CAT Shearer EL2000 Operation & Maintenance Manual BI628443 - PDF DOWNLOAD

BI628443

ID-Nr. BI628443 March 2013

Operation and Maintenance Manual Shearer EL 2000 Serial-No.: Doc-No.:

LSX20137 SHEL2000-034 BA 00

SAFETY.CAT.COM SAFETY.CAT.COM

BI628443

© 2003 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.

BI628443

Operating Manual

Original operating manual

Shearer EL2000 Doc. no.: SHEL2000-034 BA 00

Caterpillar Global Mining Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@cat.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.mining.cat.com

BI628443

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 introduce modifications as a result of technical developments without previous notice.

Caterpillar Global Mining Europe GmbH, Lünen 2013E A Caterpillar Inc. Company

BI628443

Table of content

Table of content 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Who is this operating manual intended for? . . . . .

1.3

2. Introduction Your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

E

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

2.4 2.4

Electrical isolation of the shearer . . . . . . . . . . . . . .

To electrically isolate the shearer: . . . . . . . . . . . . . . . . . . . .

Overview of the safety instructions . . . . . . . . . . . . .

Starage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation (Electrical) (Chapter 5) . . . . . . . . . . . . . . . . . . . . .

Operation (Mechanical) (Chapter 5) . . . . . . . . . . . . . . . . . . .

Technical Data (Chapter 6) . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

2.11 2.11

2.12 2.12 2.14 2.16 2.18 2.20

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions for despatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short-Term-Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Long-Term-Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Units, Dimensions and Weights . . . . . . . . . . . . . . . . .

Before Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport of the Components . . . . . . . . . . . . . . . . . . . . . . . .

Doc. no.: SHEL2000-034 BA 00

3.3 3.3 3.3 3.4 3.4 3.4

3.6 3.6 3.6 3.6

Transporting The Machine Underground . . . . . . . .

3.7

Cutting Drum Removal . . . . . . . . . . . . . . . . . . . . . . . .

3.10

Ranging Arm Hydraulic Cylinder Removal . . . . . .

3.12

EL58B Ranging Arm Motor Removal . . . . . . . . . . . .

3.13

EL62F Ranging Arm Removal . . . . . . . . . . . . . . . . . .

3.14

EL53A Haulage Downdrive Removal . . . . . . . . . . . .

3.15

VPSP / 01

BI628443

Table of content EL55C Haulage Motor Removal . . . . . . . . . . . . . . . .

3.17

EL57B Haulage Unit Removal . . . . . . . . . . . . . . . . . .

3.18

EL56BN Hydraulic Pump Motor Removal . . . . . . . .

3.20

Hydraulic Reservoir Removal . . . . . . . . . . . . . . . . . .

3.21

Control Box (EL49A), Power Box (EL48A) Removal . . . . . . . . . . . . . . . . . .

3.22

EL45A Mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.24

Face Side Shoe Removal . . . . . . . . . . . . . . . . . . . . . .

3.25

4. Installation 4.4 4.4 4.6 4.6

5. Operation Introduction To Electrical Equipment . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical control boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric motor driven units . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulically actuated units . . . . . . . . . . . . . . . . . . . . . . . . .

Other electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL49A Control box . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL48A Power box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Controls (electrical) . . . . . . . . . . . . . . . . . .

Main Switch Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine 'START' pushbutton . . . . . . . . . . . . . . . . . . . . . . . .

Pilot ‘TEST’ pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine 'START/TEST' pushbutton . . . . . . . . . . . . . . . . . . .

Machine 'START RUN' pushbutton . . . . . . . . . . . . . . . . . . .

Motor START / STOP pushbutton . . . . . . . . . . . . . . . . . . . .

Motors ‘STOP’ pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop / Emergency stop lever . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio control selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3 5.4 5.4 5.5 5.6

5.9 5.9

5.13 5.13

5.15 5.17 5.17 5.17 5.17 5.17 5.18 5.18 5.18 5.18 5.18

5.19 5.19 5.20

Shearer EL 2000

E

Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil and Fluid filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning the Haulage System . . . . . . . . . . . . . . . . . .

Fault Diagnosis and Repair . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Caterpillar Global Mining Europe GmbH, Lünen 2013

Installation of the machine underground . . . . . . . .

BI628443

Table of content Electrical power distribution . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL58B Ranging Arm Motors . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor start circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quill Shaft Removal Procedure . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL56BN Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor start circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL55C Haulage Motor . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor start circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quill Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio Control System . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio Receiver Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Functions (electrical control) . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Haulage System (AC drive) . . . . . . . . . . . . . . . . . . . .

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Haulage Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction To Inverter Drive . . . . . . . . . . . . . . . . . . . . . . . .

Multiple Drives And Motors . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPACT Display Module and Keypad . . . . . . . . . . . . . . .

Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Location (quick reference guide) . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23 5.24 5.25

5.27 5.28 5.29 5.31 5.32 5.32

5.33 5.33 5.34 5.35 5.36

5.37 5.37 5.38 5.38 5.38 5.41 5.42 5.46 5.48

5.49 5.49 5.49 5.49 5.50 5.53

5.54 5.54

5.58 5.58 5.58 5.59 5.61 5.65 5.67 5.69

5.71 5.71

Maintenance (electrical) . . . . . . . . . . . . . . . . . . . . . . .

5.77

Fault diagnosis (electrical) . . . . . . . . . . . . . . . . . . . .

5.82

Diagnosis Guide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doc. no.: SHEL2000-034 BA 00

5.23

VPSP / 01

5.82 5.82

BI628443

Table of content

Operator controls (mechanical & electrical) . . . . .

Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control mode selector switch . . . . . . . . . . . . . . . . . . . . . . . .

Cooling supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency stop switch and buttons . . . . . . . . . . . . . . . . . . .

Face conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the shearer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shearer Operators Report . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mainframe (EL45A) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tollok locking assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Haulage unit (EL57B) . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downdrive system (EL53A) . . . . . . . . . . . . . . . . . . . .

Drive Quill Shaft Removal/Assembly . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ranging arm EL62F . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High speed section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ranging arm lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .

Face seal fitting instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Arm position monitoring set-up procedure . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power pack EL50A & hydraulic system . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir (Fig. 125) . . . . . . . . . . . . . . . . . . . . . . .

Reservoir Fluid Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pump (Fig. 128) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Directional Control Valve Bank (Fig. 129) . . . . . . . . . . . . . .

Solenoid Valve (Fig. 130) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ranging Arm Lifting Cylinder (Fig. 132) . . . . . . . . . . . . . . . .

Pilot Operated Check Valve (Fig. 133) . . . . . . . . . . . . . . . . .

Cowl Float Valve (Fig. 134) . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Technical Data . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.85 5.85

5.86 5.86 5.86 5.86 5.86 5.86 5.87 5.87 5.87 5.88

5.89 5.94 5.94 5.99

5.102 5.102

5.110 5.113 5.115

5.116 5.116 5.116 5.116 5.116 5.116 5.116 5.120 5.121 5.122 5.123

5.124 5.124 5.124 5.125 5.126 5.126 5.126 5.127 5.128 5.130 5.132 5.134 5.135 5.137 5.139

Shearer EL 2000

E

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.83

Caterpillar Global Mining Europe GmbH, Lünen 2013

General machine specification . . . . . . . . . . . . . . . . .

BI628443

Table of content Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shearer Cooling System (Fig.140) . . . . . . . . . . . . . . . . . . . .

Dust Suppression System (Fig. 140) . . . . . . . . . . . . . . . . . .

Fire Deluge System (Fig. 140) . . . . . . . . . . . . . . . . . . . . . . .

Cowl Flush System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ranging Arm Motor Cooling (Fig. 140) . . . . . . . . . . . . . . . . .

Ranging Arm Internal Cooler (Fig. 141) . . . . . . . . . . . . . . . .

Haulage Motor Cooling (Fig. 142) . . . . . . . . . . . . . . . . . . . . .

Haulage Unit Cooler (Fig. 143) . . . . . . . . . . . . . . . . . . . . . . .

Power Box Cooling (Fig. 144) . . . . . . . . . . . . . . . . . . . . . . . .

Pump Motor Cooling (Fig. 145) . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid Cooler (Fig. 146) . . . . . . . . . . . . . . . . . . . . .

Maintenance (mechanical) . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil and Fluid Condition Monitoring . . . . . . . . . . . . . . . . . . . .

Fault diagnosis (mechanical) . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Guide 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.140 5.140 5.140 5.141 5.141 5.141 5.142 5.142 5.143 5.143 5.144 5.144 5.145

5.147 5.147 5.148

5.158 5.158 5.158 5.159 5.159 5.160 5.161 5.161 5.162 5.162 5.163

6. Technical data Permissible Media . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shearer lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.4

Lubricants (Gear Oil) . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Lubricants (Hydraulic Fluid) . . . . . . . . . . . . . . . . . . .

6.6

Lubricants (Quill Shaft Grease) . . . . . . . . . . . . . . . .

6.7

Lubricants (Electric Motor Bearing Grease) . . . . .

6.8

Lubricants (All Other Grease Applications) . . . . . .

6.9

Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10

Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11

SPECIAL APPLICATIONS ONLY . . . . . . . . . . . . . . . . . . . . .

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6.3

6.11

Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12

Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13

Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14

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Table of content SUPERNUT tensioning system . . . . . . . . . . . . . . . . .

6.15

Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16

Diagram Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balloon Mapping Instructions . . . . . . . . . . . . . . . . . . . . . . . .

Relay Mapping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Number Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Numbering and Color Coding . . . . . . . . . . . . . . . . . . . .

Standing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug and Socket Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic & water diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 6.16 6.16 6.16 6.17 6.17 6.17 6.17 6.17

7.3

Standards and guidelines . . . . . . . . . . . . . . . . . . . . .

7.4

Referenced European standards and guidelines . . . . . . . .

Referenced USA standards and guidelines . . . . . . . . . . . . .

Referenced Australian standards and guidelines . . . . . . . .

ANNEXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 7.4 7.4

7.5

Electrical, Hydraulic, Water and Lubrication Diagrams . . . .

SUPERNUT (Downdrive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P & S Expansion Bolt System (Shoepost) . . . . . . . . . . . . . . .

Clampex clamping set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AmerCable Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pempek Radio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocol Dry Moly Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACT Cable Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Our service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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7. For your information

BI628443

1

About this manual

BI628443

BI628443

Before starting work

About this manual This chapter contains important information which will simplify the use of this manual for you. In addition it includes information about the structure of the manual and on the characters and symbols used.

Before starting work correct operating manual

If you use an operating manual which has not been written for your machine type, you will endanger yourself and others.

Ensure that the serial number on you machine corresponds with the following :

machine type

Shearer EL 2000 Ident. no.: EL2000-034 The operating manual must be accessible at all times to all persons working on, or with, this shearer.

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new operating manual

If your manual is no longer complete, has become illegible or damaged, send for a replacement immediately.

Who is this operating manual intended for?

This operating manual is intended for all persons working with or on the shearer.

All persons working with the shearer must have read this manual.

This includes persons: responsible for transport carrying out the drivage carrying out erection / dismantling operating the shearer eliminating faults carrying out routine work on the face carrying out maintenance operations carrying out repairs Supervisory persons: Instructing and / or supervising the above. cost effectiveness

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

Read this operating manual completely and carefully . In particular pay attention to the safety instructions.

Note the appearance and meaning of the safety and warning symbols.

service

Doc. no.: SHEL2000-034 BA 00

If any points are not clear , please contact our Service department .

You will find our Service address in Chapter 7 “For your information”.

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Who is this operating manual intended for? safety

Pay particular attention to Chapter 2 “Your safety”. It contains important information drawing your attention to possible sources of danger.

Observe the information and follow the instructions contained in the operating manual.

Danger!

Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are very serious injury or even death.

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Important!

Points in the text marked with this symbol contain useful information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

Items in lists are marked with bullets.

– Points in sub-lists are marked with a long dash at the start of the line.

. Points in the text marked in this way describe individual work steps. Follow these instructions step by step. They will help you carry out you work faster and, more importantly, safer.

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Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Notice!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are damage to the shearer or damage in the immediate vicinity.

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Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to moderately serious injury and / or machine damage.

BI628443

2

Your safety

BI628443

BI628443

Your safety

Introduction Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.

The Bucyrus Electra features no external components made from aluminium, or materials likely to be the source of static electricity. state of the art

The shearer has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

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The voltages and hydraulic pressures present in this machine are capable of inflicting serious injury. It is the responsibility of the user to ensure that the installation of the machine and the way in which it is operated and maintained, complies with the requirements of the Health & Safety At Work Act in the United Kingdom plus legislation and regulations of practice in the UK or elsewhere.

All external flameproof covers, glands, sockets etc. should be checked for the flameproof integrity in accordance with the legislation of the country of operation.

Do not make any modifications or alterations which could impair the safe use of the shearer. All modifications and changes must be approved by Bucyrus.

Use only original spare parts from Bucyrus. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations for accident prevention in your country. training

Observe the safety & accident prevention regulations : of the mine of the mines inspectorate and of the mining supervisory authorities

further operating manuals

Doc. no.: SHEL2000-034 BA 00

Please read also the operating manuals of the components required for operation. e.g. of gearboxes, electric motors, etc. carefully and thoroughly. Clarify any questions before starting work.

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BI628443

Personnel Personnel Operation The shearer may only be operated by qualified, trained personnel.

The shearer may only be operated by personnel who can provide proof of having been suitably trained.

The reading of the operating manual , and in particular the “ safety “ chapter must form part of this training.

You must have an adequate knowledge of: mechanics hydraulics electrics and control engineering and must be able to prove this knowledge.

As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements – safety components (pressure relief valves, extinguishers, etc.)

– the electrics (controls, signalling devices, etc.)

– the hydraulics and may only be carried out by service engineers from Bucyrus, or by specially qualified personnel of the mine.

Operating conditions Intended use The shearer has been exclusively designed and manufactured for mining of minerals, preferrably hard coal, using the longwall method. Employ the shearer only for its intended use!

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

Unauthorised use Applications not expressly listed as intended uses are unauthorised uses are not allowed to be performed with the shearer.

Bucyrus accepts no liability for injury or damage resulting from any such unauthorised use.

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Installation and repair

BI628443

Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarise yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes wearing ear protectors as the noise emissions from the shearer can at times exceed 85dB(A).

Before working on or near any part of the shearer ensure approved eye protection is worn.

Inform your colleagues : your exact location. the work you are performing. the time which you will probably require

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safety equipment

Start the shearer only when it is in a safe and good condition and all protective devices e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Keep the signalling and lighting systems in a proper functional condition.

Observe the acoustic and optical start-up warnings of the shearer.

Pre-start warning/interlock devices are designed to protect the face personnel. These devices must never be disabled.

The integrity of any on-board intrinsically safe system should be checked and maintained in original condition.

symbol plates EMERGENCY STOP

lock-out

Observe the symbol plates on the shearer.

Operate the 'EMERGENCY STOP' switch immediately, by pulling the cable suspended along the waste side of the machine, in the event of faults or irregularities in operation. Report any peculiarity to your superior allowing necessary measures to be taken immediately.

Lock-out the shearer while performing: maintenance work inspection work repair work Never enter a conveyor if conveyor and mining machine have not been locked-out.

cordon off work area

moving parts

Cordon off your work area widely for monorail and floor-mounted transport systems.

Never allow parts of your body to come between parts which could move, such as : haulage units drive wheels cutting drums etc.

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Safety instructions Storage and transport Maintain the prescribed storage periods and observe storage instructions.

Do not store materials or parts in the travel route or in your working area.

Inform persons involved about the intended transport route and the anticipated duration of transport. transport safety device

Ensure that all transport safety devices are securely fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on transport sheets.

Do not damage the treated surfaces of shafts, sealing surfaces etc. mobile handling systems

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Installation and start-up

inclined face

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

enviromental acceptability

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform supervisory personnel and the working crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

securing

Cordon off your working area with sufficient space so that other persons are not endangered.

Before working on or near any part of the shearer, isolate the electrical power supply.

Lock out the shearer and secure it to prevent unauthorized and unintentional restarting.

work in the mining track

You may only work in the mining area when you have : supported the roof to prevent falling rock. supported the face and ribs to prevent collapsing.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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

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Only use the lifting equipment which is in good condition and is designed for the loads to be handled.

BI628443

Safety instructions switched off the shearer and secured it to prevent restarting. replacing components

Before replacing defective components, switch off the machine and secure to prevent restarting.

Immediately remove defective components from the face area in order not to hinder the face crew. This also avoids the risk of these parts being inadvertently installed again elsewhere. Send these parts for repair immediately.

In inclined headings secure spare parts e.g. with chains or hoists.

original parts

Use only spare parts which satisfy the specified technical requirements. This is only ensured with original Bucyrus spare parts.

Please refer to the spare parts lists for the order reference numbers.

protective devices

Refit any protective devices removed immediately after completion of the work and check that they function properly.

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Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective equipment -hydraulic

When removing protective equipment which includes hydraulic components keep in mind that these components may be pressurized. You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

maintenance, repair

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

Ensure all hydraulic hoses are depressurised before disconnecting.

All shearer external hoses are colour coded and numbered for ease of identification. Ensure that these markers are not removed and after hose replacement, the new hose is tagged and numbered accordingly. This is to ensure that high pressure circuits are not mis-taken for low pressure circuits and vice-versa.

pressure relief valves

Make sure that pressure relief valves are always provided with protection caps. Replace defective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: the hoses are not pinched or trapped. the hoses have no bubbles or blisters. the hoses or the outer sheathes of the hoses are not abnormally rigid or hard. the outer sheath of the hose is not damaged. the connectors are securely inserted into the sockets. the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

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BI628443

Safety instructions Before removing staple locks to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is still pressurised. If the hose is difficult to turn or does not turn at all the line is still pressurised. Be sure to depressurise the line.

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurised. Be sure to depressurise the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely.

Never use nails, wire or similar materials for securing.

On completion of repair work always check all connectors and connections for leaks before pressurising the system. permissable hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn O-rings.

Fig. 1:

Example: hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

Never try to hold a pulsing hydraulic hose. Depressurise the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so that they: always have a little slack, Fig. 2:

2.8

Laying hydraulic hoses, slack RIGHT

WRONG

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

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Replace hydraulic hoses only with hoses of the same or a higher quality.

BI628443

Safety instructions are not twisted, Fig. 3:

Laying hydraulic hoses, twisting RIGHT

WRONG

are not bent directly behind the connections (distance min. 1.5 x nominal diameter), Fig. 4:

Laying hydraulic hoses, bending WRONG

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RIGHT

cannot chafe, Fig. 5:

Laying hydraulic hoses, crossing RIGHT

WRONG

are not kinked, do not have to withstand tensile strains, are protected against thermal radiation, are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: torn out, kinked, crushed, driven over or twisted (Fig.: 6) by the movement of the shearer..

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Safety instructions Fig. 6:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

2.10

Shearer EL 2000

BI628443

Electrical isolation of the shearer Electrical isolation of the shearer To electrically isolate the shearer:

. If the shearer is hauling, reduce the haulage speed to zero, stop the ranging arm, coal sizer and pump motors and then operate the `MACHINE STOP' pushbutton (see transmitter / end stations) to remove electrical power from the shearer. If a transmitter / end station control mode is not selected, use the stop / emergency stop lever to remove power from the shearer.

. Switch the shearer main switch handle to the `OFF' position, and remove the handle. Ensure the handle is kept in a safe place whilst the isolation procedure is in effect. In some applications, the main switch handle may be locked in the `OFF' position using `YOUR' personal safety lock.

. Switch the gate end panel isolating switch to the `OFF' position and secure it in this position using `YOUR' personal safety lock.

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. Un-plug the trailing cable at the gate end panel and at the Caterpillar Global Mining Europe GmbH, Lünen 2013

shearer.

. Place official warning tags on the isolators of the shearer, the gate end panel and both ends of the trailing cable to clearly identify that the isolation procedure is in effect.

To reverse this isolation procedure:

. Plug in both ends of the trailing cable. . Switch `ON' the gate end panel isolator. . Switch `ON' the shearer main switch. . Switch `ON' all pre-start water controls. . Ensure the area is clear of personnel and then start the machine.

. Select the desired control mode. . If a radio control mode is selected, switch `ON' the selected radio transmitters.

. Start the pump, ranging arm and coalsizer motors.

Operate the haulage and hydraulic functions using the selected controls.

Important!

It is possible to power the shearer when the main switch is at the `L V TEST' position whilst the test switch handle is set to `TEST'. Always ensure the test switch is set to the `RUN' position and the main switch to the `OFF' position when shearer isolation is required.

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Overview of the safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Starage and transport Danger!

YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. OBSERVE THE SAFE WORKING LOAD OF THE LIFTING SHACKLES AND KEEP A SAFE DISTANCE AWAY FROM SUSPENDED LOADS.

DO NOT DISMANTLE THE SHEARER ,UNLESS IT IS ABSOLUTELY NECESSARY FOR TRANSPORTATION PURPOSES. ALSO, DO NOT ATTEMPT TO DISMANTLE THE SHEARER BY ANY METHOD OTHER THAN SPECIFIED IN THIS DOCUMENTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. DO NOT ATTEMPT TO REMOVE THE FACE SIDE SHOES UNLESS THE MAINFRAME IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. 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. ENSURE THE DRUM IS ADEQUATELY SUPPORTED BEFORE REMOVAL OF ITS FIXINGS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. DO NOT ATTEMPT TO REMOVE THE HYDRAULIC CYLINDER UNLESS THE RANGING ARM IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. ENSURE ALL FIXINGS, CABLES, HOSES, FLAMEPROOF SURFACES AND THE MOTOR SHAFT ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR. ENSURE THE RANGING ARM IS ADEQUATELY SUPPORTED BEFORE REMOVAL OF THE RANGING ARM FIXINGS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE ARM OR INJURY TO PERSONNEL.

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Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

FAILURE TO USE SAFE LIFTING EQUIPMENT AND SPECIFIED LIFTING POINTS, MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

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Warning!

USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR THE TRANSPORT OF LOADS. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.

BI628443

Overview of the safety instructions

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ENSURE THE HAULAGE DOWNDRIVE AND THE MAINFRAME ARE ADEQUATELY SUPPORTED BEFORE REMOVAL OF THE DOWNDRIVE FIXINGS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE UNIT OR INJURY TO PERSONNEL. ENSURE THE MACHINE IS RESTRAINED FROM MOVING BEFORE HAULAGE UNIT REMOVAL IS CARRIED OUT. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL. ENSURE ALL UNIT FIXINGS, CONTROLS, DISPLAYS, CABLES, HOSES AND FLAMEPROOF SURFACES ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE UNIT. DO NOT ATTEMPT TO REMOVE THE FACE SIDE SHOES UNLESS THE MAINFRAME IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. Caution!

IN SOME CASES, THE MACHINE IS TRANSPORTED WITH ALL UNITS DRAINED OF HYDRAULIC FLUID. DO NOT OPERATE THE MACHINE UNTIL ALL UNITS ARE FILLED TO THE CORRECT LEVEL WITH APPROVED FLUID. ALSO, DO NOT OPERATE THE MACHINE UNLESS AN ADEQUATE SUPPLY OF COOLING WATER IS APPLIED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. DURING TRANSPORTATION, IT IS VERY IMPORTANT THAT MACHINED SURFACES (PARTICULARLY FLAMEPROOF AREAS) ARE ADEQUATELY PROTECTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. Important!

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the `first in, first out' principle.

Any lifting equipment used should be safety approved, free from damage and rated to the correct safe working load.

It is important that the machine is protected from the elements, in particular, rain, snow, ice, low and high temperatures, etc. In applications where the machine is subjected to freezing conditions, the cooling water system should be protected by an approved anti-freezing agent. Never operate the machine if the water system is frozen.

Failure to comply with this may result in damage to the machine.

All covers, guards and their associated fixings should be carefully packaged to ensure they are not lost during transportation. In addition to this, notes should be taken, during dismantling, to ensure that all components, cables and hoses are replaced in their proper position.

Before dismantling, it is suggested that adequate packaging is manufactured (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. See the diagrams contained in this Chapter for unit dimensions, weights and lifting points.

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Overview of the safety instructions Do not remove the cutting drums unless it is totally necessary for transportation purposes.

Refer to drum manufacturers instructions for lifting and handling of the cutting drum.

Do not remove the ranging arm hydraulic cylinders unless it is totally necessary for transportation.

Do not remove this motor unless it is totally necessary for transportation purposes.

Do not remove this unit unless it is totally necessary for transportation purposes.

Lifting shackles should only be used for assembly/disassembly of ranging arm.

Shackles are rated at 5 tonne each.

The drip feed reservoir must be removed before the downdrive can be removed from the mainframe.

Ensure the machine is adequately restrained from moving before removing the haulage motor quill shaft.

Do not remove the haulage downdrive units unless it is totally necessary for transportation purposes.

Ensure the machine is adequately restrained from moving before removing the haulage unit motor quill shaft.

Lifting shackles should only be used for assembly/disassembly of haulage unit.

Shackles are rated at 1 tonne.

Lifting shackles should only be used for assembly/disassembly of hydraulic reservoir.

Shackles are rated at 1.0 tonne.

4 Lifting shackles on top plate of mainframe should only be used for lifting the mainframe, complete with units and spall guards, but minus the ranging arms.

Shackles are rated at 20 tonne each.

Do not remove the face side shoes from mainframe unless it is totally necessary for transportation purposes.

Installation Warning!

ENSURE THE INSTALLATION AREA IS ADEQUATELY SUPPORTED DURING INSTALLATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL. ENSURE THE MACHINE UNITS ARE TRANSPORTED USING APPROVED LIFTING EQUIPMENT. ALSO, CARE SHOULD BE TAKEN TO ENSURE UNITS ARE ADEQUATELY SUPPORTED DURING THE VARIOUS STAGES OF INSTALLATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

Lifting shackles should only be used for assembly/disassembly of downdrive.

Shackles are rated at 3 tonne each.

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Ensure the machine is adequately restrained from moving before removing the output quill shaft.

BI628443

Overview of the safety instructions

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DO NOT OPERATE THE SHEARER UNLESS THE CUTTING DRUMS ARE EQUIPPED WITH A FULL COMPLEMENT OF SHARP PICKS. FAILURE TO COMPLY WITH THIS WILL RESULT IN POOR CUTTING PERFORMANCE AND MAY RESULT IN DAMAGE TO THE MACHINE. ENSURE ALL LUBRICANTS USED ARE OF THE APPROVED TYPE AND THAT THE CORRECT AMOUNT OF LUBRICANT IS APPLIED TO THE VARIOUS UNITS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. ENSURE THE MACHINE IS CONNECTED TO AN ADEQUATE SUPPLY OF WATER AND THAT, IF NECESSARY, THE WATER SUPPLIED IS FILTERED TO PREVENT THE FORMATION OF DEBRIS IN THE ON-BOARD WATER SYSTEM. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. ENSURE THE MACHINE IS CONNECTED TO AN APPROVED ELECTRICAL POWER SUPPLY AND GATE END PANEL ARRANGEMENT. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. IN APPLICATIONS WHERE HIGH TEMPERATURE AND HUMIDITY ARE PRESENT, MOISTURE MAY FORM ON SOME COMPONENTS DUE TO CONDENSATION. IN SUCH CASES, ENSURE ALL ELECTRICAL EQUIPMENT IS FREE FROM DAMPNESS BEFORE APPLYING ELECTRICAL POWER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. ENSURE ALL PERSONNEL ARE CLEAR OF THE SHEARER BEFORE POWERING IN THE `RUN' MODE. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL. ALL INSTALLATION, MAINTENANCE AND REPAIR WORK SHOULD BE CARRIED OUT BY QUALIFIED ENGINEERING PERSONNEL AND ONLY AFTER RECEIVING ADEQUATE TRAINING FROM THE MANUFACTURER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. Important!

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.

In applications featuring a left hand cowl and a left hand coal sizer, these should also be manoeuvred into practical positions at this stage.

If there is any doubt about the adequacy of the water supply available, contact the manufacturer before proceeding.

If there is any doubt about the suitability of the electrical supply or gate end panel available, contact the manufacturer before proceeding.

In instances where condensation is present, it is suggested that silica crystal sachets are placed in all flameproof units and their associated cable entry chambers. These should be replaced at the intervals specified by the manufacturer of the sachets.

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Overview of the safety instructions All drive parameter value changes should be noted (with date of change) using the check lists provided in the `Haulage System', Chapter 5.

When the installation and commissioning procedure is complete, the shearer maintenance programme should be commenced immediately. For details, refer to the `Electrical' and `Mechanical Maintenance' sections, Chapter 5.

Operation (Electrical) (Chapter 5)

DO NOT APPLY ELECTRICAL POWER TO THE RANGING ARM MOTORS UNLESS AN ADEQUATE SUPPLY OF COOLING WATER IS FLOWING THROUGH THE MOTORS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTORS. IN THE EVENT OF A STATIC STALL OF EITHER RANGING ARM MOTOR, THE EMERGENCY STOP FACILITY SHOULD BE OPERATED IMMEDIATELY. WHEN RE-STARTED, THE SHEARER SHOULD BE MOVED AWAY FROM THE OBSTRUCTION, USING THE HAULAGE CONTROLS, BEFORE RE-STARTING THE RANGING ARM MOTORS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTORS. THE OVER CURRENT AND OVER TEMPERATURE PROTECTION FOR THESE MOTORS IS SET VIA THE `COMPACT' SOFTWARE PARAMETERS. THIS PROTECTION IS SET BY THE MANUFACTURER DURING COMMISSIONING AND SHOULD NOT SUBSEQUENTLY BE ALTERED BY THE USER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTORS. DO NOT APPLY ELECTRICAL POWER TO THE HYDRAULIC POWER PACK MOTOR UNLESS AN ADEQUATE SUPPLY OF COOLING WATER IS FLOWING THROUGH THE MOTOR. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR. THE OVER CURRENT AND OVER TEMPERATURE PROTECTION FOR THIS MOTOR IS SET VIA THE `COMPACT' SOFTWARE PARAMETERS. THIS PROTECTION IS SET BY THE MANUFACTURER DURING COMMISSIONING AND SHOULD NOT SUBSEQUENTLY BE ALTERED BY THE USER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR.

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NEVER ASSUME THAT THE SHEARER IS ELECTRICALLY ISOLATED WHEN THE LIVE LINE INDICATOR IS NOT ILLUMINATED. IF IN DOUBT, CARRY OUT THE ISOLATION PROCEDURE AS DESCRIBED IN THE `PREFACE' AT THE BEGINNING OF THIS DOCUMENTATION.

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Warning!

THE REMOVABLE CHASSIS ARRANGEMENT CONTAINED WITHIN THIS UNIT IS CONNECTED TO THE UNIT VIA PLUG-IN CABLES LOCATED AT THE FACE SIDE OF THE CHASSIS. WHEN REMOVING OR REPLACING THESE CHASSIS, GREAT CARE SHOULD BE TAKEN TO AVOID DAMAGING THE CONNECTORS OR PLACING THEM IN THE WRONG POSITIONS.

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Overview of the safety instructions DO NOT APPLY ELECTRICAL POWER TO THE HAULAGE UNIT MOTOR UNLESS AN ADEQUATE SUPPLY OF COOLING WATER IS FLOWING THROUGH THE MOTOR. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR. THE OVER CURRENT AND OVER TEMPERATURE PROTECTION FOR THIS MOTOR IS SET VIA THE `COMPACT' SOFTWARE PARAMETERS. THIS PROTECTION IS SET BY THE MANUFACTURER DURING COMMISSIONING AND SHOULD NOT SUBSEQUENTLY BE ALTERED BY THE USER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR.

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WHEN CARRYING OUT MAINTENANCE/REPAIR OPERATIONS THE FOLLOWING SHOULD BE COMPLIED WITH: PERSONS SUPERVISING AND PERFORMING ELECTRICAL INSTALLATION OR MAINTENANCE MUST BE SUITABLY QUALIFIED AND COMPETENT IN THESE DUTIES. ENSURE THE SHEARER IS ISOLATED AT THE GATE END PANEL OR BY REMOVAL OF THE TRAILING CABLE, PRIOR TO CARRYING OUT ELECTRICAL MAINTENANCE, UNLESS POWER IS REQUIRED TO CARRY OUT THE CHECKS. THE SHEARER MUST BE IMMOBILISED PRIOR TO CARRYING OUT MAINTENANCE ON MOVING PARTS. WHEN WORK IS TO BE CARRIED OUT OVER, OR ON THE FACE SIDE OF THE SHEARER, BOTH THE SHEARER AND CONVEYOR (AFC) MUST BE IMMOBILISED. IN ADDITION ADEQUATE ROOF AND FACE SUPPORT MUST BE PROVIDED. ENSURE ALL HYDRAULIC AND WATER SYSTEMS ARE ISOLATED AND DE-PRESSURISED 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. BEFORE ELECTRICAL POWER IS APPLIED TO THE SHEARER, ENSURE THAT ALL FLAMEPROOF GAPS DO NOT EXCEED LEGAL LIMITS. FAILURE TO COMPLY WITH ANY OF THE ABOVE COULD LEAD TO DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. Caution!

Please ensure that the quill shaft is removed, before removing or assembling the ranging arm motor to the ranging arm. Failure to do so may result in a Damaged quill shaft.

PLEASE ENSURE THAT THE QUILL SHAFT IS REMOVED, BEFORE REMOVING OR ASSEMBLING THE HAULAGE UNIT TO THE MAINFRAME. FAILURE TO DO SO MAY RESULT IN A DAMAGED QUILL SHAFT. NEVER CHANGE THE POSITIONS OF THE SWITCHES WHILE THE INVERTER IS RUNNING. THIS MAY CAUSE LARGE SURGES OF CURRENT IN THE OUTPUT AND MAY DAMAGE THE INVERTER AND CAUSE UNPREDICTABLE MOTOR BEHAVIOR. WHEN USING HIGH VOLTAGE TEST EQUIPMENT, DO NOT CONNECT THIS EQUIPMENT TO LOW VOLTAGE CONTROL WIRING AND COMPONENTS. FAILURE TO COMPLY WITH THIS MAINTENANCE SCHEDULE COULD LEAD TO COMPONENT FAILURE AND RENDER THE SHEARER.

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Overview of the safety instructions Notice!

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.

IT IS NOT POSSIBLE TO APPLY ELECTRICAL POWER TO THE HAULAGE MOTORS UNTIL AT LEAST FIVE SECONDS AFTER THE SHEARER IS STARTED (SEE `HAULAGE SYSTEM (AC DRIVE)' SECTION, OF CHAPTER 5).

Important!

The `main switch' discussed within this documentation may be considered to be the shearer `immobilisation switch'. This switch should not be used to `STOP' the shearer except in emergency, i.e. emergency stop facility malfunction.

