently because of the conditions in the mine. This can result in different dimensions and weights. Keep this in mind when planning transport of components. Information on the dimensions can be found in section 4.

20 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

lifting points

Storage and transport Transport

3

DANGER Attaching loads Insufficient technical knowledge and/or inattention can result in severe or fatal injuries when lifting and transporting loads.

1. To lift and transport loads, only use serviceable load handling devices that are sufficiently large.

2. Attach the loads only to the lifting points provided for this purpose.

3. Make sure that boltable lifting points such as lifting eyes are completely bolted in.

4. Never stand under suspended loads.

Fig. 3: Lifting eye and load ring example

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

A

B

b

c

a

a

d A

lifting eye

B

load ring

a

load capacity 5000 kg

b

eye

c

welded onto component

d

screwed onto component

3.2.2 Before transport temperatures below freezing

It is only permitted to transport equipment at temperatures of –21oC to –40oC if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on roads in bad condition, the transport vehicle's speed must therefore be limited to a maximum of 25 km/h for truck transport.

When transporting the machine or water-conducting components of the machine at temperatures below freezing, the water-conducting components must be emptied completely and possibly filled with an antifreeze fluid (depending on the temperature and duration of transport).

EL3000 Shearer

21 / 148

3

Storage and transport Transport

electrical and electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the entire equipment are protected against harmful environmental influences by suitable packaging. The electrical cables remain in the equipment. They must be protected carefully from transport damage and the connectors must be protected from dirt.

3.2.3 Transporting the components Use machine parts are equipped with lifting eyes or load rings for transportation.

In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport.

Use suitable transport equipment such as belts, chains, etc. to transport components without load attachment points.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 4: Correct transport of machine parts

Transport boxes Machine parts for hydraulic components can be packed in transport boxes.

They should stay in these transport boxes until they reach their final place of operation. This protects them from external damage.

Make sure that the transport boxes are not damaged during transport.

Protect the transport boxes from moisture.

3.2.4 Dismantling of components It is frequently necessary to dismantle parts of the machine for underground transportation.

Dismantle parts of the machine only if it is absolutely necessary for transport.

Notes should be taken during dismantling to ensure that all components, cables and hoses are replaced in their proper position.

22 / 148

EL3000 Shearer

Storage and transport Transport

3

Before dismantling, it is recommended that you prepare adequate packaging (wooden crates for example) to store and protect the individual units, components, cables, hoses etc during transportation. These containers should be sealed and marked accordingly for ease of identification.

WARNING Switch off and support the machine Never attempt to dismantle the machine unless it is electrically isolated and adequately supported. Failure to comply with this may result in injury to personnel.

3.2.5 Transporting the machine underground

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Transporting the machine underground is highly dependant on the conditions in the mine. In many cases, it is possible to transport the shearer using special vehicles that can move the entire drive frame with installed units all the way to the face conveyor.

Carefully plan the transport of the shearer, observing the conditions in your mine and the sizes and weights of the transport units.

NOTICE Risk of damage to machined surfaces During transportation, it is very important that machined surfaces (especially in the case of intrinsically safe components) are adequately protected. Failure to comply with this may result in damage to the machine. after transport

EL3000 Shearer

After underground transport first unpack all electronic and electric equipment to allow ventilation around the components before installing and applying power.

Otherwise, condensed water might damage the electric equipment and cause machine failure.

23 / 148

4

Assembly Notes on installation

4 Assembly 4.1 Notes on installation Installation may only be performed by persons who have been adequately trained for these particular requirements.

Work on the following parts may only be carried out by service engineers authorized by Caterpillar, or by specially trained personnel of the mining company: safety components (pressure relief valves, extinguishers, etc.), the electrical system (controls, signaling devices, etc.),

tools

You need a number of tools in order to be able to install the shearer properly.

We recommend that you deposit the tool box supplied at the drive. In addition, various items of auxiliary equipment and machines are required at the point of installation. These include: lifting equipment with sufficient load capacity means of attachment with sufficient load capacity impact wrenches with accessories drill incl. accessories

tool box

The tool box supplied contains the following tools: Tab. 2: Tool box contents Tool

1P-0074

Pin removal device

550-9147

Installation aid

550-9151

Slide shoe wear gauge

549-3499

Shear shaft puller M 16X512 mm

549-3498

Shear shaft puller M 16X312 mm

549-3496

Shear shaft puller M 8X362 mm

549-3497

Shear shaft puller M 8X512 mm

541-9326

Trapping shoe feeler gauge

194-3545

Socket wrench insert, spanner gap 8 mm-3/8"

8H-8574

Extension 3/8"x74 mm, driver

8H-8576

Ratchet adapter 3/8"-1/2"

185-3630

Oil filter wrench

459-0233

Strap wrench

installation plan

The operator must conduct a risk assessment with respect to the environment in which the shearer is to be installed. The sequence of operations during installation must be adapted to the individual conditions on site. Before work commences, a detailed list of all steps to be taken with respect to transport and installation should be prepared and a corresponding installation plan compiled.

tightening torques

Tightening torques not stated in the installation instructions for the components please refer to the list in Chapter 6.

handling instructions

Pins, holes, screws and securing devices must be lubricated with grease (see All Other Grease Applications) prior to installation

connection points

24 / 148

Parts number

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

the hydraulic system (cylinders, directional control valves, hoses etc.)

Assembly Main components of the shearer

4

4.2 Main components of the shearer Fig. 5: Main components of shearer

82

120

20

40

84

92

20

1

82

90

10

10 80

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

130

80

61

5

30

30

61

3

2

5

Tab. 3: EL 3000 shearer - Main components, dimensions and weights Ite m

Quan- Description tity

Length (mm)

Width (mm)

Height (mm)

Weight (kg)

1

1

Mainframe

9840

1834

1230

21146

2

1

Shoe Post SP D-LH

1343

550

1128

1616

3

1

Shoe Post SP D-RH

1343

550

1128

1616

5

2

Skid Shoe

900

165

290

146

10

2

Ranging Arm RA 0860-WP-R1

3505

2419

1020

10478

21

2

Haulage Unit HU 150-R1

1272

1079

510

1815

30

1

Downdrive DD-150-D-LH

1800

615

1283

4187

31

1

Downdrive DD-150-D-RH

1800

615

1283

4187

40

1

Powerpack PP3

1590

1519

550

2015

61

2

Lifting Cylinder

2142-2782

400

400

1173

80

2

Ranging Arm Motor CM860M

See separate operating manual

82

2

Haulage Motor HM150MF

See separate operating manual

84

1

Pump Motor PM75M

See separate operating manual

90

1

Electrical Control Box ECB 3

2461

1509

595

2502

92

1

Haulage Transformer Box HTB3

2061

1233

595

3560

12 0

1

Spall Guard SG3-1

9042

2335

319

4211

13 0

1

Water spraying bar

2204

295

350/815

710

4.3 Installing the shearer Installation of the shearer requires careful preparation of the procedure as well as the area in which the machine is to be installed. The individual units to be installed must be prepared in an order that allows simple installation.

EL3000 Shearer

25 / 148

4

Assembly Installing the shoe post on the mainframe

WARNING Falling material You can be injured severely by falling material.

1. Secure the roof and the coal face against falling rock and collapsing.

Before starting the installation process, consult the notes taken during dismantling for transportation. These will be of particular assistance when routing cables and hoses, fitting peripheral components and replacing covers/guards etc.

WARNING Unsecured loads You can be injured severely by unsecured loads!

The machine should be installed, hosed and cabled in the following order: Attach face-side shoe posts (incl. skid shoes) to the mainframe (if required) Attach lifting cylinders to the shoe posts (if required) Attach downdrives to the mainframe (if required) Attach ranging arms to the mainframe Connect cables and hoses between the mainframe and ranging arms Connect lifting cylinders to the ranging arms. To do so, power up the powerpack of the machine and carry out preliminary checks or use a separate powerpack to extend the cylinders to the required length Attach cowls to ranging arms (if cowls present and were removed previously) Ensure all covers and guards are in position and secured Mount spall guards on mainframe (if spall guards present and were removed previously) Fill machine with oil, hydraulic fluid and grease it Position the ranging arms to fit the cutting drums. To do so, power up the machine and first carry out the necessary safety checks or use a separate power pack Attach the cutting drums to the ranging arms Attach the picks and water spraying devices to the cutting drums Commission the shearer. To do so, refer to the documents on mechanical, electrical and electronic commissioning You will find detailed descriptions of the steps listed in the following chapters.

4.4 Installing the shoe post on the mainframe To install the support foot on the drive frame, proceed as follows: 1. Support the drive frame (2) with suitable lifting or supporting devices.

26 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1. Make sure that the machine components are supported sufficiently during installation and only use approved lifting devices.

Assembly Installing the shoe post on the mainframe

4

2. Position the support foot (1) under the drive frame (2) with the aid of suitable lifting devices. Align the holes in the support foot with the holes in the drive frame.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 6: Positioning the support foot under the drive frame

2

1

1

Shoe Post

2

Mainframe

3. Prepare the two outer tapered pins by lubricating the tapered pins (3) and tapered bushes (4) with JL-M or equivalent lubricant.

EL3000 Shearer

27 / 148

4

Assembly Installing the shoe post on the mainframe

4. Slide the two tapered bushes (4) over the tapered pins (3) and place the thrust washers (5) with the recess on top.

Fig. 7: Inserting the pin

5

3

28 / 148

3

Tapered pin

4

Tapered bush

5

Thrust washer, recessed, Ø 172 mm

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

4

Assembly Installing the shoe post on the mainframe

4

5. Lubricate the threads of all three tensioning nuts (6) as well as the threads and end surface of the thrust bolts (7). Screw the thrust bolts into the tensioning nuts to where the end surfaces do not protrude through the tensioning nuts.

Fig. 8: Installing the thrust bolts in the tensioning nuts

6

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

6

Tensioning nut

7

Thrust bolt

6. Screw two tensioning nuts (6) onto the prepared tapered pins (3) hand-tight to where distance a≤ 20 mm (0.787 inch). The thrust washer (5) is then clamped between the tensioning nut (6) and tapered bush (4).

Fig. 9: Screwing the tensioning nuts onto the tapered pins

6

a 3

3

EL3000 Shearer

Tapered pin

6

Tensioning nut

29 / 148

4

Assembly Installing the shoe post on the mainframe

7. Install the outer pre-assembled tapered pins in the outer holes of the shoe post (1) from the face side to where the thrust washers (5) contact the surface.

1

1

Shoe Post

8. Tighten two oppositely positioned thrust bolts (7) to 50 Nm (37 lb ft) to anchor the tapered pins in the hole so that they no longer can be turned.

Fig. 11: Tightening two thrust bolts

50 Nm/37 lb ft 7

7

30 / 148

Thrust bolt

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 10: Inserting the tapered pins

Assembly Installing the shoe post on the mainframe

4

9. Insert threaded pin (8) into the middle hole. Place thrust washers (9) on from both sides. Screw tensioning nut (6) onto the threaded pin from the face side to where 1-2 threads of the pin protrude. Then push the threaded pin with tensioning nut in completely so that the thrust washer contacts the surface. Screw the round nut (10) onto the threaded pin from the gob side.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 12: Installing the middle threaded pin

10

9

8

9

6

6

Tensioning nut

9

Thrust washer, Ø 172 mm

8

Threaded pin

10

Round nut

10. Turn the tensioning nut (6) a 1/4 turn counterclockwise to create a gap of approx. 1-3 mm Fig. 13: Backing off the tensioning nut

6 6

EL3000 Shearer

Tensioning nut

31 / 148

4

Assembly Installing the shoe post on the mainframe

11. Screw in four thrust bolts (7) crosswise by hand or tighten hand-tight using a small wrench to center the main thread and eliminate any existing play.

Fig. 14: Tightening four thrust bolts

7

Thrust bolt

12. Next, tighten the same four thrust bolts to a torque of 140 Nm (103 lb ft).

Fig. 15: Tightening four thrust bolts to 140 Nm

140 Nm/ 103 lb ft

7 7

32 / 148

Thrust bolt

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

Assembly Installing the shoe post on the mainframe

4

13. Then tighten the same four thrust bolts (7) to a torque of 275 Nm (203 lb ft).

Fig. 16: Tightening four thrust bolts to 275 Nm

275 Nm/ 203 lb ft

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7 7

Thrust bolt

14. Tighten all thrust bolts to a torque of 275 Nm (203 lb ft) in a circle.

Fig. 17: Tightening all thrust bolts to 275 Nm

275 Nm/ 203 lb ft

15. Repeat the last step until all thrust bolts have been tightened evenly (less than 10° movement remaining). Usually, 2-3 passes suffice.

EL3000 Shearer

33 / 148

4

Assembly Installing the shoe post on the mainframe

16. For exact positioning, the outer tapered pins must first be loosened. To do so, back off the previously tightened thrust bolts (7) until they no longer protrude past the edge of the tensioning nut.

7

7

Thrust bolt

17. Unscrew the tensioning nuts (6) two turns.

Fig. 19: Unscrewing the tensioning nut two turns

2x

6

6

34 / 148

Tensioning nut

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 18: Backing off the thrust bolts

Assembly Installing the shoe post on the mainframe

4

18. Loosen the threaded pin (3). You can do this by striking it carefully with a lead or copper hammer. WARNING! Take care not to damage the threads! If the threaded pin (3) cannot be loosened in this way, use the provided removal tool in conjunction with the attached around nut.

