CAT Shearer EL1000 Operation & Maintenance Manual EM028338 - PDF DOWNLOAD

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

Operating and Maintenance Manual EL1000 Shearer

Part-No.:

4884994

Serial-No.:

LM210202

SAFETY.CAT.COM

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

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

Table of Contents

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

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

EL1000 Shearer

Table of Contents

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

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

Table of Contents

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

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

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EL1000 Shearer

About this manual

1

How to use this manual

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

1.1 How to use this manual applicable operating manual

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

Category according to Atex di-

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

rective

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

service partner

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

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

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

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

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

Purpose of this operating manual Efficiency

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

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

Safety

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

Observe the information given and follow the instructions.

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1

About this manual Signs and symbols used

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

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

1. Follow the described instructions.

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

1. Follow the described instructions.

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

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

1. Follow the described instructions.

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

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

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

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

1. Observe the provided tips and information.

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

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

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

Safety

2

Personnel

2 Safety 2.1 Personnel operation installation and repairs

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

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

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

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qualification

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

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

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

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

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

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

Unauthorized use includes the transport of persons.

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

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

That includes:

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2

Safety Operator requirements

adequate and consistent ventilation, water spraying systems.

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

It may only be restarted by an authorized person.

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

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

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

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

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

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

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

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2.2.4 Prerequisites for operation

Safety Using the machine and working on the machine

2

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

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

Become familiar with your working area.

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noise emissions

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

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

safety components

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

Keep the signaling and lighting systems in good condition.

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

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

Observe the warning signs on the machine.

emergency stop switch

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

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

electrical trips

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

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2

Safety Using the machine and working on the machine

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

danger of explosion

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

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

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

Observe the separate operating manuals for the components used.

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

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

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

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

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

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

Secure all moving parts.

Never walk or stay under unsecured components or suspended loads.

means of attachment

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

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

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

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

mobile handling systems

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

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

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

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the coal face has been secured against collapsing and

Safety Using the machine and working on the machine

2

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

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

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

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

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

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

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

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

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

Fig. 1: Go/no-go zones

radio mode

EL1000 Shearer

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

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2

Safety Notes on the hydraulic system 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

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

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 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.

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.

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You may only carry out work in the mining area if:

Safety Notes on the hydraulic system

2

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.

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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.

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

Germany / Europe

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure date of manufacture Caterpillar ID Fig. 2: Example: Hose line, identification

1

installing hose lines

2

3

4

1

Manufacturer ID

3

Year

2

Calendar week

4

Working pressure in [bar]

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

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

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Safety Notes on the hydraulic system

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,

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.

Guide values for service life Tab. 1: Service life

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Hydraulic hose

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

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avoid direct sunlight or exposure to UV radiation,

Storage and transport Storage

3

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

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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. 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.

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.

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Storage and transport Storage

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.

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 powerpack cooler Haulage Transformer Box (HTB) cooler electric motors coal sizer motor (if installed) coal sizer gearbox (if installed) water spraying bar (if installed)

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Then seal the ports with plastic or steel plugs.

Storage and transport Transport

3

NOTICE Antifreeze fluid spilling out 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

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Lifting points 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 chapter 4.

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.

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3

Storage and transport Transport Fig. 3: Lifting eye and load ring example

A

B

b

c

a

a

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).

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.

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d

Storage and transport Transport

3

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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.

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.

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3

Storage and transport Transport

3.2.5 Transporting the machine underground 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 mainframe 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 Damage to machined surfaces

after transport

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

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

EL1000 Shearer

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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.

Assembly Notes on installation

4

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

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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 Parts number

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" [} 156]) prior to installation

connection points

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Assembly

4

Overview of EL1000 shearer

4.2 Overview of EL1000 shearer Fig. 5: Overview of EL1000 shearer

183 80

80 182

183

82

20

301

40

84

20

90

1

82 182

10 10

5

2

30

3

5

30 61

Tab. 3: EL1000 shearer - Main components, dimensions and weights Item

Quantity

Description

Length approx. (inch)

Width approx. (inch)

Height approx. (inch)

Weight approx. (~lbs)

1

1

Mainframe

332.5

65

34

29950

2

1

Shoe post SP1-180-LH

34

10

13

503

3

1

Shoe post SP1-180 RH

34

10

13

503

5

2

Slide shoe

33.5

5.5

8

201

10

2

Ranging arm RA0560

130.5

63.5

37

13642

20

2

Haulage unit HU 100

52

41

18

2509

30

2

Downdrive

23

46

22

2421

40

1

Powerpack PP2-50-30

57

43.5

18

1980

61

2

Lifting cylinder

?

?

?

1318

80

2

Ranging arm motor CM500MD

See separate operating manual

3219

82

2

Haulage motor HM100B

See separate operating manual

1213

84

1

Pump motor PM30B

See separate operating manual

551

90

1

Electrical control box ECB 2

80.5

51

19

4580

92

1

Haulage transformer box HTB2

61

50

19

12963

182

2

Cowl tilting device

183

2

Cowl

58

38

6

1058

301

1

Spall guards

333.5

45.4

9

4725

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236

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61

92

Assembly Installing the shearer

4

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.

WARNING Falling material You can be seriously injured by falling material!

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

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

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

The machine should be installed, hosed and cabled in the following order: Attach face-side support feet (incl. skid shoes) to the mainframe (if required) Attach lifting cylinders to the support feet (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 cowl to ranging arm (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 powerpack 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.

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4

Assembly Installing the shoe post and lifting cylinder on the mainframe

4.4 Installing the shoe post and lifting cylinder on the mainframe The shoe posts are installed on the shearer by means of two pins each. The outer pins secure the lifting cylinder to the shoe post. installing the shoe post assembly

To install the shoe post, proceed as follows: 1. Support the mainframe with suitable lifting or supporting devices.

2. Position the shoe post (1) under the mainframe (2) with the aid of suitable lifting devices. Align the holes in the shoe post with the holes in the mainframe.

1

2

1

Support foot

2

mainframe

3. Clean and grease the pins (3) and sockets (4) and insert into the holes.

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Fig. 6: Positioning the shoe post

Assembly Installing the shoe post and lifting cylinder on the mainframe

4

4. Push the sockets (4) to the ends of the pins (3). Push hex. head screw (5) through the sockets (4) and pins (3) from inside the shearer and secure hand-tight with washer (6) and nut (7).

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Fig. 7: Inserting the fastening material

7 6

4

4

3

3

Pin

6

Washer

4

Socket

7

Nut

5

Hex. head screw

5

5. Attach the installation aid (8) to the inner side of the shoe post and secure with hex. head screws (9).

Fig. 8: Attaching the installation aid

8

9

8

EL1000 Shearer

Installation aid

9

Hex. head screw

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4

Assembly Installing the shoe post and lifting cylinder on the mainframe

6. Push the hex. head screws (10) through the holes in the installation aid (8) and screw into the socket (4). Tighten the hex. head screw (10), pulling the socket against the installation aid to position the socket correctly.

Fig. 9: Pulling the socket against the installation aid

8

4

Socket

8

Installation aid

10

10

Hex. head screw

7. Check the position of the pin on the outside of the shoe post (face side).

The distance from the socket (4) to the surface of the recess in the shoe post should be approx. 50 mm.

8. Tighten the hex. head screw (5) to a torque of 380 Nm (280 lb ft).

Fig. 10: Checking the installation position

5

50 mm

4

4

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Socket

5

Hex. head screw

EL1000 Shearer

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4

Assembly Installing the shoe post and lifting cylinder on the mainframe

4

9. Insert sockets (11) into the holes in the shoe post and the mainframe, (12) and secure with cylinder head screws.

Fig. 11: Installing the sockets

11

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12

11

Socket

12

cylinder head screw

10. Position the lifting cylinder with the aid of suitable lifting tackle. Carefully align the holes in the shoe post and lifting cylinder.

Fig. 12: Positioning the lifting cylinder

13 13

Lifting cylinder

11. Clean and grease the pins (3) and sockets (4) and insert into the holes.

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4

Assembly Installing the shoe post and lifting cylinder on the mainframe

12. Push the sockets (4) to the ends of the pins (3). Push hex. head screw (5) through the sockets (4) and pins (3) from inside the shearer and secure hand-tight with washer (6) and nut (7).

7

4

3

4

6

3

Pin

6

Washer

4

Socket

7

Nut

5

Hex. head screw

5

13. Attach the installation aid (8) to the inner side of the shoe post and secure with hex. head screws (9).

Fig. 14: Fastening the installation aid

8 9

8

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Installation aid

9

Hex. head screw

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Fig. 13: Securing the lifting cylinder

Assembly Installing the shoe post and lifting cylinder on the mainframe

4

14. Push the hex. head screws (10) through the holes in the installation aid (8) and screw into the socket (4). Tighten the hex. head screw (10), pulling the socket against the installation aid to position the socket correctly.

Fig. 15: Positioning the socket

4

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8 10

4

Socket

8

Installation aid

10

Hex. head screw

15. Check the position of the pin on the outside of the shoe post (face side).

The distance from the socket (4) to the surface of the recess in the shoe post should be approx. 50 mm.

16. Tighten the hex. head screw (5) to a torque of 380 Nm (280 lb ft).

Fig. 16: Checking the installation position

50 mm 4

4

EL1000 Shearer

Socket

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4

Assembly Installing the downdrive on the mainframe

17. Place a cover (14) on the inner and outer sides of the shoe post and secure it with hex. head screws (15) and washers (16).