The ranging arm motors have bearings that are packed and sealed to last between panel change-outs. Grease GR1.

The power pack motor has bearings that are packed and sealed to last between panel change-outs. Grease grade GR1.

The haulage motors have bearings that are packed and sealed to last between panel change-outs. Grease grade GR1.

The double drive or single drive twin output arrangement on a shearer is configured to operate with a combination of frequency and current slaving to give the desired control and accuracy of operation.

A typical example of one of these cards is included on the next page. If difficulty is encountered in finding any of the components mentioned in this maintenance schedule, refer to the `Component Location (Quick Reference Guide)', Chapter 5 of this manual.

Operation (Mechanical) (Chapter 5) Danger!

Before working on or near any moving parts of the shearer, isolate the power supply at the main switch and remove the trailing cable, at the gate end panel.

Please ensure that all hydraulic and water hoses are fully depressurised before attempting any disconnection.

Ensure the machine is properly restricted from moving, before removing any part of the haulage system.

BEFORE REMOVAL OF THE RANGING ARM LIFTING CYLINDER OR PILOT OPERATED CHECK VALVE, THE RANGING ARM MUST BE SUPPORTED BY ADEQUATE BLOCKING. FAILURE TO DO SO WILL ALLOW THE RANGING ARM TO FALL VIOLENTLY TO THE FLOOR AND COULD RESULT IN SERIOUS INJURY. Warning!

Please ensure all orange, red and blue hoses are depressurised before disconnecting.

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Ensure that grease of the correct grade is applied to the splines before assembly. (Grade GR5)

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Each of the different radio modes are described in the `Radio Control' section, Chapter 5, of this manual.

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THE TRAILING CABLE CARRIES HIGH VOLTAGE AND MUST BE REPAIRED OR REPLACED IMMEDIATELY IF ANY DAMAGE IS FOUND. FAILURE TO DO SO MAY CAUSE SERIOUS INJURY. NEVER FORCE CONTROLS WITH LEVERS, HAMMERS ETC. AS THIS WILL MAKE THE SHEARER DIFFICULT TO OPERATE AND COULD RENDER IT UNRELIABLE AND DANGEROUS IN USE. BEFORE ATTEMPTING TO START THE SHEARER, MAKE SURE ALL PERSONNEL ARE CLEAR OF THE SHEARER AND CUTTING DRUMS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY. IF ANY OF THE EMERGENCY STOP DEVICES DO NOT FUNCTION, THE SHEARER SHOULD NOT BE USED UNTIL THE FAULT IS RECTIFIED. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY TO PERSONNEL OR DAMAGE TO THE SHEARER. IF THE GATE END PANEL TRIPS ON 'EARTH LEAKAGE', DO NOT ATTEMPT TO RESET IT. THIS SHOULD BE CARRIED OUT

BY A QUALIFIED FACE ENGINEER. BEFORE REMOVAL OF THE RANGING ARM LIFTING CYLINDERS OR PILOT OPERATED CHECK VALVES, THE RANGING ARMS MUST BE SUPPORTED BY ADEQUATE BLOCKING. FAILURE TO DO SO WILL ALLOW THE RANGING ARMS TO FALL VIOLENTLY TO THE FLOOR AND COULD RESULT IN SERIOUS INJURY. DURING THE ROTATING CONDITION THE OPERATOR MUST KEEP THE COWL(S) FUNCTION SWITCH OR BUTTON SELECTED, (I.E. ON RADIO TRANSMITTER OR END STATION).

FAILURE TO DO SO WILL RESULT IN THE COWL(S) ASSEMBLY VIOLENTLY RUNNING TO THE BOTTOM DEAD CENTRE POSITION, CAUSING CAViTATIONAL PROBLEMS WITHIN THE HYDRAULIC COWL MOTORS. ENSURE THAT ALL HYDRAULIC AND WATER HOSES ARE DEPRESSURISED BEFORE ATTEMPTING DISCONNECTION. FAILURE TO COMPLY WITH THIS MAY RESULT IN SERIOUS INJURY. HOT OIL CAN CAUSE BURNS. IF THE OIL IS SUFFICIENTLY HOT FOR THIS TAKE GREAT CARE. Caution!

In the event of a static stall of either ranging arm motor, the emergency stop facility should be operated immediately. When re-started, the shearer should be moved away from the obstruction, using the haulage controls, before starting the motors. Failure to comply with this may result in damage to the motors.

DO NOT ATTEMPT TO ISOLATE THIS COOLING SUPPLY AT ANY TIME WHILST THE SHEARER MOTORS ARE RUNNING, AS DAMAGE TO THE MOTOR SEALING ARRANGEMENTS WILL OCCUR. FAILURE TO REMEDY THESE EXCESS GRADIENTS MAY CAUSE SEVERE DAMAGE TO BOTH THE FACE CONVEYOR AND THE SHEARER. ALTERING THE HORIZON BY MORE THAN 40MM PER CUT CAN CREATE DIFFICULTY IN CONVEYOR ADVANCEMENT AND/OR DIFFICULTY IN SETTING ROOF SUPPORTS, THEREBY CREATING ROOF CONTROL PROBLEMS.

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Overview of the safety instructions MECHANICAL FACE SEALS AND OTHERS OF THIS TYPE ARE PRECISION SEALING DEVICES AND SHOULD BE HANDLED AND FITTED WITH GREAT CARE. TROUBLE FREE RUNNING CANNOT BE ASSURED UNLESS THE ABOVE FITTING INSTRUCTIONS ARE COMPLIED WITH. FAILURE TO COMPLY WITH THIS MAINTENANCE SCHEDULE COULD LEAD TO COMPONENT FAILURE AND RENDER THE SHEARER UNSAFE. Notice!

The emergency stop should be used in emergencies only.

The PSW and PBF parameters are derived from a common PDD.

Both ranging arms are connected to remote oil filling stations, located on the waste side of the machine. These stations are clearly labelled.

All fluid entering the hydraulic reservoir must be passed through a filter.

Reservoir is connected to a remote oil filling station, located on the waste side of the machine. This station is clearly labelled.

If difficulty is encountered when trying to find any of the components mentioned in this maintenance schedule, refer to the appropriate section of the manual, i.e. Haulage Unit, Ranging Arm, etc.

For grease and oil filling details, refer to the individual units.

Cleanliness is essential. Contamination of the sample must be avoided.

Measurement of solid contaminant levels without other analysis is not recommended. Levels under 1.5% can sometimes cause severe damage.

The following three steps only apply to machines fitted with brakes.

Technical Data (Chapter 6) Danger!

This equipment utilises high pressure hydraulics. If in any doubt regarding the correct assembly and operation of this equipment, do not attempt to use it before reading the following information.

Failure to comply with this may result in serious injury.

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Both haulage units are connected to remote oil filling stations, located on the waste side of the machine. These stations are clearly labelled.

Downdrive top bearings are connected to remote grease stations, located on the waste side of the machine. These stations are clearly labelled.

Oil must not wet any other surface.

Before carrying out calibration steps below, the machine arms must be level with the machine and preferably on a level base.

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Important!

All four hinge pins are connected to remote greasing stations, located on the waste side of the machine. These stations are clearly labelled. Prior to applying lubricant to hinge pin arrangement, ensure that the weight of the ranging arm is fully supported. (e.g. ranging arm lowered until drum rests on the floor, or ranging arm lowered until arm rests on support).

BI628443

Overview of the safety instructions Caution!

ALWAYS USE THE RECOMMENDED LUBRICANTS AT THE SPECIFIED INTERVALS. FAILURE TO COMPLY WITH THIS COULD LEAD TO COMPONENT FAILURE AND RENDER THE SHEARER UNSAFE. DO NOT OVER FILL UNITS AS THIS WILL CAUSE OVER HEATING AND LEAD TO COMPONENT FAILURE. DO NOT UNDER FILL UNITS AS THIS WILL CAUSE OVER HEATING, EXCESSIVE WEAR AND LEAD TO COMPONENT FAILURE. DO NOT OVER GREASE AS THIS WILL CAUSE OVER HEATING AND LEAD TO COMPONENT FAILURE. DO NOT UNDER GREASE AS THIS WILL CAUSE OVER HEATING, EXCESSIVE WEAR AND LEAD TO COMPONENT FAILURE. DO NOT USE UN-APPROVED LUBRICANTS. APPROVED LUBRICANTS HAVE PROPERTIES WHICH ENSURE OPTIMUM PERFORMANCE AND MAXIMUM LIFE. USE OF THE WRONG LUBRICANT TYPE OR GRADE WILL LEAD TO REDUCED PERFORMANCE AND LIFE. Caterpillar Global Mining Europe GmbH, Lünen 2013

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DO NOT FILL UNITS WITH THE WRONG TYPE OF LUBRICANT. ENSURE LUBRICANTS ARE FREE FROM CONTAMINATION BEFORE AND DURING FILLING. FAILURE TO COMPLY WITH THIS WILL LEAD TO COMPONENT FAILURE. Notice!

Use only hydraulic fluids and gear oils approved by Bucyrus!

These fluids and oils have been tested at Bucyrus and guarantee a reliable operation of their respective systems.

Important!

On start-up of a new machine, or when a new unit is installed, it is imperative that after a maximum of ten shifts working, the oil or fluid is drained from the unit. 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 recommended period for replacement of the lubricant in the units is once per month.

This is only a typical example of the relay mapping system. The exact co-ordinates of the relay 34/X vary from machine to machine.

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Overview of the safety instructions

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3

Storage and transport

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Storage

Storage and transport This chapter contains important information on the correct storage and transport of the shearer.

Observance of the instructions and tips will increase the service life and availability of the shearer. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage Conditions for despatch 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 anti-freeze fluid.

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gearboxes

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.

As in some regions transport of the machine is not allowed with fluids in those cases a preservative coating is applied to the gearboxes´ internals prior to despatch. 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.

anti-corrosion protection

Components with temporary anti-corrosion protection are protected for about six 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.

General instructions avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, spare parts made of rubber or plastic, such as seals and hoses as well as hydraulic fluids, in closed rooms at 15C to 25C.

moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, for example using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed using blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs.

natural aging

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

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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Storage frost protection for oil cooler

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

Short-Term-Storage During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components do not need to be removed. Such components require special protection against high temperatures, dirt and moisture.

Long-Term-Storage During 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.

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

Then seal the ports with plastic or steel plugs. storage of motors

In order to prevent damage to the motor, drain all cooling water off from 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.

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 Caterpillar upon request.

Storing used equipment The points listed above, with the exception of the one concerning anti-corrosion protection, can be applied in the same way to the storage of hydraulic components that have already been in use. anti-corrosion protection

If the hydraulic system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed in advance and then filled with a suitable corrosion inhibitor (e.g. HYDROCOR® CV 50*). If this is not done, then the hydraulics components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

For storage the following parts for conveying water must be completely drained, and also filled with an anti-freeze fluid (50/50 mix): Ranging arm coolers Haulage unit coolers Power pack coolers Electrical control box cooler *

3.4

HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany.

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If the equipment is to be stored for more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frost-proofing fluid such as e.g. CV 50.

Caterpillar Global Mining Europe GmbH, Lünen 2013

hydraulic components

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Storage Electrical motors Coalsizer motor (if applicable) Coalsizer gear box (if applicable) Spray bar (if applicable)

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Important!

Make sure to plug off the exhaust lines of each unit after you filled it with the anti-freeze fluid!

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Transport Transport Load Units, Dimensions and Weights Observe the transport sheets for the various transport units.

They contain information on: Dimensions Weight lifting points centre of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and assembly.

Before Transport

Electrical and electronic components

Transport of equipment at temperatures between -21 C and -40 C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be sub-jected to sudden impact 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 poor roads, the transport vehicle speed must therefore be limited to max. 25 kph for truck transport.

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be care-fully protected against transport damage and soiling of the connections.

Transport of the Components Machine parts

Shearer, gearboxes, motors, etc. are equipped with lifting shackles and eyes for transport.

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

Danger!

YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. OBSERVE THE SAFE WORKING LOAD OF THE LIFTING SHACKLES AND KEEP A SAFE DISTANCE AWAY FROM SUSPENDED LOADS. Warning!

USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR THE TRANSPORT OF LOADS. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.

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Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibiting/frost-proofing fluid (e.g. CV 50).

Caterpillar Global Mining Europe GmbH, Lünen 2013

Temperatures below freezing

BI628443

Transporting The Machine Underground The machine should be removed from the delivery vehicle using adequate lifting equipment.

Important!

Any lifting equipment used should be safety approved, free from damage and rated to the correct safe working load.

Warning!

Failure to use safe lifting equipment and specified lifting points, may result in damage to the machine or injury to personnel.

Once removed from the transport vehicle, the machine should be protected from the elements by storing it under cover. It is also suggested that, if possible, the shearer should be installed on a compatible section of conveyor.

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Important!

It is important that the machine is protected from the elements, in particular, rain, snow, ice, low and high temperatures, etc. In applications where the machine is subjected to freezing conditions, the cooling water system should be protected by an approved anti-freezing agent. Never operate the machine if the water system is frozen. Failure to comply with this may result in damage to the machine.

Caution!

IN SOME CASES, THE MACHINE IS TRANSPORTED WITH ALL UNITS DRAINED OF HYDRAULIC FLUID. DO NOT OPERATE THE MACHINE UNTIL ALL UNITS ARE FILLED TO THE CORRECT LEVEL WITH APPROVED FLUID. ALSO, DO NOT OPERATE THE MACHINE UNLESS AN ADEQUATE SUPPLY OF COOLING WATER IS APPLIED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE.

Transporting The Machine Underground Warning!

DO NOT DISMANTLE THE SHEARER ,UNLESS IT IS ABSOLUTELY NECESSARY FOR TRANSPORTATION PURPOSES. ALSO, DO NOT ATTEMPT TO DISMANTLE THE SHEARER BY ANY METHOD OTHER THAN SPECIFIED IN THIS DOCUMENTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL. The first step in the machine dismantling procedure is to remove all guards and mainframe access covers.

Important!

All covers, guards and their associated fixings should be carefully packaged to ensure they are not lost during transportation. In addition to this, notes should be taken, during dismantling, to ensure that all components, cables and hoses are replaced in their proper position.

It is suggested that the units are separated from the mainframe in the following order: Cutting Drums

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Transporting The Machine Underground Cowls Ranging Arms Haulage Downdrives Warning!

DO NOT ATTEMPT TO REMOVE THE FACE SIDE SHOES UNLESS THE MAINFRAME IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

Important!

Before dismantling, it is suggested that adequate packaging is manufactured (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. See the diagrams contained in this Chapter for unit dimensions, weights and lifting points.

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Caution!

DURING TRANSPORTATION, IT IS VERY IMPORTANT THAT MACHINED SURFACES (PARTICULARLY FLAMEPROOF AREAS) ARE ADEQUATELY PROTECTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE.

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Warning!

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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Transporting The Machine Underground Fig. 7:

Unit location

20 18

17

19

1

13

12

4

11

2 16

3

16

7

5 & 14

8 9 & 10

6 & 15

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Tab. 1: Unit weights and location

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Item No. Unit Description

Unit Weight (lbs)

1

LH Ranging arm (EL62F)

16534

2

RH Ranging arm (EL62F)

16534

3

LH Ranging arm motor (EL58B)

3240

4

RH Ranging arm motor (EL58B)

3240

5

LH Haulage unit (EL57B)

2462

6

RH Haulage unit (EL57B)

2462

7

LH Haulage motor (EL55C)

1543

8

RH Haulage motor (EL55C)

1543

9

Power Pack (EL50A)

2314

10

Pump motor (EL56BN)

802

11

Control box (EL49A)

2429

12

Power box (EL48A)

5784

13

Mainframe (EL45A)

37588

14

LH Haulage downdrive (EL53A)

4217

15

RH Haulage downdrive (EL53A)

4217

16

Ranging arm lifting cylinder

3527

17

LH Cowl

3100

18

RH Cowl

3100

19

LH Drum

10585

20

RH Drum

10585

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Cutting Drum Removal Cutting Drum Removal The handling, transport and storage diagram for this procedure is included as Fig. 8.

Warning!

ENSURE THE DRUM IS ADEQUATELY SUPPORTED BEFORE REMOVAL OF ITS FIXINGS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

. Remove water system spider taking care not to damage `O' rings.

. Remove twenty (20) M30 bolts and store them for transportation.

. Ensure drum is adequately supported.

. Place the drum within its pre-prepared crate.

Important!

Refer to drum manufacturers instructions for lifting and handling of the cutting drum.

3.10

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Caterpillar Global Mining Europe GmbH, Lünen 2013

ranging arm, taking care not to damage it or the ranging arm.

(Insert support bars in case of premature release from square hub).

E

. Using M30 bolts as jacking screws, withdraw the drum from the

BI628443

Cutting Drum Removal Cutting drum

42 ins

Fig. 8:

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74 ins

Weight: 10585

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3.11

BI628443

Ranging Arm Hydraulic Cylinder Removal Ranging Arm Hydraulic Cylinder Removal The diagram for this procedure is Fig. 9.

Important!

Do not remove the ranging arm hydraulic cylinders unless it is totally necessary for transportation.

Warning!

DO NOT ATTEMPT TO REMOVE THE HYDRAULIC CYLINDER UNLESS THE RANGING ARM IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

. Remove small cover over ram anchor pin. Withdraw ram anchor pin using a suitable all threaded bar and a slide hammer or hydraulic jack.

. Disconnect the hydraulic connections to the cylinder.

taking care not to damage it or surrounding components.

. Place the cylinder and associated material within its pre-prepared crate.

Fig. 9:

3.12

Ranging arm lifting cylinder

Cylinder closed centres

58.6 ins

Cylinder open centres

85.6 ins

Cylinder stroke

27.0 ins

Cylinder weight

3527 lbs

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Withdraw the cylinder from the ranging arm and mainframe,

E

. Remove the cylinder fixings and store them for transportation.

BI628443

EL58B Ranging Arm Motor Removal EL58B Ranging Arm Motor Removal The handling, transport and storage diagram for this procedure is included as Fig. 10.

Important!

Do not remove this motor unless it is totally necessary for transportation purposes.

Warning!

ENSURE ALL FIXINGS, CABLES, HOSES, FLAMEPROOF SURFACES AND THE MOTOR SHAFT ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR.

. Remove the appropriate covers, guards and surrounding components to gain access to the motor, it's fixings, cables and hoses.

. Withdraw the motor quill shaft and store it for transportation. . Disconnect any cables connected to the motor. Whilst cables Caterpillar Global Mining Europe GmbH, Lünen 2013

E

are being disconnected, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

. Remove the cooling water hoses from to the motor and store them for transportation.

. Remove the motor fixings and store them for transportation. . Withdraw the motor from the ranging arm, taking care not to damage it or its associated cables.

. Place the motor within its pre-prepared crate.

Fig. 10:

EL58B Ranging arm motor

1

Motor diameter

23 ins

Motor length

37.5 ins

Motor weight

3240 lbs

1

1 1.Motor lifting points/”Draw off” holes

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3.13

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EL62F Ranging Arm Removal EL62F Ranging Arm Removal The handling, transport and storage diagram for this procedure is included as Fig. 11.

Important!

Do not remove this unit unless it is totally necessary for transportation purposes.

Warning!

ENSURE THE RANGING ARM IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE ARM OR INJURY TO PERSONNEL.

. Remove the appropriate covers, guards and surrounding components to gain access to the ranging arm, it's fixings, cables and hoses.

. Disconnect the cables connected to the cutter motor and the

and the arm cooler and store them for transportation.

. Disconnect the hydraulic hoses between the ranging arm and the mainframe.

. Remove the ranging arm to mainframe hinge pins and store them for transportation (see Tollok assembly, chapter 5, Mainframe section).

. Withdraw the ranging arm from the mainframe, taking care not to damage it or its associated cables and hoses.

. Place the unit within its pre-prepared crate.

Important!

Lifting shackles should only be used for assembly/disassembly of the ranging arm.

Shackles are rated at 5 tonne each.

Fig. 11:

EL62F ranging arm

1

Ranging arm length (hinge point to nose of arm) 132 ins

1

1.Ranging arm lifting points

Ranging arm width (shroud to drum shaft flange) 84.4 ins Ranging arm height (epicyclic flange) 35.4 ins Ranging arm weight (without motor) 16534 lbs

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Caterpillar Global Mining Europe GmbH, Lünen 2013

. Remove the cooling water hoses from the ranging arm motor

E

inclinometer. Whilst cables are being disconnected, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

BI628443

EL53A Haulage Downdrive Removal EL53A Haulage Downdrive Removal The handling, transport and storage diagram for this procedure is included as Fig. 12.

Important!

The drip feed reservoir must be removed before the downdrive can be removed from the mainframe.

Important!

Do not remove the haulage downdrive units unless it is totally necessary for transportation purposes.

Warning!

ENSURE THE HAULAGE DOWNDRIVE AND THE MAINFRAME ARE ADEQUATELY SUPPORTED BEFORE REMOVAL OF THE DOWNDRIVE FIXINGS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE UNIT OR INJURY TO PERSONNEL.

. Remove the appropriate covers, guards and surrounding comCaterpillar Global Mining Europe GmbH, Lünen 2013

E

ponents to gain access to the downdrive and its fixings.

Important!

Ensure the machine is adequately restrained from moving before removing the output quill shaft.

. Remove the haulage unit output quill shaft and store it for transportation.

. Remove six (6) M30 and two (2) M36 Supernut fixings and store them for transportation.

. Withdraw the downdrive from the mainframe, taking care not to damage it or surrounding components. (Use 3 tonne lifting shackles).

Important!

Lifting shackles should only be used for assembly/disassembly of downdrive.

Shackles are rated at 3 tonne each.

. Place the downdrive components within its pre-prepared crate.

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3.15

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EL53A Haulage Downdrive Removal Fig. 12:

EL53A Haulage downdrive

1 Downdrive height

38.7 ins

Downdrive width

54.6 ins

Downdrive depth

27.5 ins

Downdrive weight

4217 lbs

1

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

2

1 1.Lifting shackles (3 tonne each) 2.Holes for jacking bolts 3.Pockets for pinch bar

3.16

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BI628443

EL55C Haulage Motor Removal EL55C Haulage Motor Removal The handling, transport and storage diagram for this procedure is included as Fig. 13.

Important!

Do not remove this motor unless it is totally necessary for transportation purposes.

Warning!

ENSURE ALL FIXINGS, CABLES, HOSES, FLAMEPROOF SURFACES AND THE MOTOR SHAFT ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR.

. Remove the appropriate mainframe covers, guards and surrounding components to gain access to the motor, its fixings, cables and hoses.

Important!

Ensure the machine is adequately restrained from moving before removing the haulage unit motor quill shaft.

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. Remove the motor quill shaft and store it for transportation. . Disconnect any cables connected to the motor. Whilst cables are being disconnected, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

. Remove the cooling water hoses from to the motor and store them for transportation.

. Remove the motor fixings and store them for transportation. . Remove the motor from the mainframe using drawbolts, taking care not to damage it or its associated cables.

. Place the motor within its pre-prepared crate.

Fig. 13:

Haulage motor

1

1 1 “Drawbolt” Lug, tapped Motor dimension 'A' Motor dimension 'B'

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Motor dimension 'C' 41.8 ins Motor weight 18.1 ins

15.2 ins 1366 lbs

3.17

BI628443

EL57B Haulage Unit Removal EL57B Haulage Unit Removal The handling, transport and storage diagram for this procedure is included as Fig. 14.

Important!

Do not remove this unit unless it is totally necessary for transportation purposes.

Warning!

ENSURE THE MACHINE IS RESTRAINED FROM MOVING BEFORE HAULAGE UNIT REMOVAL IS CARRIED OUT. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL.

. Remove the appropriate components to gain access to the unit. . Remove the downdrive as previously described.

. Remove the cooling water hoses from to the motor and store them for transportation.

(Apply protective blanks to any exposed ports or hose ends).

. Remove eight (8) M24 hex. headed bolts and store them for transportation.

. Withdraw the unit from the mainframe using (drawholes provided in gearbox shell), taking care not to damage it or surrounding components.

. Place the unit within its pre-prepared crate.

Important!

Lifting shackles should only be used for assembly/disassembly of haulage unit.

Shackles are rated at 1 tonnes.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

temperature transducer. During cable disconnection, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

(Ensure all exposed cable ends are adequately protected).

E

. Disconnect any cables connected to the motor and oil level

BI628443

EL57B Haulage Unit Removal Fig. 14:

Haulage unit

C

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

B

2

1

A

1 Motor lifting shackles (1 tonne each) 2 Extraction draw holes

Haulage dimension 'A' Haulage dimension 'B'

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48 ins Haulage dimension 'C' 19.6 ins Haulage weight

32.5 ins 2462 lbs

3.19

BI628443

EL56BN Hydraulic Pump Motor Removal EL56BN Hydraulic Pump Motor Removal This is a AE160, 60 kW, pump motor Fig. 15.

Important!

Do not remove this motor unless it is totally necessary for transportation purposes.

Warning!

ENSURE ALL FIXINGS, CABLES, HOSES, FLAMEPROOF SURFACES AND THE MOTOR SHAFT ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MOTOR.

. Remove the appropriate mainframe covers, guards and surrounding components to gain access to the motor, it's fixings, cables and hoses.

. Remove the hydraulic pump plus the motor quill shaft and store are being disconnected, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

. Remove the cooling water hoses from the motor and store them for transportation.

. Remove the motor fixings and store them for transportation. . Remove the motor from the mainframe, taking care not to damage it or its associated cables.

. Place the motor within its pre-prepared crate.

Fig. 15:

EL56BN Hydraulic pump motor

1

1

Motor diameter 12.5 ins 1.Motor lifting points

3.20

Motor length

22.8 ins

Motor weight

802 lbs

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Disconnect any cables connected to the motor. Whilst cables

E

them for transportation.

BI628443

Hydraulic Reservoir Removal Hydraulic Reservoir Removal The handling, transport and storage diagram for this procedure is included as Fig. 16.

Important!

Do not remove this unit unless it is totally necessary for transportation purposes.

. Remove the appropriate components to gain access to the unit. . Drain fluid from reservoir. . Remove two (2) M20 fixing screws and store them for transportation.

. Withdraw the reservoir from the mainframe, taking care not to damage it or surrounding components.

. Place the reservoir within its pre-prepared crate.

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. Assembly. Reverse the above procedure.

Important!

Lifting shackles should only be used for assembly/disassembly of hydraulic reservoir.

Shackles are rated at 1 tonne each.

Fig. 16:

Hydraulic reservoir

1

1

Doc. no.: SHEL2000-034 BA 00

1.Reservoir lifting shackles (1 tonne each)

Reservoir height

16.3 ins

Reservoir width

36.6 ins

Reservoir length

41.7 ins

Reservoir weight

529 lbs

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3.21

BI628443

Control Box (EL49A), Power Box (EL48A) Removal Control Box (EL49A), Power Box (EL48A) Removal The handling, transport and storage diagrams for this procedure are included as Fig. 17 & 18.

Important!

Do not remove this unit unless it is totally necessary for transportation purposes.

Warning!

ENSURE ALL UNIT FIXINGS, CONTROLS, DISPLAYS, CABLES, HOSES AND FLAMEPROOF SURFACES ARE ADEQUATELY PROTECTED DURING TRANSPORTATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE UNIT.

. Remove the appropriate mainframe covers to gain access to the units, their fixings, cables and hoses.

. Remove the water hoses from the units and store them for transportation.

. Pull all cables through the mainframe towards the units and prepare them so that they do not obstruct unit removal.

. Remove the unit fixings and store them for transportation. . Remove the units from the mainframe, taking care not to damage them or their associated cables.

. Place the units within their pre-prepared crates.

3.22

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

incoming cable if connected). Cables should be disconnected at their remote end, i.e. not at the unit. Whilst cables are being disconnected, they should be checked against the machine wiring diagrams to ensure that they are reconnected properly during installation.

E

. Disconnect any cables connected to the units (including the

BI628443

Control Box (EL49A), Power Box (EL48A) Removal Fig. 17:

EL49A Control box

1

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1.Lifting points on top of box

Fig. 18:

Control box length (incl. flanges)

28.5 ins

Control box length

21.6 ins

Control box height

15 ins

Control box width

34.7 ins

Control box weight

1102 lbs

EL48A Power box

1

1.Lifting points on top of box

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Power box length (incl. incoming cable)

88.5 ins

Power box length

79 ins

Power box height

15.2 ins

Power box width (incl. cable entries)

44 ins

Power box width

39 ins

Power box weight

5784 lbs

3.23

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EL45A Mainframe EL45A Mainframe The handling, transport and storage diagram for this procedure is included as Fig. 19.

The mainframe houses the control box, power box, power pack, LH haulage unit, LH downdrive, RH haulage unit, RH downdrive. It also provides the hinge points for the LH and RH ranging arms.

. Dismantle the ranging arms from the mainframe.

Important!

4 lifting shackles on the top plate of the mainframe should only be used for lifting the mainframe, complete with units, but minus the ranging arms.

(These shackles are rated at 20 tonne each).

Fig. 19:

EL45A mainframe and spall guards

1.Mainframe lifting shackles (20 tonne each)

3.24

Mainframe length

323 ins

Mainframe height

42.7 ins

Mainframe width

79.7 ins

Mainframe weight

37588 lbs

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

1

E

1

BI628443

Face Side Shoe Removal Face Side Shoe Removal The handling, transport and storage diagram for this procedure is included as Fig. 20.

Important!

Do not remove the face side shoes from mainframe unless it is totally necessary for transportation purposes.

Warning!

DO NOT ATTEMPT TO REMOVE THE FACE SIDE SHOES UNLESS THE MAINFRAME IS ADEQUATELY SUPPORTED. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

. Remove the shoe fixings. . Remove hinge pin and store it for transportation. . Withdraw the shoe from the mainframe.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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. Place the shoes within their pre-prepared crate.

Fig. 20:

Face side shoe

Skid shoe length

35.4 ins

Skid shoe height

8.6 ins

Skid shoe width

7.7 ins

Skid shoe weight

303 lbs

Doc. no.: SHEL2000-034 BA 00

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3.25

Caterpillar Global Mining Europe GmbH, Lünen 2013

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BI628443

Face Side Shoe Removal

3.26

Shearer EL 2000

BI628443

4

Installation

BI628443

BI628443

Installation of the machine underground

Installation Installation of the machine underground Before the shearer is installed underground, it is suggested the gate area is prepared and the units positioned in a manner for ease of assembly. These instructions are given as a general guide and will vary from mine to mine.

Warning!

ENSURE THE INSTALLATION AREA IS ADEQUATELY SUPPORTED DURING INSTALLATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL. Important!

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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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The machine should be constructed, hosed and cabled in the following order:

. Fit the face side shoes to the Mainframe (if previously removed).

. Install the Mainframe onto the Armoured Face Conveyor.

Warning!

ENSURE THE MACHINE UNITS ARE TRANSPORTED USING APPROVED LIFTING EQUIPMENT. ALSO, CARE SHOULD BE TAKEN TO ENSURE UNITS ARE ADEQUATELY SUPPORTED DURING THE VARIOUS STAGES OF INSTALLATION. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

. Move the left hand Cutting Drum, Ranging Arm and Hydraulic Cylinder (in that order) into position on the face and position ready for installation.

Important!

In applications featuring a left hand cowl and a left hand coal sizer, these should also be manoeuvred into practical positions at this stage.

. Move the left hand Haulage Unit into place and secure it within the Mainframe (if previously removed).

. Fit the left hand Haulage Motor and Downdrive (if previously removed).

. Move the right hand Haulage Unit into place and secure it within the Mainframe (if previously removed).

. Fit the right hand Haulage Motor and Downdrive (if previously removed)

. Install the flameproof EL48A and EL49A boxes within the Mainframe.

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4.3

BI628443

Installation of the machine underground . Fit the Powerpack complete to the Mainframe (if previously removed).

. Connect the left hand Ranging Arm to the Mainframe (if previously removed).

. Fit the left hand Hydraulic Cylinder to the Mainframe (if previously removed), connect it to the Ranging Arm.

. Install the left hand Cutting Drum (do not fit picks at this stage). . Connect the right hand Ranging Arm to the Mainframe (if previously removed).

. Fit the right hand Hydraulic Cylinder to the Mainframe (if previously removed), connect it to the Ranging Arm.

. Install the right hand Cutting Drum (do not fit picks at this stage).

. Connect all on-board cables and hoses in accordance with the

Warning!

DO NOT OPERATE THE SHEARER UNLESS THE CUTTING DRUMS ARE EQUIPPED WITH A FULL COMPLEMENT OF SHARP PICKS. FAILURE TO COMPLY WITH THIS WILL RESULT IN POOR CUTTING PERFORMANCE AND MAY RESULT IN DAMAGE TO THE MACHINE.

Greasing Before the machine is put to work, the individual units should be greased in accordance with the instructions contained within `Chapter 5' of this documentation package.

Oil and Fluid filling In addition to the previously mentioned `Greasing', approved types and amounts of oil and hydraulic fluid should also be applied to the individual units before the shearer is put into operation (see `Chapter 5').

Warning!

ENSURE ALL LUBRICANTS USED ARE OF THE APPROVED TYPE AND THAT THE CORRECT AMOUNT OF LUBRICANT IS APPLIED TO THE VARIOUS UNITS. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE.

. Connect an approved trailing water hose to the main inlet connection provided and connect it to the mine supply.

4.4

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Replace all covers and guards. . Lubricate the machine units. . Fit the top guards. . Install a complete set of approved picks to the drums.

E

supplied electrical and hydraulic diagrams.

BI628443

Installation of the machine underground Important!

If there is any doubt about the adequacy of the water supply available, contact the manufacturer before proceeding.

Warning!

ENSURE THE MACHINE IS CONNECTED TO AN ADEQUATE SUPPLY OF WATER AND THAT, IF NECESSARY, THE WATER SUPPLIED IS FILTERED TO PREVENT THE FORMATION OF DEBRIS IN THE ON-BOARD WATER SYSTEM. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE.

. Connect a correctly rated electrical trailing cable to the main power connection provided and connect it to an approved gate end panel.

Important!

If there is any doubt about the suitability of the electrical supply or gate end panel available, contact the manufacturer before proceeding.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Warning!

ENSURE THE MACHINE IS CONNECTED TO AN APPROVED ELECTRICAL POWER SUPPLY AND GATE END PANEL ARRANGEMENT. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

. Switch on all on-board water systems, i.e. Main Inlet, Pre-Start Warning, Cooling etc and check that they are operating efficiently. Once it has been proved that all systems are operating properly, the water supply may be isolated before proceeding to the next step.

. Power the shearer and commission the Haulage (AC Drive) system.