Fig. 20: Loosen the threaded pin

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

3

Threaded pin

19. Tighten the tensioning nuts by hand as far as possible. Make sure that the thrust washers (5) are in contact with the support foot (no air under the thrust washer). If the tapered pin (3) can still be turned, tighten two thrust bolts (7) in the tensioning nuts to 50 Nm (37 lb ft) so that the tapered pin is held tightly again.

EL3000 Shearer

35 / 148

4

Assembly Installing the shoe post on the mainframe

20. Screw the round nuts (10) with thrust washers (11) onto the two outer tapered pins hand-type from the gob side.

10, 11

10

Round nut

11

Thrust washer, Ø 206 mm

21. Back off the round nuts to create a gap of 8 mm (0.3 inch) between the round nuts (10) and thrust washers (11). You can check the size of the gap by measuring the distance from the round nut to the end of the tapered pin (3) before and after backing off the round nut.

Fig. 22: Backing off the round nuts (sectional view)

8 mm 6

36 / 148

5

4

3

10

11

3

Tapered pin

6

Tensioning nut

4

Tapered bush

10

Round nut

5

Thrust washer, recessed, Ø 172 mm

11

Thrust washer, Ø 206 mm

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 21: Attaching the round nuts

Assembly Installing the shoe post on the mainframe

4

22. Back off the tensioning nuts (6) a quarter turn to create a gap of approx.

1-3 mm. WARNING! When backing off the tensioning nuts (6), make sure that the round nuts (10) are no longer moved!

Fig. 23: Backing off the tensioning nuts

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6

6

Tensioning nut

23. Tighten four thrust bolts (7) crosswise to 275 Nm (203 lb ft). Do not tighten more than half a turn (180°) per thrust bolt. Repeat this step until the movement remaining is approx. 45°.

Fig. 24: Tightening four thrust bolts

275 Nm/ 203 lb ft 7

7

EL3000 Shearer

Thrust bolt

37 / 148

4

Assembly Installing the shoe post on the mainframe

24. Tighten all thrust bolts (7)to a torque of 275 Nm (203 lb ft) in a circle. Repeat this step until all trust bolts have less than 10° to turn.

Fig. 25: Tightening the thrust bolts in a circle

275 Nm/ 203 lb ft

7

Thrust bolt

25. Check on the gob side whether the round nut (10) is held securely axially and no longer can be moved.

26. Check that the thrust bolts for the center connection are tight. Tighten all thrust bolts to 275 Nm (203 lb ft) in a circle.

Fig. 26: Tightening all thrust bolts to 275 Nm

275 Nm/ 203 lb ft

This completes installation of the shoe post.

Loosening the connection

NOTICE Risk of machine damage from incorrect loosening of the connections The thrust bolts can buckle and make loosening of the connection impossible.

1. Never use a compressed-air tool to loosen the thrust bolts.

2. Always loosen the thrust bolts in steps; never loosen a bolt completely in one step.

1. Loosen each thrust bolt (7) in all three tensioning nuts (6) by turning each one counterclockwise a quarter turn in a circular pattern.

38 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

Assembly Installing the shoe post on the mainframe

4

2. Repeat this step a second and a third time; then loosen all thrust bolts completely.

Fig. 27: Loosening the thrust bolts in steps

1. 2.

3.

1. 2.

3.

1. 2.

3.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

7

Thrust bolt

3. Remove the tensioning nuts (6) and thrust washers (9).

Fig. 28: Removing the tensioning nuts

6

6

Tensioning nut

4. Loosen the round nuts on the gob side. First, place the removal tool on the middle round nut (10).

5. Tighten four thrust bolts of the removal tool crosswise to 25 Nm (18 lb ft).

6. Then tighten the same four thrust bolts to 55 Nm (40 lb ft).

7. Switch to tightening in a circular pattern and tighten all thrust bolts of the removal tool to 55 Nm (40 lb ft) until the threaded pin (5) is loosened. ð The threaded pin can be removed.

EL3000 Shearer

39 / 148

4

Assembly Installing the lifting cylinders on the shoe post

8. Loosen the round nut on each of the two outer tapered pin connections.

Proceed as described above, using the removal tool (12) and tightening of the thrust bolts (13).

4

3

11

12

13

10

3

Tapered pin

11

Thrust washer, Ø 206 mm

4

Tapered bush

12

Removal tool

10

Round nut

13

Thrust bolt

4.5 Installing the lifting cylinders on the shoe post The lifting cylinders are fastened to the shoe post by means of ram anchor pins.

The anchor bolts are secured by a hex. head bolt and a retaining plate.

40 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 29: Loosening the round nuts (sectional view)

Assembly Installing the lifting cylinders on the shoe post

4

There are lifting eye links (1) on the underside of the mainframe which can be used to hold the cylinders in place during installation. To install the cylinders, proceed as follows: Fig. 30: Positioning the lifting cylinder

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

3

2 1

Lifting eye

2

Lifting cylinder

3

Mainframe

1. Position the lifting cylinder (2) under the mainframe (3).

2. Carefully align the holes in the shoe post and lifting cylinder.

Fig. 31: Fastening the lifting cylinder

7

5, 6 4 4

Ram anchor pin

6

Hex. head screw

5

Nord-Lock washer

7

Retaining plate

3. Grease and insert the ram anchor pin (4) through the holes. You might have to use a hydraulic hollow cylinder or a soft mallet to push the ram anchor pin into position.

EL3000 Shearer

41 / 148

4

Assembly Installing the downdrive on the mainframe

4. Attach the Nord-lock washer (5) to the hex. head bolt (6). Push the bolt through the ram anchor pin (4) and screw the bolt into the retaining plate (7).

5. Tighten the hex. head screw (6) to a torque of 1300 Nm (959 lb ft).

6. Secure the lifting cylinder to the mainframe to prevent it from falling.

The cylinder is now installed on the shoe post and can be connected to the hoses of the hydraulic powerpack

4.6 Installing the downdrive on the mainframe The downdrives (1) are fastened to the mainframe by means of 8 threaded pins (4, 5). The threaded pins are screwed into threaded plates (6, 7) and secured with tensioning nuts (3). Protect the tensioning nuts with grease-filled protective caps (2).

1

3

2

7

4

5

6

1

Downdrive

5

Threaded pin, 700 mm

2

Protective cap

6

Threaded plate with 3 holes

3

Tensioning nut M 42

7

Threaded plate

4

Threaded pin, 590 mm

To install, proceed as follows: 1. Clean contact surfaces on downdrives and drive frame, and lubricate with general-purpose grease (e.g. Copaslip or equivalent).

NOTICE Crushing hazard Hydraulic hoses or other machine parts near the site of installation can be damaged during an inobservant installation. Make sure not to damage any of the surrounding machine parts when fitting the downdrive to the drive frame.

42 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 32: Overview of installation elements

Assembly Installing the downdrive on the mainframe

4

2. Use appropriate lifting devices to position the downdrive (1) on the mainframe and align its holes with the holes in the mainframe.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 33: Positioning the downdrive on the drive frame

1

1

Downdrive

3. Clean and lubricate eight threaded pins (4, 5). Place threaded plates (7) in the pockets provided in the mainframe. Push the two top threaded pins (4) through the holes in the downdrive and screw them into the threaded plates (7) in the drive frame. The distance from the surface of the downdrive (1) to the beginning of the threaded pin (not the square head on the threaded pin!) should be approx. 35 mm (1.38 inch). Push the bottom six threaded pins (5) through the holes in the downdrive. Position the two

EL3000 Shearer

43 / 148

4

Assembly Installing the downdrive on the mainframe

threaded plates with 3 holes (6) in the mainframe and screw the bottom threaded pins (5) into the threaded plates with 3 holes (6) to where the threaded pins are flush with the threaded plate.

Fig. 34: Installing the threaded pins

35 mm 1.38 in 1

4

5

6

1

Downdrive

6

Threaded plate with 3 holes

4

Threaded pin, 590 mm

7

Threaded plate

5

Threaded pin, 700 mm

4. Push the thrust washers (8) of the tensioning nuts over the threaded pins.

Fig. 35: Positioning the thrust washers

8

8

44 / 148

Thrust washer

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

Assembly Installing the downdrive on the mainframe

4

5. Check that the thrust bolts (8) of the tensioning nuts (3) do not protrude past the contact surface and are well lubricated.

Fig. 36: Preparing the tensioning nuts

6

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

3

Contact surface of tensioning nut M42

6

Thrust bolt

6. Screw the first tensioning nut (3) onto a threaded pin (2). Secure the tensioning nut hand-tight. If necessary, insert a screwdriver between the thrust bolts.

Fig. 37: Installing the first tensioning nut

3

3

EL3000 Shearer

Tensioning nut

45 / 148

4

Assembly Installing the downdrive on the mainframe

1. Screw the remaining tensioning nuts hand-tight onto the threaded pins.

2. Begin by tightening the first tensioning nut; first turn the tensioning nut 1/4 turn counterclockwise so that thee is a gap of 1-3 mm between the tensioning nut and thrust washer.

Fig. 39: Backing off the tensioning nut 1/4 turn

46 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 38: Installing the remaining tensioning nuts

Assembly Installing the downdrive on the mainframe

4

3. Screw in four thrust bolts crosswise by hand to center the main thread and eliminate any existing play.

Fig. 40: Tightening four thrust bolts

1

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

4

2

4. Tighten the same four thrust bolts to a torque of 36 Nm (26.55 lb ft).

Fig. 41: Tightening four thrust bolts to 36 Nm

1

36 Nm/ 26.55 lb ft

3

4

2

EL3000 Shearer

47 / 148

4

Assembly Installing the downdrive on the mainframe

5. Tighten the same four thrust bolts to a torque of 72 Nm (53.10 lb ft).

Fig. 42: Tightening four thrust bolts to 72 Nm

1

72Nm/ 53.10 lb ft

3

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

4

2

6. Tighten all thrust bolts to 72 Nm (53.10 lb ft) in a circle.

Fig. 43: Tightening to 72 Nm in a circle

1

72 Nm/ 8

53.10 lb ft

2

7

3

6

4 5

7. Perform the tightening procedure on all tensioning nuts.

8. When all tensioning nuts have been installed and tightened, carry out a final check to ensure even pin loading. Tighten all thrust bolts again to a value of 72 Nm (53.10 lb ft) in a circle.

48 / 148

EL3000 Shearer

Assembly Moving the shearer onto the conveyor

4

9. Fill the protective caps (2) with grease and place on the tensioning nuts.

Fig. 44: Installing the protective caps

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

2

Protective cap

4.7 Moving the shearer onto the conveyor Moving the drive frame onto the conveyor depends on the conditions in the mine. In most cases the transport units are brought in from the tail gate end and are then assembled on the face conveyor.

WARNING Unforeseen movements Dangerous situations may arise due to unforeseen movements of the machine when moving the shearer onto the face conveyor. As a result, you or others could be seriously injured or even killed.

1. Note the space available in your mine and plan the procedure with this in mind. Conduct a risk assessment if the planning shows that the operation cannot be carried out safely without assessing the risks.

Tip Plan the installation steps!

Consider the assembly steps of the shearer before bringing the transport units to the face. Place the machine parts on the face conveyor in a manner that guarantees easy installation (e.g. LH-hand parts on the LH-hand side).

EL3000 Shearer

49 / 148

4

Assembly Moving the shearer onto the conveyor

To drive the mainframe onto the conveyor, maneuver the trapping shoe (5) onto the rack bar (6) of the conveyor.

Fig. 45: Moving the shearer on to the conveyor

3

4

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

2

5

6

1

Coal face

4

Mainframe

2

Entry to tail gate end

5

Trapping shoe

3

Conveyor

6

Rack bar

To then drive the shearer further onto the face conveyor, a hydraulic motor can be attached to the haulage unit on the face side of the shearer. The motor is fitted to the first motion shaft of the haulage unit and is driven by a separate power pack.

Connect the hydraulic motor to the haulage unit: 1. Remove the cover from the coupling housing (1) on the first motion shaft.

50 / 148

EL3000 Shearer

Assembly Moving the shearer onto the conveyor

4

2. Remove the retaining ring (2).

Fig. 46: Removing the retaining ring

2

1

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

Coupling housing

2

Retaining ring

Tip Important!

Oil may flow out of the coupling housing when you remove the plug. Make sure to use a suitable container to collect the oil.

3. Pull out the plug (3) using a T-key (4). The plug has an internal thread of 12 mm.

Fig. 47: Removing the plug

3

4

3

EL3000 Shearer

Plug

4

T-key

51 / 148

4

Assembly Moving the shearer onto the conveyor

4. Prepare the hydraulic motor (5) for installation. To do so grease the motion shaft of the motor and place the adapter (6) on the motion shaft.