Fig. 17: Installing the covers

14

16 14

Cover

15

Hex. head screw

16

Washer

4.5 Installing the downdrive on the mainframe The downdrives (1) are fastened to the mainframe by means of 8 threaded pins (2). The threaded pins are secured with tensioning nuts (3). Covers (4) protect the tensioning nuts.

Fig. 18: Overview of installation elements

1 2

3

4

1

Downdrive

3

Tensioning nut M36

2

Threaded pin, 730 mm

4

Cover

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

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15

Assembly

4

Installing the downdrive on the mainframe

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

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

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Fig. 19: Positioning the downdrive on the mainframe

1

1

EL1000 Shearer

Downdrive

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4

Assembly Installing the downdrive on the mainframe

3. Clean and lubricate six threaded pins (2). Push the threaded pins through the holes and screw into the threaded sockets in the mainframe. 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.

38 mm (1.5 inch).

Fig. 20: Installing the threaded pins

1

2

1

Downdrive

2

Threaded pin

4. Push the thrust washers (5) of the tensioning nuts over the threaded pins.

Fig. 21: Positioning the thrust washers

5

5

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Thrust washer

EL1000 Shearer

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38 mm 1.5 in

Assembly Installing the downdrive on the mainframe

4

5. Check that the thrust bolts (6) of the tensioning nuts (3) do not protrude and are well lubricated.

Fig. 22: Preparing the tensioning nuts

6

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3

3

Tensioning nut M36

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. 23: Installing the first tensioning nut

3

3

EL1000 Shearer

tensioning nut

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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. 25: Backing off the tensioning nut 1/4 turn

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Fig. 24: 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. 26: Tightening four thrust bolts

1

3

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4

2

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

Fig. 27: Tightening four thrust bolts to 36 Nm

1

36 Nm/ 26.55 lb ft 3

4

2

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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. 28: Tightening four thrust bolts to 72 Nm

1

72 Nm/ 53.10lb ft 3

4

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2

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

Fig. 29: Tightening to 72 Nm in a circle

1

72 Nm/ 53.10 lb ft 6

2

5

3

4

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.

9. Fill the space between the thrust bolts completely with grease.

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EL1000 Shearer

Assembly

4

Installing the ranging arm on the mainframe

10. Place O-rings (7) on the covers (4) and secure the covers on the threaded pins using the hex. head screws (9) and washers (8).

Fig. 30: Installing the covers

4 7

8

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9

4

Cover

8

Washer

7

O-ring

9

Hex. head screw

4.6 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: 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. 31: Oiling the clamping sets

1

3

2

EL1000 Shearer

1

Outer ring

2

Front thrust ring

3

Rear thrust ring

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4

Assembly Installing the ranging arm on the mainframe

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. 32: Oiling the pins and hole walls

5

4

Joint pin

5

mainframe

NOTICE Using wrong oils!

The use of wrong oils can damage the machine.

1. Do not use oils and greases containing molybdenum sulfide or other highpressure additives, Teflon and silicone additives as well as internal lubricants that reduce the coefficients of friction considerably. Oil-free assembly of the clamping set tapers results in differences between the table and calculated values.

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4

Assembly Installing the ranging arm on the mainframe

4

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

Fig. 33: Loosening the clamping screws

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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. 34: Securing the front thrust ring

2

6

2

EL1000 Shearer

Front thrust ring

6

Clamping screw

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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. 35: 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 (7) on the mainframe (5).

2. Make sure that the ranging arm (7) is positioned horizontally in line with the mainframe (5).

Fig. 36: Positioning the ranging arm

5

5

mainframe

7

7

ranging arm

3. Insert a washer (8) in the hole in the joint bracket. Grease the washer so that it does not fall out.

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6

Assembly Installing the ranging arm on the mainframe

4

4. Insert ranging arm (7) into the joint eye on the mainframe and align the through holes in the ranging arm with the through holes in the mainframe.

Fig. 37: Inserting the washer

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7

8

1

2

5. Install the cover (8) on the face side joint pins (4) using bolts (9) and washers (10). Fasten the cover for the gobside joint pins using cyl. head screws.

Fig. 38: Installing the cover on the joint pins

4

8

9 10

EL1000 Shearer

4

Joint pin

9

Hex. head screw

8

Cover

10

Washer

43 / 158

4

Assembly Installing the ranging arm on the mainframe

6. Insert the joint pins (4) into the holes from the outside (cover must be in contact against the mainframe). Ensure that the "X" marking on the pin points horizontally to the side of the mainframe on the face side.

Fig. 39: Inserting the joint pin

4

4

4

Joint pin

7. Install the inner clamping sets (11) on the joint pins (4). Remove the clamping screws used for securing and screw them back into the threaded holes provided. Tighten the clamping screws hand-tight to secure the joint pins in position.

Fig. 40: Installing the inner clamping sets

11

11

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Inner clamping set

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X

Assembly Installing the ranging arm on the mainframe

4

8. Remove the hex. head screws (9), washers (10) and cover (8) from the joint pin.

Fig. 41: Removing the cover

8

9

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10

8

Cover

9

Hex. head screw

10

Washer

9. Install the outer clamping sets (12) on the joint pins (4). Remove the clamping screws used for securing and screw them back into the threaded holes provided. Tighten the clamping screws hand-tight to secure the joint pins in position.

Fig. 42: Installing the outer clamping sets

12

12

12

EL1000 Shearer

Outer clamping set

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4

Assembly Installing the ranging arm on the mainframe

10. 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. 43: Tightening the clamping screws

1: 70 Nm/

6

8

52 lb ft

9

3

4 10

2: 110 Nm/

7 5

80 lb ft

2 3: 145 Nm/ 107 lb ft

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

12. Install the covers (8, 13, 14) on the joint 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. 44: Installing the covers

8

9, 10 13 14 8

Cover

13

Cover

9

Hex. head screw

14

Cover

10

Washer

15

cylinder head screw

13. 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.

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1

Assembly Installing the lifting cylinder on the ranging arm

4

4.7 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.

Tip Installation of pins Do not grease the pins before you install them. Degrease pins in case they were greased before. moving the cylinder into position

There are lifting eyes (b) on the underside of the mainframe which can be used to hold the lifting cylinders (a) in place during installation. To install the lifting cylinders, proceed as follows:

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1. Extend the lifting cylinder until the through holes in the cylinder and ranging arm are aligned. To do so start the powerpack of the shearer or use a separate powerpack to extend the cylinder to the required length.

2. From the face side, insert pin (1) into the through holes (do not grease pin).

You might have to use a hydraulic hollow cylinder or a soft mallet to push the pin into position.

Fig. 45: Inserting the pin

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).

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4

Assembly Installing the lifting cylinder on the ranging arm

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

3, 4

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1

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Fig. 46: Tightening the pin

2

1

Pin

3

Nord-Lock washer

2

Retaining ring

4

Hex. head screw

EL1000 Shearer

Assembly Installing the spall guards

4

4.8 Installing the spall guards The spall guards (3, 4, 5, 6, 7) consist of five steel segments that are mounted on the mainframe. The spall guards are fastened to hinge brackets (1) attached to the mainframe. The first and last steel segments have two hinge brackets each; the center three steel segments have one hinge bracket each.

Each steel segment has a hydraulic cylinder installed between the hinge brackets (2) on the mainframe and the upper end of the spall guard and which extends or retracts the spall guards. The hoses are connected to the cylinders in accordance with the separate hose diagram.

Fig. 47: Installing the spall guards

6

5

4

3

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7

22, 25, 28

23, 24, 27

33, 35, 36

30, 24, 27 1 31, 35, 36 32, 35, 36 2 21, 25, 28

EL1000 Shearer

1

Hinge bracket for spall guard

24

Washer

2

Hinge bracket for cylinder

25

Washer

3

Spall guard 1

26

Washer

4

Spall guard 2

27

Locking clip, 5x32

5

Spall guard 3

28

Locking clip, 8x42

6

LH spall guard

31

Hex. head screw M 20x45

7

RH spall guard

32

Hex. head screw M 20x90

21

Pin 30x160

35

Retaining washer

22

Pin 30x110

36

Hex. nut M 20

23

Pin 20x75

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4

Assembly Installing the shearer drum on the ranging arm

4.9 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.

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.

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

Fig. 48: Preparing the working area

1

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.

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

Assembly

4

Installing the shearer drum on the ranging arm

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).

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

Fig. 49: Installing the cutting drum

2

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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.

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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. 50: 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.

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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.

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Fig. 51: 41_Installing the spray nozzles

1 2 3

4

EL1000 Shearer

1

ranging arm

6

spray nozzle

2

cutting drum

7

pick holder

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4

Assembly Moving the shearer onto the conveyor

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

Fig. 52: Installing a pick

2

7

2

cutting drum

7

pick holder

8

picks

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

4.10 Moving the shearer onto the conveyor Moving the mainframe 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. This may seriously hurt or kill you.

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.

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8

Assembly Moving the shearer onto the conveyor

4

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).

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

Fig. 53: Moving the shearer on to the conveyor

3

4

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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 powerpack.

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4

Assembly Moving the shearer onto the conveyor

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

Fig. 54: Removing the cover on the haulage unit

1

cover

2. Check that the O-ring is mounted on the motor housing (2). Install the motor housing (2) using bolts (3) and washers (4).