Warning!

IN APPLICATIONS WHERE HIGH TEMPERATURE AND HUMIDITY ARE PRESENT, MOISTURE MAY FORM ON SOME COMPONENTS DUE TO CONDENSATION. IN SUCH CASES, ENSURE ALL ELECTRICAL EQUIPMENT IS FREE FROM DAMPNESS BEFORE APPLYING ELECTRICAL POWER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE. Important!

In instances where condensation is present, it is suggested that silica crystal sachets are placed in all flameproof units and their associated cable entry chambers. These should be replaced at the intervals specified by the manufacturer of the sachets.

Doc. no.: SHEL2000-034 BA 00

VPSP / 01

4.5

BI628443

Installation of the machine underground Commissioning the Haulage System The haulage motors are controlled by a microprocessor based drive arrangement known as the `AC Drive' system. This is normally commissioned by the manufacturer before the machine is despatched to the customer. However, in some applications, some parameters may require to be changed to suit particular face conditions. In such instances, the system may be `fine tuned' by accessing the `Parameter Change' mode, via COMPACT, and inputting parameter values in accordance with the information contained within the `Haulage System' section, Chapter 5, of this documentation. (see `Parameter Values').

Important!

All drive parameter value changes should be noted (with date of change) using the check lists provided in the `Haulage System (AC drive)' section, Chapter 5.

. After completing and checking the commissioning procedure,

. Check the shearer is operational in all control modes and in particular, that all stop/emergency stop, earth leakage, general protective systems etc are functioning properly.

. The shearer is now ready for operation.

Important!

When the installation and commissioning procedure is complete, the shearer maintenance programme should be commenced immediately. For details, refer to the `Electrical' and `Mechanical Maintenance' sections, Chapter 5.

Fault Diagnosis and Repair In the event of operational problems being experienced, refer to the electrical and mechanical `Fault Diagnosis' sections in Chapter 5.

These sections consist of `simple to use' guides which suggest steps which should be taken to diagnose both electrical and mechanical/hydraulic system problems.

The `Component Location' section, Chapter 5, should be consulted if difficulty is experienced in finding any of the electrical components discussed in the diagnostic guides.

In addition to this, the COMPACT manual explains the significance of the COMPACT on-board control and monitoring system.

A copy of all electrical and hydraulic diagrams are provided with this manual.

Warning!

ALL INSTALLATION, MAINTENANCE AND REPAIR WORK SHOULD BE CARRIED OUT BY QUALIFIED ENGINEERING PERSONNEL AND ONLY AFTER RECEIVING ADEQUATE TRAINING FROM THE MANUFACTURER. FAILURE TO COMPLY WITH THIS MAY RESULT IN DAMAGE TO THE MACHINE OR INJURY TO PERSONNEL.

4.6

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Warning!

ENSURE ALL PERSONNEL ARE CLEAR OF THE SHEARER BEFORE POWERING IN THE `RUN' MODE. FAILURE TO COMPLY WITH THIS MAY RESULT IN INJURY TO PERSONNEL.

E

switch `ON' the previously tested water systems and power the shearer using the `RUN' mode.

BI628443

5

Operation

BI628443

BI628443

Introduction To Electrical Equipment

Operation Introduction To Electrical Equipment The electrical sections contained within this manual are included to systematically explain the function, operation and location of the electrical equipment employed in the Caterpillar Electra 2000 Double Ended Ranging Drum Shearer.

General The Electra 2000 incorporates the latest in microprocessor based technology and is designed to provide a reliable shearer combining high power with simple mechanical construction. To achieve this, it is made up of a number of independent electric motor driven units housed within, or attached to a robust shell known as the `Mainframe' (see Fig. 21).

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The Mainframe, as the major structural member of the shearer, houses two haulage units, two downdrives, hydraulic power pack, a centrally located control box and a power box. In addition to this, it also provides simple mechanical connections for two ranging arms.

This principal of `Traverse' construction offers several advantages over the conventional `In-line' shearer which uses one central electric motor to drive all on-board units. For example: Maintenance is easier as most units and their electric motors are removable from the waste side without the need to separate shearer sections. Units can be removed complete, or the motors may be withdrawn independently.

All units within the Mainframe are protected from external forces produced by cutting and hauling.

The absence of mechanical connections between the individual mechanical units eliminates problems associated with transmission from one unit to another and the holding together of these units. As a further result, all gearing is simpler, quieter and more reliable.

The major units can loosely be considered as belonging to three categories, i.e. `Electrical control', `electric motor driven' and `hydraulically actuated'.

Fig. 21:

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Typical mainframe

5.3

BI628443

Introduction To Electrical Equipment Electrical control boxes The shearer incorporates a centrally located electrical control box designated EL49A, and a power box designated EL48A highlighted in Fig. 22.

These units, as well as containing the majority of the shearers electrical control components, provide the connections to all motors and `peripheral' control devices. The cables are connected by means of cable entry chambers and flameproof glands which are located on the face side of the units.

Water hoses are fitted to the face side of the EL48A power box for cooling the Caterpillar drive, the main transformer, and two internal cooling jackets to provide general cooling within the box.

Fig. 22:

Control box locations

2

1.EL49A control box

1

2.EL48A power box

Electric motor driven units There are several electric motor driven units in any particular machine configuration. The positions of these motors are identified in Fig. 23.

The electric motors, all of which are water cooled, are identified as follows: Two three phase induction motors which are mounted one on each Ranging Arm and are used to drive their respective cutting drums. The motors are commonly referred to as boom or cutter motors.

A three phase induction motor which is mounted within the Hydraulic Power Pack and, as the name suggests, is incorporated to provide the shearers hydraulic power. This motor is also known as the `Pump' motor.

Two three phase induction motors which are fitted one to each Haulage Unit and are used to provide haulage power.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

The trailing cable from the gate end panel is connected into the left hand waste side of the EL48A box by means of a suitable connector..

E

In addition to the face side features, the control boxes provide a variety of operator controls and electronic display units which are located at the waste side of the units. The electronic displays may be viewed through windows on the flameproof covers of their associated section.

BI628443

Introduction To Electrical Equipment Fig. 23:

Electric motor locations

1

3

4

5

1.LH Ranging arm motor 2.RH Ranging arm motor 3.LH Haulage motor

2

4.RH Haulage motor 5.Pump motor

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Hydraulically actuated units The hydraulically actuated units shown in Fig. 24 consist of: The Ranging Arms which are raised and lowered by means of their respective hydraulic cylinders.

Control of the hydraulic actuators is achieved by means of a group of identical electro/hydraulic control valves. These devices, which each consist of a hydraulic valve arrangement, two electrical solenoids and a manual control handle, are explained in the `Hydraulic Functions (Electrical Control)' section of this documentation.

Fig. 24:

Hydraulic actuated unit location

1

3

1.LH Ranging arm lifting cylinder 2.RH Ranging arm lifting cylinder

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3 Electro/hydraulic control valves

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Introduction To Electrical Equipment Other electrical equipment In addition to the previously mentioned electrical equipment, the shearer also utilises a number of smaller `General' components, most of which are cable connected to the face side from the control box. These components, the positions of which are identified in the `Component Location (Quick Reference Guide)' section, consist of: Two (2) battery powered, operator held radio transmitters providing the operator/operators with complete remote control of most machine functions (remote from shearer).

A receiving aerial, (antenna) mounted at the end of the mainframe. connected to the radio receiver unit within the control section via a co-axial cable.

Two (2) ranging arm angle potentiometers, integral with the hinge pins, on the waste side of the ranging arms. These potentiometers provide the ranging arm angle feedback used in automatic steering.

Two (2) indication beacons, within end displays, are visible at the waste side and used to identify whether both ends of the machine are in the automatic steering mode or not. These components each feature one amber and one green lamp.

An encoder driven by one of the haulage units and used to provide the haulage controller with speed and direction related feedback.

A set of smart junction boxes which provide connections for temperature, level and pressure transducers and feedback information to the `COMPACT Module' for system health monitoring.

For details of which units the above components are connected to, refer to the `diagrams' section of Chapter 6.

Electrical diagrams To achieve ease of understanding, the electrical systems discussed in the various sections of this manual are extracts from the complete schematic and wiring diagrams that accompany this manual.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

An intrinsically safe smart solenoid driver box conveniently mounted at the waste side. This box is used as a termination point for the electro / hydraulic control valve cables which operate the ranging arms, cowls, indication beacons, plus the multicore cable connecting them to the face side of the EL49A box.

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A group of electro/hydraulic control valves with manual control facility mounted at the waste side of the hydraulic power pack and used to control the hydraulic functions. These valves may in some instances be referred to as the `Solenoids'.

BI628443

Introduction To Electrical Equipment Electrical circuits The electrical circuits discussed within the manual consist of: The `Pilot' circuits, showing which conditions must be satisfied before electrical power will be applied to the shearer (gate end panel energised).

The `Main Power distribution' circuit, showing how the main incoming power to the shearer is applied to the windings of the AC motors and the haulage system.

The `Control Power Distribution' circuit, showing how the main incoming power is transformed and distributed to the various on-board electrical control systems.

The `COMPACT' circuits which, as well as showing all inputs and outputs, show the control, monitoring and protective capabilities of the micro-processor based COMPACT module.

The `Radio Control' circuit, showing how the shearers radio control system is energised and operated in the appropriate radio control modes.

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The `Hydraulic Functions Control' circuit, showing how the solenoids of the electro/hydraulic control valves are energised in response to the operators end station or radio controls.

The `Haulage Control' circuit, showing how the shearer's microprocessor based haulage system (Caterpillar Drive) is controlled electrically in response to the operator's radio controls.

The `Electrical Monitoring' circuits, showing how the shearer's on-board electronic monitoring interfaces with the respective control circuits.

The `Health Monitoring System' circuits showing how critical mechanical components are monitored by the COMPACT Module via temperature, level and pressure transducers.

Introduction to electrical diagrams

The components shown in the electrical diagrams contained within this manual are identified by using an alpha-numeric coding system.

Typical examples from this system, which is illustrated in the first schematic diagram within Chapter 6, are: the component identified as 5/A, is a contact of the switch operated by the stop lever on the waste side of the EL49A box.

Further examples indicate that 75 is a Motor winding thermostat; and 155/A is a 12 volt intrinsic safe power supply.

Details of these devices and their respective connection numbers are also included in the first schematic diagram within Chapter 6.

Before proceeding to the various electrical sections, it is suggested that the electrical symbols illustrated in Fig. 25 are studied and understood.

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Introduction To Electrical Equipment Electrical symbols

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Fig. 25:

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EL49A Control box EL49A Control box This section explains the main features of the flameproof EL49A Control Box.

General The single unit EL49A control box is designed to accommodate electrical control components up to 250V. Cable entry chambers at the face side, provide the electrical connections between the unit and its associated devices.

The waste side of the unit consists of operator controls, inspection windows and a pilot test access cover.

EL49A control box location

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Fig. 26:

1 1.Control box

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EL49A Control box Fig. 27:

Control compartment cover 3

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2

1

5 1.Pushbuttons 2.COMPACT screen 3.Emergency stop lever

4 4.Keypad 5.Pilot test access cover

UNIT CONTENTS The electrical components contained within this unit are, where possible, fitted to a removable chassis arrangement designed to provide accessibility.

Warning!

THE REMOVABLE CHASSIS ARRANGEMENT CONTAINED WITHIN THIS UNIT IS CONNECTED TO THE UNIT VIA PLUG-IN CABLES LOCATED AT THE FACE SIDE OF THE CHASSIS. WHEN REMOVING OR REPLACING THESE CHASSIS, GREAT CARE SHOULD BE TAKEN TO AVOID DAMAGING THE CONNECTORS OR PLACING THEM IN THE WRONG POSITIONS.

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EL49A Control box The components within the ‘Control’ compartment area typically consist of: AC-DC Power Supply Unit Data Communication Unit (207) Motor 'Start' Pushbutton Operated Switch (4/T) Motor 'Stop' Pushbutton Operated Switch (5/B) Machine 'Start' Pushbutton Operated Switch (4/A) Emergency Stop Lever Operated Switch (5/A) Normal Pilot Circuit Diode Component (8) Radio Receiver (36) Intrinsically Safe Power Supply ‘1’ (12V DC for I.S. Keypad) (155/A) Intrinsically Safe Power Supply ‘2’ (12V DC I.R. Supply) (155/A)

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Monitoring LED’s for Intrinsically Safe Power Supplies ‘1 & 2’ (64) Caterpillar Global Mining Europe GmbH, Lünen 2013

COMPACT Unit and Display Pilot Lamp Indicators Control CCT Breakers (see Power Distribution section) Pilot circuit relay (34/RR)

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1 COMPACT screen 2 Emergency stop switch 3 Circuit breakers 4 COMPACT unit 5 Miniature relay 6 COMPACT Power supply 7 I.S. Power supply

4

10

1

4

13 I.S. Barrier

12 Aerial isolator

11 IMAR Unit

10 Relays

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9 DC/DC power supply

8 Radio

10

11

9

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3

2

12

13

5

6

7 8

Fig. 28:

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EL49A Control box Control compartment chassis component location

Shearer EL 2000

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EL48A Power box EL48A Power box This section explains the main features of the flameproof EL48A Power Box.

General The power box general layout is designed to accommodate all HV components.

The box has a skeleton cover fixed to the waste side and two covers fitted to the skeleton cover.

The L.H. cover provides access to HV compartment (above 600V) It also has a visible disconnect handle arrangement and FLP viewing window.

The main components within the HV compartment are: HV contactor chassis Visible disconnect switch E

3-Phase haulage transformer Caterpillar Global Mining Europe GmbH, Lünen 2013

Control transformer The R.H. cover provides access to the LV compartment. It has a drive circuit breaker operating handle and an access cover to allow connection of a drive display/diagnostic unit.

The main components within the LV compartment are: AC drive Drive circuit breaker Surge protection units The incoming cable area is located on the waste, L.H. side of the box. The box also has cable entry areas at the L.H. and R.H. sides on the face side. On the L.H. side there are two cutter motor, pump motor and two auxiliary cable entries. On the R.H. side there are two haulage motor and two auxiliary cable entries which run to EL49A control box.

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

Fig. 29:

EL48A power box location

1

1.EL48A power box

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EL48A Power box Fig. 30:

Component location

3

8 2

5 4

6

7

HV compartment 1.HV contactor chassis 2.Visible disconnect switch 3.3-Phase haulage transformer 4.Control transformer

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LV compartment 5.AC drive 6.Drive circuit breaker 7.Methane monitor PSU 8.Voltage monitor transformer

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Operator Controls (electrical) Operator Controls (electrical) This section identifies the location of, and explains how to use the various shearer controls. The position of these are shown in Fig. 31 & 32.

Fig. 31:

Operator controls location 7

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5

4

3

2

1.Machine 'START' 2.Pilot 'TEST' 3.Machine 'START' test 4.Machine 'START' run

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6

8

5.Motors START/STOP 6.Motors 'STOP' 7.Emergency stop lever 8.Keypad

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Operator Controls (electrical) Fig. 32:

Operator controls location

2

1.Main switch interlock handle

2.Main switch handle

Important!

The `main switch' discussed within this documentation may be considered to be the shearer `immobilisation switch'. This switch should not be used to `STOP' the shearer except in emergency, i.e. emergency stop facility malfunction.

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1

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Operator Controls (electrical) Main Switch Handle The two-position main switch handle, Fig. 33, may be used to switch `ON' or `OFF' the cutter motor main circuit. For example, when the handle is on the `ON' position, the shearer may be powered with both motors available for starting (see pushbuttons).

The `OFF' position allows the machine control transformer to be powered for testing purposes.

Fig. 33:

Main switch handle

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2

3

1.Interlock handle 2.Cut-out

3.Main handle

To operate the handle, pull the spring loaded interlock handle upwards, turn the interlock handle counter clockwise until the cutout in the rim allows the main handle to move, then rotate the main handle to the desired position.

Machine 'START' pushbutton This is a machine pre-start function allowing the methane system set-up to be initiated only.For full machine functions see “Machine 'START RUN' pushbutton.

Pilot ‘TEST’ pushbutton The ‘pilot test’ pushbutton, when operated with the ‘main switch’ in the ‘OFF’ position, allows the machine to be powered with all functions available except the cutter motors, pump motor, or haulage system tramming. This function is for test interrogation of COMPACT faults.

Machine 'START/TEST' pushbutton The machine START/TEST pushbutton when operated places the shearer in test mode.

Machine 'START RUN' pushbutton The machine start run pushbutton when operated with the ‘main switch’ in the ‘ON’ position allows all functions on the machine to be powered.

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Operator Controls (electrical) Motor START / STOP pushbutton The motor start/stop pushbutton must be pressed and held, followed by the appropriate keypad button in order to ’start or ’stop’ any individual motor.

Motors ‘STOP’ pushbutton The motor ’STOP’ pushbutton, when operated, will de-energize all motors.

Stop / Emergency stop lever This lever, which is connected to a length of chain at the waste side of the shearer, provides a ‘Run’ mode emergency stop facility that may be operated from anywhere along the shearers length. When operated, power is totally removed from the shearer. A mechanical latch arrangement is provided as an additional safety feature.

Radio control selection The operator is provided with the option of selecting several different ‘RADIO’ modes of shearer control. These methods, which are known as control modes may be selected using the ‘COMPACT Module’ commissioning pages.

Important!

Each of the different radio modes are described in the 'Radio Control' section, Chapter 5, of this manual.

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A numeric keypad is used by the operator to communicate with the COMPACT system. The keypad has twelve keys to allow data entry. The use of the keys is explained in the COMPACT (machine control system), Chapter 6.

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Keypad

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Pilot circuit Pilot circuit This section explains the electrical conditions which must be satisfied in order to apply electrical power to the shearer, i.e. the electrical pilot circuits.

General 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. Although pilot circuit electrical components can vary from machine to machine, usually they consist of switches, relay contacts, and a diode. A typical pilot circuit will consist of two parts, a `START' circuit and a `RUN' circuit. 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.

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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 energise. When this relay is energised, one of its normally open contacts closes, causing the high voltage main AC contactor coil to be energised. Thus switching the three phase power from the gate end panel to the shearer via the main cores of the trailing cable.

Notice!

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.

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Pilot circuit Fig. 34:

Typical pilot circuit Gate End Panel

Trailing Cable

Shearer

Main Contactor Main Circuits

3 Phase Power

Fuses

Main Contactor Coil

Main Cores Pilot Core

Control Circuits Pilot Circuits

Pilot Circuit Control Relay Earth Core

The simplified diagram above, illustrates the relationship between a typical gate end panel, trailing cable and shearer.

Pilot circuit The shearer has one pilot circuit. The pilot circuit powers the shearer with all main circuits energised, and the shearer control circuits with the main circuits isolated.

The normal power circuit is therefore the circuit used to power the shearer for every day use, i.e. coal cutting. The test power circuit on the other hand is used, as the name suggests, for test purposes. This facility is of particular use to maintenance personnel as it permits the inspection of the shearers on board electronic monitoring units even after the event of most shearer power down faults.

The following is a detailed description of the individual electrical components of the normal power pilot circuit. For the purpose of this description, refer to the pilot circuit schematic diagram included in Chapter 6.

5.20

Initial connection

The pilot core of the trailing cable, on entering the shearer is initially terminated at a conveniently positioned connector located within the terminal chamber compartment of the EL48A.

Pilot circuit coupler

If data transmission is required by means of the pilot core on the main incoming cable then a pilot circuit coupler is connected in series to the pilot circuit. A connection from this coupler is taken to the data transmission system modem. The coupler and modem are situated on the main chassis within the low voltage control box.

Switch contact (5/A)

This normally closed contact will interrupt the pilot circuit if the stop/ emergency stop lever is operated.

The emergency stop facility is provided by the attachment of the lever to a length of wire rope or chain located at the front of the machine. This stop facility is not self re-setting, for example, when the lever is released after being operated, it is mechanically latched to the stop position. When the latch is released, the lever is returned via a spring to the neutral position. This causes the switch contact to return to its normally closed position.

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Low Voltage Transformer

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Pilot circuit Switch contacts (4/L), (10/A/1), (10/A/2)

The visible disconnect interlock switch (4/L) is closed in both rested positions of its handle. It is only opened in the transition between these two positions.

There are two auxiliary switches on the visible disconnect switch.

Switch (10/A/1) is connected to the pilot circuit and is closed in the closed position of the main handle.

Switch (10/A/2) is connected in the pilot circuit test branch and is closed in the open position of the main handle.

Switch contact (4/A/1)

This normally open switch contact is part of the machine power ‘ON’ pushbutton assembly and is closed by means of a flameproof spindle.

Diode (8)

Relay contact (34/R/1)

This diode is responsible for rectifying the pilot voltage to the DC value necessary to energise the gate end panel, thus providing pilot core to earth core short circuit protection.

This normally open contact within ‘COMPACT’ is connected into the pilot ‘Run’ circuit.

It will energise 6 seconds after machine power up.

Should ‘COMPACT’ detect a fault other than routine, i.e. ‘safety critical’ the pilot circuit will be interrupted via this contact.

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Low voltage test circuit The low voltage test circuit consists of the main switch auxiliary contact(10/A/2), power ‘on’ switch (4/B), and diode (8). The circuit is the means by which the shearer may be started while all of the electric motor power circuits are isolated. Whenever this mode is required the main switch must be operated to the ‘off’ position.

When the main switch is in this position the auxiliary contact (10/A/1) is opened and the auxiliary contact 10/A/2 is closed. By pressing the power ‘on’ pushbutton the switch contact (4/B) is closed energising the gate end panel via contacts (10/A/2), 4/B and the test circuit diode (8). The test circuit is retained via retaining relay contacts (34/T) and (34/T/1)..

Pilot voltage indicator Two LEDS visible through the compact display window give indication that a voltage is present within the pilot circuit. They are initiated via a flameproof pushbutton on the cover of the EL49A control box.

Pilot circuit test points By referring to the pilot circuit diagram within the diagrams section, it can be seen that various stages of the pilot circuit are connected to a group of connectors. This arrangement, which is conveniently located under a small flameproof cover on the EL49A control box provides a useful method of carrying out pilot circuit point to point testing.

Notice!

It is not possible to apply electrical power to the haulage motors until at least five seconds after the shearer is started (see `Haulage System (AC drive)' section, of Chapter 5).

(In some installations an intelligent motor termination unit may be used).

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Pilot circuit

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Electrical power distribution Electrical power distribution This section explains how the main three phase power supply from the gate end panel is applied to the main circuits; and also how it is then transformed, rectified and distributed to the various low voltage control circuits.

General Power distribution may be considered as two systems, these being: The `Main Power Distribution' system.

The `Control Power Distribution' system.

Both of these systems are introduced in basic form in the diagram below.

Fig. 35:

Typical power distribution diagram

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Gate End Panel

Trailing Cable

Shearer

Main Contactor Main Circuits

3 Phase Power

Fuses

Main Contactor Coil

Main Cores Pilot Core

Pilot Circuit Control Relay Low Voltage Transformer

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Control Circuits Pilot Circuits

CONTROL POWER SYSTEM

Earth Core

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Electrical power distribution Main power distribution The main power distribution system is illustrated in the block diagram included as Fig. 36.

Fig. 36:

Main power distribution block diagram Vacuum Contactor

LH Cutter

Motor

RH Cutter

Vacuum Contactor

Motor

Vacuum Contactor

Pump Motor

Contactor Start

Circuits

LH Haulage

Gate End

Main Switch

Panel

H.V. Fuses

Main Transformer

Circuit

Breaker

Twin Output

AC Drive RH Haulage

Motor

Control Transformer

To Control Circuits

By referring to the block diagram, it can be seen that the 3-phase power from the gate end panel on entering the EL48A box via the incoming cable entry, is initially connected to the `LINE' side of the main switch (via cable entry chamber three phase connections).

Warning!

NEVER ASSUME THAT THE SHEARER IS ELECTRICALLY ISOLATED WHEN THE LIVE LINE INDICATOR IS NOT ILLUMINATED. IF IN DOUBT, CARRY OUT THE ISOLATION PROCEDURE AS DESCRIBED IN THE `PREFACE' AT THE BEGINNING OF THIS DOCUMENTATION. Also connected to the line side of the main switch is the primary winding of a step down transformer. It is this transformer which is responsible for supplying all shearer control circuits (see `Control Power Distribution').

The `LOAD' side of the main switch is connected to the windings of the Cutter Motors and Pump Motor (via pushbutton controlled contactors); plus, the primary windings of the Main Transformer which steps down the voltage to a value suitable for the Haulage System.

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Motor

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Electrical power distribution The secondary windings of the main transformer are connected (via circuit breaker) to the AC drive system used to control the Haulage Motors.

The main power distribution circuit is included in Chapter 6.

Control power distribution The control power distribution system is illustrated in the block diagram included as Fig. 37.

Fig. 37:

Control power distribution block diagram Incoming

3300V Supply

Control

Transformer

110V

24V

110V

CB6 CB5

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Earth Leakage Detection Circuit

CB4 0V

SMART System

7.5V I.S. Power Supply Unit

12V I.S. Power Supply Unit

COMPACT Power Supply Unit

12V I.S. Power Supply Unit

CB9

Left Cutter Contacto r Control Circuit

CB10

Right Cutter Contactor Control Circuit

CB11

Pump Contactor Control Circuit

Infra-Red Trans.

I.S. Keypad

Main Central Display

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Modem

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Solenoid Driver Box

Radio Receiver

Can-bus System

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Electrical power distribution COMPACT display (power supply monitoring LED's)

The control power distribution system diagram is shown in Chapter 6. To find any of the components described in this section, i.e. fuses etc., refer to the `Component Location (Quick Reference Guide)' section, Chapter 5.

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Fig. 38:

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EL58B Ranging Arm Motors EL58B Ranging Arm Motors This section explains the main features of the electric motors fitted to the ranging arms.

The locations of these motors are illustrated in Fig. 39.

Fig. 39:

Ranging arm motors location

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1.LH Ranging arm motor 2.RH Ranging arm motor

Warning!

Do not apply electrical power to the ranging arm motors unless an adequate supply of cooling water is flowing through the motors.

Failure to comply with this may result in damage to the motors.

In the event of a static stall of either ranging arm motor, the emergency stop facility should be operated immediately.

When re-started, the shearer should be moved away from the obstruction, using the haulage controls, before re-starting the ranging arm motors.

Failure to comply with this may result in damage to the motors.

The over current and over temperature protection for these motors is set via the `COMPACT' software parameters. This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user.

Failure to comply with this may result in damage to the motors.

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EL58B Ranging Arm Motors General The ranging arm motors (cutter motors) (Fig. 40) are incorporated to drive the cutting drums.

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 over temperature and over current 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 Arms and electrical protection for the motors.

The over temperature protection facility is provided by means of thermostats and resistance temperature detectors (RTD's) which are located within the motors and connected to a ‘Can-Bus and relay monitoring system.

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

Ranging arm motor (waste side view)

6

4

5 1

1

2

2 1

1

3

3

1

1 2 1.Fixing holes 2.Extraction holes 3.Lifting points

5.28

4.Water outlet 5.Water inlet 6.Terminal chamber

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Fig. 40:

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EL58B Ranging Arm Motors System operation The operation of one of the ranging arm motors and its protective features are illustrated in the block diagram included as Fig. 41.

As can be seen from the diagram, the motor is supplied from the gate end panel, via the main switch, after electrical power is applied to the shearer and the motor contactor is energised. The contactor being energised/de-energised in response to the operation of designated pushbuttons (see 'Operator Controls').

Fig. 41:

Ranging arm motor block diagram GATE END PANEL 3 PH POWER TRAILING CABLE 3 PH POWER

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LINE SIDE MAIN SWITCH LOAD SIDE 3 PH POWER MOTOR START/STOP

CONTACTOR

3 PH POWER

RESISTANCE TEMPERATURE DETECTORS

MOTOR TEMP

MOTOR WINDINGS

MOTOR TEMP

THERMOSTATS

MOTOR CURRENT TEMPERATURE FEEDBACK

3 PHASE CURRENT MONITOR

HAULAGE SYSTEM

TEMPERATURE FEEDBACK

COMPACT

START

STOP

PILOT CIRCUIT RELAYS

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EL58B Ranging Arm Motors The over temperature protection facility is provided by means of five (5) thermostats and six (6) resistance temperature detectors (RTD's) which are located within the motor, and connected to a `CAN-BUS' interface module that is monitored by the COMPACT unit.

The RTD's are used to monitor the temperature of the end bearings, the windings and the cooling water.

The thermostats are used to monitor the temperature of the windings and the cooling water.

The motor current is monitored by means of a three phase current transducer assembly consisting of three current transformers and a conditioning circuit.

COMPACT unit display screen

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Fig. 42:

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The feedback from the temperature and current transducers is constantly monitored by the shearers' on-board COMPACT unit. This module is capable of displaying the temperature and current values via a visual display unit (Fig. 42) and, should it become necessary, electrical power can be removed from the contactors if any of the parameters become excessive. The power removal feature is made possible by means of a COMPACT unit.

In addition to being monitored by the COMPACT unit, the current transducer feedback is connected to the haulage system 'AC Drive' to provide a load protection system for the ranging arms and motors. This system causes the shearer operators 'set' haulage speed to be overridden by a lesser speed value and will be reduced at a rate proportional to motor current being above 100% of rated full load current.

The ranging arm motors main, control and protection circuits diagram are included in the Chapter 6.

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EL58B Ranging Arm Motors Motor start circuits The ranging arm motor start circuits, enable the motors to be started individually or sequentially when the shearer is powered in the 'RUN' mode and the pre-start conditions are satisfied. This is achieved using a two pushbutton start sequence that controls vacuum contactors to switch three phase power on to the respective motors.

The following is a description of the main features of this circuit; for the purpose of this description, refer to the relevant schematic diagram included in Chapter 6.

I.S. keypad

Switch contact 4/A

Pushbutton operated switch when used in conjunction with the relevant keypad pushbutton, initiates the start sequence of the motor via COMPACT. After a pre-start delay a second push of the selected buttons starts the circuit.

Switch contact 5/A

This is the normally closed pushbutton contact of the motor `Stop' circuit. When open, the motor contactor is de-energised, via COMPACT causing power to be removed from the motor.

Relay coils (115/LC and 115/RC)

Energised in response to the appropriate ranging arm motor keypad button and motor 'Start' pushbutton (after second push) being operated.

Relay contacts (115/LC/1 and 115/RC/1)

Normally open contact of relays (115/LC and 115/RC) connected to COMPACT for monitoring.

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The I.S. keypad, mounted on the EL49A, is used to select either individual or sequence motor starts

Motor details

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Motor Type/Model

EL58B

kW

600

Rating

CONTINUOUS

Voltage

4160

Frequency/Cycles

60

Insulation Class

H

Amps

97

Voltage Range

1900 - 4600

RPM

1784

Starting Current

8.0 x FLC

Starting Torque

1.6 x FLT

No of Phases

3

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EL58B Ranging Arm Motors Quill Shaft Removal Procedure Caution!

Please ensure that the quill shaft is removed, before removing or assembling the ranging arm motor to the ranging arm. Failure to do so may result in a Damaged quill shaft.

QUILL SHAFT REMOVAL PROCEDURE (waste side) (Fig. 43)

. Remove screws (1) and cover (2). . Remove circlip (3) and withdraw end plug (4) from the rotor shaft.

. Insert puller bar and withdraw quill shaft (5). . Inspect quill shaft for damage and replace if necessary. . To assemble, reverse above procedure.

Quill shaft removal (waste side)

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 43:

E

Important!

Ensure that grease of the correct grade is applied to the splines before assembly. (Grade GR5)

3

1

2

4

5

1.End cover 2.Circlip 3.Stopper

4.'O' Ring 5.Quill shaft

Lubrication Lub Point

Description

Lubricant

Quill shaft

GR5

Schedule

Inspect/Grease

MONTHLY

Important!

The ranging arm motors have bearings that are packed and sealed to last between panel change-outs. Grease grade GR1.

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EL56BN Pump Motor EL56BN Pump Motor This section explains the main features of the electric motor fitted within the hydraulic power pack. The location of this motor is illustrated in Fig. 44.

Fig. 44:

Pump motor location

1

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1.Pump motor

Warning!

Do not apply electrical power to the hydraulic pump motor unless an adequate supply of cooling water is flowing through the motor.

Failure to comply with this may result in damage to the motor.

The over current and over temperature protection for this motor is set via the `COMPACT' software parameters. This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user.

Failure to comply with this may result in damage to the motor.

General The hydraulic pump motor is incorporated to drive the pump which supplies the shearers' hydraulic power. The motor, which is of the water cooled, three phase induction type, is started via a contactor and monitored to provide earth leakage, over temperature and over current protection.

The over temperature protection facility is provided by means of five (5) thermostats and six (6) resistance temperature detectors (RTD's) which are located within the motor, connected to a `CANBUS' interface module and monitored by the COMPACT unit.

The over current protection is provided by means of a three phase current monitor assembly located within the EL48A control box.

A typical pump motor is shown in Fig. 45.

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EL56BN Pump Motor Fig. 45:

Pump motor

1

2

1.Water connections

1

2.Terminal chamber

As can be seen from the diagram, the motor is supplied from the gate end panel, via the main switch. After electrical power is applied to the shearer, the motor contactor is energised. The contactor being energised/de-energised in response to the operation of designated pushbuttons (see `Operator Controls').

The temperature transducers within the motor consist of six resistance temperature detectors (RTD's) and five thermostats and are connected to a `Can-Bus' system.

The over temperature protection facility is provided by means of three (3) thermostats which are located within the motor and are connected to a thermal trip relay, located in the EL49A control compartment, and is monitored by the COMPACT unit.

The RTD's are used to monitor the temperature of the both end bearings, the windings and the cooling water.

The thermostats are used to monitor the temperature of the windings and the cooling water.

The motor current is monitored by means of a three phase current transducer assembly consisting of three current transformers and a conditioning circuit.

The feedback from the temperature and current transducers is constantly monitored by the shearers' on-board COMPACT unit via the `CAN-BUS'.

The COMPACT unit is capable of displaying the temperature and current values via a visual display unit and, should it become necessary electrical power can be removed from the contactors if any of the parameters become excessive.

The hydraulic pump motor main, control and protection circuits diagram is included in Chapter 6.

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The operation of the hydraulic pump motor and its protective features are illustrated in the block diagram included as Fig. 46.