Fig. 48: Installing the adapter

5

5

Hydraulic motor

6

Adapter

5. Lubricate the O-ring (7) and place it around the base of the motor shaft.

Fig. 49: Installing the O-ring

7

5

5

52 / 148

Hydraulic motor

7

O-ring

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6

Assembly Installing the ranging arm on the mainframe

4

6. Push the shaft of the hydraulic motor (5) into the coupling housing (1) and secure with bolts.

Fig. 50: Installing the hydraulic motor

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1 5

1

Coupling housing

5

Hydraulic motor

7. Connect the hydraulic motor to an appropriate external power pack.

8. If the haulage unit has a brake, release the brake manually or using the hydraulic system.

You can now drive the shearer slowly onto the face conveyor.

4.8 Installing the ranging arm on the mainframe Each ranging arm is fastened to the mainframe by means of two hinge pins and four clamping sets.

Before the ranging arms can be installed, the components must be prepared.

Proceed as follows:

EL3000 Shearer

53 / 148

4

Assembly Installing the ranging arm on the mainframe

1. Clean and coat the outer side of the outer rings (1) and inner sides of the thrust rings (2, 3) with a light oil (e.g. Ballistol Universal Oil or Klüber Quietsch-Ex).

Fig. 51: Oiling the clamping sets

1

1

Outer ring

2

Front thrust ring

3

Rear thrust ring

2. Clean and coat the joint pins (4) and insides of the holes in the mainframe (5) with a light oil (e.g. Ballistol Universal Oil or Klüber Quietsch-Ex).

Fig. 52: Oiling the pins and hole walls

4

5

4

54 / 148

Hinge pin

5

Mainframe

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

2

Assembly Installing the ranging arm on the mainframe

4

NOTICE Using wrong oils Risk of machine damage from using wrong oils.

1. Oils and greases containing molybdenum sulfide or other high-pressure additives, Teflon and silicone additives as well as internal lubricants that reduce the coefficients of friction considerably must not be used. Oil-free assembly of the clamping set tapers results in differences between the table and calculated values.

3. Loosen the clamping screws (6) several turns so that the thrust rings separate slightly from the outer ring.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 53: Loosening the clamping screws

6

6

Clamping screw

4. For easier assembly, hold the front thrust ring (2) securely. Do this by removing two clamping screws (6) and threading them into the back-off threads of the front thrust ring.

Fig. 54: Securing the front thrust ring

2

6

2

EL3000 Shearer

Front thrust ring

6

Clamping screw

55 / 148

4

Assembly Installing the ranging arm on the mainframe

5. For easier assembly, hold the rear thrust ring (3) securely. Do this by removing two clamping screws (6) and threading them into the back-off threads for the rear thrust ring (3).

Fig. 55: Securing the rear thrust ring

2

3

2

Front thrust ring

3

Rear thrust ring

6

Clamping screw

To install the ranging arm on the mainframe, proceed as follows: 1. Use appropriate lifting devices or a special vehicle to position the ranging arm on the mainframe.

2. Make sure that the ranging arm (2) is positioned horizontally in line with the mainframe (1).

Fig. 56: Positioning the ranging arm

1

56 / 148

1

Mainframe

2

Ranging arm

2

3

3

Lifting eye 8 load capacity = 8000 kg

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6

Assembly Installing the ranging arm on the mainframe

4

3. Place contact washers (4) in the through holes in the joint brackets. Grease contact washers to prevent them from falling out.

Fig. 57: Inserting contact washers

1 4

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

4

1

Mainframe

2

Ranging arm

4

Contact washer

4. Insert ranging arm into the joint eye on the mainframe and align the through holes in the ranging arm with the through holes in the mainframe.

EL3000 Shearer

57 / 148

4

Assembly Installing the ranging arm on the mainframe

5. Push hinge pin (5) into the through holes.

Fig. 58: Inserting the hinge pin

5

5

1

Mainframe

2

Ranging arm

5

Hinge pin

6. Place hex. head screws (8) and washers (9) in the cover (7) and screw the hex. head screws into the holes in the hinge pins.

58 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

1

Assembly Installing the ranging arm on the mainframe

4

7. Align the hinge pins horizontally (cover must be lie flat on the drive frame).

Ensure that the "X" marking on the pin points horizontally to the side of the mainframe on the face side.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 59: Aligning the hinge pin with cover

7 8, 9

7

Cover

8

Hex. head screw

9

Washer

8. Install the inner clamping sets (10) on the hinge pins (5). Tighten the clamping screws loosely to hold the hinge pin in position.

Fig. 60: Installing the inner clamping sets

10

5

EL3000 Shearer

Hinge pin

5

10

Clamping set KTR 401

59 / 148

4

Assembly Installing the ranging arm on the mainframe

9. Remove the covers from the hinge pins.

10. Install the outer clamping sets (10) on the hinge pins (5).

Fig. 61: Installing the outer clamping sets

5 10

5

Hinge pin

10

Clamping set KTR 401

11. Tighten the clamping screws crosswise evenly in increments in several iterations: In the first step tighten to 70 Nm (52 lb ft), in the second step to 110 Nm (80 lb ft) and in the third step to 145 Nm (107 lb ft).

Fig. 62: Tightening the clamping screws

9

5

1 16

13 3 7 11

15 2 6

12 8 4 14 10

1: 70 Nm/ 52 lb ft

2: 110 Nm/ 80 lb ft

3: 145 Nm/ 107 lb ft

12. Prior to installation, fill the covers (8, 13, 14) with grease.

60 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

10

Assembly Installing the lifting cylinder on the ranging arm

4

13. Install the covers (8, 13, 14) on the hinge pins, using hex. head bolts (9), washers (10) and cylinder head screws (15). Tighten the hex. head screws (9) to 230 Nm (170 lb ft).

Fig. 63: Installing the covers

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

8

9, 10 13 14 8

Cover

13

Cover

9

Hex. head screw

14

Cover

10

Washer

15

Cylinder head screw

14. Connect all necessary cables and hoses (e.g. electrics, sensor systems, cooling water, water spraying system, hydraulics) to the ranging arm. The required information can be found in the corresponding diagrams.

4.9 Installing the lifting cylinder on the ranging arm The lifting cylinders are fastened to the ranging arm by means of pins. The pins are secured by a retaining ring and a hex. head screw. moving the cylinder into position

There are lifting eye (b) on the underside of the drive frame which can be used to hold the lifting cylinders (a) in place during installation. To install the lifting cylinders, proceed as follows: 1. Extend the lifting cylinder until the through holes in the cylinder and ranging arm are aligned. To do so start the power pack of the shearer or use a separate power pack to extend the cylinder to the required length.

EL3000 Shearer

61 / 148

4

Assembly Installing the lifting cylinder on the ranging arm

2. Grease and insert pin (1) into the through holes from the face side. You might have to use a hydraulic hollow cylinder or a soft mallet to push the pin into position.

a

1

Pin

a

Lifting cylinder

b

1

b

Lifting eye

3. Push hex. head screw (4) and Nord-Lock washer (3) into pin and retaining ring (2).

62 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 64: Inserting the pin

Assembly Installing the shearer drum on the ranging arm

4

4. Tighten the hex. head screw (4) to a torque of 1332 Nm.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 65: Tightening the pin

3, 4

1

2

1

Pin

3

Nord-Lock washer

2

Retaining ring

4

Hex. head screw

4.10 Installing the shearer drum on the ranging arm WARNING Risk of tipping over Installation of the cutting drums affects the center of gravity of the machine. If the cutting drums are heavy enough, the machine's center of gravity can shift to a point where the shearer can tip over. As a result, you or others could be seriously injured or even killed.

1. Before starting to work, assess the possible shifting of the machine's center of gravity as the result of installing the cutting drums.

2. If there is a risk of the machine tipping over, install the cutting drums only if the machine has been secured adequately, for instance, by connecting it firmly to the conveyor by means of the trapping shoes.

To install the cutting drum on the ranging arm, proceed as follows: 1. Prepare a sufficiently large working area. The working area must be cordoned off in accordance with applicable regulations.

EL3000 Shearer

63 / 148

4

Assembly Installing the shearer drum on the ranging arm

2. Move the cutting drum and the shearer into position.

Fig. 66: Preparing the working area

3

2

4

1

Coal face

3

Cutting drum

2

Working area

4

Shearer

3. Align the ranging arm horizontally.

4. Disconnect power from the shearer and secure it against being switched on again unintentionally.

5. Use suitable lifting gear to raise the cutting drum to the square hub of the ranging arm.

6. Install suitable, provisional bolts (4) in the holes in the cutting drum (2) and the square hub (3).

64 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

Assembly

4

Installing the shearer drum on the ranging arm

7. Tighten the bolts until the cutting drum is fully in position on the square hub.

Fig. 67: Installing the cutting drum

2

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

3

4

1

Ranging arm

3

Square hub

2

Cutting drum

4

Bolt

8. Exchange one bolt after another with the bolts shown on the parts list and tighten.

9. Tighten the bolts in accordance with the torque table in chapter 6.

EL3000 Shearer

65 / 148

4

Assembly Installing the shearer drum on the ranging arm

10. Install the water distribution plate (5). Be sure to grease the seals prior to insertion. Tighten the bolts to the correct torque.

Fig. 68: Installing the water distribution plate

3

5

4

2

Cutting drum

4

Cylinder head screw

3

Square hub

5

Water distribution plate

11. Make sure that the cutting drum (2) can rotate freely.

12. Remove plugs from the water spraying equipment and backflush the cutting drum with water.

13. Insert the spray nozzles and secure with staples.

66 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

Assembly Installing the shearer drum on the ranging arm

4

14. Switch on the water spraying system for the cutting drum and check that all spray nozzles function properly.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 69: 41_Installing the spray nozzles

1 2 3

4

EL3000 Shearer

1

Ranging arm

6

Spray nozzle

2

Cutting drum

7

Pick holder

67 / 148

4

Assembly Connecting the shearer

15. Install picks (8) in the pick holders (7). Make sure not to damage the pick tips.

Fig. 70: Installing a pick

2

7

2

Cutting drum

7

Pick holder

8

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

8

Picks

16. Install cover plate over water distribution plate if present.

4.11 Connecting the shearer 4.11.1 Electrical connection The shearer must be connected to a suitable electrical power supply cable. Additional information can be found in the electrical diagrams.

4.11.2 Water connection The shearer has to be connected to an appropriate water supply. The water system of the shearer has the following functions: to provide cooling for the shearer units to provide dust suppression The inlet for the water supply is located near the power pack and is clearly identified. Additional information on the water system can be found in the water supply diagrams.

68 / 148

EL3000 Shearer

Assembly Greases, oils and hydraulic fluids

4

4.12 Greases, oils and hydraulic fluids Before starting the shearer, check if all necessary parts have been greased and if all oil levels and the hydraulic fluid level are correct.

For additional information, see Maintenance and "Permissible media" [} 145].

4.13 Commissioning the shearer The shearer must be commissioned under the instructions of Caterpillar technicians or qualified mine personnel.

WARNING Installation errors

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

The first time you put the shearer into service, hazards may occur which would not occur during normal operation, e.g. due to installation errors. As a result, you or others could be seriously injured or even killed.

1. Make sure that nobody is present in the hazardous area of the shearer and the conveyor system when you start operating the shearer. Keep a safe distance from the shearer and the conveyor!

Important information Follow the additional information in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

4.13.1 Before commissioning The following work has to be performed before starting up the shearer: align conveyor remove all tools, auxiliary equipment, etc. from the shearer, the conveyor and your working area check that all bolted connections are tightened to the correct torque check the hydraulic connections and lines for leakage or damage check that all supply lines are installed properly check the hydraulic connectors. In particular, check that the staples are completely pushed in

DANGER Thrashing hydraulic hoses You could be seriously injured or even killed by a hydraulic hose that is thrashing about.

1. Only use the correct size of staple to secure connector sockets. Push the staples on completely, using both sides of the staple. Never use nails, wire or similar materials.

2. If staple retainers are used, ensure that when working on hose connections the staple retainers are reinstalled on completion of the work. check the oil level and the cooling of the gearboxes

EL3000 Shearer

69 / 148

4

Assembly Commissioning the shearer

check that the hydraulic reservoir is filled to the correct level check the cooling of the electric motors check the rotational direction of the electric motors check the electrical connections

4.13.2 Adjusting the cable arm The cable arm holds the trailing cable that supplies electricity to the shearer.

Before the shearer is commissioned and when the cable arm is being replaced, the load monitoring system of the cable arm must be zeroed. During this procedure, the trailing cable must not put any tension or compression forces on the cable arm. More detailed information on the adjustment procedure can be found in the operating manual for the PMC Evo-S control system.

commissioning document

The shearer is commissioned under the instruction of Caterpillar technicians.

During commissioning all functions of the machine are tested, the machine settings are adjusted and the machine control is set up. All commissioning steps, settings and, as may be the case, problems will be documented in a commissioning document for the shearer.

After commissioning, observe the following points before releasing the shearer: inspect the shearer once again thoroughly for installation errors, damage or other faults check the functions of the shearer and the safety systems once again

releasing the shearer for operation

When the inspection after commissioning reveals no further faults and all the functions can be performed without problems, the shearer can be released for operation.

4.13.4 Retightening bolted connections Bolts may become loose or even released when bolted connections or components settle!