Fig. 55: Installing the motor housing

2

1

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coupling housing

3, 4

2

Retaining ring

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1

Assembly Moving the shearer onto the conveyor

4

3. 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. 56: Installing the adapter

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5

6 5

hydraulic motor

6

adapter

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

Fig. 57: Installing the O-ring

7

5

5

EL1000 Shearer

hydraulic motor

7

O-ring

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4

Assembly Moving the shearer onto the conveyor

5. Slide the shaft of the hydraulic motor (5) into the motor housing (2).

Fig. 58: Inserting the hydraulic motor

2

1

2

6. Secure the hydraulic motor to the motor housing using bolts (8) and washers (9). Tighten bolts to 80 Nm. Fig. 59: Installing the hydraulic motor

5

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5

hydraulic motor

8

Bolt

8, 9 9

Washer

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5

Assembly Connecting the shearer

4

7. Connect the hydraulic motor to an appropriate external powerpack.

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Fig. 60: Connecting the hydraulic motor

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.

4.11 Connecting the shearer 4.11.1 Electrical connection The shearer must be connected to a suitable electrical power supply cable. For further information see "Electrical components" [} 140] and 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. For further information on the water system, see Water System and the diagrams for the water supply.

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" [} 154].

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4

Assembly Commissioning the shearer

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

WARNING Installation errors 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.

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

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 Hydraulic hoses thrashing about 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 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

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

Assembly Dismantling and removing the shearer

4

4.13.2 Commissioning the shearer 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 opera-

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tion

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.

4.13.3 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

4.13.4 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" [} 86]).

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.

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

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4 Assembly

Dismantling and removing the shearer

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Operation Start of work

5

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

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 dangerous area Persons working close to the shearer can be seriously hurt or killed by sudden movement of the shearer.

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

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5

Operation Control elements

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. 61: Control elements

4

5

6

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3

2

1

19

7

8

18

17

16

15

14

13

11

12

9 10

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Operation MMC/ Electrical Control Box

1

LH status display (green=Automatic mode,

11

emergency stop switch

5

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orange= manual mode 2

circuit breaker for frequency converter

12

field of view

3

LED display

13

main display

4

circuit breaker for pump motor

14

reset buttons

5

reset buttons

15

release button for main disconnect switch

6

RH status display

16

main disconnect switch (visual disconnect)

7

RH radio receiver

17

field of view

8

motor start/stop button

18

LH wireless remote control

9

RH wireless remote control

19

LH radio receiver

10

USB remote control

5.3 MMC/ Electrical Control Box 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 (ECB2).

The main display on the ECB2 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.

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5

Operation MMC/ Electrical Control Box

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

1

2

3

4

5

6

17

16

15

7

19

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8

9

10

11

12

13

14

18

1

headlights on/off (if headlights are installed)

11

start coal sizer (if coal sizer is installed)

2

start machine

12

stop coal sizer (if coal sizer is installed)

3

start motors in sequence

13

test ground-fault electrical circuits

4

stop motors in sequence

14

reset ground-fault circuits

5

start LH cutter motor

15

MMC display

6

stop LH cutter motor

16

control circuit test points

7

start RH cutter motor

17

emergency stop

8

stop RH cutter motor

18

methane display

9

start pump motor and haulage motor

19

reset low-voltage circuit breaker

10

stop pump motor and haulage motor

EL1000 Shearer

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Fig. 62: ECB2 control elements - low-voltage area

Operation Wireless remote control

5

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.

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Fig. 63: USB remote control

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.

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

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5

Operation 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.

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Fig. 64: Wireless remote control

Operation Wireless remote control

5

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.

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

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Fig. 65: General control 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.

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5

Operation Wireless remote control

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.

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

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Fig. 66: Switching on the remote control

Operation Wireless remote control

5

Press and hold the "SHIFT/ON" (1) and "HAUL/HALT" (3) keys Fig. 67: Switching off the remote control

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

1

3

EL1000 Shearer

1

"SHIFT/ON" key

2

"STOP" key

3

"HAUL/HALT" key

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5

Operation Wireless remote control

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. 68: General control buttons

3

1 2 4

6

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)/

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10

end of display: open next page

11

activate keypad mode

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5

Operation Wireless remote control

5

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

Fig. 69: Shift buttons

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1

EL1000 Shearer

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)

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5

Operation Wireless remote control

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

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Fig. 70: Start/stop motors

Operation Wireless remote control

5

5.4.6 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. 71: Numeric keypad

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3

4 6

5

7 1 1

2

3

4

5

6

7

8

9

*

0

#

2

9 8

EL1000 Shearer

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

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5

Operation Wireless remote control

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.

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:

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Fig. 72: Activating the setup mode

1

1

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Activate setup mode (4 buttons)

EL1000 Shearer

Operation Starting the shearer

5

Five buttons serve to navigate through the setup mode: Fig. 73: Navigation in the setup mode

1

2

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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

5.5 Starting 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.

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5

Operation What to observe during operation

NOTICE Overheating as a 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. Press the release button (2), and turn on the main switch (visible disconnect switch) on the ECB2 electronic control unit (position “I”).

Notice on work safety Additional Information Additional 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.

1 1

main switch

3

2 2

release button

5. Power up the shearer. This is done by pressing the “MACHINE START” button (3). 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 ECB2 electronic control unit or the wireless remote control for this.

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.

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.

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Fig. 74: Main switches on the ECB2 electronic control unit

Operation Stopping the shearer

5

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!

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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 The emergency stop may be used in emergencies only.

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.

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.

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5

Operation Maintenance

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.

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.

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 can be seriously hurt or killed by an electric shock.

1. Ensure the shearer is isolated at the gate end or 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.

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

Operation Maintenance

5

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

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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

Check

M40

Cover plates secured?

Check

Visual inspection

Ranging arms 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

Check, lubricate

Lubricating/replacing the quill shaft

M100 Oil leaks?

Check

Maintenance of the ranging arms

M110 Joint pins in mainframe

Lubricate

Maintenance of the ranging arms

M120 Pin connection on lifting cylinder

Check

Maintenance of the ranging arms

M130 Lifting cylinder damage?

M140 Fluid sample for analysis

EL1000 Shearer

Check

Maintenance of the ranging arms Check

Maintenance of the ranging arms

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5

Operation

No.

Maintenance point

Maintenance daily

weekly

monthly

every three months

Comment/ Reference

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

M195 Switching between cowl flushing/downdrive flushing functioning?

Check

Maintenance of the ranging arms

Check

Maintenance of the cutting drums

M210 Picks and pick holders M220 Connecting pins tight?

Check

Maintenance of the cutting drums

M230 Can rotate freely?

Check

Maintenance of the cutting drums

M240 Damaged?

Check

Maintenance of the cutting drums

M250 Oil leakage (from ranging arm)?

Check

Maintenance of the cutting drums

M260 Dust suppression nozzles

Check

Maintenance of the cutting drums

Check

Maintenance of the haulage units

haulage unit M270 oil level 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

powerpack M330 Fluid level

Check

Maintenance of the power pack

M340 Working pressure

Check

Maintenance of the power pack

M350 Leakage?

Check

Maintenance of the power pack

M360 Filter condition

Check

Maintenance of the power pack

M370 Hoses and connections

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Check

Maintenance of the power pack

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Cutting drums

Operation Maintenance

No.

Maintenance point

daily

weekly

every three months

Comment/ Reference

M390 Fluid sample for analysis

Check

Maintenance of the power pack

M400 filters

Check/ replace

Maintenance of the power pack

M405 Tank breather filter

Change

Maintenance of the power pack

M410 Pump bracket tight?

Check

Maintenance of the power pack

M420 Motor bracket tight?

Check

Maintenance of the power pack

M430 Control valves tight?

Check

Maintenance of the power pack

M435 Spider wear

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monthly

5

Check

M440 Hydraulic fluid

Maintenance of the power pack Change

Maintenance of the power pack

Water System M450 Valves operate?

Check

M460 Visible hoses and connections

Check

M470 Flow and pressure values (MMC)

Check + note

downdrives M490 Bearings

Lubricate

"Maintenance of the downdrives" [} 108]

M495 Drive shaft

Lubricate

"Maintenance of the downdrives" [} 108]

M500 Trapping shoe pin connection

Check

"Maintenance of the downdrives" [} 108]

M505 Trapping shoe lubrication points

Lubricate

"Maintenance of the downdrives" [} 108]

M510 Gear condition

Check

M530 Trapping shoe wear part

"Maintenance of the downdrives" [} 108] Check

M540 Tensioning nut torque

"Insert on trapping shoe" [} 110] Check

"Maintenance of the downdrives" [} 108]

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

Maintenance point

daily

weekly

monthly

every three months

Comment/ Reference

General

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5

Operation

No.

Maintenance point

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

E40

Trailing cable: Connection to ECB2 and monitoring unit

Visual inspection

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?

Maintenance daily

weekly

monthly

every three months

Comment/ Reference

Check Check

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 powerpack 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 2

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Visual inspection/ knocking test

Operation Maintenance

No.

Maintenance point

daily

weekly

monthly

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

every three months

5

Comment/ Reference

Trigger/ check Visual inspection/ knocking test

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Main transformer unit HTB2 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 E255

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

EL1000 Shearer

Check

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Operation Maintenance

5.9.5 Oil and fluid analyses NOTICE Contaminated operating fluids Contaminated operating fluids 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.

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 burns.

1. If the oil is sufficiently hot, take great care and make sure you wear your Personal Safety 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.

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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.

Operation Maintenance

5

5.9.6 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. 75: Maintenance points on ranging arm RA0560

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M180

M160 M50

M120

M130

M190 C, M140 M95, M150

C, M140 M80

B, M170

M90

B, M170

M200

G, M195

EL1000 Shearer

M110

A, M195

F, M195

E, M170

D, M170

A

ranging arm overfill point

E

double epicyclic stage oil fill valve

B

oil drain

F

downdrive/cowl water flushing on/off

C

fluid sample

G

downdrive/cowl water flushing selection lever

D

oil fill valve, high-speed section

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5

Operation Maintenance Tab. 6: Maintenance of the ranging arm

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" [} 88]

M100

Oil leaks?