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System operation

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EL56BN Pump Motor Fig. 46:

Pump motor block diagram

GATE END PANEL 3 PH POWER TRAILING CABLE 3 PH POWER LINE SIDE MAIN SWITCH LOAD SIDE 3 PH POWER

MOTOR START/STOP

CONTACTOR

3 PH POWER

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THERMAL TRIP RELAY

RESISTANCE TEMPERATURE DETECTORS

MOTOR TEMP

MOTOR WINDINGS

MOTOR TEMP

THERMOSTATS

MOTOR CURRENT TEMPERATURE FEEDBACK

3 PHASE CURRENT MONITOR

HAULAGE SYSTEM

TEMPERATURE FEEDBACK

COMPACT

START

STOP RELAY CONTROL PILOT CIRCUIT RELAYS

PILOT CIRCUIT CONTROL

Motor start circuit

I.S. keypad

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The hydraulic pump motor start circuit, enables the motor to be started when the shearer is powered in the `RUN' mode and the pre-start conditions are satisfied. This is achieved using a two push button operation to control the contactors to switch three phase power on to the motor.

The following is a description of the main features of this circuit; for the purpose of this description, refer to the relevant schematic diagram included in Chapter 6.

The I.S. keypad, mounted on the EL49A, is used to select either individual or sequence motor starts.

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EL56BN Pump Motor Switch contact 4/T

Pushbutton operated switch when used in conjunction with the relevant keypad pushbutton, initiates the start sequence of the motor via COMPACT. After a pre-start delay a second push of the selected buttons starts the circuit.

Switch contact 5/B

This is the normally closed pushbutton contact of the motor `Stop' circuit. When open, the motor contactor is de-energised, via COMPACT causing power to be removed from the motor.

Vacuum contactor 115/P

Energised in response to the pump motor button and motor 'Start' pushbutton (after second push) being operated.

Motor Type/Model

EL56BN

kW

60

Rating

CONTINUOUS

Voltage

4160

Frequency/Cycles

60

Insulation Class

H

Amps

11

Voltage Range

1900—4600V

RPM

1775

Starting Current

9.1 x FLC

Starting Torque

2.4 x FLT

No of Phases

3

Connection

Star

E

Motor details

Normally open contact of relay (115/P) connected to COMPACT for monitoring.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Vacuum contactor auxiliaries 115/P/1

Lubrication Important!

The pump motor has bearings that are packed and sealed to last between panel change-outs.

Grease grade GR1.

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EL55C Haulage Motor EL55C Haulage Motor This section explains the main features of the electric motor fitted within the haulage unit. The location of this motor is illustrated in Fig. 47.

Fig. 47:

Haulage motor location

1

1

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1.Haulage motor

Warning!

Do not apply electrical power to the haulage unit motor unless an adequate supply of cooling water is flowing through the motor.

Failure to comply with this may result in damage to the motor.

The over current and over temperature protection for this motor is set via the `COMPACT' software parameters. This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user.

Failure to comply with this may result in damage to the motor.

General The haulage motors are incorporated to provide power for the shearer's haulage control system. These motors, which are of the water cooled, three phase induction type, are operated (one per haulage unit) via a micro-processor based transistor drive system and monitored to provide earth leakage, over temperature and over current protection.

The over temperature protection facility is provided by means of five (5) thermostats and six (6) resistance temperature detectors (RTD’s) which are located within the motor, connected to a ‘CANBUS’ interface module and thermal trip relay monitored by the COMPACT unit.

The over current protection of the haulage system is provided by means of a three phase current monitor assembly located within the EL48A power box.

A view of a typical EL55C haulage motor is shown in Fig. 48.

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EL55C Haulage Motor Fig. 48:

Typical haulage motor

1

1 1.Water connections

2.Terminal chamber

Motor operation Refer to `Haulage system (AC drive)' section, Chapter 5.

Motor start circuit Refer to `Haulage system (AC drive)' section, Chapter 5.

Motor removal procedure

. Disconnect all electrical cables and water hoses. . Remove motor end cover. . Remove circlip and brass stopper. . Remove short shear shaft and long quill shaft. . Slacken M24 hex-headed screws 2 off, and remove. . Insert one of the M24 screws into the tapped hole, and ease the motor from its spigot and keyed location in the mainframe.

. Use suitable packing beneath the motor to prevent damage when locations have been broken.

Use the recommended torque setting for re-assembly. (See Chapter 6).

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2

BI628443

EL55C Haulage Motor Motor Type/Model

EL55C

kW

125

Rating

CONTINUOUS

Voltage

600V

Frequency/Cycles

0—60—120 Hz

Insulation Class

H

Amps

154

Voltage Range

0 - 660 V

RPM

0 - 1774 - (3600)

Starting Current

7.3 x FLC

Starting Torque

1.45 x FLT

No of Phases

3

Connection

Star

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Motor details

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EL55C Haulage Motor Fig. 49:

Haulage motor block diagram 3 PH POWER

TRANSFORMER

3 PH POWER

CIRCUIT BREAKER

3 PH POWER SERIAL COMMS

RESISTANCE TEMPERATURE DETECTORS

MOTOR TEMP

MOTOR WINDINGS

MOTOR TEMP

TEMPERATURE FEEDBACK

THERMOSTATS

TEMPERATURE FEEDBACK

COMPACT

STOP

5.40

START

Shearer EL 2000

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AC DRIVE

BI628443

EL55C Haulage Motor Quill Shaft Warning!

PRIOR TO STARTING THIS WORK, NORMAL SAFETY PRACTICES SHOULD BE OBSERVED WITH REGARD TO COAL FACE SUPPORT, SHEARER AND CONVEYOR ISOLATION. THIS PROCEDURE DOES NOT REPLACE THE NEED FOR A LOCAL JSA TO BE PERFORMED BY PERSONS APPOINTED BY THE MINE MANAGEMENT. CATERPILLAR UNDERGROUND STANDARD WORKING PROCEDURES ONLY APPLY WHEN FITTING APPROVED SPARE PARTS. BEFORE WORKING ON OR NEAR ANY MOVING PART OF THE SHEARER, ISOLATE THE POWER SUPPLY AT THE MAIN SWITCH AND REMOVE THE TRAINING CABLE AT THE GATE END PANEL. ENSURE THAT SITE SPECIFIC ISOLATION PROCEDURES ARE FOLLOWED.

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PLEASE ENSURE THAT ALL HYDRAULIC AND WATER HOSES ARE DE-PRESSURISED BEFORE ATTEMPTING DISCONNECTION. Caution!

PLEASE ENSURE THAT THE QUILL SHAFT IS REMOVED BEFORE REMOVING OR ASSEMBLING THE HAULAGE UNIT TO THE MAINFRAME. FAILURE TO DO SO MAY RESULT IN A DAMAGED QUILL SHAFT. Fig. 50:

Haulage motors New Style Haulage Motor

Old Style Haulage Motor

1 1 Access cover

2 2 Terminal cover plate

To get access to the quill shaft on the Old Style haulage motors the terminal cover plate has to be removed.

To get access to the quill shaft on the new style haulage motors only the access cover has to be removed.

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EL55C Haulage Motor Removal Procedure Fig. 51:

Typical arrangement

1

2 3 5 4 Short quill shaft 5 Cover 6 Stopper

. Remove four (4) M10 cap screws, washers and withdraw cover.

(New style) Remove six (6) M10 cap screws and washers from the terminal cover plate. Insert four (4) M10 jacking bolts into the terminal cover and remove the cover. (Old style)

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1 Haulage gearbox 2 Haulage motor 3 Long quill shaft

6

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4

BI628443

EL55C Haulage Motor Removal 1 New Style Haulage Motor

Old Style Haulage Motor

1 M10 cap screws 2 Access cover

1 M10 cap screws 2 Terminal cover plate

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Fig. 52:

. Remove circlip.

Fig. 53:

Removal 2

1

1 Circlip

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EL55C Haulage Motor . Insert M16 puller bar and withdraw stopper.

Fig. 54:

Removal 3 Old Style Haulage Motor

1 1 1 Stopper

. Insert the M10 puller bar and withdraw the short quill shaft. If the quill shaft has failed both halves of the short quill shaft will need to be pulled out.

Important!

The long quill shaft and the short quill shaft may come out as one piece.

Fig. 55:

Removal 4

2

1

1 Short quill shaft

5.44

2 Long quill shaft

Shearer EL 2000

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New Style Haulage Motor

BI628443

EL55C Haulage Motor . Insert M12 puller bar and withdraw long quill shaft.

Fig. 56:

Removal 5

2 3

1

1 M12 Puller bar

2 Long quill shaft

. Inspect the long and short quill shaft for damage and replace if Caterpillar Global Mining Europe GmbH, Lünen 2013

E

necessary. Check the condition of the ‘O’ Ring on the gearbox end of the long quill shaft and replace if damaged.

Fig. 57:

Removal 6

1 'O' Ring

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EL55C Haulage Motor Assembly Procedure

. Apply lubricant to ‘O’ Ring before re-fitting the long quill shaft.

Important!

Ensure that grease of the correct grade is applied to the splines before assembly. (Caterpillar Grade GR5)

. Insert M12 puller bar into the long quill shaft. Ensure that the quill shaft is pushed fully home and remove puller.

Fig. 58:

Assembly 1

1 M12 Puller bar

. Insert M10 puller bar into short quill shaft and fit into long quill shaft. Fit the quill shaft into the rotor splines and rotate the quill shaft to line up the splines on the long quill shaft. Ensure that the quill shaft is pushed fully home.

Fig. 59:

Assembly 2

2

3

1

1 Short quill shaft 2 Long quill shaft

5.46

3 M10 puller bar

Shearer EL 2000

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1

BI628443

EL55C Haulage Motor . Inspect stopper ‘O’ ring for damage. Replace if damaged. Apply fluid film to stopper, ensure ‘O’ ring is lubricated, insert M16 puller bar into stopper and ensure that the stopper is fully located in to rotor shaft allowing circlip to be fitted.

Fig. 60:

Assembly 3

2

3

1

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1 Short quill shaft 2 Long quill shaft

3 M10 puller bar

. Re-fit the circlip. Ensure that it is fully engaged in the groove.

Fig. 61:

Assembly 4

1 1 1 Circlip

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EL55C Haulage Motor . Refit access cover or terminal cover depending on arrangement. Secure with M10 cap screws and washers. Torque to 77 Nm (57lbf.ft).

Fig. 62:

Assembly 5 New Style Haulage Motor

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Old Style Haulage Motor

2

1 1 Access cover

2 Terminal cover plate

Lubrication QUILL SHAFT Lub Point

Description

Lubricant

Quill shaft

GR5

Schedule

Inspect/Grease

MONTHLY

MOTOR BEARINGS Important!

The haulage motors have bearings that are packed and sealed to last between panel change-outs.

(Caterpillar Grade GR1)

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Radio Control System Radio Control System This section explains the operation of the shearers' radio control facility. This facility, consists of a system designed to provide the operator / operators with a means of remotely controlling all shearer functions.

General The radio control system comprises of the following main components: Two intrinsically safe, operator held, battery powered, Radio Transmitters (TXA and TXB).

A Radio Receiver Unit.

A shearer mounted Receiving Aerial (antenna).

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There are four different `Modes' of control associated with this system, these providing the facility for one or two man operation of the shearer from the transmitters. Which of these control modes is in effect, is chosen by the operator via the `COMPACT' Module' pushbuttons.

Key Features Bi-directional communications between the receiver and transmitter.

Safe operation in close proximity to any number of radio controlled systems identical or other radio systems.

A maximum of three active transmitters per system with multiple systems available per machine/system.

Self diagnostic checks on transmitters & receiver.

Universal communications protocol for all machines to theControl System.

High reliability.

User friendly operation and displays.

Adjustable distance of operation for safety reasons.

System operation The main function of the radio system is to inform the Control System of the operator’s requests.

The standard radio receiver system contains no logic control or digital outputs it simply communicates with the Control System through a bi-directional serial communications link (4 wire RS485 and RS232). All logic and output control is done via the Control System. The radio system is responsible for ensuring the integrity of the data received from the transmitters and for maintaining the data links to the Control system and transmitters.

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Radio Control System The transmitters are capable of only recognising the receiver they are connected to and vice versa. The radio system is capable of uniquely attaching receivers with transmitters to prevent other transmitters or receivers activating inadvertently which may be in the same area. For example, there may be three or more radio systems operating in the same area, e.g. Shearer, Shields, Miner, etc.

Under normal operation, the operator will request a function that will then be passed to the receiver and then via the serial communications link to the Control System. The Control System then actions the request. The control system will respond via the same communications link back to the receiver, which will then transmit the message back to transmitter handset for display. The transmitters will also have the optional ability to display certain information and messages when instructed via the Control System.

A two-way communication link is provided between the radio receiver and each transmitter. The link is capable of:

Optional diagnostic help, displayed on transmitter LCD of potential radio system problems.

Transmitter Each transmitter, one of which is shown in Fig. 63, has an array of momentary action pushbuttons to control the machine functions.

It also has an alpha numeric display.

The display is capable of being viewed underground with the use of a miner’s cap lamp and be one display type for all applications.

The display has a graphical pixel driven system displaying a of four (4) lines of twenty (20) characters.

The Control system sends information (data) to be displayed on each transmitter if required. Such information may be machine speed, motor currents, temperatures, warnings, trips, etc which under normal operation may be difficult to see on the systems main displays.

The display has a backlight. Both the display and backlight is capable of turning on/off via communications and / or button/function presses. The display and backlight also has a sleep/power save mode facility.

The first line of 20 Characters is seen to be the operator’s indication of the transmitter/machine functions. The next 2 lines will be used for machine information. The last line will be used for Radio information.

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Verifying link efficiency as 0 – 100% of each transmitter / receiver link in use.

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Confirming transmitter button presses by received information back to respective transmitter and on a LED for each button and/or displayed on LCD of transmitter if required.

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Radio Control System Transmitter

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Fig. 63:

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Radio Control System Radio function definitions

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Fig. 64:

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Radio Control System Radio Receiver Unit The Radio Receiver Unit, which is illustrated in Fig. 65, and its associated interface equipment, are mounted on a chassis housed within the control section. The electrical interface between the Receiver and its associated external circuitry, is provided via four connectors, these being: A 5-way data transmission connector (R1) which is used to provide a serial communications link between the radio receiver and the COMPACT Module. This connector is intended for future use.

A 5-way data transmission connector (R2) which is used to provide a serial communications link between the radio receiver and the COMPACT Module. This connector is in use initially.

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A ten way connector (R3) which is used to provide the power supply to to the receiver. This supply is set to operate between +9v And +32v dc. The connector also has the provision of 2 volt free contacts (24v, 1A Max) which allows optional external functions to be selected. These contacts are controlled via the serial link with the Control System.

A variable analogue voltage output is also included within this connector. The voltage output is dc variable from 0 to 10 volts and a high resolution of 12 bits. Control of the variable output is via the Control System in response to messages sent from the serial link.

A co-axial aerial cable connector(R4) which provides the connection for the cable between the externally mounted aerial and the receiver. This cable is connected is connected in series with a barrier arrangement (aerial isolator) which is also located within the control section.

The receiver also includes a line of 8 LED’s which give operational status of watchdog, transmitter A, transmitter B and the COMPACT module.

Fig. 65:

Radio receiver unit

3

4

1 5

2

1 Connector R1 2 Connector R2 3 Connector R3

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4 Connector R4 5 LED's

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Hydraulic Functions (electrical control) Hydraulic Functions (electrical control) This section explains the electrical operation of the shearer hydraulic functions. These being the functions that utilises the power supplied from the hydraulic pump for their operation.

The hydraulic pump is located within the hydraulic power pack and is driven by the `Hydraulic Pump' motor (see Fig. 66).

Fig. 66:

Hydraulic functions

1.Hydraulic pump motor 2.Hydraulic power pack pump

General The hydraulic functions, most of which are controlled by Electro/ Hydraulic control valves, are categorised, these being: Solenoid and Manual Control.

The manual handles fitted to the electro/hydraulic control valves are incorporated for test purposes only. These handles should not be used to operate their associated functions whilst the shearer is cutting and/or hauling.

There may be several hydraulic functions. These functions and the category which their control valves fall into are as follows: Left Hand Ranging Arm Raise and Lower Right Hand Ranging Arm Raise and Lower Cowls Rotate Coalsizer (if fitted) The illustration included as Fig. 68 highlights the main features of the hydraulic functions fitted in this particular application.

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1&2

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Hydraulic Functions (electrical control) Fig. 67:

Hydraulic function location 4

4

3 1

1.LH Ranging arm lifting cylinder 2.RH Ranging arm lifting cylinder

3 Combi directional control valves 4.Cowls

The `Solenoid and Manual Control' valves each consist of a `Main' valve, a `Pilot' valve, two (2) electrical solenoids and a manual handle; thus providing the option of either electrical or mechanical operation.

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The operator is provided with the facility to electrically control the solenoids from the radio transmitters. Each solenoid being energised via the shearers' on board radio receiver unit in response to the relevant radio transmitter controls being operated.

Electric connections

The electrical connections to each electro/hydraulic control valve solenoid are provided by means of a length of cable connected via a plug and socket arrangement. The individual solenoid cables are connected, to a Solenoid junction block, which in turn is connected via a multi-core cable to the face side of the control section and then to the COMPACT unit.

The electrical connections between the control section, the solenoid junction block and the solenoids are illustrated in a wiring diagram included in Chapter 6.

Typical hydraulic function operation

The operation of a typical function such as `Right Arm Raise' for example, is illustrated in the block diagram included as Fig. 68.

Referring to the block diagram, it can be seen that the method of hydraulic function control desired by the operator chosen, is being achieved via the Radio Receiver. Once the shearer is successfully powered, the operator may activate the functions (or control the haulage speed and direction) from the selected radio transmitters.

When the desired function pushbutton on a selected control station (for example ‘Right Arm Raise’) is operated, a unique message is sent from the transmitter to the radio receiver unit. The receiver recognises this message and responds via the serial link to the COMPACT unit which in turn activates the solenoid driver unit.

Once the Solenoid driver is activated, a 12V DC intrinsically safe supply is switched by an opto-coupler on to the coil of the ‘Right Arm Raise’ solenoid. The operation of the function can be monitored by looking at a LED on the solenoid.

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Hydraulic Functions (electrical control) When the solenoid is energised the `Pilot Valve' is opened which in turn causes the `Main Valve' to open. The main valve when open directs the flow from the hydraulic pump to the right ranging arm cylinder thus causing the arm to raise until the operator pushbutton is released.

The manual handle, when operated, opens the main valve directly.

For the purpose of this description, refer to the electrical schematic diagrams included in Chapter 6. From these diagrams, it can be seen that when a function switch on an appropriate transmitter is operated, for example ‘Right Ranging Arm Raise’, a unique message is sent from the transmitter to the radio receiver unit which communicates via a serial link to the COMPACT module. This switches a +ve 12V DC supply (via COMPACT) to the solenoid driver input side of the ‘Right Ranging Arm Raise’ plug and returns via the common 0V. From the diagrams, it can also be seen that once the Solenoid driver is energized as explained, its solid state switch, which is connected in series with the ‘Right Ranging Arm Raise’ solenoid, is activated into conduction. This causes the solenoid to be energized by the 12V DC output from the intrinsically safe power supply unit.

When the function is being operated automatically (auto steering selected), the Solenoid driver is activated in response to a command via the previously mentioned serial link.

All other ranging arm functions are similar in operation to that described for the `Right Ranging Arm Raise' function.

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Typical circuit description

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In addition to the above control methods, the ranging arm functions may also be operated automatically when automatic steering is in use. This feature is explained in the `COMPACT shearer automation system' section of this manual. In this explanation, the right arm raise function is used as an example. The other ranging arm functions are identical in operation to this function.

BI628443

Hydraulic Functions (electrical control) Fig. 68:

Typical hydraulic function block diagram MANUAL CONTROL HANDLE

ELECTRIC MOTOR

M

H

HYDRAULIC PUMP

MAIN VALVE H

H

ACTUATOR

H PILOT VALVE M SOLENOID COIL

12VDC LED 12VDC

E

12VDC

Caterpillar Global Mining Europe GmbH, Lünen 2013

COMPACT

SOLENOID DRIVER

12VDC

12VDC

RF

RADIO RECEIVER

INTRINSICALLY SAFE POWER SUPPLY

RF AERIAL ISOLATOR

AERIAL

H - HYDRAULIC M - MECHANICAL RF - RAPID FREQUENCY

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Haulage System (AC drive) Haulage System (AC drive) This section explains the electrical aspects of the shearer's haulage control system, i.e. the system that enables the shearer to be moved along the coalface in both directions within a variable speed range.

Basic System Operation The AC drive system is a controlled inverter arrangement providing a variable voltage and frequency output to control the speed and direction of one or two haulage motors. When two motors are used with one inverter unit the motors power cables are connected to their individual output section of the inverter. The output drive modules are set to operate in a `master' and `slave' mode.

The COMPACT Colour Display Unit provides system performance and status information for each drive output module.

For the purpose of the following explanation, refer to the appropriate schematic diagram included in Chapter 6.

As can be seen from the diagram, the drive system is supplied from the secondary windings of the main transformer via an optional circuit breaker and/or fuses for the inverter drive Power Modules.

The primary windings of this transformer are connected to the gate end panel via the main switch and the trailing cable.

The Power Module uses the input to satisfy the main power requirements. Control, or auxiliary requirements are derived on-board the Power Module.

The Power Module provides a variable AC output in order to control the speed and direction of the haulage motors.

The drive features in-built haulage control cards, which are incorporated to control the power section. These cards collect and collate haulage related operating data and provide system performance and status via the COMPACT Colour Display Unit and the serial communications link to the COMPACT unit. Display features and parameter functions are accessed using a number of designated pushbuttons on the keypad.

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The haulage system consists mainly of two electric motor driven 'Gear Modules', with each unit providing a separate mechanical output via a waste side 'Output Module' and 'Downdrive' arrangement.

In addition to this, each 'Haulage Unit' features accessible 'shear shafts', providing input and output over-torque protection. These shafts are commonly referred to as 'quill shafts'.

For further details relating to the mechanical aspects of the haulage system, refer to the 'Haulage Unit' section of this Chapter.

The AC drive motors (one per 'Haulage Unit'), are operated via a microprocessor based transistor drive system. Each motor is connected to a individual output section of the drive unit.

The main features of this system are: Twin Output AC Drive Module – This is the haulage system controller, housing the diode and transistor bridges used to power the motors. The input/output control interface is also contained within this unit.

COMPACT Colour Display Module and associated Keypad.

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General Description

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Haulage System (AC drive) Haulage Circuit Description For the purpose of these descriptions, refer to the appropriate schematic diagrams included in Chapter 6.

Main Circuit When the shearer is powered, with the main switch in the 'ON' position, the power from the gate end panel is connected to the primary side of the haulage transformer. The current at this point is measured by a current transducer arrangement which is monitored by COMPACT. The secondary side of the transformer provides a 600V supply output (via circuit breaker and/or fuses) to the haulage system Drive.

As well as the main power to the drive, there is an auxiliary 110V supply from the control transformer.

The transformer has internal temperature transducers that are used by the COMPACT system to provide temperature protection and monitoring.

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The output from the drive to the motor(s) is a variable voltage, variable frequency supply that is used to control the speed of the haulage motors.

The drive system is also capable of internally monitoring temperatures, speeds, currents etc. Additionally, COMPACT is also capable of monitoring these functions either directly or through the communications serial link between it and the drive (see diagram in Chapter 6).

Monitoring Circuits Both the Drive and COMPACT can monitor temperatures, currents and haulage motor speeds using transducers whose outputs can be connected via the relevant inputs.

Temperature monitoring

The drive system continually monitors its own operating temperatures and if safe operating boundaries are exceeded inhibits operation until within acceptable limits.

Current monitoring

The main supplies to each Ranging Arm motor are passed through 3-phase current monitors. This provides current feedback to the drive module which then uses this information to inhibit and control the haulage speed, and therefore shearer load, should either of the cutter motors be subjected to pre-set threshold overload values.

Additionally, the drive will inhibit operation if preset instantaneous and timed overload limits are exceeded by either of the Ranging Arm Motors.

The system will react to whichever Ranging Arm Motor load is the greater.

Current levels are displayed on COMPACT display.

Machine position encoder

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The machine position encoder is connected to the COMPACT unit via a Can-Bus network along with the other Can-Bus interface modules. The purpose of the encoder is to send accurate information regarding the position and speed of the machine. The encoder is mechanically connected to the appropriate haulage unit gearbox and housed in a flameproof junction box.

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Haulage System (AC drive) Radio Control Circuits When the shearer is powered and a radio control mode is selected, the radio receiver is switched 'ON'.

The radio modes are selected as follows via the COMPACT keypad.

In two-man operation radio mode, the haulage can only be controlled by one transmitter at any time. The transmitter that receives haulage control is dependent on which transmitter requests it first.

If both transmitters were to request haulage control at the same time, it would be awarded to neither, or if, whilst the haulage is being controlled by one transmitter, the second transmitter also requests control, the haulage system will stop.

Transmitter Control Circuit The radio transmitter haulage controls consist of: Haulage - REQUEST/STOP pushbutton.

Haulage Speed - INCREASE/DECREASE pushbuttons

When the operator selects a direction, a corresponding contact (Haul Right or Haul Left) closes within the receiver. These contacts supply the Drive with the selected haulage direction signals.

In order to make the machine move, the operator must now increase the haulage speed by operating the speed increase pushbutton. When this action is carried out, the radio receiver responds by supplying the Drive with a 0 to +5ve variable speed signal.

A communication link, using the RS-485 standard, is used to carry control requests between the radio receiver and COMPACT. Another RS-485 standard communication link is provided between COMPACT and the drive system to control haulage speed and direction operations.

In addition to these two communication links there is a direct wire connection between the radio receiver and the drive system. This serves as a back-up to the communication links.

Double Drive Operation In applications configured to operate with two drive output modules (each output module controlling a single motor) operating in a Master / Slave arrangement, the `Master' drive is cabled and wired in the same manner as if it were a single drive.

Control wiring links are added between the `Master' and `Slave' output modules to ensure that speed and load sharing is achieved.

Effectively all command and load control operations are finalised by the `Master'. Speed, direction and current limits are then passed to the `Slave' from the `Master'. The `Slave' then operates its motor to these limits.

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When the appropriate radio transmitter haulage request pushbutton is pressed, the radio receiver awards haulage control to that transmitter, provided the other transmitter haulage request pushbutton is not operated simultaneously (two man mode only). The receiver will indicate which transmitter has been awarded haulage control by closing either transmitter 'A' Haulage Control or transmitter 'B' Haulage Control.

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Haulage Direction - LEFT/RIGHT pushbuttons

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Haulage System (AC drive) Both the `Master' and the `Slave' output modules are programmed with the same parameter set-up and operate with identical software. Manual switches are set to determine which will be the `Master' and which will be the `Slave'.

The `Master' / `Slave' functions of the drives can be changed simply by altering the manual switches.

Introduction To Inverter Drive Induction Motor Characteristics Standard industrial squirrel cage induction motors are wound to match the supply voltage and frequency which prevails in the country where they will be used or are manufactured. When it is desired to operate an induction motor at variable speeds, it is necessary to consider the effect of voltage and frequency on flux and torque.

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An induction motor depends for its operation on the rotating field created by the balanced three-phase currents in the stator (field) winding. The magnitude of the field is controlled not by the strength of the current, but by the voltage impressed on the field windings by the supply. This is because the resistance of the field windings results in only a small voltage drop, even at full load current, and therefore the supply voltage must be balanced by the emf induced by the rotating field. This emf depends on the product of three factors: total flux per pole, total number of turns per phase of the field winding, rate of field rotation.

This can be expressed as where

E Ø N f k

E = kØNf

is the induced emf, is the total flux per pole, is the number of turns per pole, is the frequency, is a constant.

If the applied voltage is increased, the emf must increase to balance, and if the frequency is held constant the flux per pole must increase also, since the number of turns per pole is fixed.

For economy of material, the magnetic circuits of standard motors are designed to operate very close to saturation at rated voltage and frequency. This is the optimum condition for the production of maximum torque. At rated frequency, any further increase of voltage cannot increase torque but will cause current, and consequently losses, to rise.

For optimum acceleration, or rapid response to an increase in load torque, Ø should be maximum to maximise the torque, as the designer intended. Equation (1) can be restated as: Ø= E kNf or

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Ø= 1 x E kN f

(2)

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Haulage System (AC drive)

The Drive used on the shearer is a standard drive repackaged so that it can be accommodated on board the machine. It is based on an industrial drive that is designed for general applications.

Drive Configuration To operate an induction motor successfully in all varieties of industrial applications a drive must at least be capable of varying both voltage and frequency, for which it is necessary to separate the input from the output. This is most conveniently done by rectifying the supply and inverting the dc output. Variable output voltage can be obtained by varying the dc bus voltage and maintaining the gain of the inverter constant. The gain is the ratio of ac output to dc input. Alternatively, the dc bus voltage can be uncontrolled and the gain varied. This latter method is usually achieved by pulse-width modulation (PWM) control of the inverter, Fig. 69D.

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The second operating condition where departure from a constant V/f ratio is beneficial is at low speeds, where the voltage drop arising from stator resistance becomes significantly large. This voltage drop is at the expense of the flux. As the applied frequency approaches zero, the optimum voltage becomes equal to the stator IR drop. To maintain a constant flux in the motor at low speeds the voltage must be increased to compensate for the stator-resistance effect. Compensation for stator resistance is called `voltage boost', Fig. 69C, and most drives offer some form of adjustment so that the degree of boost can be matched to the winding resistance. It is also normal to taper the boost to zero as the frequency increases.

A refinement is to increase the degree of voltage boost for loads that impose a high starting torque, since the IR drop will be greater because of the increased current. Automatic load-dependent control of the voltage boost in this manner has practical advantages for many applications.

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This shows that, since N is fixed and k is constant, a linear relationship must be maintained between emf (and consequently the applied voltage) and frequency, if flux is to remain constant at different speeds. This linear relationship is known as `constant V/f' (or V/Hz). Drives possessing this essential feature are usually called `variable voltage variable frequency' (vvvf) drives.

The speed of a motor at full rated voltage and normal V/f ratio is called its `base speed', expressed in Hz or rpm as convenient.

Although constant V/f control is an important underlying principle, departures from it enable the speed range to be extended both above and below the base speed. Operation of the motor at speeds above its base speed is achieved by increasing the output frequency of the inverter above the rated frequency while the applied voltage remains at maximum value. The V/f characteristic is typically as shown in Fig. 69A, which also shows the change above base speed. Since V is constant above base speed, the flux falls as the frequency increases, Fig. 69B, in direct proportion to the V/f ratio. The ability of the motor to produce torque is correspondingly reduced; full load current produces less torque as speed increases, and in fact the power output remains constant. There are many applications which are well suited by the constant-power characteristic in the region above base speed.

BI628443

Haulage System (AC drive) The use of a mathematically-advanced PWM switching strategy to control the latest high power high speed semiconductor switching devices – insulated gate bipolar transistors (IGBT) – in the power output bridge enables the output waveform to be closely approximated to a pure sine wave. The dc input voltage can then be derived from a simple diode bridge rectifier which, besides being highly reliable, also has the advantage of reducing significantly the amplitude of harmonics in the output of the inverter.

Equipped with suitable control functions, a PWM-IGBT inverter is capable of providing any voltage from zero to input line voltage, over a frequency range from zero to some practical maximum considerably above the rated frequency of standard squirrel cage motors. The control function is also capable of enabling the voltage to be raised at low frequencies to increase torque at low speeds, and it is relatively simple to arrange that the phase sequence of the output can be changed to enable the motor to reverse. These functions are the basic minimum and they can, with a suitable control system, be considerably extended.

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Digital control logic is essential to gain the full advantage of a PWM switching strategy applied to the IGBT output bridge. The speed and adaptability of digital logic makes it feasible to extend the scope of the control functions in two important directions. One is to equip the drive to monitor and protect itself and the motor; the other is to enable the performance of the drive and motor to be refined to take account of the widest possible variety of applications. A further advantage of digital control is the precision with which operating parameters can be adjusted, and maintained without drifting from set values. A standard interface makes it possible to accept external analogue signals into the control scheme, and also to provide analogue signal outputs. Finally, digital control makes communication with other digital devices simple to implement and operate through industrial standard serial communication links.

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Haulage System (AC drive) Fig. 69:

Graphs and block diagrams

'Base speed'

Typical mains V supply voltage

Constant torque region



Constant power region

100%

415V Typical mains supply frequency

Typical loss of flux

V/f ratio

Variable motor speed - ideal-voltage-to-frequency characteristic.

B

f

50Hz typical

Variable motor speed - typical flux-to-frequency characteristic.

E

A

'Base speed'

f

Hz

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V 100%

Boost f

C

Voltage boost to increase torque at low frequency. (Not to scale)

SEND & RECEIVE DRIVE LOGIC

M

The principle of a PWM inverter drive system

D

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Haulage System (AC drive) Multiple Drives And Motors Where two or more motors are mechanically coupled, either directly or by being connected to the same drive train such as a conveyor or shearer haulage system, the output of the drives is equalised by operating them in master/slave configuration. Three arrangements are possible – frequency slaving, current slaving, and electrical paralleling.

Frequency Slaving If the available motors are precisely matched, being from the same manufacturer and of identical type, rating and construction, frequency slaving is possible. All drives are then slaves, in which all operating parameters must be identical. The speed command, however derived, is fed to all drives. Electrically, this is the same as operating two or more motors from a common supply.

E

A digital process controller can always serve to operate multiple drives, since this is one of the common applications of control by serial communications link. Alternatively, several drives can receive a speed control signal from a single speed-control potentiometer.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Current Slaving If the available motors are not identical, or to improve accuracy of load sharing, current slaving is the preferred solution, Fig. 70A. The load reference signal from the output terminal of the drive chosen as the master is connected to the torque reference input terminal of the slave drive or drives. Parameters controlling overload and over current protection must be set to equal values in each of the drives. Both motors then operate with the same load current and share the load equally.

Electrical Paralleling Two motors can be operated in parallel from the power output terminals of a single suitably-rated drive. This arrangement may be economical, but the following requirements must be observed – Both motors must be of identical manufacture, preferably having been specified for this duty. This is necessary to minimise the risk of unequal load-sharing.

Each motor must be fitted with a motor protection relay, since the drive is not able to protect the motors individually.

Important!

The double drive or single drive twin output arrangement on a shearer is configured to operate with a combination of frequency and current slaving to give the desired control and accuracy of operation.

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Haulage System (AC drive) Fig. 70:

Drive block diagrams

Master L1 L2 L3 PE

U V W PE

M Load output 19 CON2

Slave L1 L2 L3 PE

U V W PE

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Torque reference input 4 CON2

Two or more mechanically-coupled motors in master/slave operation by current-slaving.

A

COMPACT Colour Display and Keypad LOGIC

PWM ASIC DRIVE INTER FACE

P

Control Circuits

POWER

Supply

DC Link Choke

B

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SMPS

Brake Option

Schematic block diagram of the power system and control..