This is why you have to retighten the following bolted connections of the shearer after an initial operating time of approximately 60 hours. When doing so, observe the respective torque required or the required tensioning force. bolted connections of the cutting drums connections of the electric motors Superbolt fasteners of the downdrive

4.13.5 Changing oils and hydraulic fluid It is recommended that all oils be replaced after the first two weeks of production. After the first replacement, oil and hydraulic fluid are monitored by taking samples and contamination analysis (see "Oil and fluid analyses" [} 97]).

70 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

4.13.3 Commissioning the shearer

Assembly Dismantling and removing the shearer

4

4.14 Dismantling and removing the shearer drawing up a removal plan

personnel

A removal plan must be drawn up before the shearer can be dismantled. The removal plan helps you to coordinate dismantling and transport work. Dismantling should be carried out in the most favorable sequence, usually in reverse installation order. Dismantling depends on the conditions prevailing in the mine.

Dismantling and removal operations may only be performed by persons with sufficient knowledge of the work to be performed and who have been adequately trained for these particular requirements.

4.14.1 Important instructions for dismantling handling sensitive components

Protect all exposed shafts, hubs, labyrinth channels and flanges from corrosion, dirt and damage.

Seal all open lines and separation points with protective caps or plugs.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Pack loose parts, screws, etc. in suitable containers in order to protect the components from dirt and damage.

EL3000 Shearer

71 / 148

5

Operation Start of work

5 Operation 5.1 Start of work Carefully perform the daily maintenance activities listed in the maintenance tables when you start the shift. This will ensure a better reliability and performance of the shearer: 1. clean the shearer from any debris that might obstruct the operation of the shearer

3. check oil and hydraulic fluid levels. Fill up if necessary. Grease the grease nipples as stated in the maintenance tables. Further information can be found in the section “Maintenance” 4. check that the cutting drums can rotate freely 5. check all flameproof covers, cable inlets, safety equipment, controls and inspection covers for damage 6. check that the water supply is correct to all parts of the shearer 7. check that the emergency stop is working correctly 8. check if further maintenance is necessary in accordance with the maintenance tables (e.g. weekly, monthly, quarterly) Work may not be started until the perfect condition and proper functioning of the shearer and the entire conveyor system have been checked and the daily maintenance activities have been performed.

DANGER Persons in the hazardous area Sudden starting of the shearer can severely injure or even kill persons working near the shearer.

1. When you start up the shearer, make sure that nobody is present in the hazardous area around the shearer.

72 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2. check the shearer for any visible defects, e.g. cracks, leakages, broken or missing parts or wear. This includes hoses and cables, wear of the picks on the cutting drums, wear of the skid shoes as well as wear of the inserts in the trapping shoes (gobside). Additional information on wear measurements can be found in the "Replacing worn parts" section of this chapter

Operation Control elements

5

5.2 Control elements The main control and monitoring elements are situated on the gob side of the shearer. The following image will give you an overview of the control and monitoring elements.

Fig. 71: Control elements

5

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

2

4

3

6

10

7

11

8

12

9

13

14

EL3000 Shearer

73 / 148

5

Operation MMC/ Electrical Control Box

1

LH end display

8

Motor start/stop button

2

Reset button

9

RH transceiver

3

Circuit breaker for LH frequency converter

10

LH wireless remote control

4

Circuit breaker for RH frequency converter

11

Main disconnect switch

5

RH end display

12

Cutter motor isolation switch

6

LH transceiver

13

RH wireless remote control

7

Main display

14

USB remote control

The machine has a mobile machine control (MMC) that processes the operator ´s control commands and gives detailed information of the status of various machine components. The main control components are located in the electronic control unit (ECB3).

The main display on the ECB3 electronic control unit shows information about the machine control and can be used with the USB remote control or the wireless remote control to change settings.

74 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5.3 MMC/ Electrical Control Box

Operation

5

MMC/ Electrical Control Box

Tip Important!

Additional information on the MMC control system can be found in the separate operating manual for the machine control.

Fig. 72: ECB3 control elements - low-voltage area

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

18

15

16

17

EL3000 Shearer

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

Headlights on/off (if headlights are installed)

10

Stop pump motor and haulage motor

2

Start machine

11

Start coal sizer (if coal sizer is installed)

3

Start motors in sequence

12

Stop coal sizer (if coal sizer is installed)

4

Stop motors in sequence

13

Test ground-fault electrical circuits

5

Start LH cutter motor

14

Reset ground-fault circuits

6

Stop LH cutter motor

15

Emergency stop

7

Start RH cutter motor

16

Control circuit test points

8

Stop RH cutter motor

17

Reset low-voltage circuit breaker

9

Start pump motor and haulage motor

18

MMC display

75 / 148

5

Operation Wireless remote control

USB remote control The USB remote control serves to navigate through the various menus of the control system and is connected to the machine via a cable with an OS-4 connector.

The remote control is intrinsically safe and thus suitable for use in potentially explosive areas. More information on the remote control button functions can be found in the separate operating manual for the control system.

5.4 Wireless remote control With the certified, intrinsically safe wireless radio frequency remote control, you can directly control individual functions of the machine. The remote control is supplied with energy by a rechargeable battery. This is charged in a special charging station.

76 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 73: USB remote control

Operation Wireless remote control

5

Notice on work safety Additional information Additional information can be found in the separate operating manual for the charging station.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 74: Wireless remote control

Notice on work safety Safe work procedures during commissioning When a wireless remote control is being used on the machine for the first time, safe work procedures must be prepared for function tests and checks of the machine.

5.4.1 General operating elements NOTICE Wireless remote control maintenance Observe the specified maintenance interval of 12 months for the wireless remote control! Failure to do so can result in failure of the wireless remote control. The membrane control pad in particular must be replaced annually.

EL3000 Shearer

77 / 148

5

Operation Wireless remote control

The following figure shows the top part of the device with general operating elements and display.

1

display

3

"Back" key

2

symbol on the display

4

"Input" key

a

keystroke/synchronization

5

"Page up" key

b

active wireless connection

6

"Page down" key

c

charging status

The display (1) has three symbols in the topmost line (2a-c). They show events and statuses of the remote control.

The yellow ring (2a) flashes when there is a keystroke (optical confirmation of the keystroke).

The radio tower (2b) indicates an existing connection to the wireless receiver. If it lights up green, remote control and receiver are synchronized. If it lights up grey, remote control and receiver are not synchronized.

The battery symbol (2c) indicates the remaining capacity of the built-in rechargeable battery. If only the lower third of this symbol is illuminated in yellow, you should recharge the remote control soon.

The ESC and ENT keys (ESC = cancel/back, ENT = enter/confirmation) are equivalent to those on a computer keyboard. They are not activated on every machine.

You can scroll page by page in the display with the "Page up" (5) and "Page down" (6) buttons.

78 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 75: General control elements and display

Operation Wireless remote control

5

5.4.2 Switching the wireless remote control on/off You can switch on the wireless remote control by pressing the "SHIFT/ON" key (1) and holding it for longer than 5 seconds.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 76: Switching on the remote control

1

1

"SHIFT/ON" key - Switches on the remote control

There are two possible ways to turn off the wireless remote control: press and hold the "STOP" (2) key

EL3000 Shearer

79 / 148

5

Operation Wireless remote control

Press and hold the "SHIFT/ON" (1) and "HAUL/HALT" (3) keys Fig. 77: Switching off the remote control

2 Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

3

80 / 148

1

"SHIFT/ON" key

2

"STOP" key

3

"HAUL/HALT" key

EL3000 Shearer

Operation Wireless remote control

5

5.4.3 General control buttons The following image shows the general buttons for controlling the shearer. Special functions are treated in the following sections.

Fig. 78: General control buttons

3

1 2 4

6

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5 9

7 8

12

10 11

15

13 14

18

16 17 19

21

20

1

slowly raise LH ranging arm

12

start/stop motors

2

stop all motors/ turn off remote control

13

rotate LH cowl counterclockwise (if installed)

3

slowly raise RH ranging arm

14

programming on/off

4

slowly lower LH ranging arm

15

rotate RH cowl clockwise (if installed)

5

shift (for blue buttons)/switch on remote control

16

rotate LH cowl clockwise (if installed)

6

slowly lower RH ranging arm

17

automatic mode on/off

7

increase feed rate to the left (when moving to the left)/

18

rotate RH cowl counterclockwise (if installed)

decrease feed rate to the right (when moving to the right) 8

activate (in combination with button 7/9)/ deactivate haulage motor

19

LH ranging arm: switch from automatic mode to manual mode

9

increase feed rate to the right (when moving to the right)

20

cooling water on/off (programmable in MMC, setup mode)

21

RH ranging arm: switch from automatic mode to manual mode

decrease feed rate to the left (when moving to the left)/

EL3000 Shearer

10

end of display: open next page

11

activate keypad mode

81 / 148

5

Operation Wireless remote control

5.4.4 Shift keys The following image shows the buttons that can be activated after pressing and holding the "SHIFT" key.

Fig. 79: Shift buttons

82 / 148

2

3

4

5

6

7

8

9

10

11

1

SHIFT key (press and hold)

7

RH cutting drum: water on/off

2

rapidly raise LH ranging arm

8

programming key (MMC, setup mode)

3

rapidly raise RH ranging arm

9

programming key (MMC, setup mode)

4

rapidly lower LH ranging arm

10

programming key (MMC, setup mode)

5

rapidly lower RH ranging arm

11

programming key (MMC, setup mode)

6

LH cutting drum: water on/off

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

Operation Wireless remote control

5

5.4.5 Numeric keypad The remote control buttons can be used to simulate the USB keypad and navigate through the pages of the mobile machine control (MMC). The numeric keypad is activated by simultaneously pressing the SHIFT and KEYPAD buttons (> 1 second). You can then select from the numbers 0-9.

Fig. 80: Numeric keypad

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

4 6

5

7 1 1

2

3

4

5

6

7

8

9

*

0

#

2

9 8

10

1

activate numeric keypad

6

TAB (jump to next input field)

2

numeric keypad (numbers 0-9)

7

ENTF (delete entry left of cursor)

3

F1 (reset function, machine mode)

8

navigation (then use the buttons "2" (up), "4" (left), "6" (right) or "8" (down)

4

F3 (confirm page number)

9

open fault list

5

open previous page

10

ENTER key

5.4.6 Starting/stopping motors To start a motor, proceed as follows:

EL3000 Shearer

83 / 148

5

Operation Wireless remote control

By simultaneously pressing "MOTOR STOP/START", you can start individual motors or a sequence of motors. The following buttons serve to start motors:

3

2

1 4 6

5

7

1

activate motor stop/start function

5

motor selection: pump motor

2

motor selection: LH cutter motor

6

motor selection: haulage frequency converter

3

motor selection: RH cutter motor

7

motor selection: motor sequence

4

motor selection: coal sizer (if installed)

Tip Motor selection After choosing a motor or the sequence you will hear a prestart warning. After that you have to press the same buttons again (“MOTOR START/STOP” and selected motor/sequence) to reconfirm the order. Only then will the motor/motors be started. If you do not press the buttons again, the motor start procedure will be stopped and inhibited for 10 seconds.

5.4.7 Setup Mode Notice on work safety Additional information Additional information on the setup mode can be found in the operating manual for the wireless remote control.

84 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 81: Start/stop motors

Operation Wireless remote control

5

To change settings you have to activate the setup mode of the transmitter. To do so you have to press the following 4 buttons together: Fig. 82: Activating the setup mode

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

1

EL3000 Shearer

Activate setup mode (4 buttons)

85 / 148

5

Operation Wireless remote control

Five buttons serve to navigate through the setup mode: Fig. 83: Navigation in the setup mode

1

3 5

4

1

Up

4

Selection/enter

2

Down

5

Right

3

Left

To leave the setup mode, you have to press and hold the “STOP” key or select “Save and exit” on the display menu

86 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

Operation Commissioning the shearer

5

5.4.8 Shift keys The following image shows the buttons that can be activated after pressing and holding the "SHIFT" key.

Fig. 84: Shift buttons

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

6

7

8

9

10

11

1

SHIFT key (press and hold)

9

programming key (MMC, setup mode)

6

LH cutting drum: water on/off

10

programming key (MMC, setup mode)

7

RH cutting drum: water on/off

11

programming key (MMC, setup mode)

8

programming key (MMC, setup mode)

5.5 Commissioning the shearer Starting procedure If you have observed all items in the previous sections on operation, you can begin the starting procedure: 1. Make sure that there are no persons on the conveyor or close to the shearer.

2. Inform all persons involved that the shearer is going to be started.

3. Before starting the shearer, turn on the cooling water supply.

EL3000 Shearer

87 / 148

5

Operation Commissioning the shearer

NOTICE Risk of overheating as the result of insufficient cooling water supply The machine can be damaged as the result of overheating. Never turn off the cooling water supply to the machine when the motors are operating.

4. Turn on both main switches (visible isolation switches) on the ECB3 electronic control unit (position “I”).

Notice on work safety Important!

Further information concerning the control of the shearer can be obtained in the manual of the machine control (MMC). Make sure to have read and understood the manual before you start the shearer.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 85: Main switches on the electronic control unit

1

1

Main switch for shearer

2

2

Main switch for cutting elements

5. Power up the shearer. This is done by pressing the “MACHINE START” button. The main display of the low voltage section will light up. On the main page of the display you can obtain a good overview of the shearer and whether all machine units are working correctly.