Visual inspection

M110

Joint pins in mainframe

Joint 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" [} 154]

M120

Pin connection on lifting cylinder

Visual inspection

M130

Lifting cylinder damage?

Visual inspection, machine shut down (see "Electrical isolation of the shearer" [} 79])

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 .

Oil capacity of high-speed section: 28 l Oil capacity of epicyclic section: 30 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

Lubricate, for lubricants: see "Permissible media" [} 154]

M195

Switching between cowl flushing/downdrive flushing functioning?

Switch on flushing (F) and operate the selection lever (G).

M200

Cowls (if installed)

Lubricate, for lubricants: see "Permissible media" [} 154]

Lubricating/replacing the quill shaft The shear 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:

DANGER Quill shaft shooting out of motor When the quill shaft is jammed and you start the motor, the quill shaft can shoot out of the motor. This can seriously hurt or kill you.

1. Make sure that the electrical supply to the shearer has been switched off and secured against unintentional startup.

2. When the quill shaft is jammed, do not try to loosen it by powering up the shearer and starting the motor.

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Ranging arms

Operation Maintenance

5

Notice on work safety Correct working height Ensure that the ranging arm is lifted up high enough and the motor housing is above the spill plate. This will ensure that the shear shaft can be pulled out.

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 79]) 2. Remove the retaining ring (1) and motor housing cover (2).

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Fig. 76: Removing the motor housing cover

1

2

1

retaining ring

2

motor housing cover

3. Remove cylinder head screws (3) and washers from the shear shaft cover (4) and then remove the shear shaft cover (4).

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5

Operation Maintenance Fig. 77: Removing the shear shaft cover

3

3

cylinder head screw

4

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4

shear shaft cover

4. Remove the retaining ring (5).

Fig. 78: Removing the retaining ring

5

5

Retaining ring

5. Screw puller (M16) into shear shaft (6) and pull shear shaft (6) out of the ranging arm gearing and ranging arm motor.

Tip Broken shear shaft If the shear shaft has sheared, then two parts need to be removed from the motor. Ensure that no broken parts remain in the motor.

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Operation Maintenance

5

Fig. 79: Pulling out the shear shaft

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6

6

Shear shaft

6. Inspect the shear shaft (6) for damage and replace if necessary.

Fig. 80: Inspecting the shear shaft

6 6

Shear shaft

7. Lubricate the shear shaft gearing (see "Quill Shaft Grease" [} 156]).

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

8. Push the shear shaft (6) into the motor with the aid of the puller (M16). If you have difficulty pushing the shear shaft gearing into the ranging arm gearing, proceed as follows: 9. Slowly rotate the shear 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 shear shaft while turning the shearer drum. This will help you mesh the shear shaft gearing with the ranging arm gearing.

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5

Operation Maintenance Fig. 81: Inserting the shear shaft

6

shear shaft

10. Ensure that the shear shaft (6) is pushed in completely and that the groove for the retaining ring is visible.

11. Install the retaining ring (5).

Fig. 82: Installing the retaining ring

5

5

Installing the retaining ring

12. Install the shear shaft cover (2).

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6

Operation Maintenance

5

Fig. 83: Installing the shear shaft cover

4

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1 4

shear shaft cover

13. Secure the shear shaft cover (4) with cylinder head screws (3) and retaining washers.

14. Tighten the cylinder head screws (3) to a torque of 77 Nm (57 lb-ft).

Fig. 84: Installing the shear shaft cover

3

4

3

cylinder head screw

4

shear shaft cover

15. Install the motor housing cover (2) and secure it with a retaining ring (1).

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5

Operation Maintenance Fig. 85: Installing the motor housing cover

1

1

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retaining ring

2

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2

motor housing cover

EL1000 Shearer

Operation Maintenance

5

5.9.7 Maintenance of the cutting drums Fig. 86: Cutting drum maintenance points

M230 M210

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M220

M260

M240

M250

Tab. 7: Cutting drum maintenance

EL1000 Shearer

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?

Remove the cutting drum cover and check for correct tightening torque of the connecting bolts by means of a torque wrench

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

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Operation Maintenance

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

Fig. 87: Haulage unit HU100 maintenance points

A, M300, M320

M290

M280

C, M310 A

oil filling point

B

oil drain spindle

C

wear indicator

Tab. 8: Haulage unit maintenance

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No.

Maintenance point

Notes

M270

oil level

Check the oil level electronically using the MMC machine control and 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" [} 97] for details of removal, inspection and installation of the shear shaft

M300

Fluid sample for analysis

Take a fluid sample from both haulage units at the oil drain point in accordance with point M320. If the analysis indicates that the oil must be changed, drain the oil and refill to the correct oil level.

Oil capacity: approx. 22 l (5.8 gal) Oil grade: see "Gear Oil" [} 154]

EL1000 Shearer

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B, M300, M320

Operation Maintenance

M310

Brake wear (if brake installed)

5

Open the cover C7 over the haulage unit 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 Please contact your Caterpillar dealer if the brake is worn.

M320

Oil change (If no analysis was carried out)

Place a collection vessel under the oil drain. Remove the cover over the haulage unit. Turn the oil drain spindle counterclockwise until it stops. Oil begins to flow out of the drain under the machine. To stop oil draining, turn the oil drain spindle clockwise. Refill with fresh oil at the oil filling point (A).

Oil capacity: 22 l (5.8 gal) Oil grade: see "Gear Oil" [} 154]

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

DANGER Quill shaft shooting out of motor When the quill shaft is jammed and you start the motor, the quill shaft can shoot out of the motor. This can seriously hurt or kill you.

1. Make sure that the electrical supply to the shearer has been switched off and secured against unintentional startup.

2. When the quill shaft is jammed, do not try to loosen it by powering up the shearer and starting the motor.

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 79] ).

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

CAUTION Pressurized hose lines!

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

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

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5

Operation Maintenance

4 2

cylinder head screw

3

retaining washer

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Fig. 88: Removing the screws from the access cover

2, 3 4

cover

4. Remove the cover (4).

Fig. 89: Removing the cover

4 cover

5. Remove the retaining ring (5).

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Operation Maintenance

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Fig. 90: Removing the retaining ring

5 5

retaining ring

6. Screw puller (M16) into the shaft plug (6) and pull out the shaft plug (6).

Fig. 91: Removing the shaft plug

6 6

shaft plug

7. Screw the puller (M16) into the rear threads of the short shear shaft (7).

Pull the short shear shaft out of the motor. If the short shear shaft cannot be pulled out, it must be pressed out of the long shear shaft behind it. In this case, screw the puller farther through the short shear shaft so that the puller pushes the short shear shaft out of the gearing of the long shear shaft.

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5

Operation Maintenance

Tip Broken shear shaft If the shear shaft has sheared, then two parts need to be removed from the motor. Ensure that no broken parts remain in the motor.

7 7

short shear shaft

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

Fig. 93: Inspecting the short shear shaft

7

7

short shear shaft

9. Screw puller (M8) into the long shear shaft (8) and pull the long shear shaft out of the haulage unit gearing and haulage motor.

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Fig. 92: Removing the short shear shaft

Operation Maintenance

5

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Fig. 94: Removing the long shear shaft

8 8

long shear shaft

10. Inspect the long shear shaft (8) for damage and replace if necessary.

Check the condition of the internal and external gearing. Check the condition of the O-ring (9) on the long shear shaft and replace if damaged.

Fig. 95: Inspecting the long shear shaft

8 8

long shear shaft

9

9

O-ring

11. Lubricate the O-ring (9) for the long shear shaft and the long shear shaft (8) (see "Quill Shaft Grease" [} 156]).

12. Push the long shear shaft (8) into the motor with the aid of the puller (M8).

13. Ensure that the long shear shaft (8) is pushed into the motor completely.

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5

Operation Maintenance

8 8

long shear shaft

14. Lubricate the short shear shaft (7) (see "Quill Shaft Grease" [} 156]).

15. Screw the puller (M12) into the wider end of the short shear shaft (7).

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

Fig. 97: Screwing the puller into the short shear shaft

7 7

short shear shaft

16. Push the short shear shaft (7) into the motor and the gearing of the long shear shaft (8) with the aid of the puller (M16 rear threads/M20 front threads). It may be necessary to rotate the short shear shaft (7) slightly.

17. Rotate the short (7) and long shear shaft (8) so that the gearing of the long shear shaft (8) meshes with the haulage unit gearing. Ensure that the short shear shaft (7) is pushed into the long shear shaft (8) completely.

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EL1000 Shearer

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Fig. 96: Pushing the long shear shaft into the motor

Operation Maintenance

5

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Fig. 98: Installing the short shear shaft

7 7

Short shear shaft

18. Unscrew the puller from the short shear shaft.

19. Inspect O-ring (10) on shaft plug. Replace, if necessary.

20. Ensure that the O-ring (10) is lubricated.

21. Lubricate the shaft plug (6) (see "Quill Shaft Grease" [} 156]).

22. Screw puller (M16) into the shaft plug (6) and push the shaft plug into the motor. Ensure that the O-ring (10) on the shaft plug is not damaged.