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Haulage System (AC drive) COMPACT Display Module and Keypad The COMPACT display module, Fig. 71, provides all the visual information on the machine operation. This display is visible through a window on the control box flameproof door.

COMPACT module

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Fig. 71:

A numeric keypad, Fig. 72, is used by the operator to communicate with the COMPACT system. This keypad is situated to the right of the COMPACT display window.

Fig. 72:

Keypad

These two units provide the means whereby the drive system parameters may be viewed, set up and changed.

The COMPACT manual contains all the information relating to the set up and operation of the drive system.

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Haulage System (AC drive) Traction drive parameters (Set up pages 25 & 26).

These pages allow the user to enter ten drive parameter numbers for each drive of his choice.

Traction drive parameter update (Set up page 27).

These pages allow the user to view or change the parameter of the drive of his choice.

Traction drive system (Set up page 2).

This is the traction or haulage drive menu page.

Communications status menu (Page 50).

This is the menu for the status of the communications systems.

Drive status (Run page 502).

This is the traction or haulage drive system communication status page.

Master drive data (Run pages 512 & 513).

These pages display ten user selected drive parameters.

Failure modes (Set up page 54).

This is the communication monitoring failure mode page.

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This is the menu for the data received by the various communications systems.

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Communications data menu (Run page 501).

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Haulage System (AC drive) Configuration Switches The configuration switches are located at the extreme right of the electronics module.

The four switches are used to determine the configuration of the inverter bridges.

The configuration switches appear as above. The switches have `piano key' actuators that are position UP for OFF and DOWN for ON. Fig. 73:

Appearance of configuration switches

LEFT

ENABLE

MASTER

RIGHT

ENABLE

MASTER

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LEFT ENABLE This switch is used to disable the left hand output bridge (terminals T1,T2,T3) in order to provide a half-power limp mode.

LEFT MASTER This is used to determine whether the left hand control card functions as a MASTER or a SLAVE. RIGHT ENABLE This switch is used to disable the right hand output bridge (terminals T4,T5,T6) in order to provide a half-power limp mode.

RIGHT MASTER This is used to determine whether the right hand control card functions as a MASTER or a SLAVE. If this configuration setting is the same as that of the left hand control card the inverter functions with both bridges in parallel under the control of the left hand card. The right hand card becomes inactive.

Caution!

Never change the positions of the switches while the inverter is running. This may cause large surges of current in the output and may damage the inverter and cause unpredictable motor behavior.

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Haulage System (AC drive)

LEFT ENABLE

LEFT MASTER

RIGHT ENABLE

RIGHT MASTER

MODE

LH CARD

RH CARD

1

ENABLE

MASTER

ENABLE

MASTER

Parallel master inverter

Master Full Power

Inactive

2

ENABLE

MASTER

ENABLE

Twin master/ slave inverter, left hand master

Master Half Power

Slave Half Power

3

ENABLE

SLAVE

ENABLE

Twin slave/ master inverter, right hand master

Slave Half Power

Master Half Power

4

ENABLE

SLAVE

ENABLE

Parallel slave inverter

Inactive

Slave Full Power

5

ENABLE

MASTER

DISABLE

Parallel master inverter in half-power limp mode

Master Half Power

Inactive

6

ENABLE

SLAVE

DISABLE

Twin master/ slave inverter in master only limp mode

Master Half Power

Inactive

7

ENABLE

SLAVE

DISABLE

Twin slave/ master inverter in slave only limp mode

Slave Half Power

Inactive

8

ENABLE

SLAVE

DISABLE

Parallel slave inverter in half-power limp mode

Inactive

Slave Half Power

9

DISABLE

MASTER

ENABLE

Parallel master inverter in half-power limp mode

Master Half Power

Inactive

10

DISABLE

MASTER

ENABLE

Twin master/ slave in slave only limp mode

Inactive

Slave Half Power

11

DISABLE

SLAVE

ENABLE

Twin slave/ master inverter in master only limp mode

Inactive

Master Half Power

12

DISABLE

SLAVE

ENABLE

Parallel slave inverter in half-power limp mode

Inactive

Slave Half Power

13..16

DISABLE

X

DISABLE

Inverter disabled

Inactive

Inactive

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MASTER

MASTER

MASTER

MASTER

MASTER

X

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MODE

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Tab. 2: Switch positions and modes

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Component Location (quick reference guide) Component Location (quick reference guide) This section provides a quick means of identifying the location of all electrical components. These components are considered in the following categories: General EL48A Power Box EL49A Control Box

General The units and their compartments are illustrated in Fig. 74.

Electrical control boxes and compartment locations

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Fig. 74:

1

2

3

1.EL48A Power box HV compartment 2.EL48A Control box AC drive compartment 3.EL49A Control box

The components contained within the electrical control boxes and compartments, are illustrated in Figs. 75 to 80 respectively.

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6

10

5.72 11

6.End display

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10.Pre-start alarm 11.Headlights

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5.SMART transducer manifold

9.Infra-red unit

9

3.Solenoid driver box (behind gauges) 4.SMART junction box

8

7.Arm transducer junction box (face side) 8.Methane monitor

4&5

2

7

Fig. 75:

1.Machine position encoder (face side) 2.Canbus junction box

3

1

7

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Component Location (quick reference guide) Electrical component location (general)

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BI628443

Component Location (quick reference guide) Fig. 76:

EL48A LH cover 2

1

3

5

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4

1 Cover fixings 2 Window (isolator ON/OFF position) 3 Flameproof cover Fig. 77:

4 Main switch handle 5 Main switch interlock handle

EL48A RH cover 1

1 Cover fixings 2 Drive circuit breaker handle

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3

2

3 Drive diagnostic unit access cover

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Component Location (quick reference guide) Fig. 78:

Component location

3

8 2

5 4

6

7

HV compartment 1.HV contactor chassis 2.Visible disconnect switch 3.3-Phase haulage transformer 4.Control transformer

5.74

LV compartment 5.AC drive 6.Drive circuit breaker 7.Methane monitor PSU 8.Voltage monitor transformer

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1

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Component Location (quick reference guide) Fig. 79:

EL49A Control compartment cover 3

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2

1

5

1 Pushbuttons 2 COMPACT screen 3 Emergency stop lever

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4

4 Keypad (behind cover) 5 Pilot test access cover

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5.76

1 COMPACT screen 2 Emergency stop switch 3 Circuit breakers 4 COMPACT unit 5 Miniature relay 6 COMPACT Power supply 7 I.S. Power supply

4

10

1

4

13 I.S. Barrier

12 Aerial isolator

11 IMAR Unit

10 Relays

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9 DC/DC power supply

8 Radio

10

11

9

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3

2

12

13

5

6

7 8

Fig. 80:

8

7

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Component Location (quick reference guide) Control compartment chassis component location

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BI628443

Maintenance (electrical) Maintenance (electrical) This section provides a comprehensive electrical maintenance schedule consisting of daily, weekly, monthly and three monthly investigations. It is suggested that this schedule is adopted to ensure maximum reliability and safety. The section consists mainly of convenient check list cards for instructing maintenance engineers on which investigations must be carried out and also, for keeping records of the results obtained on carrying out the prescribed investigations.

Important!

A typical example of one of these cards is included on the next page. If difficulty is encountered in finding any of the components mentioned in this maintenance schedule, refer to the `Component Location (Quick Reference Guide)', Chapter 5 of this manual.

Caution!

When using high voltage test equipment, DO NOT connect this equipment to low voltage control wiring and components.

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Caution!

Failure to comply with this maintenance schedule could lead to component failure and render the shearer.

Warning!

When carrying out maintenance/repair operations the following should be complied with: PERSONS SUPERVISING AND PERFORMING ELECTRICAL INSTALLATION OR MAINTENANCE MUST BE SUITABLY QUALIFIED AND COMPETENT IN THESE DUTIES. ENSURE THE SHEARER IS ISOLATED AT THE GATE END PANEL OR BY REMOVAL OF THE TRAILING CABLE, PRIOR TO CARRYING OUT ELECTRICAL MAINTENANCE, UNLESS POWER IS REQUIRED TO CARRY OUT THE CHECKS. THE SHEARER MUST BE IMMOBILISED PRIOR TO CARRYING OUT MAINTENANCE ON MOVING PARTS. WHEN WORK IS TO BE CARRIED OUT OVER, OR ON THE FACE SIDE OF THE SHEARER, BOTH THE SHEARER AND CONVEYOR (AFC) MUST BE IMMOBILISED. IN ADDITION ADEQUATE ROOF AND FACE SUPPORT MUST BE PROVIDED. ENSURE ALL HYDRAULIC AND WATER SYSTEMS ARE ISOLATED AND DE-PRESSURISED 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. BEFORE ELECTRICAL POWER IS APPLIED TO THE SHEARER, ENSURE THAT ALL FLAMEPROOF GAPS DO NOT EXCEED LEGAL LIMITS. Failure to comply with any of the above could lead to damage to the machine or injury to personnel.

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Maintenance (electrical)

DAILY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

General 8

Check main switch for correct functioning, pushbuttons, keypad..

2

Also by operator at start of shift

Check emergency stop button and radio transmitter stop for correct functioning

1

Also by operator at start of shif

Check all main operations for correct functioning, ie. haulage speed and direction, raisie/lower of ranging arm, cowl rotation clockwise/counterclockwise

0

Necessary after repair on the machine. App. 5 minutes

0

Necessary after repair on the machine. App. 2 minutes

Check trailing cable where it enters EL48 box. Check visually the cable towing assembly and its monitoring devices.

5

Ensure that the acoustic audible warning signal sounds as it is commissioned for haulage pump and cutter motors.

1

Activate “Earth Fault” test device and check LED's

3

Radio Transmitter

5.78

Remove any dirt and moisture from the units

0.5

Check units for damage and security of antenna and exchange where necessary

0.5

Check the condition of the battery units and battery retaining clip and ensure batteries are loaded

0.5

Check that all operator functions can be activated

0.5

Estimated completion time (daily)

22

By the operator before the start of a shift

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Check all utilized LEDs illuminate

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Visual inspection for damage to all flameproof covers, cable entries, protective guards, control handles, and inspection windows

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Maintenance (electrical)

WEEKLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

General 60

Operate all earth leakage and lockout test facilities

2

Estimated completion time (daily)

62

Visual inspection / Knocking test

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Check that all flameproof covers, cable entry devices, blanking elements and fixings are of the correct type and in position and secure where practically possible (see manual)

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Maintenance (electrical)

MONTHLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

General Check the operation of the COMPACT module, document motor parameter and start-up operational values,information from the error logs

0

Check and document parameter values of all haulage systems. All parameters must be set to normal performance data

0

Via connections to surface communications

Ranging Arm Motor LH

Cable entry chamber must be clean and dry

3

Check all CANBUS connectors

5

Check all flameproof surfaces for damage ensuring that all flameproof gaps do not exceed the legally prescribed limits

5

Covers are disassembled for procedures as per 234, 236

E

20

Ranging Arm Motor RH Check visable connections of main and transducer cables. Check cables and cable insertion points for damage

20

Cable entry chamber must be clean and dry

3

Check all CANBUS connectors

5

Check all flameproof surfaces for damage ensuring that all flameproof gaps do not exceed the legally prescribed limits

5

Covers are disassembled for procedures as per 238, 240

Control Box (EL49A) Check condition of all flameproof flanges, studs, threads, dowel pins and washers from the outside, and ensure that all flameproof gaps do not exceed the prescribed legal limits

5

Activate “Earth Fault” test device and check LED's

0

Visual inspection / Knocking test

Covered at daily inspection

Haulage Drive Box (EL48A)

5.80

Check condition of all flameproof flanges, studs, threads, dowel pins and washers from the outside, and ensure that all flameproof gaps do not exceed the prescribed legal limits

5

Activate “Earth Fault” test device and check LED's

0

Estimated completion time (monthly)

76

Visual inspection / Knocking test

Covered at daily inspection

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Check visable connections of main and transducer cables. Check cables and cable insertion points for damage

BI628443

Maintenance (electrical)

QUARTERLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

20

Visual check / Knocking test.

Tightness of bolt connections to be checked

20

Visual check / Knocking test.

Tightness of bolt connections to be checked

5

Visual check / Knocking test.

Tightness of bolt connections to be checked

5

Visual check / Knocking test.

Tightness of bolt connections to be checked

5

Visual check / Knocking test.

Tightness of bolt connections to be checked

5

Visual check / Knocking test.

Tightness of bolt connections to be checked

Pump Motor Visual inspection for damage to all flameproof covers, cable entries, protective guards.

Check all flameproof gaps for damage ensuring that all flameproof gaps do not exceed the prescribed legal limits.

Haulage Motor LH Visual inspection for damage to all flameproof covers, cable entries, protective guards.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Check all flameproof gaps for damage ensuring that all flameproof gaps do not exceed the prescribed legal limits.

Haulage Motor RH Visual inspection for damage to all flameproof covers, cable entries, protective guards.

Check all flameproof gaps for damage ensuring that all flameproof gaps do not exceed the prescribed legal limits.

Electro Hydraulic Control Valves Check operation of control valves

5

Beacons and Siren Pre-start Alarms Check for cleanliness and damage of the beacons and pre-start alarm on right and left machine ends

5

Visual check of beacons

Trolex Junction Boxes Check that the box is securely fitted

5

Free boxes from any dirt and moisture

5

Visually inspect condition of all cables

5

If applicable

SMART Junction Boxes (three boxes) Check that all three boxes are securely fitted

6

Visually inspect condition of external cable entry point

15

Estimated completion time (quarterly)

106

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Fault diagnosis (electrical) Fault diagnosis (electrical) This section provides 2 simple trouble shooting guides if the shearer fails to power up. If after answering `YES' or `NO' to the questions in guides 1 and 2 and the shearer successfully powers up, further fault and alarm diagnosis will be carried out by COMPACT.

Diagnosis Guide 1.

Symptom: The shearer fails to power up when the machine `START' pushbutton is operated.

. STEP 1. Is the Gate End Panel switched `ON' and in a healthy state?

– NO: Rectify this and try again to start the shearer.

YES: Move to Step 2.

. STEP 2. Is the main switch handle at the `ON' position?

. STEP 3. Operate the pilot test pushbutton.

Does either of the pilot circuit indicators illuminate?

– NO: Check the pilot cores of the trailing cable.

YES: Consult the pilot circuit schematic diagram.

The circuit is healthy up to the last lamp to be illuminated.

All pilot circuit components and wiring beyond this lamp should be checked.

Diagnostic Guide 2.

Symptom: The shearer powers up when the machine `START' pushbutton is operated and powers down when the pushbutton is released.

. STEP 1. Has the machine `START' pushbutton been operated for over 6 seconds?

– NO: Operate the machine `START' pushbutton and release after 6 seconds.

YES: Move to Step 2.

. STEP 2. Check the wiring to the pilot retaining contact within COMPACT. When the shearer has been successfully powered up the COMPACT display unit will detect any other fault or alarm condition.

(Refer to the `COMPACT fault diagnosis', of the COMPACT manual).

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– NO: Rectify this and try again to start the shearer.

YES: Move to Step 3.

BI628443

General machine specification

General machine specification Machine Height (From Floor)

58.1 ins

Drum Diameter

74 ins

Drum Web

42 ins

Distance between shoe centres 270 ins Distance between drum centres 538 ins RANGING ARM (EL62B) Length, drum centre to trunnion 114 ins Cutter Motor (EL58B)

600 kW

Drum speed fitted

39.4 rpm

Caterpillar Global Mining Europe GmbH, Lünen 2013

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HAULAGE (EL57A) Haulage System

Jumbotrack Std.

Drive System

A.C. Drive

Haulage Motors (EL55C)

100 kW AC

Maximum Pull @ 49.35 ft.min

73.49 tonnes

Maximum Speed @ 36.75 tonnes 98.69 ft/min POWER PACK (EL50A)

Doc. no.: SHEL2000-034 BA 00

Electric Motor (EL56BN)

60 kW

Hydraulic Pump Output

110 lpm, max.

Maximum working pressure

240 bar

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General machine specification

Fig. 81:

Unit location

20 18

17

19

1

13

12

4

11

2 16

3

16

7

5 & 14

8 9 & 10

6 & 15

5.84

Unit Weight (lbs)

1

LH Ranging arm (EL62F)

16534

2

RH Ranging arm (EL62F)

16534

3

LH Ranging arm motor (EL58B)

3240

4

RH Ranging arm motor (EL58B)

3240

5

LH Haulage unit (EL57B)

2462

6

RH Haulage unit (EL57B)

2462

7

LH Haulage motor (EL55C)

1543

8

RH Haulage motor (EL55C)

1543

9

Power Pack (EL50A)

2314

10

Pump motor (EL56BN)

802

11

Control box (EL49A)

2429

12

Power box (EL48A)

5784

13

Mainframe (EL45A)

37588

14

LH Haulage downdrive (EL53A)

4217

15

RH Haulage downdrive (EL53A)

4217

16

Ranging arm lifting cylinder

3527

17

LH Cowl

3100

18

RH Cowl

3100

19

LH Drum

10585

20

RH Drum

10585

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item No. Unit Description

E

Tab. 3: Unit weights and location

BI628443

General machine specification

Hoses All external hoses are colour coded for ease of identification. The following code applies: BLACK = ZERO PRESSURE ORANGE = LOW PRESSURE RED = HIGH PRESSURE BLUE = WATER GREEN = OIL FILLING Warning!

Please ensure all orange, red and blue hoses are depressurised before disconnecting.

Abbreviations Listed below are the abbreviations which may be used in this manual: Caterpillar Global Mining Europe GmbH, Lünen 2013

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P.F.F. . Pick Face Flushing B.F.F. . Back Face Flushing psi . . . . Pounds per Square Inch I.S.O. . International Systems Organisation bar . . . . I.S.O. Unit of Pressure lbs.ft . . Pounds Feet Kg.m . . Kilogram Metre ac . . . . Alternating Current dc . . . . Direct Current kW . . . . Kilowatt hp . . . . Horse Power Imp . . . Imperial lpm . . . Litres per Minute gpm . . . Gallons per Minute rpm . . . Revolutions per Minute Hyd . . . Hydraulic Mech . . Mechanical Elect . . Electrical V. . . . . Volts R. . . . . Resistance A. . . . . Amperes C. . . . . Capacitance V.G. . . Viscosity Grade I.S. . . . Intrinsically Safe S.W.L. Safe Working Load L.H. . . . Left Hand R.H. . . Right Hand A.F.C. . Armoured Flexible Conveyor L.E.D. . Light Emitting Diode P.T.F.E. Polytetrafluoroethylene R.T.D. . Resistance Temperature Detector R.F. . . . Radio Frequency CT . . . . Current Transformer

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Operator controls (mechanical & electrical) Operator controls (mechanical & electrical) Electrical Supply Examine the trailing cable for damage or defects and ensure that plugs and sockets are clean, dry and protected from water. The cable handler should be checked for security and that it is arranged to trail properly behind the machine.

Systematic monitoring and cleaning of the cable trough is essential to ensure that the cable does not catch on any debris, projections, or misaligned spillplates.

Warning!

The trailing cable carries high voltage and must be repaired or replaced immediately if any damage is found. Failure to do so may cause serious injury.

Machine controls

The operator must ensure that all control handles are in the 'OFF' or 'NEUTRAL' position prior to start-up.

Caution!

In the event of a static stall of either ranging arm motor, the emergency stop facility should be operated immediately. When re-started, the shearer should be moved away from the obstruction, using the haulage controls, before starting the motors. Failure to comply with this may result in damage to the motors.

Warning!

Before attempting to start the shearer, make sure all personnel are clear of the shearer and cutting drums. Failure to do so may result in serious injury.

Control mode selector switch The control mode selector switch should be set at the desired mode position (i.e. radio, end station or manual).

Cooling supply The cooling water supply for the shearer motors and units must be turned on before starting the shearer.

Caution!

Do not attempt to isolate this cooling supply at any time whilst the shearer motors are running, as damage to the motor sealing arrangements will occur.

Emergency stop switch and buttons The 'ON/OFF' buttons on the radio transmitters and the `Motor Stop' buttons on the control box must be operated at least once per shift to ensure correct operation.

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Warning!

Never force controls with levers, hammers etc. as this will make the shearer difficult to operate and could render it unreliable and dangerous in use.

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Excessive force is not required when operating any of the machine controls. If controls are difficult or impossible to operate, this should be reported to the face engineer immediately.

BI628443

Operator controls (mechanical & electrical) The 'emergency stop' pull chain which runs the length of the shearer and is attached to the emergency stop switch of the control box, should be clear of obstructions and should also be operated at least once per shift.

Warning!

If any of the emergency stop devices do not function, the shearer should not be used until the fault is rectified. Failure to do so may result in serious injury to personnel or damage to the shearer.

Face conditions The operator should constantly check for obstructions, bad roof or floor conditions etc., well in advance of the shearer, so that any necessary remedial or avoiding action can be taken 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

Caution!

Failure to remedy these excess gradients may cause severe damage to both the face conveyor and the shearer.

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 40mm per cut, up or down.

Caution!

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

To eliminate the problem of altering the face advance horizon dramatically, it is easier to check the horizon and correct slightly, if required, after every cut.

Stopping the shearer Normal Procedure To stop the shearer from cutting, the haulage speed should be reduced to zero using the -ve ramp pushbutton, select 'Haul Stop', 'Cutter Stop' and then power down the shearer.

Notice!

The emergency stop should be used in emergencies only.

Electrical trips Warning!

If the gate end panel trips on 'earth leakage', do not attempt to reset it. This should be carried out by a qualified face engineer.

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Operator controls (mechanical & electrical) Shearer Operators Report

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The shearer operator knows his own machine and when it is not performing correctly he should be constantly on the look out for any unusual behaviour 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. If the operator takes care of his shearer in this way, shearer reliability and safety will inevitably follow.

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Mainframe (EL45A) Mainframe (EL45A) The mainframe forms the backbone of the shearer. It is a substantial box section which houses or suports the following units: Control Units.

Haulage Units.

Haulage Motors.

Downdrive Modules.

Hydraulic Power Pack.

The mainframe also provides simple trunnions, at each end, to support the ranging arms, machined facings to attach the downdrive modules, anchor points to attach the face side shoes and ranging arm cylinder anchors.

All units in, or attached to the mainframe, are self contained.

Fig. 82: Shows waste side and plan view.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 83: Shows mainframe face side view.

Fig. 84: Shows arm hinge pin arrangement.

Fig. 85: Shows ranging arm lifting cylinder anchor.

Fig. 86: Shows face side skid shoe arrangement.

Fig. 87: Shows face side skid shoe wear limit.

Fig. 101:Shows ranging arm hinge point lubrication.

Doc. no.: SHEL2000-034 BA 00

VPSP / 01

5.89

1

2

4

4

6

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Shearer EL 2000

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7 Access cover (electrical boxes)

6 Access covers (power pack)

5 Access cover (haulage motor)

Caterpillar Global Mining Europe GmbH, Lünen 2013

4 Access cover (haulage unit)

3

4

5

2

4 1

Fig. 82:

1 Hinge point 2 Mainframe lifting points 3 Acess cover (water material)

5

7

BI628443

Mainframe (EL45A) Waste side and plan view

7

5

1

6

Doc. no.: SHEL2000-034 BA 00

VPSP / 01 4.Access covers (cylinder valve blocks)

2

4

7.Access covers (hinge points)

6.Access covers (general)

5.Face side skid shoes

E

1

5

7

Fig. 83:

1.Access covers (haulage units) 2.Access covers (power pack material) 3.Access covers (electrical control boxes)

4

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

BI628443

Mainframe (EL45A)

Face side view

5.91

BI628443

Mainframe (EL45A) Fig. 84:

Hinge pin arrangement 1

1

2 3

3 2 1 Hinge pins 2 Access cover for pin

Fig. 85:

Caterpillar Global Mining Europe GmbH, Lünen 2013

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3 Tollok assemblies Ranging arm cylinder anchor

2

1

1 Anchor pin end cover 2 Cylinder anchor pin

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BI628443

Mainframe (EL45A) Fig. 86:

Face side skid shoe

1

3

2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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5

4 1 Shoe post 2 Skid shoe 3 Hinge pin

5 End cover

Face side skid shoe wear limit

10 mm max. wear

Fig. 87:

4 Distance pieces

Doc. no.: SHEL2000-034 BA 00

VPSP / 01

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Mainframe (EL45A) Tollok locking assemblies Installation

. Carefully clean the bore and pin contact surfaces and ensure all sharp edges are removed. Finally apply a light oil film.

. Check that the upper and inner Tollok's rings are balanced to the cone elements, and ensure that the Tollok assembly is not pulled apart as it may impair the location of the jacking points.

Fig. 89:

Tollok assembly

. Insert thrust washers into hinge casting.

Fig. 90:

Thrust washers

1 1 Thrust washers

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Hinge pin

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 88:

BI628443

Mainframe (EL45A) . Support ranging arm in a level position and insert the lifting bracket and pivot bracket into the jaws of the hinge casting ensuring that the bores are in alignment.

E

Fig. 91:

Ranging arm location

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Insert puller bars into hinge pins and carefully locate through hinge casting, lifting bracket and pivot bracket bushes.

Fig. 92:

Hinge pin

2 1 1 Hinge pin

Doc. no.: SHEL2000-034 BA 00

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2 Puller bar

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BI628443

Mainframe (EL45A) . Remove four (4) M10 x 70 cap screws and replace with four (4) M10 x 120 cap screws. Insert Tollok assemblies into the locations in the hinge casting. Start with the outside assemblies and then the inner assemblies.

Tollok assembly

. Remove the M10 x 120 cap screws from the waste and face side Tollok assemblies and fit outer covers to hinge pins with three (3) M16 set screws.

. Push outer covers and hinge pins fully in to hinge casting and secure with four (4) M20 set screws.

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Fig. 93:

BI628443

Mainframe (EL45A) Fig. 94:

Outer cover

2 1

1 M16 screws

2 M20 screws

. Using the long cap screws, manipulate the inside Tollok Caterpillar Global Mining Europe GmbH, Lünen 2013

E

assemblies into position, flush with the end of the hinge pin.

. Remove the four (4) M10 x 120 cap screws and replace with the existing M10 x 70 cap screws previously removed.

. Tighten the inside Tollok assemblies starting with the bottom screw first (2 or nearest the bottom) by hand, then 1, 3, and 4 so as to distribute the load until the inner and upper rings reach the pin and the hinge casting bore. This has to be carried out on the remaining screws using the same tightening pattern.

(Fig. 96A) Fig. 95:

Inside Tollok assembly location 1

2 3 3

5

6

6

4 1 Lifting bracket 2 Pivot bracket 3 Thrust washer

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4 Outer cover 5 Hinge pin 6 Tollok assembly

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Mainframe (EL45A) Fig. 96:

Torque pattern

1 5

9

10

1

2

7

4

9

3

3

8

8

4

10 2

6

7

6

5

B

A

. Remove outer covers and insert four (4) M10 x 120 cap screws and manipulate the Tollok assemblies into position until they are flush with the end of the hinge pins.

. Remove the four (4) M10 x 120 cap screws and replace with the existing M10 x 70 cap screws previously removed.

E

Outside Tollok assembly

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 97:

. Tighten the outside Tollok assemblies starting with the bottom screw first (2 or nearest the bottom) by hand, then 1, 3, and 4 so as to distribute the load until the inner and upper rings reach the pin and the hinge casting bore. This has to be carried out on the remaining screws using the same tightening pattern.

(Fig. 96A)

. Set the torque wrench at 25Nm and torque both inside Tollok assemblies using the cross torque pattern previously described. (Torque every screw once only). This should now be carried out on the outside Tollok assemblies. (Fig. 96A)

. Set the torque wrench at 49Nm and torque both inside Tollok assemblies using the cross torque pattern previously described. (Torque every screw once only). This should now be carried out on both outside Tollok assemblies. (Fig. 96A)

. Again with the torque wrench set at 49Nm, starting at screw number 1, proceed in a circular pattern and torque both inside Tollok assemblies. This should now be carried out on both outside Tollok assemblies. (Fig. 96B)

. Replace outer covers and secure.

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Mainframe (EL45A) Dismantling

. Support ranging arm in a horizontal and level position. . Remove outer covers. . Loosen and unscrew all the M10 x 70 cap screws on the outer and inner Tollok assemblies.

. Insert four (4) M10 x 120 cap screws in the tapped holes on the front cone. Ensure cap screws are oiled.

Front cone unlocking

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 98:

1 2 1 M10 x 70 cap screws

2 M10 x 120 cap screws

. Tighten the cap screws alternately until the front cone unlocks, which may occur before this procedure is concluded.

. Withdraw front cone, remove cap screws and insert cap screws into the middle ring tapped holes to release the rear cone.

Fig. 99:

Rear cone unlocking

1

1 Middle ring

Doc. no.: SHEL2000-034 BA 00

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2

2 M10 x 120 cap screws

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BI628443

Mainframe (EL45A) . Again tighten the cap screws alternately until the rear cone unlocks, which may occur before this procedure is concluded.

. The Tollok assembly can now be extracted from each bore and hinge pin.

. Carry out this procedure to remove all four Tollok assemblies.

Re-Use of Tollok Assembly If in any doubt regarding suitability for re-use, discard and use new Tollok assembly and install per above procedure.

5.100

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 100: Tollok assembly removed

BI628443

Mainframe (EL45A) Fig. 101: Ranging arm hinge points lubrication

1 A

Caterpillar Global Mining Europe GmbH, Lünen 2013

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A

1 Hinge pin grease entry points Lub Point

A

Description

Hinge points

Lubricant

GR3

Schedule

Inject

DAILY

Recommended lubricants and their specifications can be found in 'Permissible Media', Chapter 6 of this manual Important!

All four hinge pins are connected to remote greasing stations, located on the waste side of the machine. These stations are clearly labelled.

Prior to applying lubricant to hinge pin arrangement, ensure that the weight of the ranging arm is fully supported. (e.g. ranging arm lowered until drum rests on the floor, or ranging arm lowered until arm rests on support).

Doc. no.: SHEL2000-034 BA 00

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Haulage unit (EL57B) Haulage unit (EL57B) Danger!

Before working on or near any moving parts of the shearer, isolate the power supply at the main switch and remove the trailing cable, at the gate end panel.

Please ensure that all hydraulic and water hoses are fully depressurised before attempting any disconnection.

Ensure the machine is properly restricted from moving, before removing any part of the haulage system.

General

This consists of a quill shaft arrangement driving a primary gear with a lip seal on the motor end of its journal. This seal arrangement, and a `O' ring located on the haulage unit end of the long quill shaft, prevents oil contamination of the electric motor. The high speed section has two (2) further reduction gears.

Quill shaft access is detailed in the Haulage motor section, Chapter 5.

A set of change speed gears are also located in this section and are identified in Fig. 104. A 5 psi (0.4 bar) relief valve, combined in the dipstick, is fitted to the top face of the high-speed section, to facilitate air breathing.

Slow speed section

Oil monitoring

An oil level and temperature transducer is fitted into the slow speed section of this haulage unit. This transducer is monitored by the COMPACT shearer control system.

Encoder drive

An encoder drive facility is provided on the 4th motion shaft. Both haulage units are suitable for providing the drive but the encoder is only fitted on the left hand unit. (Fig. 105) The purpose of the encoder unit is to provide machine position monitoring. See Haulage system (AC drive) section, Chapter 5, for further information. 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.

Coolers

Fig. 107 shows the location of both sets of inlet and outlet water connections, for the haulage unit coolers. These coolers are linked in series and require a minimum flow of 18 litres per minute (4.75 US gpm) at a maximum pressure of 30 bar (450 psi).

(Refer to Water system section, Chapter 5, for further information).

Unit to mainframe retention

5.102

This section consists of a reduction gear mesh and a double epicyclic arrangement, at the output end. All gearing in the haulage unit is lubricated by splash action, from the common reservoir.

This self contained modular unit slides horizontally into the mainframe from the face side. The unit is spigot located in the mainframe, and is retained by four (8) M24 bolts and tapped plates.

Torque settings for these bolts can be found in Chapter 6.

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

High speed section

E

The handable haulage unit, driven by a water cooled ac electric motor, is mounted to the mainframe as indicated in Fig. 102.

The gear transmission of the haulage unit consists of a high-speed section and a slow-speed section. Refer to Fig. 104.

Doc. no.: SHEL2000-034 BA 00

Haulage unit

Downdrive

VPSP / 01 1 LH Haulage unit 2 LH Haulage motor

1

2

E

4

3 RH Haulage unit 4 RH Haulage motor

Haulage motor

Caterpillar Global Mining Europe GmbH, Lünen 2013

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BI628443

Haulage unit (EL57B)

Fig. 102: Haulage system location

5.103

BI628443

Haulage unit (EL57B) Fig. 103: Outside views

2

3

4

1 5

E

6

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

6

7

4

3

2

1 Haulage gearcase 2 Double epicyclic 3 Motor input 4 Encoder drive material

5.104

5 Temperature/Level transducer 6 Monitoring material 7 Oil level dipstick/breather

Shearer EL 2000

BI628443

Haulage unit (EL57B) Fig. 104: General arrangement 5 7

9

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4

6 3

8

2 1

1 Motor quill shaft 2 1st Motion shaft 3 2nd Motion shaft 4 3rd Motion shaft 5 Sun gear

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6 Double epicyclic 7 Output to downdrive 8 Change speed gears 9 Encoder drive material

5.105

BI628443

Haulage unit (EL57B) Fig. 105: Encoder

Caterpillar Global Mining Europe GmbH, Lünen 2013

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1

2 Encoder

3

4

1 Drive from sun gear 2 Flexible drive

5.106

3 Gear reduction 4 Absolute encoder

Shearer EL 2000

BI628443

Haulage unit (EL57B)

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 106: Dipstick arrangement

Fig. 107: Cooler arrangement

Doc. no.: SHEL2000-034 BA 00

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Haulage unit (EL57B) Fig. 108: Lubrication

A

C E

Caterpillar Global Mining Europe GmbH, Lünen 2013

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A

D B

A

Unit Capacity: Lub Point

Description

A

Oil filling

B

Drain

C

20 litres

Lubricant

G3

Schedule

Fill

AS REQUIRED

Oil level dipstick

Inspect

WEEKLY

D

Breather (1 - 5 psi)

Inspect

WEEKLY

E

Temperature transducer

COMPACT

CONTINUOUS

Recommended lubricants and their specifications can be found in 'Permissible Media', Chapter 6 of this manual.

Important!

Both haulage units are connected to remote filling stations located on the waste side of the machine. These stations are clearly labelled.