6. Start the motors of the shearer. You can use the buttons on the ECB3 electronic control unit or the wireless remote control for this.

88 / 148

EL3000 Shearer

Operation What to observe during operation

5

5.6 What to observe during operation 5.6.1 Operator's Report The shearer operator should be constantly on the look out for any unusual behavior of the machine and also listen for any abnormal noises. He should immediately report any irregularities, apparent defects, faults or damage (however slight and unimportant they may seem) to the face engineer.

5.6.2 Face conditions The operator of the machine must constantly check for obstructions, bad roof or floor conditions etc., well in advance of the shearer, so that any necessary remedial or preventive action can be initiated in good time before damage or delay is caused.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

The face line should be surveyed regularly for alignment. Part shears should be taken along the face, if required, to keep the face line straight.

Rapid changes of gradient along the face should be graded out to an acceptable value for the face conveyor (A.F.C.).

NOTICE Different gradients along the face If excessive changes of gradient along the face cannot be equalized, severe damage to both the face conveyor (AFC) and shearer may result.

If the face advance is allowed to stray from the correct cutting horizon, great care must be taken when trying to return to the original horizon.

Ensure that the maximum change is no more than 40 mm per cut, up or down.

Tip Deviation from cutting horizon Altering the horizon by more than 40 mm per cut can create difficulty in conveyor advancement and/or difficulty in setting roof supports, thereby creating roof control problems.

To avoid the problem of having to change the cutting horizon too severely, it is easier to check the horizon after every cut and, if necessary, make slight changes.

5.7 Stopping the shearer To stop the shearer from cutting, the feed rate should be reduced to zero using the keys on the wireless remote control. Then press the "Haul/Halt" key (stop feed), turn off the cutter motors and finally switch off the shearer.

Notice on work safety Emergency stop switch The emergency stop switch may be used in emergencies only.

EL3000 Shearer

89 / 148

5

Operation Electrical isolation of the shearer

5.8 Electrical isolation of the shearer To electrically isolate the shearer, proceed as follows: 1. If the shearer is operating, reduce the feed rate to zero.

2. Press the "STOP" key to turn off all motors and the wireless remote control. If control via the wireless remote control is not activated, use the emergency-stop switch to disconnect the shearer from the power supply.

3. Lever on main switch in "0" position. Make sure the levers are secured against unintentional restarting. In some applications, the levers may be locked in the "0" position using `YOUR' personal safety lock.

4. Switch the gate end panel isolation switch to the "OFF" position and secure it in this position using your personal safety lock.

To reverse this isolation procedure: 1. Remove the personal safety lock on the gate end panel.

2. Switch `ON' the gate end panel isolation switch.

3. Remove personal safety locks from the main switches on the shearer.

4. Switch `ON' the shearer main switch.

5. Make sure that the water supply is turned on.

6. Ensure that the area is clear of personnel and then start the machine.

7. Select the desired control mode.

8. If a wireless control mode is selected, switch `ON' the selected wireless remote controls.

9. Switch on the motors.

10. Operate the haulage and hydraulic functions using the selected controls.

5.9 Maintenance 5.9.1 Maintenance instructions Please observe the following instructions: In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the conveyor system as a whole, we recommend a general maintenance plan to be drawn up. You can, for example, create a checklist using this operating manual and the manuals of the other components.

Damage to machinery could occur as the result of maintenance work which has been carried out inadequately which in turn could lead to considerable costs. Be sure to observe the specified maintenance intervals.

Only use suitable and approved tools for maintenance work.

Only use original Caterpillar spare parts when replacing components.

90 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5. Place official warning tags on the isolation switches of the shearer, the gate end panel and both ends of the trailing cable to clearly identify that the shearer is switched off.

Operation Maintenance

5

5.9.2 Important instructions Keep in mind that only appropriately qualified individuals are allowed to carry out maintenance tasks on the shearer.

DANGER Electric shock You could be seriously injured or even killed by an electric shock.

1. Ensure the shearer is isolated at the gate end panel or by removal of the trailing cable, prior to carrying out electrical maintenance, unless power is required to carry out the work. If you cannot disconnect power from the machine, conduct a risk assessment to evaluate the risks that may possibly arise and take measures to minimize them.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

DANGER Moving parts Moving or falling parts can cause serious injury.

1. The shearer must be immobilized before you carry out maintenance on moving parts. When work needs to be carried out over or on the face side of the shearer, both the shearer and conveyor (AFC) must be immobilized.

In addition, adequate roof and face support must be provided.

WARNING Hot fluids under pressure You could be seriously injured by hot fluids escaping under pressure.

1. Ensure all hydraulic and water systems are isolated and depressurized prior to maintenance of these systems. When maintenance may involve the draining or removal of oil or water from any unit or system, caution must be exercised as this fluid may be hot or under pressure.

5.9.3 Maintenance intervals (mechanical) Tab. 4: Maintenance intervals (mechanical) No.

Maintenance point

daily

weekly

monthly

every three months

Comment/ Reference

General M10

Contamination

Clean

M20

Missing/damaged parts

Check

M30

Skid shoe wear

M35

Cable arm

M40

Cover plates secured?

M45

Check gearbox oil filling filter

Visual inspection Check

Lubricate

Open the covers on the cable arm, 3 lubricating nipples Check Check the filter every time you add oil (Indicator on the filter)

Ranging arms

EL3000 Shearer

91 / 148

5

Operation

No.

Maintenance point

daily

M50

Oil levels

Check

Maintenance of the ranging arms

M60

Lifting cylinder operation

Check

Maintenance of the ranging arms

M80

Water supply tight?

Check

Maintenance of the ranging arms

M90

Cover plates secured?

Check

Maintenance of the ranging arms

M95

Motor shear shaft

Maintenance

monthly

every three months

Check, lubricate

Comment/ Reference

Lubricating/replacing the quill shaft

M100 Oil leaks?

Check

Maintenance of the ranging arms

M110 Joint pins in drive frame

Lubricate

Maintenance of the ranging arms

M120 Pin connection on lifting cylinder

Check

Maintenance of the ranging arms

M130 Lifting cylinder damage?

Check

Maintenance of the ranging arms

M140 Fluid sample for analysis

Check

Maintenance of the ranging arms

M150 Motor bracket tight?

Check

Maintenance of the ranging arms

M160 Wear and correct positioning of joint pins

Check

Maintenance of the ranging arms

M170 Oil change (If no analysis was carried out)

Change

Maintenance of the ranging arms

M180 Cover plate on high-speed section

Check

Maintenance of the ranging arms

M190 Water pipe seals

Lubricate

Maintenance of the ranging arms

Check

"Maintenance of the cutting drums" [} 112]

cutting drums M210 Picks and pick holders

M220 Connecting pins tight?

Check

"Maintenance of the cutting drums" [} 112]

M230 Can rotate freely?

Check

"Maintenance of the cutting drums" [} 112]

M240 Damaged?

Check

"Maintenance of the cutting drums" [} 112]

M250 Oil leakage (from ranging arm)?

Check

"Maintenance of the cutting drums" [} 112]

M260 Dust suppression nozzles

Check

"Maintenance of the cutting drums" [} 112]

Haulage unit

92 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

weekly

Operation Maintenance

No.

Maintenance point

M270 oil level

daily

weekly

monthly

every three months

Check

5

Comment/ Reference Maintenance of the haulage units

M280 Motor bracket tight?

Check

Maintenance of the haulage units

M290 Motor shear shaft

Check, lubricate

Lubricating/replacing the quill shaft

M300 Fluid sample for analysis

Check

Maintenance of the haulage units

M310 Brake wear (if brake installed)

Check

Maintenance of the haulage units

M320 Oil change (If no analysis was carried out)

Change

Maintenance of the haulage units

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Power pack M330 Fluid level

Check

"Maintenance of the power pack" [} 126]

M340 Working pressure

Check

"Maintenance of the power pack" [} 126]

M350 Leakage?

Check

"Maintenance of the power pack" [} 126]

M360 Filter condition

Check

"Maintenance of the power pack" [} 126]

M370 Hoses and connections

Check

"Maintenance of the power pack" [} 126]

M390 Fluid sample for analysis

Check

"Maintenance of the power pack" [} 126]

M400 Pressure and return filter

Check/ replace

"Maintenance of the power pack" [} 126]

M405 Tank breather filter

Change

"Maintenance of the power pack" [} 126]

M410 Pump bracket tight?

Check

"Maintenance of the power pack" [} 126]

M420 Motor bracket tight?

Check

"Maintenance of the power pack" [} 126]

M430 Control valves tight?

Check

"Maintenance of the power pack" [} 126]

M435 Pump coupling wear

Check

"Maintenance of the power pack" [} 126]

M440 hydraulic Fluid

Change

"Maintenance of the power pack" [} 126]

Water System

EL3000 Shearer

93 / 148

5

Operation

No.

Maintenance point

Maintenance

daily

M450 Valves operate?

Check

M460 Visible hoses and connections

Check

M470 Flow and pressure values (MMC)

Check + note

weekly

monthly

every three months

Comment/ Reference

Downdrives Lubricate

Maintenance of the downdrives

M495 Drive shaft

Lubricate

Maintenance of the downdrives

M500 Trapping shoe pin connection

Check

Maintenance of the downdrives

M505 Trapping shoe lubrication points

Lubricate

Maintenance of the downdrives

M510 Gear condition

Check

M520 Gear lubrication

Maintenance of the downdrives

Check

M530 Trapping shoe wear part

Maintenance of the downdrives Check

M540 Tensioning nut torque

"Insert on trapping shoe" [} 132] Check

Maintenance of the downdrives

water spraying bar (if installed) M710 Lifting cylinder operation

Check

"Water spraying bar maintenance" [} 129]

M720 Pin connection on lifting cylinder

Check

"Water spraying bar maintenance" [} 129]

M730 Lifting cylinder damage?

M740 lubricating nipple

Check

"Water spraying bar maintenance" [} 129]

Lubricate

"Water spraying bar maintenance" [} 129]

5.9.4 Maintenance intervals (electrical) Tab. 5: Maintenance intervals (electrical) No.

Maintenance point

daily

weekly

monthly

every three months

Comment/ Reference

General E10

Damage on any explosion protection cover plates, cable entries, protective plates, control levers and inspection windows

Visual inspection

E20

Correct operation of the main switch, buttons, keyboard…

Check

Also by operator at start of shift

E30

Correct operation of the emergency-stop switch and stopping with via control

Check

Also by operator at start of shift

94 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M490 Bearings

Operation Maintenance

No.

Maintenance point

E40

Trailing cable: Connection to ECB3 and monitoring unit

E50

Start-up warning for haulage unit, pump and ranging arm motors

E60

Methane concentration

E70

All explosion protection cover plates, cable entries, plugs and brackets: Correct version, in position and tight?

daily

weekly

monthly

every three months

5

Comment/ Reference

Visual inspection Check Check Visual inspection/ knocking test

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Wireless remote controls E90

Contamination and moisture

Remove

E100

Wireless remote control defective?

Check/ replace

E110

Rechargeable batteries charged?

Check

E120

Can all operating functions be executed?

Check

By operator at start of shift

Control system (MMC) E130

Does the MMC control system function correctly?

Check

E140

Motor parameters, start-up operating parameters

Note

E150

Haulage system parameters

Check/ record

E155

CIOS modules and brackets tight?

Check

E160

Information from error logs, inactive functions, oil levels, motor temperatures, status of the winding thermostats, water pressure and flow rate values, hydraulic pressures

Record

E170

Motor winding insulation and consistency values for all motors

By connecting to control station above ground

Check whether CIOS modules on power pack and at the end regions are tight.

If necessary, tighten by hand

Record

Ranging arm motor E180

Connection of main and sensor cables. Cable and feedthrough points

Check

E190

Cable entry housing dry and clean?

Check

E200

Connection of motor transmitter unit

Check

E210

Explosion protection cover plates damaged?

Gap dimensions for explosion protection correct?

Check

Cover plates removed

Electrical Control Box ECB 3 E215

All ground fault and shutdown devices

E220

Condition of all explosion protection flanges, pins, threads, spring dowel pins and nuts? (outside only)

Check

E230

Gap dimensions for explosion protection correct?

Check

EL3000 Shearer

Trigger/ check Visual inspection/ knocking test

95 / 148

5

Operation

No.

Maintenance point

Maintenance

daily

weekly

monthly

every three months

Comment/ Reference

Main transformer unit HTB3 E235

Ground fault test unit and LEDs

Trigger/ check

E240

Condition of all explosion protection flanges, pins, threads, spring dowel pins and nuts? (outside only)

Check

E250

Gap dimensions for explosion protection correct?

Check

Visual inspection/ knocking test

Pump motor Connection of motor transmitter unit

Check

E260

Explosion protection cover plates, cable entries, protective plates damaged?

Check

E270

Gap dimensions for explosion protection correct?

Check

Visual inspections/ knocking test, Check strength of bolted connections

Haulage motors E275

Connection of motor transmitter unit

Check

E280

Explosion protection cover plates, cable entries, protective plates damaged?

Check

E290

Gap dimensions for explosion protection correct?

Check

Visual inspections/ knocking test, Check strength of bolted connections

Electro-hydraulic control valves E300

Control valves functioning correctly?