Fig. 99: Installing the shaft plug

10 6

EL1000 Shearer

Shaft plug

6 10

O-ring

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5

Operation Maintenance

23. Install the retaining ring (5) in the groove in front of the shaft plug.

5 5

Retaining ring

24. Install cover (4). Secure the cover (4) with cylinder head screws (2) and retaining washers (3).

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

Fig. 101: Installing the covers

4

104 / 158

2

cylinder head screw

3

Retaining washer

2, 3 4

Cover

EL1000 Shearer

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Fig. 100: Installing the retaining ring

Operation Maintenance

5

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Reinstall at their original location machine parts that were located in front of the cover and were removed previously.

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5

Operation Maintenance

5.9.9 Maintenance of the power pack Fig. 102: Powerpack PP2 maintenance points

20 19, M435

3, M340

5

4, M340

2

1

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7, M420

13, M330 21

12, M410 6

9

14, M405

16, M440

8, M380, M430 15, M390, M440

10, M360

18

106 / 158

1

cooling water pressure

12

hydraulic pump

2

inlet water pressure

13

oil level gauge

3

hydraulic system pressure

14

tank breather filter

4

hydraulic control pressure

15

oil drain (via hose)

5

haulage unit brake / spare pressure gauge (0-40 bar)

16

oil filling point

6

hydraulic reservoir

17

filter indicator

7

pump motor

18

return filter cover

8

valve block

19

hub

9

oil cooler

20

feeler gauge

10

return filter

21

spider

17

EL1000 Shearer

Operation Maintenance

5

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Tab. 9: Haulage unit maintenance

EL1000 Shearer

No.

Maintenance point

Notes

M330

Fluid level

Electricity still supplied to the machine, but haulage motor isolated. Check the fill level with the aid of the MMC system and at the oil-level gauge on the powerpack. Add hydraulic fluid, if necessary.

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 check of the filter indicator (17) while the powerpack is running at normal temperature. If the filter indicator remains in the "out" position, the filter element must be changed. Depressurize the system, unscrew the cover of the return filter (18) and replace the filter.

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" [} 86] for additional information. If the analysis indicates that the hydraulic fluid must be changed, drain the hydraulic fluid (15) and refill to the correct fill level at the oil filling point (16).

Hydraulic fluid grade: see "Hydraulic Fluid" [} 155]

M405

Tank breather filter

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

M435

Pump coupling wear

Open the maintenance flap over the pump, remove the inspection screw and measure the wear on the spider (21) by inserting a feeler gauge between the spider (21) and hub as shown. If the wear exceeds a value of 5 mm, replace the spider. Detailed instructions for replacing the spider are provided here: "Hydraulic pump drive gear" [} 121]

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" [} 155]

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Operation

5

Maintenance

5.9.10 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. 103: Downdrive maintenance points

M490

M510

M540 M505

M505 M500 M530

Tab. 10: Downdrive maintenance

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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" [} 110] for details.

M540

Tensioning nut torque

Random check and knocking test.

EL1000 Shearer

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M495

Operation Maintenance

5

5.9.11 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.

Replacing a skid shoe To replace a worn slide shoe, raise the shoe post so that the weight of the machine is taken off the pin (1). Then remove the bolts (4) with the Nord-Lock washers (3), the cover (2) and the pin, and replace the slide shoe.

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Fig. 104: Replacing a slide shoe

1 2 3

EL1000 Shearer

1

Pin

3

Nord-Lock washer

2

Cover

4

Hex. head screw

4

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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 Unsecured machine parts When working under the machine unsecured machine parts can seriously hurt or kill you.

1. Secure the ranging arm, for example with wood or with chains.

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EL1000 Shearer

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Fig. 105: Trapping shoe wear gauges

Operation Maintenance

5

For the wear measurement, a combination of wear gauges with different thicknesses is inserted between the insert 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 insert.

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Fig. 106: Trapping shoe wear measurement

1 1

Trapping shoe

2

Rack bar

3

2

3

Combination of wear gauges

The wear limit of the inserts 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

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5

Operation Maintenance

17 mm under the rack bar Fig. 107: Trapping shoe wear limits

max.(a+b)=20 mm b

17 mm max.

Replacing an insert

WARNING Be careful! Risk of tipping over!

If you remove two trapping shoes on the conveyor at the same time and very heavy cutting drums are installed, there is a risk of the shearer tipping over.

This could damage the machine severely and under certain circumstances you could be seriously injured or even killed.

1. Before starting work, check whether the machine can tip over if you remove both trapping shoes at the same time. Never remove both trapping shoes at the same time if the machine could tip over.

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.

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EL1000 Shearer

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a

Operation Maintenance

5

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

Fig. 108: Removing the rack bars

1

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7

1

EL1000 Shearer

Trapping shoe

7

Rack bar

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Operation

5

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. 109: Removing the wear part

1 4

3

5 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).

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6

Operation Maintenance

5

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

Fig. 110: Installing the rack bars

1

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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

WARNING Risk of tipping over If you remove two trapping shoes on the conveyor at the same time and very heavy cutting drums are installed, there is a risk of the shearer tipping over.

This could seriously injure or even kill you.

1. Before starting work, check whether the machine can tip over if you remove both trapping shoes at the same time. Never remove both trapping shoes at the same time if the machine could tip over.

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 adjacent rack bars (1) so that the rack bars (1) are positioned loosely on the conveyor.

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5

Operation Maintenance

3. Switch on the shearer again and move it onto the two rack bars (1) 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 (1) in the trapping shoe (2) can be detached from the conveyor.

6. Remove the rack bars (1) from the trapping shoe (2).

Fig. 111: Removing the rack bars

2

1

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rack bar

2

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1

trapping shoe

EL1000 Shearer

Operation Maintenance

5

7. Remove seven cylinder head screws (3) at the pin (4).

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Fig. 112: Removing the cylinder head screws

3 4 3

cylinder head screw

4

pin

8. Remove pin (4). The pin has an M30 thread to facilitate removal.

Fig. 113: Removing the pin

4

4

EL1000 Shearer

pin

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5

Operation Maintenance

9. Remove the trapping shoe (2) and drive gear subassembly (5).

Fig. 114: Removing the trapping shoe and drive gear

2

2

trapping shoe

5

drive gear

10. Check the drive gear subassembly for wear. If only the drive gear (6) is damaged, it can be replaced. If the cylindrical lantern gear (7) is damaged, the entire drive gear subassembly should be replaced.

Fig. 115: Replacing the drive gear, if necessary

6

7

6

drive gear

7

cylindrical lantern gear

11. Lubricate the new drive gear. Place unit consisting of trapping shoe (2) and drive gear (5) under the downdrive.

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EL1000 Shearer

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5

Operation

5

Maintenance

12. Lower the shearer so that the unit consisting of trapping shoe (2) and drive gear (5) is positioned in the downdrive housing (8).

Fig. 116: Positioning the trapping shoe in the downdrive

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5

2

2

trapping shoe

5

Drive gear

8

Downdrive

13. Check whether the installation aid (9) in mounted on the pin (4).

14. Align the trapping shoe (2) and drive gear (5). Once the through hoes in the downdrive housing and the unit consisting of trapping shoe and drive gear are aligned perfectly, install pin (4).

Fig. 117: Centering the pin

4 9 4

EL1000 Shearer

Pin

9

Installation aid

119 / 158

5

Operation Maintenance

15. Install seven cylinder head screws (3) in the pin (4) and tighten them to a torque of 545 Nm (402 lb ft).

3 4 3

cylinder head screw

4

pin

16. Insert the rack bars (1) into the trapping shoe (2).

17. Lower the shearer so that the rack bars (1) are back in their original position on the conveyor.

Fig. 119: Installing the rack bars

2

1

1

trapping shoe

7

rack bar

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

19. Shut down the shearer.

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EL1000 Shearer

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Fig. 118: Removing the cylinder head screws

Operation Maintenance

5

20. Fasten the rack bars (1).

Hydraulic pump drive gear The wear on the drive gear in the pump coupling of the powerpack can be measured using the feeler gauge. Proceed as follows: wear measurement

1. Remove the cover C2 (4) over the pump.

2. Remove the plug (3) in the pump motor flange adapter (2).

Fig. 120: Removing the plug

6

5 4

3

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2 1

1

pump motor

4

cover

2

pump motor flange adapter

5

pump

3

plug

6

suction pipe

3. Measure the wear on the drive gear by pushing the feeler gauge (8) between the drive gear (7) and hub (9). The drive gear must be replace if the wear exceeds 5 mm.

Fig. 121: Measuring the wear 8 9

1 2

5

7 6

replacing the drive gear

EL1000 Shearer

1

pump motor

7

spider

2

pump motor flange adapter

8

feeler gauge

5

pump

9

hub

6

suction pipe

To replace the drive gear, proceed as follows:

121 / 158

5

Operation Maintenance

1. Remove the suction pipe (6) between the tank and pump (5). A valve in the tank ensures that no hydraulic fluid can escape from the tank.

Fig. 122: Removing the suction pipe

6

5

pump

6

Suction pipe

2. Remove four hex. head screws (10) and washers (11) from the distributor block (12). The pump (5) can now be removed from the distributor block (12) for the following steps.

Fig. 123: Removing the pump from the distributor block

5

10, 11

12

122 / 158

5

pump

11

washer

10

hex. head screw

12

distributor block

EL1000 Shearer

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5

Operation Maintenance

5

3. Remove the hex. head screws (13) and washers (14) from the pump motor flange adapter (2).

Fig. 124: Removing the flange adapter

2

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13, 14

2

pump motor flange adapter

13

Hex. head screw

14

Washer

4. Pull the pump (5) and pump motor flange adapter (2) off the motor. If necessary, use jacking screws on the pump motor flange adapter (2).