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Oil level can be manually checked with the dipstick

Fill haulage unit until COMPACT reads 100% (20 litres)

E

1 Dipstick and breather 2 Transducer

4

Caterpillar Global Mining Europe GmbH, Lünen 2013

3

75% Oil Level

100% Oil Level (20 litres)

180% Oil Level

2

3 Transducer float 4 Transducer monitoring range

1

BI628443

Haulage unit (EL57B)

Fig. 109: Haulage unit transducer/dipstick oil level relationship

5.109

BI628443

Downdrive system (EL53A) Downdrive system (EL53A) The downdrive system transmits the power from the haulage unit output shaft, via the quill shaft, to the output drive sprocket. This, in turn, engages with the haulage rack wheel. The complete drive system slides horizontally into the mainframe from the waste side. It is spigot located and retained by means of six (6) M30 and 2 M36 Supernuts.

(Refer to Supernut tensioning and removal procedure, Chapter 6).

Fig. 110: Downdrive system Downdrive

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Haulage motor

Haulage unit

1

2

1 LH Downdrive 2 RH Downdrive

5.110

Shearer EL 2000

BI628443

Downdrive system (EL53A) Fig. 111: Downdrive front and rear views

3

3

4

4

Caterpillar Global Mining Europe GmbH, Lünen 2013

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2

5

6

1

6

1 Quill shaft 3 Lifting Shackles 5 M30 Supernuts

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2 Quill shaft access cover 4 M36 Supernuts 6 Trapping shoe

5.111

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Downdrive system (EL53A) Fig. 112: Downdrive component location

2

3

4

1 Drive gear 2 Downdrive housing

3 Idler wheel 4 Drive sprocket

5.112

18mm, max. wear

5mm, as new

Fig. 113: Trapping shoe wear limits

10mm, as new 20mm, max. wear

Shearer EL 2000

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Downdrive system (EL53A) Drive Quill Shaft Removal/Assembly Caution!

Please ensure that the quill shaft is removed, before removing or assembling the DOWNDRIVE to the mainframe. Failure to do so may result in a Damaged quill shaft.

. Remove drip feed reservoir. . Remove three M20 screws and withdraw grease access cover. . Remove four M20 screws and lift out sprocket guard. . Remove grease nipple/set screw from retaining cover. . Remove eight M16 screws and withdraw retaining cover. . Insert puller bar into support bar and withdraw quill shaft. . Examine quill shaft for wear or damage and if necessary replace.

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. Ensure that drive quill shaft cavity is clean. If splines are not in alignment use a pinch bar in the drive sprocket pocket of the rack bar to inch the splines into alignment.

Important!

Ensure that grease of the correct grade is applied to the splines before assembly. (Grade GR5)

. Pack quill shaft cavity and quill shaft with grease, then insert quill shaft. When fully inserted draw back 25mm approx. before removing puller bar.

. Locate retaining cover over support bar 'O' ring and push fully home. Secure with M16 screws.

. Replace grease nipple/set screw, sprocket guard and grease access cover.

. Replace drip feed reservoir. . Ensure all items are secure.

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Downdrive system (EL53A) Fig. 114: Drive quill shaft 2

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7 1 M20 screws 2 Grease access cover 3 Sprocket guard 4 Grease nipple/set screw

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5 M16 screws 6 Retaining cover 7 Support bar 8 Quill shaft

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Downdrive system (EL53A) Lubrication Fig. 115: Downdrive lubrication A C D

B

E Caterpillar Global Mining Europe GmbH, Lünen 2013

E

F

A Lub Point

Description

Drip Feed Reservoir Capacity: 10 litres Lubricant

Schedule

A

Top bearings

GR3

Inject

DAILY

B

Quill shaft

GR5

Inspect/Inject

MONTHLY

C

Bottom bearings

GR3

Inject

DAILY

D

Drive gears

G3

Drip Feed

CONTINUOUS

E

Drip feed reservoir filling point

G3

Fill

AS REQUIRED

F

Drip feed reservoir oil level

Inspect

AS REQUIRED

Recommended lubricants and their specifications can be found in 'Permissible Media', Chapter 6 of this manual.

Important!

Downdrive top bearings are connected to remote grease stations located on the waste side of the machine. Drip feed reservoir filling points are also connrcted to remote filling points located on the waste side. These stations are clearly labelled.

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Ranging arm EL62F Ranging arm EL62F Introduction The `handable' ranging arm, is driven by a water cooled ac motor.

A detailed explanation of the water supply can be found in the Water system section, in Chapter 5 of this manual.

The ranging arm motor is mounted in a shroud which is an integral part of the arm. A lifting bracket arrangement, located at either end of the mainframe, raises and lowers the arm via the lifting cylinder.

This arrangement is shown in Fig. 116.

General The ranging arm is divided into three sections.

The high speed or change gear section.

The idler section.

The sun gear and double epicyclic section.

In the high speed section, the first motion shaft is driven by a splined quill shaft which can be fitted or withdrawn from the face side or the waste side of the shearer.

The drive from the first motion shaft continues through the second and third motion shafts, three idler gears, before reaching the double epicyclic and final drive. The final drive is by means of a square hub at the cutting drum.

Drum speed The drum speed can be varied by changing the gears on the first and second motion shafts. Access is gained via two covers on the face side of the arm.

The following are examples of drum speeds available: 32.8, 37.4, 45.2 rpm @ 50Hz 39.4, 44.9, 54.3 rpm @ 60Hz Drum speed fitted 44.9 rpm.

Seals The lip seals fitted to the primary gear journals prevent oil entering the ranging arm motor, via the quill shaft chamber. The output shaft (drum shaft) bearing is protected by a heavy-duty mechanical seal. All other seals in the ranging arm are `O' ring type seals.

Cooler A cooler arrangement is fitted in the high speed section.

(See Fig. 118)

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High speed section

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3 Arm lifting cylinder 4 Motor shroud 5 Ranging arm motor 6 Cutting drum 7 Arm position monitoring

1 Ranging arm to mainframe hinge points 2 Lifting bracket

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Ranging arm EL62F

Fig. 116: Ranging arm component location

5.117

5.118 5

3 Access covers 4 Heavy duty double epicyclic assembly 5 Ranging arm motor 6 Arm position monitor

1 Hinge points 2 High speed section

3

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Ranging arm EL62F

Fig. 117: Ranging arm

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Ranging arm EL62F Fig. 118: Cooler

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1 Water connections Fig. 119: Lifting bracket material

2

1

4 3

1 Lifting bracket 2 Tapered bushes

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3 Tapered pin 4 Access cover

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Ranging arm EL62F Ranging arm lifting cylinder These are double-acting cylinders that are fixed at the block end to the mainframe by means of a stepped pin suitably retained and at the clevis end by a similar arrangement.

Warning!

BEFORE REMOVING ANY OF THE HYDRAULIC CYLINDERS, PILOT OPERATED CHECK VALVE BLOCKS OR HOSES BETWEEN THE PILOT OPERATED CHECK VALVE AND DIRECTIONAL CONTROL VALVE, ENSURE THAT THE APPROPRIATE RANGING ARM IS FULLY SUPPORTED AND ALL RELEVANT HOSES ARE DE-PRESSURISED. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY.

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Fig. 120: Hydraulic cylinder

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Ranging arm EL62F Face seal fitting instructions

. Only remove from original wrapping immediately before installation.

. Thoroughly de-grease housing surfaces that will contact the rubber rings of the seal with a clean solvent. Wipe dry.

. Remove rubber toric from seal half and position fitting tool.

Take care not to damage the seal face.

. Replace the rubber toric on the metal ring, making sure it has not twisted and is seated correctly.

. Place the seal half evenly on the housing and take care not to damage the seal face, or cause injury. Apply even pressure.

For large diameters, it is recommended that two (2) people carry out this stage. (See Fig. 121A).

. The seal will slip into the housing.

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. Remove the fitting tool. . The seal face should now sit parallel with the housing. The rubber should not be sitting wavelike or partly bulged out of bore. (See Fig. 121B)

. Wipe clean the seal face with a lint free wiper and apply a thin film of clean oil (S.A..E. 30) to sealing face.

Fig. 121: Face seal fitting

B

As assembled

A

Important!

Oil must not wet any other surface.

Caution!

Mechanical face seals and others of this type are precision sealing devices and should be handled and fitted with great care. Trouble free running cannot be assured unless the above fitting instructions are complied with.

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Ranging arm EL62F Arm position monitoring set-up procedure Important!

Before carrying out calibration steps below, the machine arms must be level with the machine and preferably on a level base.

. Remove M10 hex. hd. screws (1) and withdraw cover (2). . Loosen hollow set screws (3). . Check and confirm that hollow set screw (4) is tightened onto the flat of the shaft. (Note: this is normally done at build, and at this stage is only required to be visually checked).

. Power up the machine in test mode and view run page 63. The left arm voltage should read 5V.

. If this is not the case then rotate the shaft of the potentiometers by using the two adjustment holes to rotate alignment bush (5) until the voltage for the left arm displays 5V.

. To hold the alignment bush in position, hollow set screws (3) . Repeat steps above for the right hand arm. . Now carry out test procedure to check heights and if there are any backlash issues.

. Replace cover (2) and retain with hex. hd. Screws (1).

For further information, please refer to the COMPACT manual.

Fig. 122: Arm position monitoring set-up

2

1

3

5

4

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must be tightened and retained with Loctite 243.

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Ranging arm EL62F Lubrication Fig. 123: Lubrication and monitoring C

F

G

H

B

E Caterpillar Global Mining Europe GmbH, Lünen 2013

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D A

B

B

Unit Capacity: 66 litres Lub Point

Description

Lubricant

Schedule

A

Wet cutting seals

GR3

Inject

DAILY

B

Remote oil fill

G3

Fill

AS REQUIRED

C

Breather

Inspect

MONTHLY

D

Oil level sight glass

Inspect

DAILY

E

Temperature monitoring

COMPACT

CONTINUOUS

F

Drain (on bottom face)

G

Drain (on bearing housing)

H

Oil sampling point (behind cover)

AS REQUIRED

Recommended lubricants and their specifications can be found in 'Permissible Media', Chapter 6 of this manual.

Important!

Both ranging arms are connected to remote oil filling stations located on the waste side of the machine. These stations are clearly labelled.

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Power pack EL50A & hydraulic system Power pack EL50A & hydraulic system Introduction The power pack unit provides the hydraulic system power for the shearer auxiliary functions.

The Symbolic diagram is shown at the end of this section as Fig. 130.

General The components within the power pack unit are assembled within a compartment of the mainframe. All are accessible from the waste side of the shearer. The hydraulic pump is driven by a dedicated electric motor, also housed in the power pack area.

Fig. 124: General arrangement 1 7

9

4

5 8 3

6

1 Pump motor 2 Relief valve 3 Control valve bank 4 Hydraulic pump 5 Return filter

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2

6 Pressure filter 7 Reservoir 8 Remote tell tale 9 Gauges 10 Cooler

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Power pack EL50A & hydraulic system Hydraulic Reservoir (Fig. 125) An oil level and temperature transducer is fitted in the reservoir and is monitored by the COMPACT control system.

The reservoir also contains a fluid level gauge and a breather/filter.

Fig. 125: Reservoir

1

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2 3 6

7

4

6

1. Fluid level & temperature transducer 2. Fluid level sight glass 3. Suction point 4. Filling point

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5. Breather/filter 6 Drain plugs 7 Access cover

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Power pack EL50A & hydraulic system Reservoir Fluid Filling A diverter valve, incorporated in the RH cowl circuit, powers an onboard filling pump to fill the reservoir, via a pressure filter, ensuring clean fluid is always fed into the reservoir. This valve requires manual operation to power the fluid filling pump.

Hydraulic Fluid Cooling The hydraulic fluid is cooled by means of a cooler, in-line type, on the reservoir return line.

The tube stack is fully floating so that thermal stresses are minimised and it can be easily removed should cleaning be necessary.

1

2 4 3 2 1 1 End cover 2 'O' Ring

3 Tube stack 4 Casing

Manifold Block Pressure Filter (Fig. 127) The filter is a spin on type, with a 10m renewable element.

Return Line Filter (Fig. 127) The return flow from the main valve bank is returned to the reservoir via the return filter and cooler. This ensures that the hydraulic fluid is kept to a cleanliness standard that is acceptable to provide efficient and reliable operation of the hydraulic system.

The return filter assembly contains a by-pass valve which will open if the filter element becomes blocked. In this condition no filtering of the fluid takes place.

Prior to the by-pass valve opening, an indication of the filter becoming dirty is provided by a differential pressure indicator.

The filter has a 25m renewable element.

Safety Relief Valve (Fig. 127) The safety relief valve provides over pressure protection for the hydraulic pump in the event of a blocked filter element in the pressure filter assembly. This is located on the manifold block assembly..

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Fig. 126: Cooler

BI628443

Power pack EL50A & hydraulic system Fig. 127: Manifold block

1

3 2

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1 Pressure filter 2 Return line filter

3 Relief valve 4 Fluid filling point

Hydraulic Pump (Fig. 128) The hydraulic pump is a Commercial/Intertech, 110 lpm, high pressure gear pump. The pump is mounted directly to the electric motor and driven by a flexible coupling arrangement, from the pump motor output shaft.

Fig. 128: Hydraulic pump

3 1

2

1 Gear pump 2 Power pack motor

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3 Flexible drive coupling

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Power pack EL50A & hydraulic system Directional Control Valve Bank (Fig. 129) This valve bank provides the facility for controlling the following shearer functions.

Raising and lowering the ranging arms Cowl rotation (if fitted) Raising and lowering the spraybar Raising and lowering the spall guards.

The valve bank construction consists of the following sections, Inlet section 1-off PVG32 basic module 5-off PVG120 basic module 2-off

When one or more of the main spools are actuated, the highest load pressure is fed through the shuttle valve circuit (10) to the spring chamber behind the pressure adjustment spool (6), and completely or partially closes the connection to the reservoir.

Pump pressure is applied to the right-hand side of the pressure adjustment spool (6). The pressure relief valve (1) will open should the load pressure exceed the set value, diverting pump flow back to the reservoir.

In a pressure-compensated basic module the compensator (14) maintains a constant pressure drop across the main spool – both when the load changes and when a module with a higher load pressure is actuated.

With a non pressure-compensated basic module incorporating a load drop check valve (18) in channel P, the check valve prevents return fluid flow.

The basic module can be supplied without the load drop check valve in channel P for functions with over-centre valves.

The shock valves (13) with fixed setting and the suction valves (17) on ports A and B are used for the protection of the individual working function against overload and/or cavitation.

An adjustable LS pressure limiting valve (12) can be built into the A and B ports of pressure-compensated basic modules to limit the pressure from the individual working functions. The LS pressure limiting valves save energy compared with the shock valves: with the shock valves all the fluid flow to the working function will be led across the combined shock and suction valves to reservoir if the pressure exceeds the fixed setting. with LS pressure limiting valves a fluid flow of about 2 l/min (0.5 US gal/min) will be led across the LS pressure limiting valve to reservoir if the pressure exceeds the valve setting.

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When the pump is started and the main spools in the individual basic modules (11) are in the neutral position, fluid flows from the pump, through connection P, across the pressure adjustment spool (6) to reservoir. The fluid flow led across the pressure adjustment spool determines the pump pressure (stand-by pressure).

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Combi section 1-off

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Fig. 129: Directional control valve

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Power pack EL50A & hydraulic system Solenoid Valve (Fig. 130) The directional control valves are solenoid-operated, spool-type directional control valves. They control the start, stop and direction of a flow of fluid.

The directional control valves essentially consist of the housing (1), one or two solenoids (2), the control piston (3) and one or two return springs (4).

When not actuated, the control piston (3) is held in the central or initial position by the return springs (4). The control piston (3) is actuated by wet pin solenoids (2).

For perfect function, ensure that the pressure chamber of the solenoid is filled with fluid.

An auxiliary actuating device (6) allows the control piston (3) to be moved without energizing the solenoid.

Fig. 130: Solenoid valve

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When the solenoid (2) is no longer energized, the return springs (4) move the control piston (3) back into its rest position.

E

The force from the solenoid (2) is exerted via the plunger (5) on the control piston (3), pushing the latter out of its rest position into the desired end position. This enables fluid to flow in the necessary direction, P A and B T or P B und A T.

BI628443

Power pack EL50A & hydraulic system Fig. 131: Main combi valve bank

2

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4 5 1

3

6

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6

1 End plate 2 Inlet section 3 PVG32 basic module

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4 PVG120 basic module 5 Combi section 6 Solenoid vlaves

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Power pack EL50A & hydraulic system Ranging Arm Lifting Cylinder (Fig. 132) The lifting cylinder is housed in the mainframe with the piston end anchored by a pivot pin. The rod end of the cylinder is anchored to the ranging arm lifting bracket by a pivot pin. The cylinder is fitted with a valve block which contains two relief valve cartridges and two pilot operated counterbalance valve cartridges. The valve block is sub-plate mounted on the rear of the cylinder.

Cylinder Valve Block (Fig. 132)

As the piston moves forward fluid is displaced from the rod side and passes through the opposite counterbalance valve which is pilot-operated to an open position by a pilot signal from the raise supply. The fluid displaced from the cylinder is returned to the reservoir via the main valve bank and return line filter.

When the desired ranging arm position is achieved and the operating signal is released, the pressure supply from the main control valve is dissipated. This allows both non-return valves to close locking the fluid in the desired position.

When lowering the ranging arm, the sequence of events is the same as raising the arm, except that the supply fluid from the main control valve enters the rod side of the cylinder.

To ensure that the ranging arm cannot ”run away” under its own weight, the counterbalance valve will react to the fluctuating supply pressure and create a `braking' action on the lifting cylinder exhaust flow and hence ranging arm. This action prevents erratic cylinder movement and cavitation of the cylinder.

Clearly the braking action requirements on the lowering side will be far greater than that for the raise side. This difference is effected by fitting different ratio pilot valves to each of the counterbalance valves. It is therefore essential that these valves are fitted to the correct ports as indicated by the Parts Manual.

While the shearer is Cutting through the face, external forces (i.e. floor heave, roof movement etc) may cause extreme pressures to develop within the lifting cylinder.

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To raise or lower the ranging arm, the appropriate function has to be selected (i.e. at the radio transmitter or end station). When the ranging arm is to be raised, fluid supplied via the main valve bank passes through the non- return valve and into the piston side of the lifting cylinder.

E

Warning!

BEFORE REMOVING ANY OF THE HYDRAULIC CYLINDERS, PILOT OPERATED CHECK VALVE BLOCKS OR HOSES BETWEEN THE PILOT OPERATED CHECK VALVE AND DIRECTIONAL CONTROL VALVE, ENSURE THAT THE APPROPRIATE RANGING ARM IS FULLY SUPPORTED AND ALL RELEVANT HOSES ARE DE-PRESSURISED. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY.

BI628443

Power pack EL50A & hydraulic system This pressure is limited by the crossline relief valves. When the piston side of the cylinder is subjected to a pressure in excess of 28 MPa (4000 psi), the relief valve will open and fluid from the piston side can flow to the rod side of the cylinder. As the rod side has a smaller volume than the piston side, the excess flow is directed to the reservoir via the main control valve (which will be in the neutral position) and the return filter. When the rod side of the cylinder is subjected to the excess pressure, the other relief valve will open and fluid will be directed to the piston side of the cylinder. As the rod side is smaller in volume than the piston side, the fluid displaced will be insufficient to fill the piston side.

This deficiency is made by fluid from the return line.

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Fig. 132: Ranging arm lifting cylinder

297 bar 275 bar

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Power pack EL50A & hydraulic system Pilot Operated Check Valve (Fig. 133) To raise or lower the spall guards, the appropriate function has to be selected (i.e. at the radio transmitter or end station). When the guards are to be raised, fluid supplied via the main valve bank passes through the pilot operated valve block into the piston side of the lifting cylinders.

As the pistons move forward fluid is displaced from the rod side of the cylinders and passes through an in-line non-return valve (fast up/slow down). The fluid displaced from the cylinders is returned to the reservoir via the main valve bank and return line filter.

When the desired ranging position is achieved and the operating signal is released, the pressure supply from the main control valve is dissipated. This allows both non-return valves, in the pilot operated valve block, to close locking the fluid in the desired position.

Caterpillar Global Mining Europe GmbH, Lünen 2013

A flow divider in this circuit allows the spall guards to be raised and lowered at the same time.

Fig. 133: Pilot operated check valve 1

1

1

2

2

2

2

2

1

2

1.Supply / exhaust to and from combi valve bank 2.Pressure / exhaust ports to and from spall guard cylinders

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When lowering the guards, the sequence of events is the same as raising the guards, except that the supply fluid from the main control valve enters the rod side of the cylinders.

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Power pack EL50A & hydraulic system Cowl Float Valve (Fig. 134) The cowl float valve has been incorporated into the hydraulic circuit to allow the cowl to float while cutting and stop the cowl from rotating violently downwards.

Fig. 134: Cowl float valve 1

2

4

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3 11 US gpm

1 Service ports 2 Counterbalance & non-return cartridges 3 Motor ports

4 Float spool

Float condition (Fig. 135) When the shearer is cutting, the cowl blade is free to move up or down depending upon the undulations of the floor. This is achieved by the hydraulic circuit operating as a `closed-loop' between the cowl motor and the cowl float valve.

Fig. 135: Cowl float condition

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Power pack EL50A & hydraulic system Rotating condition (Fig. 129) To rotate the cowl, a command is made by the operator at radio transmitter/end station. Fluid supplied via the main valve bank passes through one of the non-return valves in the cowl float valve to the cowl motors. The same fluid supply, prior to the non-return valve, pilot-operates the float spool to a closed position allowing system pressure to increase to a level that will turn the cowl.

As the fluid pass through the cowl motor, it is exhausted from the cowl float valve via the counterbalance valve. This valve is pilotoperated to an 'open' position by the same fluid supply that closes the float spool. Should the cowl attempt to over-run as it passes over top-dead-centre, the pilot pressure to the counterbalance valve will fall and the counterbalance valve will tend to 'close' causing a braking action on the rotation of the cowl. This condition will only be maintained whilst the operator command is maintained.

Fig. 136: Cowl rotating condition

Diverter Valve These valves are manually operated to provide a flushing of the cowl drive arrangement and are located on the waste side.

Fig. 137: Diverter valves

A

1 Diverter valves

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Warning!

DURING THE ROTATING CONDITION THE OPERATOR MUST KEEP THE COWL(S) FUNCTION SWITCH OR BUTTON SELECTED, (I.E. ON RADIO TRANSMITTER OR END STATION).

FAILURE TO DO SO WILL RESULT IN THE COWL(S) ASSEMBLY VIOLENTLY RUNNING TO THE BOTTOM DEAD CENTRE POSITION, CAUSING CAViTATIONAL PROBLEMS WITHIN THE HYDRAULIC COWL MOTORS.

E

The fluid exhausted from the cowl float valve is returned to the reservoir via the main valve bank.

BI628443

Power pack EL50A & hydraulic system Hydraulic System Technical Data 110 lpm

Pressure Relief Valve

240 bar

Directional Valve Bank: Pilot Relief Valve PVG32 Module PVG120 Module

23 bar 64.7 lpm 94.6 lpm

Ranging Arm Raise/Lower

72.3 litres/min

Pressure Filter

15 m

Return Filter

20 m

Ranging Arm Cyl. Relief Valve

275 bar

Reservoir

140 litres

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Hydraulic Pump

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Fig. 138: Hydraulic symbolic circuit

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Power pack EL50A & hydraulic system Lubrication The power pack hydraulic reservoirs are filled from a hydraulic fluid filling point on the waste side of the shearer.

Important!

All fluid entering the hydraulic reservoir must be passed through a filter.

Fig. 139: Power pack lubrication points

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A

C 1

Reservoir Capacity: 140 litres 3

B

1 Reservoir 2 Hydraulic pump Lub Point

Description

A

Reservoir filling

B

Fluid level gauge

C

Fluid level & temperature transducer

D

Pump flexible coupling

3 Breather

Lubricant

H2

Schedule

Fill

AS REQUIRED DAILY

GR5

COMPACT

CONTINUOUSLY

Inspect/Grease

On installation or whenever pump is assembled to motor

Recommended lubricants and their specifications can be found in 'Permissible Media', Chapter 6 of this manual.

Important!

Reservoir is connected to a remote oil filling station, located on the waste side of the machine. This station is clearly labelled.

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Water System Water System Introduction Warning!

ENSURE THAT ALL HYDRAULIC AND WATER HOSES ARE DEPRESSURISED BEFORE ATTEMPTING DISCONNECTION. FAILURE TO COMPLY WITH THIS MAY RESULT IN SERIOUS INJURY. The functions of the shearer water system are: To provide cooling for the shearer units.

To provide a fire deluge system.

To provide dust suppression.

Shearer Cooling System (Fig.140) The cooling circuit comprises of coolers for the following: Ranging Arms Ranging Arm Motors Haulage Units Haulage Motors Power Pack Motor Hydraulic Circuit Power Box (AC Drive & Transformer) The cooling supply is distributed by two manifold blocks mounted on the waste side of the shearer.

The supply to each cooler is as follows: L.H. Ranging Arm

9.2 US gpm

L.H. Ranging Arm Motor

9.2 US gpm

L.H. Haulage Motor/Haulage Unit

5.2 US gpm

Pump Motor/Hydraulic Fluid Reservoir

5.2 US gpm

Haulage Drive Box (transformer & AC drive)

5.2 US gpm

R.H. Haulage Unit/Haulage Motor

5.2 US gpm

R.H. Ranging Arm Motor

9.2 US gpm

R.H. Ranging Arm

9.2 US gpm

The exhaust flow from each unit cooler, exhausts to atmosphere, via exhaust spray blocks on the waste side of the shearer. The exception is the ranging arm cooler exhaust which exhausts to atmosphere on the waste side.

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Water enters the machine via a trailing hose where it is monitored by a pressure gauge and displayed by COMPACT. The supply is then passed to two manifold blocks, via a inlet ON/OFF valve, where it is distributed to the shearer cooling system. It also feeds the dust suppression, and spraybar systems.

A supply, taken prior to the ‘Y’ strainer, feeds the fire deluge and cowl flush systems.

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The Water Schematic diagram (Fig. 140) is shown at the end of this section.

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Water System Dust Suppression System (Fig. 140) Each cutting drum is fed from the inlet supply and monitored by water pressure gauges. Further dust suppression is provided by spraybar systems, located at each end of the shearer, controlled by manual ball valves.

Fire Deluge System (Fig. 140) A supply of water floods the shearer with water and is controlled by two manually operated ball valves.

Cowl Flush System

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A water supply, controlled by manually operated ball valves, is supplied from the fire deluge system to the cowl drive arrangements on both arms.

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Water System Ranging Arm Motor Cooling (Fig. 140) Cooling is achieved by passing a water flow through an integral `scroll type' water jacket around the motor stator and through the motor end bearing housings.

The porting for this cooling is illustrated in Fig. 140.

Fig. 140: Ranging arm motor cooling

1

1 Water inlet 2 Water outlet

Ranging Arm Internal Cooler (Fig. 141) Oil in the ranging arm is cooled by passing a water flow through a finned cooler located in the high speed section of the ranging arm.

Fig. 141: Ranging arm internal cooler

1

1

1 Cooler connections

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Water System Haulage Motor Cooling (Fig. 142) The haulage unit motor is cooled by supplying a water flow through an integral water jacket around the motor stator. The inlet and outlet ports are located, on the motor stator, at 180 degrees from the fixing points.

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Fig. 142: Haulage motor cooling

1 1 Water connections

Haulage Unit Cooler (Fig. 143) Oil in the haulage unit gearbox is cooled by passing a water flow through two coolers, connected in series. One cooler is located in the top of the high speed section and one in the bottom of the high speed section.

Fig. 143: Haulage unit cooler

1

1.Cooler connections

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Water System Power Box Cooling (Fig. 144) This unit is cooled by passing a cooling supply through an internal cooling path, embedded inside the box.

Fig. 144: Power box cooling

2 1 Water inlet 2 Water outlet

Pump Motor Cooling (Fig. 145) The Pump Motor is cooled by passing cooling water through two water jackets on the stator.

The porting for these coolers is located on square standoffs at the non-drive end of the motor.

Fig. 145: Pump motor cooling

1 1.Water connections

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Water System Hydraulic Fluid Cooler (Fig. 146) The hydraulic fluid is cooled via a cooler located in the power pack.

Fig. 146: Hydraulic fluid cooler 1

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Water System

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Fig. 147: Water symbolic circuit

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Maintenance (mechanical) Maintenance (mechanical) Introduction This section provides a comprehensive mechanical maintenance schedule consisting of daily, weekly, monthly and three monthly investigations. It is suggested that this schedule is adopted to ensure maximum reliability and safety.

The section consists mainly of convenient check list cards for instructing maintenance engineers on which investigations should be carried out and, also, for keeping records of the results obtained on carrying out the prescribed investigations.

A typical example of one of these cards is included on the next page.

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Important!

If difficulty is encountered when trying to find any of the components mentioned in this maintenance schedule, refer to the appropriate section of the manual, i.e. Haulage Unit, Ranging Arm, etc.

For grease and oil filling details, refer to individual units as above.

Caution!

FAILURE TO COMPLY WITH THIS MAINTENANCE SCHEDULE COULD LEAD TO COMPONENT FAILURE AND RENDER THE SHEARER UNSAFE. When carrying out maintenance/repair operations, the following should be complied with:

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Maintenance (mechanical)

Introduction Condition monitoring can provide an accurate picture of machine health and can be a valuable aid in planning maintenance. Oil and fluid condition is one of the most commonly monitored parameters in underground machinery and usually, and most usefully, the condition of oil debris is included in the analysis.

Oil condition monitors are standard but there are a number of widely varying techniques for measuring and analysing the debris in oil. Some are relatively simple and can be conducted on-site; others are highly sophisticated utilising very costly equipment.

Oil condition monitoring is useful not only as a guide to machine condition and oil condition but also to determine if the correct lubricants are in use. The use of correct lubricants is essential to maximise machine life and reliability.

SAMPLING INSTRUCTIONS The detail of sampling techniques will vary somewhat depending on the intended method of analysis, but the following general rules will apply:

. Ensure that the area around the sampling point is free from dirt before removing plug or other closure.

Important!

Cleanliness is essential. Contamination of the sample must be avoided.

. 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. Warning!

HOT OIL CAN CAUSE BURNS. IF THE OIL IS SUFFICIENTLY HOT FOR THIS TAKE GREAT CARE.

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Warning!

PERSONS SUPERVISING AND PERFORMING INSTALLATION OR MAINTENANCE MUST BE SUITABLY QUALIFIED AND COMPETENT IN THESE DUTIES. UNLESS POWER IS REQUIRED TO CARRY OUT THE CHECKS, ENSURE THE SHEARER IS ISOLATED AT THE MAINGATE CONTROLLER, OR BY REMOVAL OF THE POWER CABLE, PRIOR TO CARRYING OUT MAINTENANCE. THE SHEARER MUST BE IMMOBILISED PRIOR TO CARRYING OUT MAINTENANCE ON MOVING PARTS. WHEN WORK IS TO BE CARRIED OUT OVER, OR ON THE FACE SIDE OF THE SHEARER, BOTH THE SHEARER AND CONVEYOR (AFC) MUST BE IMMOBILISED, IN ADDITION, ADEQUATE ROOF AND FACE SUPPORT MUST BE PROVIDED. ENSURE ALL HYDRAULIC AND WATER SYSTEMS ARE ISOLATED AND DE-PRESSURISED 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. BEFORE ELECTRICAL POWER IS APPLIED TO THE SHEARER, ENSURE THAT ALL FLAMEPROOF GAPS DO NOT EXCEED LEGAL LIMITS.

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Oil and Fluid Condition Monitoring

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Maintenance (mechanical) . The sample must be taken within 15 minutes of machine stopping.

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

OIL CONDITION LIMITS Viscosity If the viscosity of the oil is found to be + 20% of the nominal grade viscosity the oil should be renewed. e.g.

ISO VG 460

Change oil if viscosity at 40C rises to 552 cSt or falls to 368 cSt. If the oil contains viscosity index improvers the viscosity at 100C should also be checked and the oil changed if the viscosity is found to be + 20% of the nominal viscosity at 100C. Where possible the cause of the change should be established.

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If the analysis gives quantative information of additives, the oil should be changed if the levels alter by more than 15% of their original level.

Flash Point Cognisance should be taken of the legal minimum flash point.

OIL CONTAMINATION ANALYSIS Water Ingress of water, even in small amounts, denigrates the quality of the oil. However some water is often present due to breathers etc.

Hydraulic fluids should be renewed if the water contamination rises to 0.5%. Gear oils should be changed if the level of contamination rises to 0.2%. The point of ingress should be established wherever possible - look for loose covers, faulty seals, gaskets or `O' rings, leaking coolers etc.

Solids Solid contamination is frequently very abrasive. Solid contamination is the cause of most hydraulic failures and hydraulic fluids should be maintained to a fluid cleanliness level of ISO 4406 18/1 4. Gear oils should be replaced if the insolubles rise to 1.5% by weight. The point of ingress of the contaminant should be sought.

Important!

Measurement of solid contaminant levels without other analysis is not recommended. Levels under 1.5% can sometimes cause severe damage.

Debris Examining the oil in a machine for evidence of debris is a widely used method for monitoring machine condition. When a component is beginning to fail the amount of wear debris usually increases markedly. However the overall analysis must be considered before forming judgement. For instance ingress of solid contamination or water will often crate a high level of wear debris which is thus not necessarily indicative of incipient failure.

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Maintenance (mechanical)

If the normal wear causes the level of iron to rise to 500 parts per million the oil should be changed.

Fig. 148: Debris graph

Possible Cycle

Fe Concentration

100 hrs

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Running in.

1

Change oils after 100 hours running.

2

Normal wear has resulted in Fe level of 500 ppm.* Oil change.

3

Ingress of solid contaminant during re-filling.

Change oil.

4

Seal failure.

5

Renew seal and change oil.

6

Sudden rise in debris level.

7

Change oil.

8

Rise maintained - change oil.

9

Rise maintained - incipient failure likely.

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Results of spectographic or other quantative analysis are easiest interpreted when laid out in graphical form. When a change in the rate of increase of wear debris occurs the oil should be changed. Causes of wear debris other than imminent failure should be investigated by analysis e.g. ingress of water or solid contaminant. If the rate of increase is maintained and the cause has not been established, drain flush and refill once more. If the rate of increase is still maintained early failure is possible and appropriate action should be taken.

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Some methods of analysis can lead to an identification of the process that is causing the debris, usually by an examination of the particle size, shape and composition. The most common method of oil debris analysis is spectographic analysis. The spectograph detects and quantifies the relative concentration of many elements present in the sample. One of the limits of the spectograph is that it only measures the chemical components of the oil. It gives no indication of particle size and cannot analyse particles larger than about 10 micron, will not distinguish between different types of wear and does not usually give much information about which component is about to fail. Nonetheless it is very useful as an indicator of general machine condition and can provide an accurate picture when used with other analysis.