Check

Start-up warning sirens E310

Cleanliness of and damage to start-up warnings at left and right

Check

Visual inspection of the flashing light

Visual inspections/ knocking test, Check strength of bolted connections

Motor of coal sizer (if installed) E320

Connection of motor transmitter unit

E330

Explosion protection cover plates, cable entries, protective plates damaged?

Check

E340

Gap dimensions for explosion protection correct?

Check

96 / 148

Check

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

E255

Operation Maintenance

5

5.9.5 Oil and fluid analyses NOTICE Contaminated lubricants and chemicals Contaminated lubricants and chemical can damage the machine.

1. Replace all oils and the hydraulic fluid after the first two weeks of production. Then continue routine oil sampling as stated in the maintenance tables.

If the gear oils and hydraulic fluid are not changed every three months the condition of the fluids must be monitored via sampling. Monitoring the condition of oils and hydraulic fluids can provide an exact picture of the condition of the machine and help determine the correct time to change the oil.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Caterpillar has developed a special maintenance program for monitoring oils that evaluates the condition of the oil and detects early signs of internal component wear. This oil analysis tool from Caterpillar is called SOS Oil Analysis. It is part of the SOS service program. SOS Oil Analysis has four components: Component wear Oil condition Oil contamination Oil identification These four components of the analysis are used to evaluate the condition of the machine and detect possible problems. For this purpose, guidelines have been developed on the basis of years of experience and analysis of machine failures.

A systematically implemented SOS Oil Analysis program helps reduce repair costs and shorten downtimes.

Contact your Cat dealer for further information on the SOS service program.

Sampling Please observe the following points when taking an oil sample: Ensure that the area around the sampling point is free from dirt. If necessary, clean the sampling plug to prevent contamination of the sample.

Ensure that the machine has been running for at least 5 minutes before last stopping, and that the oil temperature is at least 40 °C.

CAUTION Hot oil Hot oil can cause severe burns.

1. Be very careful when working with hot oil and wear your personal protective clothing and equipment.

The sample must be taken within 5 minutes of machine stopping.

Label sample with complete information. Successful analysis and diagnosis depends on accurate and complete information.

Removal of an oil sample takes place at the oil sampling points indicated for the individual machine components. Use devices that are approved for underground mines to take the sample.

EL3000 Shearer

97 / 148

5

Operation Maintenance

5.9.6 Filling oil and hydraulic fluid The shearer has a central system for filling oil and hydraulic fluid. This system allows all units to be filled by means of an off-board pump. Filling takes place at a central point on the right-hand downdrive. The procedure for filling with oil and hydraulic fluid as well as setting the pressure relief valve are described in greater detail in the following.

Filling procedure with off-board pump All components (ranging arm high-speed section, ranging arm epicyclic section, haulage units) are filled with gear oil from a central filling point (1) using an offboard pump. To fill a certain unit, the corresponding valve (4, 5, 6) for the unit must be opened so that oil can enter. Filling the power pack with hydraulic fluid also takes place at a central filling point (2).

DANGER of machine damage due to incorrect filling!

Always fill only one unit at a time! Follow the instructions and bleed the filled unit as indicated. Fill the next unit, if required, only after this.

The following figure shows the valves on the right-hand side for components on the right-hand side and the central filling points. The valves for the components on the left-hand side are located at the equivalent locations on the left-hand side of the shearer.

Fig. 86: Overview of filling with off-board pump

1

2

4 5 6

gear oil

1

Gear oil filling point

4

Ranging arm valve, high-speed section

2

Hydraulic fluid filling point

5

Ranging arm valve, epicyclic section

6

Haulage unit valve

To fill with gear oil using an off-board pump, proceed as follows: 1. Remove coal from beneath the valve block so that the unit to be filled can be bled during the filling process.

2. When filling a ranging arm: Position the ranging arm horizontally with the aid of the control system.

3. Completely open valve for the unit to be filled (4, 5, 6).

98 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

NOTICE

Operation Maintenance

5

4. Connect filling hose to the filling point (1).

5. Start the filling process. Observe the fill level at the corresponding oil-level gauge. Do not overfill the unit. If you noticed that too much oil has been filled, drain oil until the desired fill level is reached (as a rule: to the halfway mark in the oil-level gauge).

6. Shut off the pump once filling is complete and disconnect the filling hose from the filling point (1).

7. Bleed the filled unit for 4 minutes.

8. Completely close the valve of the filled unit (4, 5, 6). hydraulic fluid

To fill with hydraulic fluid using an off-board pump, proceed as follows: 1. Connect filling hose to the filling point (2).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2. Start the filling process. Observe the fill level at the oil-level gauge. Do not overfill the unit. If you noticed that too much hydraulic fluid has been filled, drain hydraulic fluid until the desired fill level is reached (as a rule: to the halfway mark in the oil-level gauge).

3. Shut off the pump once filling is complete and disconnect the filling hose from the filling point (2).

Adjusting the throttle valve The oil filling system on the shearer has a pressure relief valve (1) to prevent buildup of excessive pressure in the gear oil filling filter. In the event of excessively high pressure, the valve opens and oil can escape through the outlet (2) to the left of the downdrive. A throttle valve (3) is used to regulate the pressure.

Causes of escaping oil: The valve for the unit to be filled was not opened and the oil being pumped cannot flow into the system.

The oil filter is fouled.

The temperature is too low; the oil is too viscous.

The factory setting of the throttle valve (3) is the fully open position. If it is observed during operation that the pressure relief valve opens too early or too late, the throttle valve (3) must be readjusted using a square socket wrench.

EL3000 Shearer

99 / 148

5

Operation Maintenance

NOTICE DANGER from closing the pressure relief valve!

Never completely close the throttle valve. This prevents oil filling completely and the oil filling pump can be damaged. Close the throttle valve only to the point where oil no longer escapes from the outlet. Check beforehand that the oil filling filter is not fouled.

Fig. 87: Adjusting the pressure limiter

3

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

2

100 / 148

1

Pressure relief valve

2

Oil outlet

3

Throttle valve

EL3000 Shearer

Operation Maintenance

5

5.9.7 Maintenance of the ranging arms The following figure shows the right-hand ranging arm. The maintenance points on the left-hand ranging arm are located at the equivalent positions.

Fig. 88: Maintenance points on ranging arm

M80

M90 A, M170

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M110,M190

M180

M160

C, M140

M50

B, M170

M100

M60, M130

M170

M120

B, M170

M95 M150

A

Oil filling point

B

Oil drain point

C

Oil sample removal point

Tab. 6: Maintenance of the ranging arm Ranging arms

EL3000 Shearer

M50

Oil levels

Ranging arms horizontal, machine shut down, check oil levels

M60

Lifting cylinder operation

Raise and lower both ranging arms

M80

Water supply tight?

Visual inspection

M90

Cover plates secured?

Visual inspection

M95

Check/lubricate shear shaft

see "Lubricating/replacing the quill shaft" [} 102]

M100

Oil leaks?

Visual inspection

M110

Hinge pins in mainframe

Hinge pins are connected to a central lubrication supply.

Before lubricating, ensure that the weight of the ranging are is fully supported (e.g.: cutting drum resting on the floor or ranging arm is resting on support) For lubricants: see "Permissible media" [} 145]

101 / 148

Operation Maintenance

M120

Pin connection on lifting cylinder

Visual inspection

M130

Lifting cylinder damage?

Visual inspection, machine shut down (see "Electrical isolation of the shearer" [} 90])

M140

Fluid sample for analysis

The oil change interval depends on the result of the analysis

M150

Motor bracket tight?

Acoustic emission testing

M160

Wear and correct positioning Visual inspection for "play" between joint pin and mounting of joint pins hole

M170

Oil change (If no analysis was carried out)

Drain oil (high-speed section and epicyclic section) and refill. For details of the filling process, see "Filling oil and hydraulic fluid" [} 98].

Oil capacity of high-speed section: 42 l Oil capacity of epicyclic section: 60 l

M180

Cover plate on high-speed section

Visual inspection of whether cover plate is fastened securely.

Check for oil leaks.

Check the tightening torques of all bolts.

M190

Water pipe seals

The seals for the water pipe are connected to a central lubrication supply. Lubricant: see "Permissible media" [} 145]

Lubricating/replacing the quill shaft The quill shaft is removed and installed with a puller that is supplied with the special tools for the shearer. To replace the shear shaft, proceed as follows:

Notice on work safety Correct working height!

Before isolating the power to the shearer, ensure that the ranging arm is lifted up high enough and the motor housing is above the spill plate. This will ensure that the quill shaft can be pulled out.

Notice on work safety Important!

This procedure does not replace the need for a local risk assessment. Identify the risks that may occur in your mine and make sure the results are being observed during maintenance works.

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 90])

102 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5

Operation

5

Maintenance

2. Remove hex. head screws (7) and Nordlock washers from the motor housing cover (8) and then remove motor housing cover (8).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 89: Removing the motor housing cover

8

7

Hex. head screw

7

8

Motor housing cover

3. Remove cylinder head screws (1) and washers from the shear shaft cover (2) and then remove the shear shaft cover (2).

Fig. 90: Removing the quill shaft cover

2

1

4

3

EL3000 Shearer

1

Cylinder head screw

3

Shaft plug

2

Quill shaft cover

4

Quill shaft

103 / 148

5

Operation Maintenance

4. Remove the retaining ring (6).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 91: Removing the retaining ring

6

3 3

104 / 148

Shaft plug

6

Retaining ring

EL3000 Shearer

Operation Maintenance

5

5. Screw puller (M10) into the shaft plug (3).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 92: Screwing the puller into the shaft plug

3

3

EL3000 Shearer

Shaft plug

105 / 148

5

Operation Maintenance

6. Pull out the shaft plug (3).

3

3

Shaft plug

7. Screw puller (M16) into quill shaft (4) and pull quill shaft (4) out of the ranging arm gearing and ranging arm motor.

106 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 93: Removing the shaft plug

Operation Maintenance

5

Tip Broken quill shaft!

If the quill shaft has sheared, then two parts need to be removed from the motor!

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 94: Pulling out the quill shaft

4

4

Quill shaft

8. Inspect the quill shaft (4) for damage and replace if necessary.

Fig. 95: Inspecting the quill shaft

4 4

Quill shaft

9. Lubricate the quill shaft gearing (see Quill Shaft Grease).

EL3000 Shearer

107 / 148

5

Operation Maintenance

Tip Insert the quill shaft correctly!

Ensure that the shear point on the shaft is located on the gob side of the motor.

10. Push the quill shaft (4) into the motor with the aid of the puller (M16). If you have difficulty pushing the quill shaft gearing into the ranging arm gearing, proceed as follows: 11. Slowly rotate the quill shaft by hand while at the same time pushing it into the motor. If the above does not work, then the cutting drum may need to be turned slowly by hand, but only if the conditions (roof, etc.) are safe.

Push against the quill shaft while turning the shearer drum. This will help you mesh the quill shaft gearing with the ranging arm gearing.

12. Ensure that the quill shaft (4) is pushed in completely.

9

4

Quill shaft

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 96: Installing the quill shaft

4

9

Shear point

13. Inspect O-ring (5) on shaft plug (3). Replace, if necessary.

14. Ensure that the O-ring (5) is lubricated.

15. Lubricate the shaft plug (3) (see Quill Shaft Grease).

16. Screw puller (M10) into the shaft plug (3) and push shaft plug (3) into the motor. Ensure that the O-ring (5) on the shaft plug is not damaged.

108 / 148

EL3000 Shearer

Operation Maintenance

5

17. Ensure that the groove for the retaining ring is visible and empty.

Fig. 97: Install the shaft plug.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

3

5

3

EL3000 Shearer

Shaft plug

5

O-ring

109 / 148

5

Operation Maintenance

18. Install the retaining ring (6) in the groove in front of the shaft plug (3).

6

3 3

Shaft plug

6

Retaining ring

19. Install the quill shaft cover (2). Secure the quill shaft cover (2) with cylinder head screws (1) and retaining washers.

110 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 98: Installing the retaining ring

Operation

5

Maintenance

20. Tighten the cylinder head screws to a torque of 77 Nm (57 lb-ft).

Fig. 99: Installing the quill shaft cover

2

4

3

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6

1

1

Cylinder head screw

4

Shear shaft

2

Quill shaft cover

6

Retaining ring

3

Shaft plug

21. Install the motor housing cover.

EL3000 Shearer

111 / 148

5

Operation Maintenance

5.9.8 Maintenance of the cutting drums Fig. 100: Cutting drum maintenance points

M220

M260

M230

M250

M240

Tab. 7: Cutting drum maintenance

112 / 148

No.

Maintenance point

Notes

M210

Picks and pick holders

Check for blunt or damaged picks. Inspect pick holders for damage. Ranging arm uncoupled, machine shut down (see )

M220

Connecting pins tight?

Raise and lower both ranging arms

M230

Can rotate freely?

Visual inspection

M240

Damaged?

Visual inspection

M250

Oil leakage (from ranging arm)?

Visual inspection

M260

Dust suppression nozzles

Open water supply for the water spraying system and check whether all nozzles function properly

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M210

Operation Maintenance

5

5.9.9 Maintenance of the haulage units The following figure shows the haulage unit on the right-hand side. The haulage unit on the left-hand side is arranged in a mirror image.