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5

Operation Maintenance

5. Replace drive gear (7).

Fig. 125: Replacing the drive gear

7

2

2

pump motor flange adapter

5

pump

7

spider

6. Reinstall all machine components in the reverse order.

NOTICE Air in the suction chamber!

When the suction pipe of the tank is removed, can can enter the suction chamber of the tank. This air must be removed before the powerpack can be started up again.

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5

Operation Maintenance

removing the air in the suction chamber

5

1. Remove the hose connected to the bleeder on the suction chamber. The connection is identified as "T0-Air Bleed".

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Fig. 126: Removing the hose

2. Leave hose off for approx. two minutes so that the air in the suction chamber can escape. Then reattach the hose.

EL1000 Shearer

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5 Operation

Maintenance

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EL1000 Shearer

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

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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:

EL1000

Noise level:

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

Mainframe Type:

MF 1-1

Construction:

One-piece frame

Ranging arms Type:

RA 560-WP-R3 (2x)

Gear ratio:

33.70 at 52.5 rpm

Oil capacity, high-speed stage:

28 l (7.4 gal)

Oil capacity, planetary stage:

30 l (7.5 gal)

Ranging arm motor Type:

CM500 MD (2x)

Rated power:

600 kW

Voltage:

2300 V

haulage unit

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6

Technical data Technical data sheet Type:

HU100-MG-R1 (2x)

gear ratio:

132.6:1

Oil capacity:

22 l (5.8 gal)

Haulage motor Type:

HM100 B (2x)

Rated power:

100 kW

Voltage:

600 V

downdrives Type:

DD1-180 LH/RH

Rack bar system:

Jumbotrack 2000

Type:

PP2-50-30

Pump rating:

49 l/min/ 12.9 gal/min

Hydraulic fluid capacity:

140 l/ 37 gal

Pump motor, type:

PM30 B

Pump motor power rating:

34 kW

Pump motor voltage:

600 V

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powerpack

lifting cylinder Type:

ZE-225/140-550 (2x)

Stroke:

550 mm

Electrical Control Box Type:

ECB 2

Haulage transformer box Type:

HTB2

Input voltage:

4160 V

Output voltage:

600 V

Frequency converter, type:

D2-100-600 ENCF, 200 kW

Accessories

128 / 158

Tools:

Tool box

Miscellaneous:

Fire extinguisher

EL1000 Shearer

Technical data Identification

6

6.3 Identification The identification of the shearer is specified below.

The shearer is identified with a serial number name plate.

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Fig. 127: Type plate serial number

1

Serial number

2

Model designation

3

Object number

The design of the shearer meets the requirements of the European Directive 94/9/EC 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.

A separate name plate provides the relevant information regarding explosion protection: Fig. 128: Explosion protection name plate in acc. with MSHA

The following data applies to this machine: Tab. 11: Explosion protection data EL1000

EL1000 Shearer

Shearer Evaluation:

18-SEA14001-0

Type or Model:

EL1000 GSS

Serial No.:

LM210202

129 / 158

Technical data Identification Evaluated as complying with:

30 CFR, Part 18

Allowable Short Circuit Current Range:

3571A to 24348 A

Max. Effective Full Load Current:

379 A

Max. Outbye 3Ø Short Circuit Setting:

2500 A

Max Clearing Time of Outbye 3Ø Short Circuit:

120 ms

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EL1000 Shearer

Technical data Mechanical components

6

6.4 Mechanical components 6.4.1 RA0560 ranging arm The ranging arm is divided into three sections: high speed section idlers section with double epicyclic stage

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In the high-speed section, the 1st motion shaft is driven by a splined shear shaft which can be fitted or withdrawn from the gob side of the shearer. The drive from the 1st motion shaft continues through a 2nd and 3rd motion shaft, a set of three idler gears, before reaching the planetary and output stage. The output is designed as a rectangular hub on the cutting drum.

The drum speed can be varied by replacement of the 1st motion shaft assembly and 2nd motion shaft assembly with varying gear teeth numbers to suit the desired drum speed. These motion shaft assemblies are accessible via covers on the gob side of the ranging arm.

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Technical data

6

Mechanical components

Fig. 129: RA0560 ranging arm

7

9

12

3

11

13

2

1

6

5

8

132 / 158

4

1

ranging arm housing

8

high-speed section cooler

2

high speed section

9

cooler connection, high-speed section

3

double epicyclic stage

10

cooling water connection, double epicyclic stage

4

1st motion shaft

11

oil-level gauge, double epicyclic stage

5

2nd motion shaft

12

oil-level gauge, high-speed section

6

3rd motion shaft

13

lifting eye, 8000 kg

7

idler gear

14

motor housing

EL1000 Shearer

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10

14

Technical data Mechanical components

6

6.4.2 Haulage unit HU100

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The haulage unit is driven by a water-cooled electric motor. It consists of a highspeed section and a low-speed section. high-speed section

The high-speed section is driven by a shear shaft. The first motion shaft has a lip seal. This seal and an O-ring located on the end of the long shear shaft prevent oil contamination of the electric motor. The high-speed section also has an intermediate gear (2nd motion shaft), two additional reduction gears (3rd and 4th motion shaft) and a spur gear.

encoder

Depending on the version of the shearer, an encoder unit is attached to the 4th motion shaft on one haulage unit or on both haulage units. The purpose of the encoder units is to provide machine position monitoring. A gear reduction is incorporated in the drive to the encoder from the 4th motion shaft. This ensures the total number of turns of the encoder will cater for the full face length.

cooling

Cooling of the haulage unit requires a flow rate of at least 15 l/min at a maximum pressure of 30 bar. Additional information on the cooling system of the shearer can be found in the water system section.

low-speed section

The low-speed section consists of a reduction gear and a double epicyclic arrangement on the output end. All gearing in the haulage unit is lubricated by splash action from the common reservoir.

oil monitoring

An oil level and temperature transducer is fitted into the low-speed section of the haulage unit. This transducer is monitored by the MMC shearer control system. Recommended lubricants and their specifications can be found in "Permissible Media" in this chapter.

oil-level gauge

An oil-level gauge that is visible once the cover over it has been removed is mounted on the haulage unit.

fastening in the mainframe

EL1000 Shearer

The haulage unit can be placed in the mainframe horizontally from the face side as a complete module. The unit is fastened in the mainframe by means of hex. head screws, Nord-Lock washers, cylinder head screws and adjustable threaded connections.

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6

Technical data Mechanical components

The following image shows the LH haulage unit. The RH haulage unit is arranged in a mirror image.

Fig. 130: Haulage unit HU 100 (LH side)

10

9

12

13 15 8

1

4 2

134 / 158

11

7

1

low-speed section housing

9

oil fill cover

2

low-speed section housing

10

oil drain

3

double epicyclic stage

11

encoder

4

shaft, first stage

12

breather (via hose or oil filling valve subassembly)

6

shaft, third stage (if present: parking brake)

13

oil sampling point (via hose)

7

shaft, fourth stage

14

oil level/temperature sensor

8

cooling water port

15

oil-level gauge

EL1000 Shearer

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14 6

Technical data Mechanical components

6

6.4.3 Downdrive DD1-180 general

The two downdrives transmit power from the haulage unit output shaft to the drive sprocket in the trapping shoes.

assembly

The entire downdrive is bolted to the gob side of the mainframe by means of Superbolt clamping elements (see "Installing the downdrive on the mainframe" [} 32]).

Fig. 131: Arrangement of downdrive DD-180

2

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3

1

1

downdrive DD1-180

2

haulage unit HU 100

3

haulage motor

The following image shows the RH downdrive. The LH downdrive is arranged in a mirror image.

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6

Technical data Mechanical components Fig. 132: Downdrive DD1-180

1

2

3

10

9

5

8

6

7

136 / 158

1

cover

6

trapping shoe

2

spur gear, z=17

7

wear part

3

bearing housing, inner

8

cylindrical lantern gear, z=10

4

housing

9

pin with installation aid

5

gear, z=23

10

bearing housing, outer

EL1000 Shearer

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4

Technical data Hydraulic components

6

6.5 Hydraulic components 6.5.1 Hydraulic system tank/motor area

The hydraulic system is fed from a 140 l (37 gal) tank (1). The hydraulic fluid is pumped through a connection block (4) by a pump (2) powered by an electric motor (3). This block contains a pressure relief valve (295 bar/ 4280 psi) (5) with a return to tank as well as a pressure sensor (6) that is connected to the control system of the shearer. A pressure gauge that measures the main system is located above the powerpack and is also connected. The hydraulic fluid is pumped through the connection block into the valve block (8) via a hose DN20 (7).

Fig. 133: Tank/motor area

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7

1

3 2 4 6

8 5

valve block

1

tank

5

pressure relief valve

2

pump

6

pressure sensor

3

electric motor

7

pressure filter

4

connection block

8

valve block

The valve block contains six main valves PVG 100 (9) that are actuated via six 4/3-position directional control valves (10). The control line system for the hydraulic system is fed via a 3-position pressure regulator (25 bar/ 362.6 psi). A pressure relief valve keeps the idling pressure at 20 bar (290 psi). The control line pressure is needed to actuate the 4/3-position directional control valves.