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Maintenance (mechanical) * Some methods of analysis give an empirical number rather than ppm.

Refer to instrument manufacturer for guidance in such cases.

Frequency of Sampling

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It is recommended that sampling is carried out weekly except on occasions of sudden changes, after which sampling intervals should be reduced as appropriate until conditions are restored to normal.

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Maintenance (mechanical)

DAILY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

20

Replacment of bit not taken into account, ranging arms out of gear, machine isolated.

Cleaning/replacement of sprays not taken into account.

Cutting drum 1

Check for blunt or damaged picks (bits) – both drums Check the pick boxes (bit holders) for damage – both drums. Ensure all dust suppression sprays (nozzles) function correctly - both drums. Check drums for damage, wear and tear, and leakages

Ranging Arm LH Check oil level (half of gauge glass).

1

Ranging arm horizontal, machine not powered

3

Check for correct functioning of ranging arm lifting cylinder.

0

Raise and lower ranging arm

4

Visual inspection Check if all covers are tight.

Check for oil leaks.

Check for water leaks on inlet distributor.

2

Checkcorrect operation of drum disengagement handle..

1

Physical check

Ranging Arm RH 11

Check oil level (half of gauge glass).

1

Ranging arm horizontal, machine not powered

12

Check for correct functioning of ranging arm lifting cylinder.

1

Raise and lower ranging arm

13

Visual inspection Check if all covers are tight.

Check for oil leaks.

Check for water leaks on inlet distributor

2

Checkcorrect operation of drum disengagement handle.

1

Physical check

1

Machine powered but not hauling

1

Machine powered but not hauling

1

Machine powered but not hauling. Check COMPACT display & reservoir sight glass

14

Haulage Unit LH 21

Check oil level in haulage unit (as shown on COMPACT)

Haulage Unit RH 26

Check oil level in haulage unit (as shown on COMPACT)

Power Pack and Hydraulics 31

Ensure that the level of fluid in power pack resevoir is filled to correct level (gauge glass).

32

Check nominal pressure value of the hydraulic system

1

33

Check system for leakages where practical.

1

Visual examination

34

Visual check of filter conditions.

1

Check pressures on COMPACT

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Maintenance (mechanical)

DAILY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

0

Check goes along with water spray nozzle check

Water System 36

Check all valves for correct functioning

37

Check all water visable hoses and fittings at the area of drive frame/ranging arms for damage and leaks, tightness, etc.

39

Check and record Water flow and pressure values on COMPACT for cooling and dust suppression

Visual examination

1

0

Full water supply to machine required. Data is monitored via WOS

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Lubrication 41

Grease both downdrives (lubrication points), check oil level in drip feed reservoirs

12

42

Grease hinge pins (rangings arms).

6

Machine not powered

43

Grease wet cutting shaft seals (ranging arms)

8

Applies to both ranging arms

44

Grease both cowls (if fitted)

10

8

Miscellaneous

46

Visual check of pin connections of ranging arm cylinders

1.5

47

Visual check of pin connections of trapping shoes

1.5

Estimated completion time (daily)

74

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WEEKLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

Ranging Arm LH 51

Check lifting (hydraulic) cylinder physical external damage

5

Visual inspection, machine isolated

52

Check security of cowl arm and blade attachment (if fitted)

5

Visual inspection / knocking test, machine isolated

53

Visual examination of cowl arm and cowl blade.

Functional rotation check (if fitted)

3

Machine powered, rotate cowls 360_, knocking test at the connecting elements.

Check lifting (hydraulic) cylinder physical external damage

5

Visual inspection, machine isolated

57

Check security of cowl arm and blade attachment

5

Visual inspection / knocking test, machine isolated

58

Visual examination of cowl arm and cowl blade.

Functional rotation check

3

Machine powered, rotate cowls 360_, knocking test at the connecting elements.

15

Remove top drive gear guard /inspection covers and allow to run for at least 1 complete rotation for full inspection, refit guard

15

Remove top drive gear guard /inspection covers and allow to run for at least 1 complete rotation for full inspection, refit guard

Downdrive LH 61

Check condition of the driving gear, intermediate gear, trapping shoe and location pins. Check drip feed reservoir is lubricating gears correctly.

Downdrive RH 66

Check condition of the driving gear, intermediate gear, trapping shoe and location pins. Check drip feed reservoir is lubricating gears correctly

Power Pack and Hydraulics 71

Check hydraulic hoses and couplings for damage and leaks where practical

72

Check all manual control handles for correct functioning / damage.

10

Visual check

2

Manual operation carried out on each handle, machine powered.

General Inspection 76

Check all mechanical covers are in position and secure.

20

Knocking test

77

Check skid shoes nearest coal face for damage, wear and secure positioning.

20

Visual check (see wear limit drawing in Mainframe Section)

78

Visual inspection of mainframe body bolts

10

Knocking test

79

Check main inlet and return hose connections into the machine for damage and leaks

2

Visual examination

Estimated completion time (weekly)

120

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Maintenance (mechanical)

MONTHLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

10

Oil changes to be determined based upon results of oil sample analysis

Ranging Arm LH 81

Take an oil sample for analysis

82

Check security of cutter motor retaining fasteners

10

Knocking test

83

Check security of drum retaining bolts and drum shaft retaining bolts

30

Faceside access required

84

Check hinge pins for wear and correct location into the mainframe

10

Visual inspection for “play” between the pins and drilled (bore) holes.

10

Oil changes to be determined based upon results of oil sample analysis

Ranging Arm RH

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86

Take an oil sample for analysis

87

Check security of cutter motor retaining fasteners

10

Knocking test

88

Check security of drum retaining bolts and drum shaft retaining bolts

30

Faceside access required

89

Check hinge pins for wear and correct location into the mainframe

10

Visual inspection for “play” between the pins and drilled (bore) holes

10

Fluid changes to be determined based upon results of fluid sample analysis

Power Pack and Hydraulics 91

Take an fluid sample for analysis

92

Replace pressure and return filters if indicators determine this requirement

15

To be done as difference pressure is indicated

93

Check security of accessible hydraulic pump fasteners

5

Physical check

94

Check security of accessible pump motor fasteners to mainframe

3

Physical check

95

Check directional control valve fasteners for security to brackets/mainframe

5

Physical check

25

(see wear limit drawing in Downdrive section)

Mainframe 101

Check goaf side trapping shoes, measure wear

Haulage Motor LH & RH 106

Dismantle quill shaft, clean, inspect, grease and reassemble

60

107

Check positioning of haulage motor attachment screws for security

10

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Maintenance (mechanical) Haulage Unit LH & RH 111

Take an fluid sample for analysis

20

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Estimated completion time (monthly)

Oil changes to be determined based upon results of oil sample analysis

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Maintenance (mechanical)

QUARTERLY CHECKS

Approx. TIME REQUIRED (min)

REMARKS

Power Pack and Hydraulics 116

Drain fluid and refill with new fluid up to the prescribed fluid level

30

Fluid changes to be determined based upon results of fluid sample analysis

20

Visual examination

180

Pressure test

Mainframe 121

Check mainframe (machine body) for material defects

Downdrive LH & RH 126

Random checks of hydraulic nuts with hydraulic tension tool and “Knock“-test

Haulage Unit LH & RH

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131

Drain oil and refill with new oil up to the prescribed oil level. (If NO contamination analysis is being carried out).

302

Oil changes shall be made based upon results of oil sample analysis

Drain oil and refill with new oil up to the prescribed oil level. (If NO contamination analysis is being carried out).

302

Oil changes shall be made based upon results of oil sample analysis

Check positioning of high speed section cover for security, check for any oil loss, check all screws are torqued correctly.

10

Ranging Arm LH 136

137

Ranging Arm RH 141

142

Drain oil and refill with new oil up to the prescribed oil level. (If NO contamination analysis is being carried out).

302

Check positioning of high speed section cover for security, check for any oil loss, check all screws are torqued correctly.

10

Estimated completion time (quarterly)

340

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Oil changes shall be made based upon results of oil sample analysis

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Fault diagnosis (mechanical) Fault diagnosis (mechanical) Introduction This section provides simple trouble shooting guides, designed to assist maintenance personnel, should it become necessary to diagnose and repair certain shearer faults.

General The section consists of a series of diagnostic guides, which lead the user through each trouble shooting step, in some cases, using questions which require the answers `YES' or `NO'.

Although the guides are comprehensive, they are not exhaustive, i.e. they can not cover every possibility. Instead, they are incorporated mainly as memory stimulates for personnel already conversant with the shearer. It is therefore suggested that the relevant sections of this manual are studied and understood before maximum benefit may be gained from this section.

Guide 2 - From Step 3 GUIDE No. 1.

Guide 3 - All functions are responding slowly from all modes of control.

Guide 4 - Ranging Arm will not raise or lower from Radio Transmitter Guide 5 - From Step 4 GUIDE No. 4.

Guide 6 - From Step 6 GUIDE No. 4 & Step 3 GUIDE No. 5.

Guide 7 - Machine will not haul Guide 8 - From Step 7 or 8 GUIDE No. 7.

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Guide 1 - No response of any Hydraulic Functions from the Radio Transmitter.

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The guides included are:

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Fault diagnosis (mechanical) Diagnostic Guide 1 Symptom: No response of any Hydraulic Functions from the End Stations / Radio Transmitter

. STEP 1. Will functions operate normally from Electro/ Hydraulic valves manual levers?

– YES: Refer to Electrical Fault Chart.

NO: Move to Step 2.

. STEP 2. Is there a sufficient quantity of fluid in the reservoirs?

– NO: Rectify.

YES: Move to Step 3.

. STEP 3. Is the vacuum reading on COMPACT above normal?

– YES: Refer to Mechanical Diagnostic Guide No. 2.

NO: Move to Step 4.

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– NO: Replace Electro/Hydraulic valve manifold.

YES: Move to Step 5.

. STEP 5. Check the pump output.

Is the pump output flow acceptable (85% of Power Pack specified output)?

– NO: Renew pump.

YES: Move to Step 6.

. STEP 6. Is the safety relief valve faulty?

– YES: Rectify.

NO: Replace Electro/Hydraulic valve manifold.

Diagnostic Guide 2 From Step 3 GUIDE No. 1 Action: Examine suction hose arrangement.

. STEP 1. Is vacuum reading still above normal on COMPACT? – NO: System healthy.

YES: Move to Step 2.

. STEP 2. Is the suction hose in good condition and free from blockage?

– NO: Rectify.

YES: Replace suction hose arrangement.

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Fault diagnosis (mechanical) Diagnostic Guide 3 Symptom: All functions are responding slowly from all modes of control.

. STEP 1. Is there a sufficient quantity of fluid in the hydraulic reservoir?

– NO: Rectify.

YES: Move to Step 2.

. STEP 2. Is the suction hose damaged or loose?

– YES: Rectify.

NO: Move to Step 3.

. STEP 3. Is the vacuum reading above normal on COMPACT? – YES: Clean or replace suction hose arrangement.

NO: Move to Step 4.

. STEP 4. Stall a function.

– NO: Adjust relief valve and secure with lock-nut.

YES: Move to Step 6.

. STEP 5. Are flow rate settings correct at the Combi Directional valve?

– NO: Adjust to correct settings.

YES: System healthy.

. STEP 6. After adjustment are the function speeds now correct?

– NO: Move to Step 7.

YES: System healthy.

. STEP 7. Check the pump output.

Is the output flow acceptable?

– NO: Renew pump.

YES: Move to Step 5.

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Does the pressure indicate 3500 PSI on COMPACT?

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Fault diagnosis (mechanical) Diagnostic Guide 4 Symptom: Ranging Arm will not raise or lower from End Stations / Radio Transmitter.

. STEP 1. Is the Ranging Arm free from obstruction?

– NO: Clear obstruction.

YES: Move to Step 2.

. STEP 2. Do other functions operate correctly from end station?

– NO: Refer to Mechanical Diagnostic Guide No. 1.

YES: Move to Step 3.

. STEP 3. Do the functions operate normally in manual?

– YES: Refer to Electrical Fault Diagnosis Guides.

NO: Move to Step 4.

. STEP 4. When attempting to raise or lower the Ranging Arm, does the pressure read 3500 PSI on COMPACT?

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– YES: Refer to Mechanical Diagnosis Guide No. 5.

NO: Move to Step 5.

. STEP 5. Exchange Electro / Hydraulic valve with another from a healthy function.

Does Ranging Arm now operate normally?

– YES: Renew faulty Combi Hydraulic valve.

NO: Move to Step 6.

. STEP 6. Remove hoses from the lifting cylinder. Using a flow meter at normal working pressure, operate function.

Is flow of 92 lpm, obtained in both directions?

– NO: Check for restricted hoses or re-adjust flow rate at the combi directional control valve bank.

YES: Refer to Mechanical Diagnostic Guide No. 6.

Diagnostic Guide 5 From Step 4 GUIDE No. 4 Action: Check the other Ranging Arm

. STEP 1. Is the system pressure reading normal on COMPACT? – NO: Adjust pilot relief and secure with lock device.

YES: Move to step 2

. STEP 2. Haul the machine away from the cut.

Is there any damage to either cylinder (eg. bent rod)?

– YES: Renew damaged cylinder.

NO: Move to step 3

. STEP 3. Remove hoses from the lifting cylinder. Using a flow meter at normal working pressure, operate function.

Is a flow of 92 lpm, obtained in both directions?

– NO: Check for restricted hoses or re-adjust flow rate at the Electro / Hydraulic valve.

YES: Refer to Mechanical Diagnostic Guide No. 6.

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Fault diagnosis (mechanical) Diagnostic Guide 6 From Step 6 GUIDE No. 4 and Step 3 GUIDE No. 5 Action: Support Ranging Arm. Connect one hose to lifting cylinder and blank the other hose, operate function.

. STEP 1. Does fluid flow freely from the open port on the cylinder?

– NO: Change double pilot operated check valve assembly (lifting cylinder block).

YES: Move to Step 2.

. STEP 2. Connect second hose to second port and blank first hose, operate function.

Does fluid flow freely from the open port on the cylinder?

– NO: Change double pilot operated check valve assembly (lifting cylinder block).

YES: System healthy.

. STEP 1. Examine Chainless Haulage System.

Is there any damage to the indirect drive system, drive chain or are there any obstructions?

– YES: Rectify or remove obstructions.

NO: Move to Step 2.

(If no parking brakes are fitted, go directly to Step 7) Important!

The following three steps only apply to machines fitted with brakes.

. STEP 2. Do parking brakes release when a haulage speed and direction is selected?

– NO: Check the electrical system associated with the brake solenoid. If satisfactory, move to Step 5.

YES: Move to Step 5.

. STEP 3. Connect a pressure gauge to brake line and select a haulage speed and direction.

Is there a brake release signal?

– NO: Check solenoid valve and hydraulic circuit from the pressure reducing valve.

YES: Move to Step 4.

. STEP 4. Reconnect brake lines, mechanically release each brake in turn.

Does the machine now haul normally?

– YES: Rectify faulty brake assembly.

NO: Move to Step 5.

. STEP 5. Remove left hand haulage unit input quill shaft cover.

Remove quill shaft, is it in good condition?

– NO: Refer to Mechanical Diagnostic Guide No. 8 YES: Refit quill shaft and move to Step 6.

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Symptom: Machine will not haul.

Refer to Electrical Diagnostic Guides before continuing.

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Diagnostic Guide 7

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Fault diagnosis (mechanical) . STEP 6. Remove right hand haulage unit input quill shaft cover.

Remove quill shaft, is it in good condition?

– NO: Refer to Mechanical Diagnostic Guide No. 8 YES: Refit quill shaft and move to Step 7.

. STEP 7. Check the R.H. haulage unit high speed section.

Is there any sign of damage?

– YES: Rectify.

NO: Move to Step 8.

. STEP 8. Check the L.H. haulage unit high speed section.

Is there any sign of damage?

– YES: Rectify.

NO: Move to Step 9.

. STEP 9. Does output drive respond with output quill shaft removed?

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– NO: Fault in slow speed gearing, renew L.H. haulage unit.

YES: Move to Step 10.

Caterpillar Global Mining Europe GmbH, Lünen 2013

. STEP 10. Refit L.H. output quill shaft. Move to R.H. haulage unit.

Does output drive respond with output quill shaft removed?

– NO: Fault in slow speed gearing, renew R.H. haulage unit.

YES: System healthy.

Diagnostic Guide 8 From Step 7 or 8 GUIDE No. 7 Action: Remove quill shaft

. STEP 1. Is it in good condition?

– NO: Rectify.

YES: Move to Step 2.

. STEP 2. Select minimum haulage speed.

Does motor turn normally?

– NO: Investigate for motor failure.

YES: Move to Step 3.

. STEP 3. Check motor coupling.

Is it in good condition?

– NO: Renew motor coupling.

YES: Replace drive shaft and cover.

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Technical data

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Permissible Media

Technical data Permissible Media This section provides the approved lubrication details for the shearer.

Notice!

Use only hydraulic fluids and gear oils approved by Caterpillar!

These fluids and oils have been tested at Caterpillar and guarantee a reliable operation of their respective systems.

General

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The main objectives of the lubrication programme 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.

Caution!

ALWAYS USE THE RECOMMENDED LUBRICANTS AT THE SPECIFIED INTERVALS. FAILURE TO COMPLY WITH THIS COULD LEAD TO COMPONENT FAILURE AND RENDER THE SHEARER UNSAFE. Inspection of lubricants taken from the machine can often reveal problems before breakdowns occur.

For example: Cloudy or emulsified oil may indicate the presence of water.

Milky or foamy oil may show the presence of air.

Dark grease may mean oxidisation has started, or contamination present.

Important!

On start-up of a new machine, or when a new unit is installed, it is imperative that after a maximum of ten shifts working, the oil or fluid is drained from the unit. 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 recommended period for replacement of the lubricant in the units is once per month.

Caution!

DO NOT OVER FILL UNITS AS THIS WILL CAUSE OVER HEATING AND LEAD TO COMPONENT FAILURE. DO NOT UNDER FILL UNITS AS THIS WILL CAUSE OVER HEATING, EXCESSIVE WEAR AND LEAD TO COMPONENT FAILURE. DO NOT OVER GREASE AS THIS WILL CAUSE OVER HEATING AND LEAD TO COMPONENT FAILURE. DO NOT UNDER GREASE AS THIS WILL CAUSE OVER HEATING, EXCESSIVE WEAR AND LEAD TO COMPONENT FAILURE. DO NOT USE UN-APPROVED LUBRICANTS. APPROVED LUBRICANTS HAVE PROPERTIES WHICH ENSURE OPTIMUM PERFORMANCE AND MAXIMUM LIFE. USE OF THE WRONG LUBRICANT TYPE OR GRADE WILL LEAD TO REDUCED PERFORMANCE AND LIFE.

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6.3

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Permissible Media Shearer lubrication 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 power pack reservoir.

Gear oil filling The shearer `gear' oil filling system has individual unit filling points.

An off board oil filling pump is used to fill the ranging arms, the haulage units and down drive lubrication reservoirs.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Caution!

DO NOT FILL UNITS WITH THE WRONG TYPE OF LUBRICANT. ENSURE LUBRICANTS ARE FREE FROM CONTAMINATION BEFORE AND DURING FILLING. FAILURE TO COMPLY WITH THIS WILL LEAD TO COMPONENT FAILURE.

6.4

Shearer EL 2000

BI628443

Lubricants (Gear Oil) Lubricants (Gear Oil) The user must in all cases make themselves aware of the Health and Safety requirements governing the use of listed or alternative products.

Caterpillar grade G3 ISO viscosity grade 320 (syn), (ISO 3448) (recommended) or ISO viscosity grade 460, ISO 3448

The oil should contain a highly refined base oil or synthesised polyalphaolefin oligomers with a balanced additive system giving full Extreme Pressure properties, high viscosity index, and good performance when judged against industry standards for the following parameters:thermal stability oxidisation resistance and stability E

corrosion inhibition Caterpillar Global Mining Europe GmbH, Lünen 2013

anti-foaming pour point boundary friction reduction shear stability compatibility with mineral oil seals compatibility and miscibility with other mineral gear oils The results should not be significantly affected by modest amounts of contamination of water or particulate matter.

Lubricants in compliance are shown in table Tab 10.

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6.5

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Lubricants (Hydraulic Fluid) Lubricants (Hydraulic Fluid) The user must in all cases make themselves aware of the Health and Safety requirements governing the use of listed or alternative products.

Caterpillar grade H2 ISO viscosity grade 100 (ISO 3448) ISO viscosity grade 68

The fluid should contain a highly refined base fluid or synthesised olefin oligomers with a balanced additive system giving a high viscosity index and good performance when judged against industry standards for the following properties:thermal stability oxidisation resistance and stability corrosion inhibition

shear stability compatibility with mineral oil seals filterability anti wear compatibility and miscibility with other mineral hydraulic oils The results should not be significantly affected by modest amounts of contamination of water or particulate matter. (In particular there must be no plating out of zinc based anti wear additives in the presence of water.)

Lubricants in compliance are shown in table Tab. 10.

6.6

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

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air release ) anti foaming ) with good balance between these

BI628443

Lubricants (Quill Shaft Grease) Lubricants (Quill Shaft Grease) The user must in all cases make themselves aware of the Health and Safety requirements governing the use of listed or alternative products.

Caterpillar grade GR5 NLGI grade 1

The grease, which must be suited to gear coupling application, should contain a highly refined base oil or synthesised hydrocarbon of very high viscosity with a balanced additive system, including molybdenum disulphide, giving good performance when judged against industry standards for the following properties:shear stability oxidisation resistance and stability fretting inhibition very high operating temperature Caterpillar Global Mining Europe GmbH, Lünen 2013

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Lubricants in compliance are shown in table Tab. 10.

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Lubricants (Electric Motor Bearing Grease) Lubricants (Electric Motor Bearing Grease) The user must in all cases make themselves aware of the Health and Safety requirements governing the use of listed or alternative products.

Caterpillar grade GR1 NLGI grade 2

The grease, which must be suited to lubrication of rolling element bearings at electric motor speed and high temperature, should contain a highly refined base oil or synthesised hydrocarbon and a balanced system giving good performance when judged against industry standards for the following properties:shear stability high temperature operation oxidisation resistance and stability

Caterpillar Global Mining Europe GmbH, Lünen 2013

compatibility and miscibility with lithium complex based mineral oil grease (initial charge) compatibility with mineral oil based grease seals wear resistance water washout resistance Lubricants in compliance are shown in table Tab. 10.

6.8

E

corrosion inhibition

Shearer EL 2000

BI628443

Lubricants (All Other Grease Applications) Lubricants (All Other Grease Applications) The user must in all cases make themselves aware of the Health and Safety requirements governing the use of listed or alternative products.

Caterpillar grade GR3 NLGI grade 1 - 2

The grease must be suited for use in heavily loaded slow moving plain and rolling element bearings subjected to vibration and shock loading. It must contain a highly refined base oil or synthesised hydrocarbon with a balanced additive system giving good performance when judged against industry standards for the following properties:water washout resistance corrosion inhibition wear resistance Caterpillar Global Mining Europe GmbH, Lünen 2013

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shear stability compatibility with lithium soap based mineral oil grease load carrying Lubricants in compliance are shown in table Tab. 10.

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Torque table Torque table RECOMMENDED TIGHTENING TORQUES FOR LUBRICATED BOLTS & NUTS I S O METRIC COARSE PITCH ISO Metric Precision Bolts Grade 8.8 ISO Metric Precision Nuts Grade 8 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

Tab. 4: Torque table (ISO metric coarse pitch) PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M4

0.70

2.0

0.28

2.8

M5

0.80

4.1

0.56

5.6

M6

1.00

7

1

9.5

M8

1.25

17

2.9

23

M10

1.50

34

4.7

46

M12

1.75

59

8

80

M16

2.00

146

20

198

M20

2.50

286

39

388

M24

3.00

494

68

670

M30

3.50

982

136

1332

M36

4.00

1719

237

2331

M42

4.50

2754

381

3734

Caterpillar Global Mining Europe GmbH, Lünen 2013

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NOMINAL SIZE

The above torque figures also apply to set screws and studs, where the effective thread engagement is equal to, or greater than, 1.5 times the nominal thread diameter.

6.10

Shearer EL 2000

BI628443

Torque table Torque table I S O METRIC COARSE PITCH ISO Metric Precision Bolts Grade 10.9 ISO Metric Precision Nuts Grade 12 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

NOMINAL SIZE

PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M16

2.00

206

28

279

M20

2.50

402

55

545

M24

3.00

695

96

942

M30

3.50

1382

191

1874

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Tab. 5: Torque table (ISO metric coarse pitch)

These figures also apply to set screws and studs where the effective thread engagement is equal to or greater than 1.5 times nominal thread diameter.

SPECIAL APPLICATIONS ONLY I S O METRIC COARSE PITCH ISO Metric Precision Bolts Grade 12.9 ISO Metric Precision Nuts Grade 12 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

Tab. 6: Torque table (ISO metric coarse pitch) NOMINAL SIZE

PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M16

2.00

247

34

335

M20

2.50

482

67

654

M24

3.00

833

115

1130

M30

3.50

1659

229

2249

These figures also apply to set screws and studs where the effective thread engagement is equal to or greater than 1.5 times nominal thread diameter.

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6.11

BI628443

Torque table Torque table RECOMMENDED TIGHTENING TORQUES FOR LUBRICATED BOLTS & SET SCREWS I S O METRIC FINE PITCH ISO Metric Precision Bolts & Set Screws Grade 8.8 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

Tab. 7: Torque table (ISO metric fine pitch) PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M4

0.50

2.2

0.3

3.0

M5

0.50

4.7

0.6

6.4

M6

0.75

7.7

1.1

10.5

M8

1.00

18

2.5

25

M10

1.25

35

4.9

48

M12

1.25

64

8.8

87

M16

1.50

156

21.6

212

M20

1.50

319

44

432

M24

2.00

541

75

733

M30

2.00

1094

151

1483

M36

2.00

1934

267

2623

M42

2.00

3121

431

4232

The above torque figures also apply to set screws and studs, where the effective thread engagement is equal to, or greater than, 1.5 times the nominal thread diameter.

6.12

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

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NOMINAL SIZE

BI628443

Torque table Torque table RECOMMENDED TIGHTENING TORQUES FOR LUBRICATED BOLTS & SET SCREWS I S O METRIC FINE PITCH ISO Metric Precision Bolts & Set Screws Grade 10.9 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

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Tab. 8: Torque table (ISO metric fine pitch) NOMINAL SIZE

PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M4

0.50

3.2

0.45

4.4

M5

0.50

6.6

0.9

9.0

M6

0.75

11

1.5

14.7

M8

1.00

26

3.5

35

M10

1.25

50

6.9

68

M12

1.25

91

12.5

123

M16

1.50

220

30

299

M20

1.50

448

62

607

M24

2.00

760

105

1031

M30

2.00

1538

213

2086

M36

2.00

2720

376

3688

M42

2.00

4390

607

5953

The above torque figures also apply to set screws and studs, where the effective thread engagement is equal to, or greater than, 1.5 times the nominal thread diameter.

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6.13

BI628443

Torque table Torque table RECOMMENDED TIGHTENING TORQUES FOR LUBRICATED BOLTS & SET SCREWS I S O METRIC FINE PITCH ISO Metric Precision Bolts & Set Screws Grade 12.9 TO BS3692 Torque figures are only valid using lubricants within the range of ISO 100 to 460.

These figures provide an induced stress equal to 75% of minimum yield stress.

Tab. 9: Torque table (ISO metric fine pitch) PITCH (mm)

Torque in Lbf.ft

Torque in Kgf.m

Torque in Nm

M4

0.50

3.8

0.53

5.2

M5

0.50

7.9

1.1

10.8

M6

0.75

13

1.8

17.7

M8

1.00

31

4.3

42

M10

1.25

60

8.4

82

M12

1.25

109

15

148

M16

1.50

264

36

358

M20

1.50

537

74

729

M24

2.00

912

126

1237

M30

2.00

1846

255

2503

M36

2.00

3264

451

4426

M42

2.00

5269

728

7144

The above torque figures also apply to set screws and studs, where the effective thread engagement is equal to, or greater than, 1.5 times the nominal thread diameter.

6.14

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

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NOMINAL SIZE

BI628443

SUPERNUT tensioning system SUPERNUT tensioning system Important!

The jackbolt value stamped on the tensioner is a standard value for that part and may not be correct for your application.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Refer to manufacturer's documentation, attached to this manual.

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6.15

BI628443

Electrical diagrams Electrical diagrams This section provides a complete set of electrical circuit diagrams; and also provides useful tips on how the information contained within these diagrams can be understood.

Diagram Identification The diagrams for this shearer consist of both SCHEMATIC and WIRING diagrams. All of these diagrams are identified by the code located at the bottom right hand corner of each diagram. Typical examples of these codes are illustrated in Fig. LEERER MERKER. In these examples, the diagrams represented are schematic (S), and wiring diagram (W)@@@@.

Relay Mapping Instructions Like the Balloon Mapping Instructions, the grid reference can also be used to locate relay contacts by using the information provided on the relay coil symbol as also illustrated in Fig. LEERER MERKER. In this example, the relay coil connections which are numbered 1 and 8 on the relay base, are connected to the external circuitry via wire numbers 747 and 600. The relay uses two contacts in this application (2) and they can be found using the grid coordinates shown (D, 2,1 and C, 0, 1).

Important!

This is only a typical example of the relay mapping system.

The exact co-ordinates of the relay 34/X vary from machine to machine.

Wire Number Color Code All electrical wires are numbered by using colored plastic wire markers. These markers as well as displaying numbers, are color coded as follows:

6.16

COLOUR

NUMBER

Black Brown Red Orange Yellow Green Blue Violet Grey White

0 1 2 3 4 5 6 7 8 9

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

In order to provide ease of understanding, all electrical diagrams employ a `Balloon Mapping' system. A summary of this system is shown in Fig. LEERER MERKER. The system, as well as making the diagrams easier to draw, provides a simple method of following electrical wiring from one diagram to another. In order to facilitate this, each diagram is equipped with a horizontal and a vertical grid reference. An example of how to use these grids is also shown in Fig LEERER MERKER. This typical example shows three wires being traced between diagrams `A' and `B'.

E

Balloon Mapping Instructions

BI628443

Electrical diagrams Wire Numbering and Color Coding All electrical wires are identified by using a wire numbering and color code system. This system which is included at the bottom of the schematic and wiring diagrams provides information relating to wire number ranges, for example (1 - 99), what color they are, (Black) and what their function is, (Pilot). A typical extract from this system is shown below. For further details, refer to any of the diagrams contained within this section.

WIRE NUMBER

WIRE COLOUR

WIRE DESCRIPTION

1 - 99 101 - 199

Black Violet

Pilot Up to and including 24Vac

Standing Instructions

E

A set of standing instructions is included to provide information relating to how the electrical diagrams should be interpreted. This information can be found at the bottom of each schematic or wiring diagram.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Plug and Socket Details Connections to most of the on board electrical components are made via quick release ten-way plug and socket connectors. Since there can be several of these connectors in close proximity to each other, a coding pin system is incorporated. This system ensures that `only' the correct plug and socket may be mated together.

Electrical Diagrams There are several separate electrical diagrams associated with this particular Shearer. These diagrams consist of Shearer schematic, Shearer wiring and cable diagrams. A complete set of electrical diagrams is provided with this manual.

Hydraulic & water diagrams There are separate hydraulic and water symbolic diagrams associated with this particular shearer. A complete set of diagrams is provided with this manual.

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6.17

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BI628443

Electrical diagrams

6.18

Shearer EL 2000

Doc. no.: SHEL2000-034 BA 00

NLGI grade 1

NLGI grade 1-2

NLGI grade 1

NLGI grade 2

NLGI grade 2

NLGI grade 2

Quill shafts: Haulage motor/ Haulage drive/ Coalsizer

Downdrive: Bearings and wheel bearings

Hydraulic pump drive couplings

Pump motor bearings

Haulage motor bearings

Cutter motor bearings

NLGI grade 1

Ranging arm cowl mechanism

NLGI grade 1-2

NLGI grade 1

Ranging arm / motor quill shaft

Ranging arm pivot pins

NLGI grade 1-2

SPECIFICATION

Ranging arm water tube seals

Lubrication Areas

Tab. 10: Recommended Lubricants

VPSP / 01

On Application

On Application

On Application

Mobiltemp 78

Mobilgrease HTS

Mobiltemp 78

Mobiltemp 78 Mobilgrease HTS

Mobiltemp 78

Mobiltemp 78

Mobilgrease HTS

MOBIL

Renolit High Temp 220 (Except EL58 - see “OTHERS” column)

Renolit High Temp 220

Renolit High Temp 220 (Except EL56 - see ”OTHERS” column)

Renolit Extreme Load 1

Renolit Extreme Load 2 Renolit LX2

Renolit Extreme Load 1

Renolit Extreme Load 2 Renolit LX2

Renolit Extreme Load 1

Renolit Extreme Load 1

Renolit Extreme Load 2 Renolit LX2

GADUS S2 V100 2/ GADUS S3 T100 2

GADUS S2 V100 2/ GADUS S3 T100 2

GADUS S2 V100 2/ GADUS S3 T100 2

Gadus S3 V460D2

Gadus S3 V460D2

Gadus S3 V460D2

Gadus S3 V460D2

Gadus S3 V460D2

Gadus S3 V460D2

Gadus S3 V460D2

SHELL

On Application

On Application

On Application

Drill Rod Grease Castrol Molub-Alloy 777-1,Castrol MolubAlloy 860/460-1

Energrease LM EP 680, Castrol MolubAlloy 777-1, Castrol Molub-Alloy 777-2

Drill Rod Grease Castrol Molub-Alloy 777-1,Castrol MolubAlloy 860/460-1

Energrease LM EP 680, Castrol MolubAlloy 777-1, Castrol Molub-Alloy 777-2

Drill Rod Grease Castrol Molub-Alloy 777-1 Castrol Molub-Alloy 860/460-1

Drill Rod Grease Castrol Molub-Alloy 777-1 Castrol Molub-Alloy 860/460-1

Energrease LM EP 680, Castrol MolubAlloy 777-1 Castrol Molub-Alloy 777-2

BP-Castrol

EP Mehrbereichsfett LM 2 EP Hightemp EK 2

EP Mehrbereichsfett LM 2 EP Hightemp EK 2

EP Mehrbereichsfett LM 2 EP Hightemp EK 2

---

Wear Protect HTP2 Longlife Grease HP2

---

Wear Protect HTP2 Longlife Grease HP2

---

---

Wear Protect HTP2 Longlife Grease HP2

ADDINOL

CATERPILLAR SHEARER LUBRICANTS FUCHS

On Application

On Application

On Application

Caltex Mine Grease Premium

RPM Grease SRI Multifak®EP grease

Caltex Mine Grease Premium

Caltex Mine Grease Premium Rockdrill grease Multifak®EP grease

Caltex Mine Grease Premium

Caltex Mine Grease Premium

CHEVRONCALTEX-TEXACO Caltex Mine Grease Premium Rockdrill grease Multifak®EP grease

(EL 58) Kluber Asonic HQ 72-102 (EL58C) Klubersynth BEP72-82

On Application

(EL 56) Kluberquiet BHQ 72-102

Quaker Mine Tech Synlith EP-220

Quaker Mine Tech Synlith EP-220

Quaker Mine Tech Synlith EP-220

OTHERS

BI628443

6.19

6.20

NLGI grade 2

ISO Viscosity grade 320 (syn) ISO 3448 or ISO Viscosity grade 460

ISO Viscosity grade 320 (syn) ISO 3448 or ISO Viscosity grade 460

ISO Viscosity grade 320 (syn) ISO 3448 or ISO Viscosity grade 460

ISO Viscosity grade 100 ISO 3448

ISO Viscosity grade 320/460 ISO 3448

All Breuer motors

Ranging arm gearbox

Haulage gearbox

Coalsizer

Hydraulic reservoir

Lubrication tank

Oils listed in the ranging arm or haulage (above).