Fig. 101: Haulage unit maintenance points

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M310

M290

M270

M280

M300 M320

Tab. 8: Haulage unit maintenance

EL3000 Shearer

No.

Maintenance point

Notes

M270

Oil level

Check oil level at the oil-level gauge. Electricity still supplied to the machine, but haulage motor isolated.

M280

Motor bracket tight?

Check bolted connection on motor bracket

M290

Motor shear shaft

See "Lubricating/replacing the quill shaft" [} 114] for details of removal, inspection and installation of the shear shaft

M300

Fluid sample for analysis

Taken oil sample from both haulage units at the oil drain point. If the analysis indicates that the oil must be changed, drain the oil and refill to the correct oil level.

Oil capacity: 28 l Oil grade: see "Gear Oil" [} 146]

M310

Brake wear (if brake installed)

Open the cover on the face side and check the wear indicator on the brake. The greater the wear indicator projects from the housing, the lower the amount of break wear. The following values can be assumed: 6.60 mm: Brake released 2.00 mm: Brake applied 0.00 mm: Brake applied and worn

113 / 148

5

Operation Maintenance

M320

Oil change (If no analysis was carried out)

Drain the oil and refill to the correct oil level. For details of the filling process, see "Filling with gear oil".

Oil capacity: 28 l Oil grade: see "Gear Oil" [} 146]

Lubricating/replacing the quill shaft The quill shaft is removed and installed with a puller that is supplied with the special tools for the shearer. To replace the quill shaft, proceed as follows:

Notice on work safety Important!

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 90] ).

2. Remove machine components located in front of the haulage motor that could present an obstruction when carrying out the procedure.

CAUTION Risk of injury from pressurized hose lines!

Make sure that all pressure is removed from hydraulic or water hoses before you disassemble them!

114 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

This procedure does not replace the need for a local risk assessment. Identify the risks that may occur in your mine and make sure the results are being observed during maintenance works.

Operation Maintenance

5

3. Move cylinder head screws (1) and retaining washers from the access cover (2) on the quill shaft and remove the cover (2).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 102: Removing the cover

1

EL3000 Shearer

2

1

Cylinder head screw

4

Short quill shaft

2

Cover

5

Long quill shaft

3

Shaft plug

115 / 148

5

Operation Maintenance

4. Remove the retaining ring (6).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 103: Removing the retaining ring

6

3

3

116 / 148

Shaft plug

6

Retaining ring

EL3000 Shearer

Operation Maintenance

5

5. Screw puller (M16) into the shaft plug (3) and pull out the shaft plug (3).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 104: Removing the shaft plug

3

3

Shaft plug

6. Screw a puller (M20) into the short shear shaft (4) and pull the short quill shaft out of the motor.

Tip Broken quill shaft!

If the short quill shaft has sheared, then two parts need to be removed from the motor!

EL3000 Shearer

117 / 148

5

Operation Maintenance

7. If the short quill shaft (4) cannot be pulled out of the motor, remove puller (M20) and screw a puller (M16) through the short quill shaft so that the puller pushes the short quill shaft out of the gearing of the long quill shaft.

Pull the short quill shaft out of the motor.

5

4 4

Short quill shaft

5

Long quill shaft

8. Unscrew the puller from the short quill shaft and inspect the short quill shaft for wear and damage. If necessary, replace the short quill shaft.

Fig. 106: Inspecting the short quill shaft

4 4

118 / 148

Short quill shaft

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 105: Removing the short quill shaft

Operation Maintenance

5

9. Screw puller (M8) into the long quill shaft and pull long quill shaft out of the haulage unit gearing and haulage motor.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 107: Removing the long quill shaft

5 5

EL3000 Shearer

Long quill shaft

119 / 148

5

Operation Maintenance

10. Inspect the long quill shaft (5) for damage and replace if necessary. Check the condition of the internal and external gearing. Check the condition of the O-ring (6) on the long quill shaft and replace if damaged.

6

5

5

Long quill shaft

6

O-ring

11. Lubricate the O-ring for the long quill shaft and the long quill shaft (see Quill Shaft Grease).

12. Push the long quill shaft (5) into the motor with the aid of the puller (M8).

120 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 108: Inspecting the long quill shaft

Operation Maintenance

5

13. Ensure that the long quill shaft (5) is pushed into the motor completely.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 109: Installing the long quill shaft

5 5

Long quill shaft

14. Lubricate the short quill shaft (4) (see Quill Shaft Grease).

15. Screw the puller (M12) into the wider end of the short quill shaft (4).

Tip Lock the puller!

Make sure that the puller is locked into the quill shaft so that the quill shaft can be rotated while being pushed into the gearing of the long quill shaft. A lock nut may have to be screwed onto the puller first.

Fig. 110: Screwing in the puller

4 4

Short quill shaft

16. Push the short quill shaft (4) into the motor and the gearing of the long quill shaft (5) with the aid of the puller (16). It may be necessary to rotate the short quill shaft (4) slightly.

EL3000 Shearer

121 / 148

5

Operation Maintenance

17. Rotate the short (4) and long quill shaft (5) so that the gearing of the long quill shaft (5) meshes with the haulage unit gearing. Ensure that the short quill shaft (4) is pushed into the long quill shaft (5) completely.

5

4 4

Short shear shaft

5

Long shear shaft

18. Unscrew the puller from the short shear shaft.

19. Inspect O-ring (7) on shaft plug. Replace, if necessary.

20. Ensure that the O-ring (7) is lubricated.

21. Lubricate the shaft plug (3) (see Quill Shaft Grease).

122 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 111: Installing the short shear shaft

Operation Maintenance

5

22. Screw puller (M16) into the shaft plug (3) and push shaft plug (3) into the motor. Ensure that the O-ring (7) on the shaft plug is not damaged.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 112: Installing the shaft plug

3

3

EL3000 Shearer

Shaft plug

7

O-ring

123 / 148

5

Operation Maintenance

23. Install the retaining ring (6) in the groove in front of the shaft plug.

6

3

3

Shaft plug

6

Retaining ring

24. Install cover (2). Secure the cover (2) with cylinder head screws (1) and retaining washers.

124 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 113: Installing the retaining ring

Operation Maintenance

5

25. Tighten the cylinder head screws to a torque of 77 Nm (57 lb-ft).

Fig. 114: Installing the covers

3 2

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

EL3000 Shearer

1

Cylinder head screw

2

Cover

3

Shaft plug

125 / 148

Operation

5

Maintenance

5.9.10 Maintenance of the power pack Fig. 115: Power pack maintenance points

1

3, M340

2

5

4, M340

14, M405

6

10

7, M420

15, M390 M440

16, M440

11, M400

13, M330 8, M380 M430

12, M410

1

Cooling water pressure

9

Oil cooler

2

Inlet water pressure

10

Return filter

3

Hydraulic system pressure

11

Pressure filter

4

Hydraulic control pressure

12

Hydraulic pump

5

Unused pressure gauge (0-40 bar)

13

Oil-level gauge

6

Hydraulic reservoir

14

Breather

7

Pump motor

15

Oil drain

8

Valve block

16

Oil filling valve (for separate oil filling system)

Tab. 9: Power pack maintenance No.

126 / 148

Maintenance point

Notes

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

9

Operation

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Maintenance

EL3000 Shearer

5

M330

Fluid level

Electricity still supplied to the machine, but pump motor isolated. Check the fill level with the aid of the MMC system and at the oil-level gauge on the power pack. Add hydraulic fluid, if necessary. For information on the filling procedure, see Filling oil and hydraulic fluid.

M340

Working pressure

Check the pressures indicated on the pressure gauges and those in the MMC system.

M350

Leakage?

Where possible, check the hydraulic system for leaks. Visual inspection.

M360

Filter condition

Visual inspection of the filters/ filter monitoring in the MMC.

M370

Hoses and connections

Where possible, inspect hydraulic hoses and couplings for damage and leaks.

M390

Fluid sample for analysis

Remove a sample of hydraulic fluid. See "Sampling" [} 97] for additional information. If the analysis indicates that the hydraulic fluid must be changed, drain the hydraulic fluid and refill to the correct fill level.

Hydraulic fluid grade: see "Hydraulic Fluid" [} 146]

M400

Pressure and return filter

Compare the pressures indicated on the pressure gauges and those in the MMC system. Replace filters, if necessary.

M405

Tank breather filter

Open the maintenance flap over the power pack. Clean the area around the tank breather filter. Remove the existing tank breather filter and replace it with a new one.

M410

Pump bracket tight?

Check accessible bolted connections

M420

Motor bracket tight?

Check accessible bolted connections

M430

Control valves tight?

Check accessible bolted connections

M440

Hydraulic Fluid

Drain the hydraulic fluid at the drain point and refill with fresh hydraulic fluid up to the correct fill level.

Hydraulic fluid grade: see "Hydraulic Fluid" [} 146]

127 / 148

5

Operation Maintenance

5.9.11 Maintenance of the downdrives The figure shows the downdrive on the right-hand side. The maintenance points on the left-hand ranging arm are arranged in a mirror image.

Fig. 116: Downdrive maintenance points

M490

M510

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M495

M540

M505

M500 M505 M530

Tab. 10: Downdrive maintenance

128 / 148

No.

Maintenance point

Notes

M490

Bearings

Lubricate bearings at the marked lubrication points on the downdrive. Pump grease into the lubrication points until fresh grease emerges.

M495

Drive shaft

Open cover in front of drive shaft and lubricate drive shaft

M500

Trapping shoe pin connection

Visual inspection

M505

Trapping shoe lubrication points

Lubricate trapping shoe at the lubrication points provided.

Pump grease into the lubrication points until fresh grease emerges.

M510

Gear condition

Remove cover plate(s) and allow to run at least one whole rotation for a complete inspection. Reinstall cover plate(s).

M530

Trapping shoe insert wear

Measure wear and replace insert, if necessary. See "Insert on trapping shoe" [} 132] for details.

M540

Tensioning nut torque

Random check and knocking test.

EL3000 Shearer

Operation Maintenance

5

5.9.12 Water spraying bar maintenance Fig. 117: Water spraying bar maintenance points

M740

M720

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

M710, M730

Tab. 11: Downdrive maintenance No.

Maintenance point

Notes

M710

Lifting cylinder operation

Raise and lower water spraying bar

M720

Pin connection on lifting cylinder

Visual inspection

M730

Lifting cylinder damage?

Visual inspection, machine shut down

M740

Lubricating nipple

Lubricate with grease

5.9.13 Replacing wearing parts It is essential to replace wear parts before they reach the lowest wear limit otherwise damage can be caused to other parts of the machine. Examine wear parts at regular intervals as specified in the maintenance tables.

Skid shoe The skid shoe wears down as the result of moving on the track of the conveyor.

The skid shoe must be replaced once the wear exceeds 10 mm. Information on how you can measure the wear using a wear gauge is provided in the following.

Wear measurement The wear of the skid shoes is measured by means of a wear gauge that is supplied with the special tools for the shearer.

To measure the wear, proceed as follows:

EL3000 Shearer

129 / 148

5

Operation Maintenance

1. Insert the pin of the wear gauge into the through hole of the skid shoe.

Fig. 118: Placing the wear gauge

3

1

1

Skid shoe

2

Wear gauge

3

Conveyor track

2. Measure the distance between the bottom end of the wear gauge (2) and the conveyor track (3). The wear limit is reached when the wear gauge touches the conveyor track or cannot be inserted into the through hole.

Fig. 119: Measure wear

>0 = OK <0=not OK

1

1

Skid shoe

2

Wear gauge

2

3

3

Conveyor track

3. Repeat the process on the other side of the skid shoe and on the second skid shoe.

130 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

2

Operation Maintenance

5

Replacing a skid shoe To replace a worn skid shoe, raise the support foot so that the weight of the machine is taken off the pin (1). Then remove the bolt (4), the cover (2) and the pin (1), and replace the skid shoe. Clean and grease the pin (1) before re-installing it Fig. 120: Replacing a skid shoe

A

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

B

2

1

3

4

5

EL3000 Shearer

1

Pin

5

Skid shoe

2

Cover

A

Gobside

3

Nord-Lock washer

B

Face side

4

Hex. head screw

131 / 148

5

Operation Maintenance

Insert on trapping shoe The wear of the inserts of the gobside trapping shoes is measured by means of wear gauges which are supplied with the special tools for the shearer.

5 4 3 2 1

1

Wear gauge 4 mm

4

Wear gauge 7 mm

2

Wear gauge 5 mm

5

Wear gauge 8 mm

3

Wear gauge 6 mm

WARNING Unsecure machine components You can be severely injured and even killed by unsecured machine components when working under the machine.

1. Secure the ranging arm by supporting it, e.g. with wood, or secure it with chains.

132 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 121: Trapping shoe wear gauges

Operation Maintenance

5

For the wear measurement, a combination of wear gauges with different thicknesses is inserted between the wear part of the trapping shoe and the track bar (2) of the conveyor as shown below in order to determine the distances between the rack bar (2) and the wear part.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 122: Trapping shoe wear measurement

1 1

Trapping shoe

2

Rack bar

3

2

3

Combination of wear gauges

The wear limit of the wear parts in the tracking shoe is reached when the distance between the rack bar and insert exceeds the following values: 20 mm on both sides of the rack bar (addition of values a and b as shown below) or

EL3000 Shearer

133 / 148

5

Operation Maintenance

17 mm under the rack bar Fig. 123: Trapping shoe wear limits

max.(a+b)=20 mm b

17 mm max.