The 4/3-position directional control valves that actuate the main valves are connected to the control system of the shearer via a CIOS block and a PowerSwitch (11). Each of the main valves has an ouput A and an output B. The outputs are assigned as follows: 1st valve, A port: raising of the LH ranging arm 1st valve, B port: lowering of the LH ranging arm 2nd valve, A port: raising of the RH ranging arm 2nd valve, B port: lowering of the RH ranging arm 3rd valve, output A: rotate LH cowl counterclockwise 3rd valve, output B: rotate LH cowl clockwise

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6

Technical data Hydraulic components

4th valve, output A: rotate RH cowl counterclockwise 4th valve, output B: rotate RH cowl counterclockwise 5th valve, output A: raising of the water spraying system beam 5th valve, output B: lowering of the water spraying system beam 6th valve, output A: not used/ optional function 6th valve, output B: not used/ optional function The return flow from the valve bank to the tank takes place through a hose DN25 (12) and first passes through the oil cooler (13).

Fig. 134: Valve bank

13

10

9

11

138 / 158

9

main valve PVG 100

12

hose DN25

10

4/3-position directional control valve (control pressure)

13

Oil cooler

11

PowerSwitch

pressure gauge bank

A bank of pressure gauges that indicate the main hydraulic pressure (from the connection block), the pressure for the brake and the pilot pressure (from the pilot pressure distributor).

lifting cylinder

The lifting cylinders on the shearer are differential cylinders. The piston side is connected to port A of the connected valves and lifts the ranging arm. The ring side of the lifting cylinders is connected to port B and lowers the ranging arm.

On the piston side, the lifting cylinders have a load holding valve (210 bar/3045 PSI) with integrated check valve which ensures that the ranging arm remains in its position when no longer pressurized. If the pressure on the piston side exceeds 210 bar/3045 PSI, the valve opens and the excess pressure is relieved slowly. If the pressure on the piston side increases to over 240 bar/3480 PSI, the excess pressure is relieved by a pressure relief valve (240 bar/3480 PSI) and fed to the ring side of the lifting cylinder so that the pressure can equalize between the two sides of the lifting cylinder.

The ring side of the lifting cylinder also has a load holding valve (240 bar/3480 PSI) with integrated check valve. If the pressure on the ring side exceeds 350 bar/5076 PSI, the excess pressure is fed to the piston side of the lifting cylinder

EL1000 Shearer

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12

Technical data Hydraulic components

6

via a pressure relief valve (350 bar/5076 PSI) so that the pressure can equalize between the two sides of the lifting cylinder. The maximum stroke of the cylinder is 550 mm.

6.5.2 Powerpack PP2 The powerpack supplies the hydraulic pressure to the hydraulic components of the shearer.

The components of the powerpack are assembled into a single unit that can be installed on and removed from the mainframe. All components are accessible from the gob side of the shearer. The hydraulic pump and the associated electric motor are also part of the powerpack.

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filters

The hydraulic fluid is filtered by a return line filter. The return filter assembly contains a bypass valve which will open if the filter element becomes blocked.

In this case, no filtering of the fluid takes place. Prior to the bypass valve opening, an indication of the filter becoming dirty is displayed on the control system (MMC).

Tab. 12: Table title Technical data – Powerpack PP2 Type:

PP-50-30

Hydraulic pump:

60 l/min/16 gal/min, constant

Operating pressure:

max. 280 bar

Hydraulic tank capacity

140 l/37 gal

Pump motor Rated power:

34 kW

Valve bank Number of valves:

6

Load pressure relief valve setting:

260 bar

External pressure relief valve setting:

295

Pilot pressure valve setting:

25 bar

Return filter Filter size:

EL1000 Shearer

12 µm

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6

Technical data Electrical components

6.6 Electrical components 6.6.1 Electrical system The electrical system of the shearer consists of three main circuits, namely: the pilot power system the main power distribution system the power system for the control components All three systems are introduced in basic form in the diagram below.

Fig. 135: Typical power distribution system

Trailing Cable

Shearer

Main Contactor 3 Phase

Main

Power

Cores

Fuses

Main

Main Power

Circuits

System

Control

Control Power

Circuits

System

Pilot Pilot Circuit

Core

Pilot Power

Control Relay Low Voltage Transformer

Pilot Circuits

Earth

System

Core

Further information concerning the three main systems can be obtained in the following descriptions.

6.6.2 Pilot Power System In general, a pilot circuit consists of a group of machine mounted electrical components which are interconnected between the "pilot" and "earth" (ground) cores of the external trailing cable. This system provides the machine operator with a fail-safe means of switching the three-phase high-voltage power supply from the gate end panel to the shearer.

A typical pilot circuit has two parts: a "START" control circuit a "RUN" control circuit

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Gate End Panel

Technical data Electrical components

6

The "START" circuit being responsible for the initial powering of the machine when the power "ON" pushbutton is operated; and the "RUN" circuit being responsible for allowing the machine to remain powered after the start sequence is successfully completed.

The pilot circuit when complete, i.e. all conditions satisfied, provides a return path for the AC pilot voltage, which is normally present on the trailing cable pilot core, to return to the gate end panel via the trailing cable earth core. Since this pilot voltage is rectified via the pilot circuit diode, this causes the low-voltage DC control relay within the gate end panel to energize. When this relay is energized, one of its normally open contacts closes, causing the high-voltage main AC contactor coil to be energized. This switches the three-phase power from the gate end panel to the shearer via the main cores of the trailing cable.

Notice on work safety

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

Incorrect operation!

Since the pilot circuit is a means of controlling the operation of a remote gate end panel, it is important that the functionality of this panel is understood as this affects the operation of the pilot circuit. For further details, refer to the gate end panel manufacturers documentation.

6.6.3 Main power distribution system The main power distribution system is shown in simplified form in the following figure.

Fig. 136: Main power distribution system

VACUUM CONTACTOR

LH CUTTER MOTOR

VACUUM CONTACTOR

RH CUTTER MOTOR

GATE END PANEL GATE END PANEL

MAIN SWITCH

VACUUM CONTACTOR

MAIN TRANSFORMER

CIRCUIT BREAKER

TWIN OUTPUT AC DRIVE GATE END PANEL

H.V. FUSES

CONTROL TRANSFORMER

CIRCUIT BREAKER

GATE END PANEL

TO CONTROL CIRCUITS

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6

Technical data Electrical components

After entering the Electrical Control Box ECB2 via the incoming cable entry, the 3-phase power from the gate end panel is initially connected to the "LINE" side of the main switch (via a three-phase termination point on the LH sidewall of the HV compartment).

WARNING Electric shock!

Never assume that the electric power supply for the shearer is disconnected. If you have any doubt, follow the procedure for disconnecting the electricity as described in chapter 5 of this manual.

The "LOAD" side of the main switch is connected to:

The main transformer (via pushbutton-actuated contactor). The main transformer steps down the voltage to a value suitable for the haulage system and the pump motor. The secondary windings of this transformer are connected (via circuit breaker) to the frequency converter used to control the haulage motors as well as (via circuit breaker) to the pump motor.

The ranging arm motors (via pushbutton-actuated contactors).

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EL1000 Shearer

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The control transformer. This transformer is responsible for supplying all shearer control circuits (see "Power system for the control components").

EL1000 Shearer

DC PSU

CB

LH TRANSCEIVER

LH TRANSCEIVER

24V

CB

CB

LH ENCODER

CB

HTB2 CIOS

DC PSU

12V

RH TRANSCEIVER

LH TRANSCEIVER

CB

CB

CB

LH CUTTER CONT

CB

110V NON IS

NTRON SWITCH HTB2

LH CUTTER CONT

ECB2 CIOS

BPLM

CB

E/L MODULE HTB2

CB

PLC

RCD

CB

24V

LH TRANSCEIVER

CB

110V IS

CONTROL TRANSFORMER

2400/4160 V

IMAR/ IMU UNIT

LH TRANSCEIVER

IPC

METHANE SYSTEM

MAIN DISPLAY

CB

LH MAINFRAME CIOS

AC DRIVE HTB2

CB

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NTRON SWITCH

CB

POWERPACK CIOS

FANS

CB

RH MAINFRAME CIOS

NTRON SWITCH

EXTERNAL IS SWITCH

110V IS PSU

Electrical components

Technical data

6

6.6.4 Power system for the control components The power distribution system for the control components is shown in the following figure.

Fig. 137: Power distribution for control components

143 / 158

6

Technical data Electrical components

6.6.5 Electrical control box ECB 2 The Electrical Control Box ECB2 is designed to accommodate a combination of both HV and LV components.

The unit is divided into two main sections: high-voltage (HV) section (a) low-voltage (LV) section (b) The following figure shows the operating elements on the gob side of the ECB2.

Fig. 138: Control unit ECB2 - Overview

b

a 9

1

3

4

5

6

7

8

1

main disconnect switch

8

motor start and stop buttons

3

control system display

9

release button for the main disconnect switch

4

reset button for LV safety switch

10

inlet for power supply trailing cable

5

cover for pilot circuit test points

a

high-voltage (HV) section

6

emergency stop

b

low-voltage (LV) section

7

methane monitoring display

All electrical components are accessible by removing the flameproof covers from the gob side of the unit.

High-voltage (HV) section The high-voltage (HV) section contains the high-voltage cable entries as well as the supply cable to the HTB2 housing. These entries are located on the gob side. The following main components are also located in the high-voltage section: High-voltage chassis (LH ranging arm motor, RH ranging arm motor, main transformer with pump motor and drive system) control transformer input voltage monitoring

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10

Technical data Electrical components

6

main disconnect switch Fig. 139: ECB3 high-voltage section

1

6

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5

2

3

4

EL1000 Shearer

1

main disconnect switch

4

incoming voltage monitoring

2

Power Line modem coupler

5

high-voltage chassis

3

control transformer

6

connection box to low-voltage (LV) section

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6

Technical data Electrical components

6.6.6 Haulage transformer box HTB2 The haulage transformer box contains the components for supplying electric power to the drive system.