Replacing an insert To replace an insert, proceed as follows: 1. Shut down the shearer and conveyor and secure against unauthorized restarting.

2. Remove fasteners from two rack bars (7) so that the rack bars (7) are positioned loosely on the conveyor.

3. Switch on the shearer again and move it onto the two rack bars (7) so that the trapping shoe (1) with the drive gear to be replaced is positioned on the two rack bars.

4. Shut down the shearer and secure against unauthorized restarting.

5. Using suitable lifting tackle, raise this shearer so that the rack bars (7) in the trapping shoe (1) can be detached from the conveyor.

134 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

a

Operation Maintenance

5

6. Remove the rack bars (7) from the trapping shoe (1).

Fig. 124: Removing the rack bars

1

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

1

EL3000 Shearer

Trapping shoe

7

Rack bar

135 / 148

5

Operation Maintenance

7. Remove the insert in the trapping shoe. To do so, remove the outside bolts (4, 5) in the key (3). If the key for the insert is difficult to remove, a jacking screw can be threaded into the middle through hole in the key to press the key (3) out of the trapping shoe.

Fig. 125: Removing the wear part

3

4

5

1

2

1

Trapping shoe

4

Nord-Lock washer

2

Insert

5

Hex. head screw

3

Key

6

Lubricating nipple

8. Screw threaded pins through the trapping shoe (1) from above in order to attach a new insert to the trapping shoe.

9. Install the key (3) and fasten it securely with screws (4, 5).

10. Insert the rack bars (7) into the trapping shoe (1).

136 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6

Operation Maintenance

5

11. Lower the shearer so that the rack bars (7) are back in their original position on the conveyor.

Fig. 126: Installing the rack bars

1

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

7

1

Trapping shoe

7

Rack bar

12. Switch on the shearer and move it out of the working area.

13. Shut down the shearer.

14. Fasten the rack bars (7).

Drive gear The sprockets are inspected visually during the weekly inspection of the downdrive gears. In case the drive gear is damaged or worn, it needs to be replaced using the procedure shown.

Replacing a drive gear To replace a drive gear, proceed as follows: 1. Shut down the shearer and conveyor and secure against unauthorized restarting.

2. Remove fasteners from two rack bars (4) so that the rack bars (4) are positioned loosely on the conveyor.

3. Switch on the shearer again and move it onto the two rack bars (4) so that the trapping shoe (2) with the drive gear to be replaced is close to the two rack bars.

4. Shut down the shearer and secure against unauthorized restarting.

5. Using suitable lifting tackle, raise this shearer so that the rack bars (4) in the trapping shoe (2) can be detached from the conveyor.

EL3000 Shearer

137 / 148

5

Operation Maintenance

6. Remove the rack bars (4) from the trapping shoe (2).

Fig. 127: Removing the rack bars

2

1

1

downdrive

2

trapping shoe

4

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

4

rack bar

7. Remove the cylinder head screws (5) and cover (6).

Fig. 128: Removing the cover

5

6

5

138 / 148

cylinder head screw

6

cover

EL3000 Shearer

Operation Maintenance

5

8. Remove the connection lines (7) with Dowty seals (8), screw fittings (9) and lubricating nipples (10).

Fig. 129: Removing the connection lines

10 7

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

8, 9

7

connection lines

9

screw fitting

8

Dowty seal

10

lubricating nipple

9.

10. Remove the cylinder head screws (11) and pin (12).

Fig. 130: Removing the pin

11 11

EL3000 Shearer

cylinder head screw

12 12

Pin

139 / 148

5

Operation Maintenance

11. Remove the trapping shoe (2) and drive gear (3).

Fig. 131: Removing the trapping shoe with drive gear

2

1

downdrive

2

trapping shoe

3

3

drive gear

12. A worn drive gear must be replaced with a new one.

13. Place unit consisting of trapping shoe and new drive gear under the downdrive.

14. Lower the shearer so that the unit consisting of trapping shoe (2) and drive gear (3) is positioned in the downdrive housing (1).

140 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

1

Operation Maintenance

5

15. Align the trapping shoe and drive gear. Once the through hoes in the downdrive housing and the unit consisting of trapping shoe and drive gear are aligned perfectly, install pin (12) and secure with cylinder head screws (11).

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Fig. 132: Centering the pin

11 11

12

cylinder head screw

12

Pin

16. Install the connection lines (7) with Dowty seals (8), screw fittings (9) and lubricating nipples (10).

Fig. 133: Installing the connection lines

10 7

8, 9

EL3000 Shearer

7

connection lines

9

screw fitting

8

Dowty seal

10

lubricating nipple

141 / 148

5

Operation Maintenance

17. Install the cylinder head screws (5) and cover (6).

Fig. 134: Installing the covers

6

5

cylinder head screw

6

cover

18. Insert the rack bars (4) into the trapping shoe (1).

19. Lower the shearer so that the rack bars (4) are back in their original position on the conveyor.

Fig. 135: Installing the rack bars

1

7

1

trapping shoe

4

rack bar

20. Switch on the shearer and move it out of the working area.

21. Shut down the shearer.

22. Fasten the rack bars (4).

142 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

5

Technical data Main components of the shearer

6

6 Technical data This chapter contains the most important technical data. Further information is given in the spare parts lists and in the separate operating manuals for the individual components. In addition, you can find information on the product IDs, tightening torque, permissible media, etc. in this chapter.

Read this chapter carefully at your leisure. Pay special attention to the safety instructions.

6.1 Main components of the shearer DANGER Modifications or changes to the machine

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Unapproved modifications or changes to the machine can seriously injure or be fatal to our you or your associates.

1. Do not make any independent modifications or changes to the machine.

2. Permission to operate the machine expires if any unapproved modifications or changes are made.

3. Modifications or changes must be approved by Caterpillar.

6.2 Technical data sheet Important information Follow the additional information in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

General Shearer type:

EL 3000

Noise level:

> 85 dB(A) (The noise emissions may temporarily exceed 85 dB (A) during certain operating phases.)

Drive frame Type:

MF 3-1

Construction:

One-piece frame

Ranging arms Type:

RA0860-WP-R1 (2x)

Gear ratio:

24/44 at 37 rpm

Oil capacity, high-speed section:

42 l

Oil capacity, epicyclic section:

60 l

Ranging arm motors Type:

CM860M (2x)

Rated power:

860 kW

Voltage:

3300 V

Haulage unit

EL3000 Shearer

143 / 148

6

Technical data Identification

Type:

HU150-R1 (2x)

Gear ratio:

137:1

Oil capacity:

28 l

Haulage motor Type:

HM150 MF (2x)

Rated power:

150 kW

Voltage:

0-600 V

Downdrives Type:

DD150-D-LH/RH

Rack bar system:

Jumbotrack 2000

Type:

PP3-200-75-E2 AUS TX

Pump rating:

200 l/min

Hydraulic fluid capacity:

300 l

Pump motor, type:

PM75 M

Pump motor power rating:

75 kW

Pump motor voltage:

3300 V

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Power pack

Lifting cylinder Type:

ZE-325/180-640 (2x)

Stroke:

640 mm

Electrical Control Box Type:

ECB 3

Haulage transformer box Type:

HTB-33-AU-RN

Input voltage:

3300 V

Output voltage:

600 V

Frequency converter, type:

D2-100-600 ENCDS (2x)

Accessories Tools:

Tool box

Miscellaneous:

Fire extinguisher

6.3 Identification The identification of the shearer is specified below.

144 / 148

EL3000 Shearer

Technical data Permissible media

6

The shearer is identified with a serial number name plate.

Fig. 136: Type plate serial number

1

Serial number

2

Model designation

3

Object number

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

The design of the shearer meets the requirements of the European Directive 2014/34/EU and DIN EN1710 as well as the guidelines of the Mine Safety and Health Administration (MSHA); and is suitable for use in potentially explosive atmospheres.

6.4 Permissible media This section provides the approved lubrication details for the shearer.

The main objectives of the lubrication program are to prevent wear and to reduce heat build-up. The lubricants specified in this section are used to reduce friction, assist in heat dissipation and prevent corrosion. Shearer lubrication includes gear oil and hydraulic fluid filling. Gear oil is used to fill the ranging arms and the haulage units, with hydraulic fluid being used to fill the powerpack reservoir. Additional information on components requiring lubricants and how they use the lubricants can be found in the "Maintenance" chapter.

NOTICE Use of lubricants Using impermissible lubricants voids any warranty claims and may result in severe machine damage!

1. Only use lubricants approved by Caterpillar!

2. Always observe the specified intervals for changing the respective lubricant!

Inspection of lubricants taken from the machine can often reveal problems before breakdowns occur: Cloudy or emulsified oil may indicate the presence of water Milky or foamy oil may show the presence of air Dark grease may mean oxidation has started, or contamination present placing into operation

EL3000 Shearer

On startup of a new machine, or when a new unit is installed, it is imperative that the gear oil or hydraulic fluid is drained from the unit after working a maximum of ten shifts. The unit should be flushed and replenished with the recommended grade of oil or fluid to the correct level. After a further ten shifts of operation, this process must be repeated. Thereafter, if `debris monitoring/oil or fluid

145 / 148

6

Technical data Permissible media

analysis' is being performed, this should dictate the periods of lubricant replacement. If, however, no monitoring/analysis is used, the lubricant in the units should generally be changed in accordance with the table in the "Maintenance" chapter.

6.4.1 Gear Oil The shearer's gear oil filling system has one filling point for the individual unit.

An off-board oil filling pump is used to fill the ranging arms, the haulage units and down drive lubrication reservoirs. Further information on using the filling system can be found in the "Maintenance" chapter.

WARNING Handling operating materials and consumables

1. When handling operating materials and consumables, read the applicable safety data sheets for these materials before starting work!

Tab. 12: Gear Oil Use:

Ranging arms, haulage units, down drive lubrication reservoirs

Specification:

ISO viscosity class: 320 (syn) Requirements per: DIN 51517, Part 3

Approved brand:

Castrol Optigear PD 320 Synth

6.4.2 Hydraulic Fluid Hydraulic fluid is used to fill the powerpack that supplies the shearer's hydraulic components. Further information on filling and filling intervals can be found in the "Maintenance" chapter.

WARNING Handling operating materials and consumables Careless handling of operating materials and consumables (e.g. grease or oil) can result in severe injury or even death.

1. When handling operating materials and consumables, read the applicable safety data sheets for these materials before starting work!

A highly refined fluid or synthetic olefin oligomers should serve as the base of the hydraulic fluid. In addition, it must have a balanced additive system providing a high viscosity index and good performance when judged against industry standards for the following properties: thermal stability oxidation resistance and stability corrosion inhibition air release/anti foaming, with a good balance of these shear stability compatibility with mineral oil seals

146 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Careless handling of operating materials and consumables (e.g. grease or oil) can result in severe injury or even death.

Technical data Permissible media

6

filterability anti-wear compatibility and miscibility with other mineral hydraulic oils The properties should not be significantly affected by modest amounts of contamination in the form of water or particulate matter. In particular, there must be no plating out of zinc-based anti-wear additives in the presence of water.

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Tab. 13: Hydraulic Fluid Use:

Hydraulic reservoir in powerpack

Specification:

Viscosity class 68 to DIN 51519 not zinc- and ash-free (ZAF)

Approved brands (examples):

Quaker Quintolubric 888-68 (fire resistant) Renolin B20 (ISO 68) Shell Tellus S2 M 68 BP Bartran 68 Addinol hydraulic fluid HLP 68 Chevron hydraulic fluid AW -M 68

6.4.3 Grease Applications The grease described here is used to lubricate all lubrication points on the shearer except for the motor shafts. Further information on the lubrication points and the lubrication intervals can be found in the "Maintenance" chapter.

WARNING Handling operating materials and consumables Careless handling of operating materials and consumables (e.g. grease or oil) can result in severe injury or even death.

1. When handling operating materials and consumables, read the applicable safety data sheets for these materials before starting work!

The grease must be suited for use in heavily loaded plain and rolling element bearings subjected to vibration and shock loading. The base should be a highly refined oil or synthetic hydrocarbon. In addition, it must have a balanced additive system providing good performance when judged against industry standards for the following properties: water washout resistance corrosion inhibition wear resistance shear stability load carrying Tab. 14: Grease

EL3000 Shearer

Use:

Lubrication points as indicated in the "Maintenance" chapter

Specification:

NLGI 1

Approved brand:

Cat Extreme Application Grease 1

147 / 148

6

Technical data Tightening torques

6.5 Tightening torques 6.5.1 Screws and bolts with ISO metric thread Tab. 15: Tightening torques at µtot. = 0.14 Pitch P (mm)

d

Coarse thread

M8

Tightening torque MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27)

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

NOTICE Tightening torques Incorrect torque may cause considerable machine damage.

1. Also follow the tightening torques for installation and maintenance stated in the spare parts lists.

148 / 148

EL3000 Shearer

Media-ID: EM029397-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

Thread (mm)