All electrical components are accessible by removing the flameproof covers from the gob side of the unit. To cool the frequency converters (5) and the transformer (2), the haulage transformer box is connected to the cooling circuit of the water system.

Fig. 140: Haulage transformer box

1 2 16 3 5

7

9

25

10 15B 15A

146 / 158

1

HTB2 housing

9

CIOS modules

2

253 kVA transformer

10

low-voltage connection means

3

600 V connection subassembly

15a

circuit breaker for frequency converter

5

frequency converter

15b

circuit breaker for pump motor

6

ground-fault circuit breaker

16

high-voltage connection

7

pushbutton subassembly

25

current transformer subassembly

EL1000 Shearer

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6

Technical data Electrical components

6

Fig. 141: Control elements

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1

EL1000 Shearer

2

3

4

1

circuit breaker for frequency converter

3

circuit breaker for pump motor

2

display window for LED functions

4

reset buttons for low-voltage circuit breakers

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6

Technical data Electrical components

6.6.7 Cutter motors The ranging arm motors drive the cutting drums. A ranging arm motor that is protected by a cover is installed on each ranging arm.

The motors, which are identical, are of the water cooled, three-phase induction type. Each motor is started via a contactor and monitored to provide ground fault, overtemperature and overcurrent protection. A further feature of these motors is that their electrical load is monitored by the haulage system to provide mechanical load protection for the ranging arm and electrical protection for the motor.

The overtemperature protection is provided by means of thermostats and resistance temperature detectors (RTDs) which are located within the motors and connected to a "Motor Data Transmitter (MDT)".

The overcurrent protection is provided by means of a three-phase current monitor assembly located within the shearer contactor section.

3

6 5

4 3

load ring

5

cooling water connection

4

cooling water connection

6

terminal box

Tab. 13: Technical data – Ranging arm motor

148 / 158

Motor type:

CM500D

Rated power:

600 kW

Voltage:

2300 V

Frequency/Cycles:

60 Hz

Insulation class:

H

Full-load current:

182.5 A

Starting current:

6.42 x full-load current (1172 A)

Starting torque:

1.13 x full-load torque (2671 lb ft)

No of phases:

3

Circuit type:

delta

Cooling water temperature.:

max. 30 °C

EL1000 Shearer

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Fig. 142: Ranging arm motor

Technical data Electrical components

6

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

6.6.8 Haulage motors The haulage motors provide power for the shearer's haulage system. These motors, which are of the water cooled, three-phase induction type, are monitored to provide ground fault, overtemperature and overcurrent protection.

NOTICE Risk of overheating Overheating can damage the motor.

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1. Overcurrent and overheating protection for this motor is set in the machine control system (MMC). This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user.

Fig. 143: Haulage motor

3

2

1

1

cooling water connection

2

terminal box

3

cable entry (600 V AC)

Tab. 14: Technical data - Haulage motor

EL1000 Shearer

Motor type:

HM100B

Rated power:

100 kW

Voltage:

0-600 V

Frequency/Cycles:

0 - 60 - 120 Hz

Insulation class:

F

Rated current:

126 A

Starting current:

5.77x full-load current

Starting torque:

1.02x full-load torque

No of phases:

3

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6

Technical data Electrical components Weight:

approx. 550 kg

Cooling water flow rate:

10 l/min

Cooling water temperature.:

max. 30 °C

Additional information can be found in the separate operating manual from the manufacture.

6.6.9 Pump motor The pump motor drives the pump for the shearer's hydraulic system. The motor, which is of the water cooled, three-phase induction type, is started via a circuit breaker and monitored to provide ground fault, overtemperature and overcurrent protection.

NOTICE Overheating can damage the motor.

1. Overcurrent and overheating protection for this motor is set in the machine control system (MMC). This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user.

Fig. 144: Pump motor

2 3

1

1

cooling water connection

2

terminal box

3

powerpack

Tab. 15: Technical data - Pump motor

150 / 158

Motor type:

PM30B

Rated power:

34 kW/60 Hz

Voltage:

600 V

EL1000 Shearer

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Risk of motor damage from overheating

Technical data Water System

Frequency/Cycles:

60 Hz

Insulation class:

H

Amps:

43 A

RPM:

1732

Starting current:

5.00x full-load current

Starting torque:

1.87x full-load torque

Weight:

approx. 250 kg/551 lb

Cooling water temperature.:

max. 35° C

Cooling water flow rate:

10 l/min / 2.64 gal/min

6

Important information Media-ID: EM028338-00-EN / Caterpillar Global Mining Europe GmbH 2018 ©

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

6.7 Water System 6.7.1 Tasks The water system of the machine consists of the following subsystems: Cooling system for the main components of the shearer Dust suppression system Rinsing system for the cowls and the downdrives Fire extinguishing system The diagrams for the shearer's water system are contained in the drawing package accompanying this manual. There you can find detailed information on the individual systems.

6.7.2 Cooling system The cooling circuit comprises of coolers for the following: ranging arms (high-speed section and epicyclic) ranging arm motors haulage unit haulage motors pump motor hydraulic system coal sizer motor/coal sizer gearbox (if installed) electric haulage drive unit HTB2 (transformer & frequency converter)

Flow control valves The supply to each cooler is regulated by a flow control valve providing the following values (these are not adjustable):

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6

Technical data Water System Tab. 16: Cooling water system flow rates LH ranging arm - High-speed section

15 l/min (3.96 gal/min)

LH ranging arm - Epicyclic section

8 l/min (2.11 gal/min)

RH ranging arm - High-speed section

15 l/min (3.96 gal/min)

RH ranging arm - Epicyclic section

8 l/min (2.11 gal/min)

LH ranging arm motor

36 l/min (9.5 gal/min)

RH ranging arm motor

36 l/min (9.5 gal/min)

LH haulage motor/gearbox

15 l/min (3.96 gal/min)

RH haulage motor/gearbox

15 l/min (3.96 gal/min)

Transformer unit

15 l/min (3.96 gal/min)

Hydraulic oil cooler/pump motor

15 l/min (3.96 gal/min)

6.7.3 Fire extinguishing system The machine has a built-in fire extinguishing system that is connected to the water supply. When actuated, up to 180 l/min of water are sprayed by two spray blocks (2) on the mainframe (one on the left, one on the right). Only the valve (1) on one side needs to be opened. This opens the water flow to both spray blocks (2).

Fig. 145: Fire extinguishing system

1

2

1

1

152 / 158

valve

2

spray block

EL1000 Shearer

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After passing through the cooler, the cooling water is directed out of the machine via distributor blocks.

Technical data Water System

6

6.7.4 Spray Boom Besides other spraying devices the shearer is equipped with a spray boom (1).

The height of the spray boom can be controlled via the hydraulic system (see "Hydraulic system" [} 137]). The valve (2) to turn on and off the water supply to the spray boom is located in the right end section.

Fig. 146: Spray Boom

1

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2 1

EL1000 Shearer

spray boom

2

valve

153 / 158

6

Technical data Permissible media

6.8 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!

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

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 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.

6.8.1 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 Unsafe handling of operating materials and consumables (such as grease or oil) can seriously harm or kill you.

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

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1. Only use lubricants approved by Caterpillar!

Technical data Permissible media

6

Tab. 17: 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

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

Unsafe handling of operating materials and consumables (such as grease or oil) can seriously harm or kill you.

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 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.

Tab. 18: Hydraulic Fluid

EL1000 Shearer

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

155 / 158

6

Technical data Permissible media

6.8.3 Quill Shaft Grease Quill shaft grease is used to lubricate the shear shafts in the motors of the ranging arms and the haulage units as well as the downdrives. Further information on the lubrication intervals and on installing/removing the shear shafts can be found in the "Maintenance" chapter.

WARNING Handling operating materials and consumables Unsafe handling of operating materials and consumables (such as grease or oil) can seriously harm or kill you.

The grease, which must be suited to gear coupling application, should contain a highly refined base oil or synthetic hydrocarbon of very high viscosity with a balanced additive system, including molybdenum disulfide, providing good performance when judged against industry standards for the following properties: shear stability oxidation resistance and stability fretting inhibition very high operating temperature Tab. 19: Quill Shaft Grease Use:

Shear shafts in cutter and haulage motors, shear shafts in downdrives

Specification:

NLGI 1

Approved brands (examples):

Mobiltemp 78 Renolit Extreme Load 1 Shell Gadus S3 V460D 2 BP Drill Rod Grease Castrol Molub-Alloy 777-1 Castrol Molub-Alloy 860/460-1

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

WARNING Handling operating materials and consumables Unsafe handling of operating materials and consumables (such as grease or oil) can seriously harm or kill you.

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

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

Technical data Permissible media

6

The grease must be suited for use in heavily loaded slow moving 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 compatibility with lithium soap-based mineral oil grease load carrying

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

Tab. 20: Grease

EL1000 Shearer

Use:

Other lubrication points as indicated in the "Maintenance" chapter

Specification:

NLGI 1-2

Approved brands (examples):

Mobiltemp 78 Renolit Extreme Load 1 Shell Gadus S3 V460D 2 BP Drill Rod Grease Castrol Molub-Alloy 777-1 Castrol Molub-Alloy 860/460-1

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6

Technical data Tightening torques

6.9 Tightening torques 6.9.1 Screws and bolts with ISO metric thread Tab. 21: 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.

158 / 158

EL1000 Shearer

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