Mobil DTE 18M Quaker Quintolubric 888-68 (Fire Resistant)

Mobilgear 634 Mobil SHC 634 Mobil SHC Gear 320

Mobilgear 634 Mobil SHC 634 Mobil SHC Gear 320

Mobilgear 634 Mobil SHC 634 Mobil SHC Gear 320

On Application

On Application

Any oils listed in the ranging arm or haulage (above) Plantolube L32GN

Centilube H76 Unigear 85w/140 Powergear 320 & M460 Renolin CKC 460 (CLP 460) Renolin Unisyn CLP 320/460 Centilube H76 Unigear 85w/140 Powergear 320 & M460 Renolin CKC 460 (CLP 460) Renolin Unisyn CLP 320/460 Centilube H76 Unigear 85w/140 Powergear 320 & M460 Renolin CKC 460 (CLP 460) Renolin Unisyn CLP 320/460 Century PWLL Centraulic AW100 Renolin B68 or B100 Powerdraulic 68 & 100

On Application

Renolit High Temp 220

Oils listed in the ranging arm or haulage (above).

Tellus S2 M 100 Tellus S2 M 68

Omala S2 G 460 Omala S4 GX 320

Omala S2 G 460 Omala S4 GX 320

On Application Omala S2 G 460/ Omala S4 GX 320

GADUS S2 V100 2/ GADUS S3 T100 2

Any oils listed in the ranging arm or haulage (above)

On Application Molygear 07 GR-XP 460 Castrol Optigear X320 Castrol Alphasyn™ EP 320 Castrol Tribol 1710 320 & 460 Molygear 07 GR-XP 460 Castrol Optigear X320 Castrol Alphasyn™ EP 320 Castrol Tribol 1710 320 & 460 Molygear 07 GR-XP 460 Castrol Optigear X320 Castrol Alphasyn™ EP 320 Castrol Tribol 1710 320 & 460 Bartan 100 Bartan 68

On Application

Oils listed in the ranging arm or haulage (above).

Hydrauliköl HLP 100 Hydrauliköl HLP 68

Getriebeöl CLP 460 Getriebeöl CLP 460 S Eco Gear 460 M Getriebeöl CKT 460 (CLP 460) Eco Gear 460 S

Getriebeöl CLP 460 Getriebeöl CLP 460 S Eco Gear 460 M Getriebeöl CKT 460 (CLP 460) Eco Gear 460 S

Getriebeöl CLP 460 Getriebeöl CLP 460 S Eco Gear 460 M Getriebeöl CKT 460 (CLP 460) Eco Gear 460 S

On Application

EP Mehrbereichsfett LM 2 EP Hightemp EK 2

Oils listed in the ranging arm or haulage (above).

Rando HD 68 or 100 Chevron hyd oil AWM 68

Meropa 460 Meropa Synthetic 320 EP Tegra®Synthetic Gear 320 PDS

Meropa 460 Meropa Synthetic 320 EP Tegra®Synthetic Gear 320 PDS

Meropa 460 Meropa Synthetic 320 EP Tegra®Synthetic Gear 320 PDS

On Application

On Application

Any oils listed in the ranging arm or haulage (above)

Castrol Hyspin AWH-M 100

Quaker Mine Tech Synthetic gear oil EP460

Quaker Mine Tech Synthetic gear oil EP460

SKF LGHP 2 grease Quaker Mine Tech Synthetic gear oil EP460

On Application

Important!

Please ensure that all used oil or grease is thoroughly cleaned and flushed, from the unit or area, before changing to any other brand or type of oil or grease.

NLGI grade 2

Coalsizer motor bearings

BI628443

Shearer EL 2000

BI628443

7

For your information

BI628443

BI628443

Our service

For your information Our service

Caterpillar Global Mining Europe GmbH, Lünen 2013

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If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.mining.cat.com).

Doc. no.: SHEL2000-034 BA 00

VPSP / 01

7.3

BI628443

Standards and guidelines Standards and guidelines Referenced European standards and guidelines Tab. 11: Referenced European standards and guidelines, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 2006/42/EC the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the approximation of the laws of the member states Directive 94/9/EC concerning equipment and protective systems intended for use in potentially explosive atmospheres

2006-05-17

1994-03-23

EN 1552

Equipment and components intended for use in potentially explosive atmospheres in underground mines Mobile extraction machines on the face - Safety requirements for shearer loaders and plough systems -

2008-08 2003-09

Referenced USA standards and guidelines Tab. 12: Referenced USA standards and guidelines, extract

Designation

Title

Date of issue

30 CFR

MINE SAFETY AND HEALTH ADMINISTRATION (MSHA) Title 30 Code of Federal Regulations (Part 18)

2006

Referenced Australian standards and guidelines Tab. 13: Referenced Australia standards and guidelines, extract

Designation

Title

MDG 16

Design Guidelines for the Construction of Longwall Shearers

7.4

Date of issue Issue B 1995

Shearer EL 2000

Caterpillar Global Mining Europe GmbH, Lünen 2013

DIN EN 1710

E

Directive of the European Parliament and the Council on apparatus liable to cause electromagnetic disturbance Directive 89/336/EEC 1992-10-28 or the performance of which is liable to be affected by such disturbance.

BI628443

ANNEXE ANNEXE Electrical, Hydraulic, Water and Lubrication Diagrams A PDF package, extracted from E-Plan, is supplied in this annexe.

SUPERNUT (Downdrive) The Tightening, Loosening and Maintenance of the downdrive retaining bolts should be carried out as per the instructions supplied in this annexe.

Important!

The jackbolt value stamped on the tensioner is a standard value for that part and may not be correct for your application.

P & S Expansion Bolt System (Shoepost) The Tightening, Loosening and Maintenance of the shoepost retaining bolts should be carried out as per the instructions supplied in this annexe.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Clampex clamping set The mounting instructions for the clamping set should be carried out as per the instructions supplied in this annexe.

AmerCable Trailing Cable The Deployment, Installation, Management and Maintenance of the trailing cable should be carried out as per the instructions supplied in this annexe.

Pempek Radio System The operating instructions for the radio system should be carried out as per the instructions supplied in this annexe.

Rocol Dry Moly Paste ACT Cable Handler Installation and unclipping procedures should be carried out as per the instructions supplied in this annexe.

Doc. no.: SHEL2000-034 BA 00

VPSP / 01

7.5

Caterpillar Global Mining Europe GmbH, Lünen 2013

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ANNEXE

7.6

Shearer EL 2000

4

Prior to Tightening:

For stubborn removal, please call for alternate procedure

©2007 Superbolt, Inc. All Rights Reserved.

10) Stuck jackbolt removal: If a jackbolt will not turn, remove, re-lube, and retighten a neighboring jackbolt and then try to turn it.

9) 1/4 turn or less!: Removing the jackbolts more than a 1/4 turn will increase the removal torque of the remaining jackbolts and you may get stuck. If this happens, you will have to retighten and start again.

Superbolt®, Inc. • P.O. Box 683 • Carnegie PA 15106 • www.superbolt.com (412) 279-1149 • FAX (412) 279-1185

Washers: Apply the correct Superbolt® lubricant to the washer face or to the jackbolt tips.

For flanges: To speed up installation, use two workers at 180º apart, following OEM pattern for tightening.

Lubricants: Jackbolts are prelubricated from the factory with either JL-G or JL-M lubricant. For the main stud any standard antiseize lubricant can be used. For reuse after temperature service, remove, clean, and re-lubricate the jackbolts with the correct Superbolt® lubricant.

Sockets: High hex stresses require the use of quality six-point impact sockets. Have several spares handy for each job and replace them at the first sign of wear. Special Superbolt® sockets may be required when using a 3/4” impact or torque wrench and jackbolt spacing is close.

For Removal:

Further Preparation Steps:

Air Impacts: If using air impacts, select a tool with an output of about 100% - 110% of the target torque. See “Air Impact Tool Selection” on page 4.

Wrenches: Select appropriate hand tools, depending on your target torque.

Torque

1) Lubricate the thread of the main stud. 2) Slide the hardened washer onto the stud. 3) Lubricate the washer face or jackbolt tips with the correct Superbolt lubricant (JL-G or JL-M).

target jackbolt torque. NOTE: The jackbolt torque stamped on the tensioner is a standard value for that part and may not be correct for your application. If you are unsure, contact Superbolt®.

Installation Sheet (shipped with product). Determine the

jackbolts are lubricated with correct Superbolt® lubricant (JL-G or JL-M). New product is lubricated at the factory. Make sure the jackbolt tips are flush (or recessed) with the bottom of the nut body.

Superbolt® Product: Confirm

7) For gasketed joints: During gasket compression, the load is transferred to the jackbolts (i.e. stud) being tightened.

Don’t be concerned if some jackbolts (or tensioners) become loose during the procedure. Continue following the procedure. Don’t spin down tensioners that become loose during gasket compression.

6) Overshooting the target torque: You may want to use 110 - 120% of the target torque for Step 3, Step 4, and for 1-2 rounds of Step 5. This may eliminate a tightening round. Be careful not to stabilize all of the jackbolts at this torque however. For long bolts or tie rods, you may want to experiment using even higher torque values. Call Superbolt before using more than 120% target torque.

5) To improve efficiency when using impacts: Don’t wait for the socket to stall completely on a specific jackbolt before advancing to the next jackbolt. It is faster, overall, to move quickly between jackbolts.

For Tightening:

4) For spinning the tensioner on and off the stud: Custom “sockets” which grip the tensioner are available.

Also, two deep well sockets inserted over two jackbolt hex’s at 180º apart can serve as “handles” for spinning the tensioners on and off the studs.

3) Back the tensioner off before tightening to provide 1/16” to 1/8” gap: The additional jackbolt extension provides easy access for oiling the jackbolt tips prior to removal. This is especially beneficial for oiling when the tensioners are inverted. Note: There may be insufficient jackbolt stroke to allow this step when tensioning exceptionally long bolts or tie rods, or when closing a gap between flanges.

2) Use of spacers: Tensioners should be positioned at the ends of the studs to minimize exposed threads and facilitate easy access to the jackbolts. A spacer (or stacked washers) can be used beneath the special hardened washer to accomplish this. A spacer will also “step over” a damaged area on a stud where years of bolting have deformed the first few threads.

1) Check threads of main stud: If possible, verify that the tensioners spin on prior to the installation date. If a tensioner is tight or will not thread on, try using lapping compound on the main thread and work the tensioner in a back and forth motion making small advances when the thread loosens up. If necessary, chase the studs with a die.

Helpful Tips

Calibrating an air impact wrench: Tighten one jackbolt until the socket rotation stops and check the jackbolt with a torque wrench. The torque required to move the jackbolt further is the output of the impact as measured on Superbolt tensioners.

100 - 170 ft-lbs: For 100 - 130 ft-lbs use a light duty 1/2” impact. For 130 - 170 ft-lbs use a heavy duty 1/2” impact.

170 - 200 ft-lbs: Use a light duty 3/4” impact on low setting. Some heavy duty 1/2” impacts will also reach this range.

Over 200 ft-lbs: For 200 - 300 ft-lbs, use a light to medium duty 3/4” impact. Over 300 ft-lbs, use a heavy duty 3/4” impact.

before starting.)

70 - 100 ft-lbs: Use a light duty 1/2” impact at a reduced pressure or setting. (Be careful not to overtighten! Calibrate the impact

Installation Preparation:

(excludes piston end, crosshead, mill motor & bearing lock nuts)

Up to 70 ft-lbs: For 15 - 35 ft-lbs use a right angle ratchet or light duty 3/8” impact. For 35 - 70 ft-lbs use a heavy duty 3/8”

impact.

Installation and Removal Instructions

Air Impact Tool Selection 90 psi air pressure (Call Superbolt for additional help with air tool selection)

NOTE: The jackbolt torque actually achieved by an air impact wrench is usually only 30 - 50% of its rated output. For minimum hand work, use an air impact with an output of 110% - 120% target torque. For maximum power, use the largest air line fitting.

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Step 4:

At 100% target torque, tighten all jackbolts in a circular pattern. Do this for all studs (1 round only). See Helpful Tip #7 about using up to 120% torque.

Spin the tensioner onto the main thread until it seats against the washer. You may want to back off the tensioner slightly as mentioned in Helpful Tip #3 on page 4.

Step 3:

At 100% target torque, tighten the same (4) jackbolts on all studs.

bilized (less than 10º rotation). This usually requires 2-4 additional passes. If using air tools, switch to a torque wrench when socket rotation is small. Use the torque wrench to stabilize at the target torque.

Repeat “STEP 4” until all jackbolts are sta-

NOTE: Product with 4 or 6 jackbolts - use a star pattern for all steps.

Tighten (4) jackbolts at 90º apart (12:00, 6:00, 9:00, and 3:00) on all studs with a partial torque (30-70%). This serves to seat the flange. If using an air impact, use a reduced setting or lightly pulse the trigger at the full setting.

Step 5:

Step 2:

Step 1:

Installation

Step 4: Remove, clean and relubricate the jackbolts prior to next use with correct Superbolt lubricant (JL-G or JL-M).

and successive rounds until all jackbolts are loose. NOTE: Usually after the 3rd or 4th round, an impact can be used to completely extract the jackbolts, one by one. For long bolts or tie rods, additional rounds may be required before removing the jackbolts with an impact tool.

Step 3: Continue loosening 1/4 turn for 3rd

studs, now loosening each jackbolt 1/4 turn in a circular pattern.

Step 2: Repeat a 2nd round as above for all

OIL

As the equipment is cooling down (around 300ºF), apply hydraulic oil to the jackbolts and washer and let sit for several hours. Thoroughly “wetdown” all components and re-apply during equipment cool down period. If the tensioner is inverted, squirt oil in the gap between the nut body and the washer. Synthetic oil can be used for oiling above 300ºF.

Step 1:

NOTE: Heating Rods can be used to reduce the removal torque required.

Step 3: Now begin with “STEP 1” of the procedure for service under 250ºF.

Step 2: Wait for tensioners to cool below 200ºF. Using a circular pattern, “crack” each jackbolt only enough to ensure movement. Do not turn beyond the break loose point. Do this for all studs.

Preparation: Above 300ºF the petroleum base of the lubricant burns off. Oil per “STEP 1” below to reduce the removal torque.

Service Over 250ºF

Loosen each jackbolt 1/8 turn following a circular pattern around the tensioner (1 round only). As you move around and get back to the first jackbolt, it will be tight again. Do this for all studs on the joint prior to the next step.

Step 1:

Preparation: Spray jackbolts with penetrating oil or hydraulic oil prior to start (especially if product is in corrosive environment).

Service Under 250ºF

carry the entire load and may be hard to turn. With extreme abuse, a jackbolt tip can deform, making removal difficult.

CAUTION! Jackbolts must be unloaded gradually. If some jackbolts are fully unloaded prematurely, the remaining jackbolts will

Removal

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P&S Tensioning Systems Ltd. Rietwiesstrasse 2 CH–8735 St. Gallenkappel Switzerland Phone +41–(0)55 284 64 64 Fax +41–(0)55 284 64 69 info@p-s.ch • www.p-s.ch

SUPERBOLT® Tensioning Systems

Instructions for Tightening – Loosening – Maintenance –

with SUPERBOLT® Expansion Bolt EBC-ø130x280 with controlled Expansion Company Bucyrus Roller Conveyor/Support bracket

With SUPERBOLT® Expansion Bolts EB or EBC you have chosen a technologically superior product.

They are purely mechanical and hence safe to use.

The following simple steps will help you with your application.

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1. Objective These instructions describe in general the installation and loosening of SUPERBOLT® Expansion Bolt EBC-Ø130x280 according to P&S assembly 10792-01. Deviations or additional instructions are specified on the P&S drawing and/or P&S certificates, which are delivered with the SUPERBOLT® Expansion Bolt.

The following information is not part of these instructions and is shown on the P&S drawing 10792-01, which is supplied with the SUPERBOLT® Expansion Bolt: - Permissible tolerance of bore Important: It is the operator’s responsibility to adhere to the tolerances. Occasionally the bores need to be measured and possible deviations reported to P&S Tensioning Systems Ltd. P&S then checks whether the SUPERBOLT® Expansion Bolts can still be used or whether changes are necessary.

The preparation and the correct alignment of the flange are beyond the responsibility of P&S and are therefore not part of these instructions.

2. Safety-Precautions SUPERBOLT® Expansion Bolts are purely mechanical and hence safe to use. When using SUPERBOLT® Expansion Bolts the same safety precautions have to be applied as with conventional bolting elements.

SUPERBOLT® Expansion Bolts are very strong. It is important that all the parts are prepared and aligned according to the specifications to avoid any damage. Deviations in size, form, position and alignment of the bores have to fall within the tolerances as stated on the P&S drawing. P&S excludes all liability resulting from disregarding our instructions.

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3. Design Fig 1 shows the design of a SUPERBOLT® Expansion Bolt EBCØ130x280. The tapered stud (C) is drawn into the tapered sleeve (D) with tensioner (G). The tapered sleeve expands until it locks the bore completely and tensions radially. The spacer (E) centres the tapered sleeve within the split line. The flex nut (A) is needed to clamp the flange together, so that an additional axial pre-load can be created within the connection.

A

B C D E

F

G

Fig. 1: Design of a SUPERBOLT® Expansion Bolt

Instead of tightening the main thread of the tensioner (G) directly, several smaller jackbolts (H) are used for tensioning. The combined force of the jackbolts actson the tapered stud (C) and hence reaches the desired axial and radial pre-load. The hardened washers (B) and (E) protect the surface of the flanges from the high area pressure, which is created under the jackbolts.

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4. Equipment and Tools The following equipment and tools are required for the installation of SUPERBOLT® Expansion Bolts: - P&S socket Conventional sockets might not fit and could fail.

- Suitable torque wrench - P&S lubricant The lubricant is specified on the P&S certificate and/or on the P&S drawing - Thickness gauge To adjust the clamping stroke of the SUPERBOLT® Expansion Bolt.

- Mallet 5. Preparation Ensure that the parts are prepared and well adjusted, so that the SUPERBOLT® Expansion Bolt can be installed without of force.

Clean bores, check for notches and edges and remove them prior to installation. Slightly lubricate bores with a rag.

SUPERBOLT® Expansion Bolts are delivered ready-to-use, pre-lubricated, meaning the tapered stud and tapered sleeve are lubricated with an extremely thin layer of lubricant JLM (approx. 10-20 µm). The jackbolts may not protrude (flush with tensioner) and the thread and spot face have to be lubricated well.

Important: Only use the lubricant which was delivered with the SUPERBOLT® Expansion Bolt and is specified on the P&S certificate and/or P&S drawing.

During the re-installation following a revision all parts need to be completely removed, cleaned, dried and lubricated again, as if it were for a new installation.

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6. Installation 6.1. Stud Installation

Step 1

Ensure that the jackbolts (F) are completely withdrawn (flash with tensioner) and are well lubricated.

Step 2

Ensure that all parts which have metal to metal contact are well lubricated, especially the main thread and the cone of the tapered stud (C), inside and outside of the tapered sleeve (D) and the contact surfaces of the washers (B) and (F).

Step 3

Pre-install the expansion bolt. Insert the tapered sleeve (D) onto the tapered stud (C).Then slide the spacer (E) with the side of countersike onto the tapered stud (C) / the tapered sleeve (D) and tighten tensioner (G) by hand.

The spacer (E) is then clamped between the tensioner (G) and the tapered sleeve (D) (refer to fig. 2).

Step 4

Insert both pre-mounted expansion bolts into the outer bores (fig. 2). Then push the pre-mounted expansion bolt so far into the bores until the spacer is flush with the support bracket (no air/space under the spacer).

Coal-side

F

G

E

D

C

Fig. 2 Installation of pre-installed parts into the bores

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6.2. Alignment of Bores

The bores of the support bracket have to be radially aligned with the bores of the machine frame. Afterwards, the support bracket has to be clamped together in order to bring the connection into full contact with the machine frame and also be fixed into this position to eliminate any movement during installation. The split lines have to be closed and need to be controlled by a thickness gauge.

Step 1

Eliminate the radial backlash of the tapered sleeve (D) by tightening two jackbolts (F) with 50 Nm, until the tapered stud (C) is fastened in the bores and cannot be turned.

Repeat Step 1 on both Superbolt® Expansion Bolts EBC alternately.

Step 2

For the axial fastening the P&S Connection is installed in the middle bores (fig. 3).

Coal-side

F

G

I

A

K

Fig. 3 P&S Connection Step 2a

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Spin on tensioner by hand tight

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Step 2b

Loosen the tensioner by approx. ¼ turn.

Gap according to size approx. 1 to 3 mm.

The actual tightening is carried out with a few steps: Step 2c

1

Insert 4 jackbolts in a star pattern by hand or with a small key to center the main thread and to eliminate the existing residual movement.

4 3 2

Step 2d

Tighten these 4 jackbolts in a star pattern with only 140 Nm.

1 Step 2e

Tighten these 4 jackbolts in a star pattern with 275 Nm.

4 3 2

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Step 2f

Change to a circular pattern and tighten all jackbolts with 275 Nm.

Step 2g

Repeat step 2f until all jackbolts are tightened evenly (less than 10º residual movement). Usually 2 to 3 rounds are sufficient; more may be required on longer bolts.

Step 3

For the precise positioning the expansion bolts have to be loosened again.

Loosen two jackbolts (F) of the pre-assembled expansion bolt until they are flush. Loosen tensioner (G) by two turns and loosen tapered stud. A mallet can be used to hit onto the tapered stud (C). Care has to be taken not to damage the thread. In case that the tapered stud (C) cannot be loosened, the dismantling procedure has to be carried out (fig. 4) by using the dismantling tools (H) and with the help of the screwed on flex nut (A). Steps 2a to 2f need to be adhered to.

Important: The torque for the jackbolt is only 25 Nm for step 2d and 55 Nm for steps 2e and 2f.

Carry out step 3 on both SUPERBOLT® Expansion Bolts EBC. Coal-side

H A Fig. 4 Loosening of SUPERBOLT® Expansion Bolt with help of dismantling tool

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Schritt 4

Remove dismantling tool (H), if used, and loosen the flex nut (A) approx. 2 turns. Screw on the tensioner (G) by hand. The spacer (E) is then clamped between the tensioner (G) and the tapered sleeve (D). Then push back the premounted expansion bolt so far into the bores until the spacer is flush with the support bracket (no air/space under the spacer; fig 2).

Eliminate the radial play of the tapered sleeve (D) by tightening two jackbolts (H) with 50 Nm, until the tapered stud (C) is fastened in the bore and cannot be turned anymore.

Repeat on both Superbolt® Expansion Bolts EBC alternately.

6.3. Adjustment of Clamping Stroke (radial pre-tension)

Step 1

Screw on flex nut (A) by hand. Then loosen flex nut (A) so that the clamping stroke s=8mm can be set/adjusted (refer to detail in drawing 10792-01).

The clamping stroke can be checked with a slide gauge. The space (mass X) between the face of the tapered stud (C) and the flex nut (A) can be used.

X1 - X2 = s

X1: Space with tightened flex nut X2: Space with loosened tensioner

Coal-side

A C

Fig. 5 Adjusting clamping stroke

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Important: The remaining gap (clamping stroke s=8mm) limits the axial movement of the tapered stud (C). The radial expansion of the tapered sleeve (D) is limited because the radial expansion relates directly to the axial movement. This limit protects the flange from overtorquing.

Step 2

Loosen the two jackbolts (F) off the tensioner (G) and loosen until they are flush. Tighten the tensioner (G) by hand and then loosen again by ¼ turn. Be careful not to move the flex nut A. Repeat step 1 and 2 for other SUPERBOLT® Expansion Bolt EBC.

7. Tightening Step 1

On tensioner (G) tighten 4 jackbolts (F) with 275 Nm following a star pattern.

Tighten to maximal half a turn (180°) per jackbolt.

Step 2

Repeat step 1 for these 4 jackbolts (F) so many times until the final turn is approx. 45°.

Step 3

Change to circular pattern and tighten all jackbolts with 275 Nm. Repeat until all jackbolts show less than 10° movement.

Flex nut (A) has to be fixed axially and is not be moved anymore.

Repeat steps 1 to 3 on both SUPERBOLT® Expansion Bolts EBC.

Step 4

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Check if the jackbolts of the P&S Bolted connection in the middle bores are fix.

Tighten in a circular pattern and check all jackbolts with 275 Nm (less than 10° movement, refer to steps 2f and 2g).

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8. Loosening Important: Loosening requires an exact procedure to avoid damage. The jackbolts must be unloaded stepwise! Under no circumstances unload single jackbolts completely at once. The remaining jackbolts would have to carry the entire load and, therefore, would be more difficult to loosen. In extreme cases jackbolts could mushroom and make loosening impossible.

Step 1

Following a circular pattern on tensioner (G) loosen each jackbolt by approx. ¼ turn. When you get back to the first jackbolt it will be tight again, however, on a lower level.

Step 2

Repeat step 1 for a second and third time. Then loosen all jackbolts completely.

Step 3

Loosen tensioners (G) and remove with the washers (E) on all SUPERBOLT® Expansion Bolts.

Step 4

Screw on dismantling tool (H) onto the flex nut (A). Tighten the 4 jackbolts in a star pattern with 25 Nm. Then tighten the same 4 jackbolts (F) with 55 Nm in a star pattern. Then switch to a circular pattern and tighten all jackbolts with 55 Nm. Repeat until the tapered stud is loose. Then the tapered stud can be dismantled. Repeat for other SUPERBOLT® Expansion Bolt.

Coal-side

Fig. 6 Loosening of Expansions Bolt using dismantling tools

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9. Air impact Tools Air impact tools have proven to be most suitable. However, with jackbolts they only reach 3050% of their rated output (lack of stroke). Therefore, the largest possible air lines and should be used. Because of the high forces used, only heavy-duty products should be chosen (e.g.

Ingersoll Rand, Dino Paoli, Atlas Copco).

Verifying the torque output of an air impact tool is easy: Tighten one jackbolt until tool stalls, measure the torque with a torque wrench (preferably with electronic gauge).

The torque can be regulated easily: Install a service unit directly in front of the air impact tool (filter, controller, oiler). Adjust the pressure at the controller and, thereby, the power of the air impact tool.

The torque output of an air impact tool can be adjusted just as easily: Tighten a jackbolt with the torque wrench to the desired torque. Then apply the air impact tool and slowly increase the pressure until the jackbolt starts turning again. Control: As soon as the air impact tool turns, the pressure of the controller should not decrease, as otherwise an unwanted pressure drop in the air line occurs. Therefore, use a generously dimensioned size air duct!

For regular usage of air impact tools the use of a control unit would be advantageous (available upon request).

Important: Because of the lower accuracy of power tools, the last tightening flex should always be performed manually with a precision torque wrench.

Attention: Never use normal air impact tools for loosening! Only for tightening!

10. Maintenance 10.1 Regular checks SUPERBOLT® Expansion Bolts do not loose their preload even after several years in service, provided they are tightened correctly. During each revision (after several years) the preload should be checked nevertheless, which should be carried out with a torque wrench adjusted to 100% target torque. Should some jackbolts unexpectedly have lost preload, it is recommended to proceed as follows: Loosen the tensioner by turning the jackbolts by approx. ¼ turn and the tensioner will remain tensioned.

Tighten each jackbolt in a circular pattern with 100% of the target torque.

Repeat until all jackbolts hold firm.

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10.2 Preventative Maintenance SUPERBOLT® Expansion Bolts do not require any preventative maintenance.

10.3 Trouble Shooting Jackbolts cannot be loosened: Loosen one jackbolt Remove this jackbolt, lubricate it and tighten it with 100% of the recommended torque. The two adjacent jackbolts then become loose.

Loosen those two jackbolts, lubricate them and tighten with 100% of the recommended torque.

The next two jackbolts become loose.

And so on Then loosen all jackbolts according to the loosening procedure.

Hardened washers are damaged after prolonged service life: Hardened washers can be reused, even if slightly damaged, by simply flipping them over.

In case of larger damages exchange against original hardened washers.

Jackbolts are missing or damaged: Replace with original jackbolts Do not use commercially available screws, as they are not suitable for such high loads.

Other problems: Flex nuts (A) are not fixed after a completed tightening procedure Please contact P&S Tensioning Systems Ltd. Telephone: +41 (0)55 284 64 64 E-Mail: info@p-s.ch

11. Consultation and Exclusion of Liability For further information on possible uses, applications and maintenance of SUPERBOLT® Expansion Bolts and Tensioners please contact P&S Tensioning Systems Ltd. P&S excludes all liability for unsuitable product selection, improper use as well as damage resulting from disregarding our instructions and directives. Changes due to technical progress are reserved.

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Information Technology Solutions INSTALLATION INSTRUCTIONS

Type L0MT IEC Ex d Oracle Enclosure

Highly ruggedized, industrial design using all industrial grade components.

Contact HQ Australia Unit 3/13 Hoyle Ave Castle Hill NSW 2154 Australia Phone +612.8853.4800 Fax +612.9894.0379 Web www.pempek.com.au

IP65 ingress rating. IEC Ex d approvals in Australia and China.

Two-way communication empowers your operators and provides a means for

United States of America 640 Bizzell Drive Lexington KY 40510 USA Phone +859.252.4439 Fax +859.252.4641 Web

A nominal operating temperature range spanning -20°C..+40°C T6 class with an

remote data-logging.

Simplifies

machine

installation

and

promotes line-of-sight operation.

www.forcedpotato.com

Type L0MT Ex d Machine Mounted Transceiver is an

Supporting a myriad of industrial communication

industrialized radio control interface module designed for

interfaces including Ethernet, RS422 and CAN, the

the rigors of underground mobile mining machinery.

Type L0MT Machine Mounted Transceiver can be integrated into almost any control system with relative

Designed to exacting requirements of IEC 60079.1 and

ease.

MSHA CFR 30, this Ex d Transceiver Module is designed for world-wide explosive atmosphere regulatory approval

A highly flexible communications protocol has been

allowing it

developed to enable routing of control data and

to be

installed into

any underground

environment after certification assessment.

D0SL0100 Issue 01

Page 1

diagnostic data with high levels of determinism.

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS Information Technology Solutions

General Specifications

The L0MT Oracle is a machine mounted radio control interface that can be used for a variety of industrial remote control/data acquisition applications where a safety critical interface is required. The apparatus is a circular enclosure that mainly comprises of brass mounting base, brass antenna flange, antenna Teflon cover and stainless steel clamping ring. Antenna cover comes in three different sizes depending on the size of the radio antenna mounted on the antenna flange.

This flameproof apparatus is not to be used for any other purpose other than to provide a suitable Ex d I and Ex d IIB T6 enclosure for general purpose/industrial electronics.

Typical application of L0MT flameproof apparatus will provide housing for radio transceiver used in underground mines on continuous miners, continuous haulages, long wall shearers, mobile bolters, Mobile roof supports, remote control scoops, remote control loaders and control room surface monitoring.

This flameproof apparatus is NOT to be opened in an explosive atmosphere until external power has been electrically isolated.

STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

Page 2

14 October 2009

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INSTALLATION INSTRUCTIONS Information Technology Solutions

Technical Description Marking/Engraving details:

STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

Company name: Pempek Systems Max surface temperature: 150 ˚C for external surface temperature of metal box group I 85 ˚C for external surface temperature of metal box group IIB Certification number: IECEx TSA 07.0016X Degree of protection: IP65 Model Number: L0MTxx Oracle Enclosure Serial Number: S/N XXXXXX Note: L0MT** Machine Mounted Transceiver come in numerous custom variations. They all only differ in operating frequency variants of 458MHz, 915MHz, 2.4GHz and 5.8GHz and its applicable dome that is made to suit application. For more details please contact manufacturer or their certified agent before ordering.

Name Plate: L0MT**

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

Page 3

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS Information Technology Solutions

Construction details: Antenna Flange M0MT0100 – Free Machining Brass Grade ISO CuZn39Pb3 Mounting Base M0MT0200‐ Free Machining Brass Grade ISO CuZn39Pb3 Teflon Cover 2.4GHz M0MT0300 – Teflon PTFE Unfilled Clamping Ring M0MT0400 – Stainless Steel 304 Shield Plate M0MT0500 ‐ Mild steel ISO 630‐Fe430A/Fe430B Antenna Cap M0MT0600 – Free Machining Brass Grade ISO CuZn39Pb3 Teflon Cover 5.8GHz M0MT0800 – Teflon PTFE Unfilled Teflon Cover 458MHz M0MT0900 – Teflon PTFE Unfilled STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11

Electrical details:

AS/IEC 61508 AS/IEC 62061 AS 4240

MSHA CFR 30 Part 18

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

Supply voltage and input signals are connected to the enclosure through certified gland.

Typical configuration consists of the following: o Radio Transceiver – Transmits and receives radio signal o Power supply o Mother board – Provides communication interfaces Maximum voltage and current shall not be able to dissipate more than maximum allowable dissipation of 15W. Higher current dissipation is only allowed if the power dissipation source is installed in the enclosure as such that the temperature of the Teflon dome will not exceed 80 ˚C and the temperature of the enclosure 150 ˚C for Ex d I and 85 ˚C for Ex d IIB at any possible installation position.

Typical supply voltage is 24VDC Typical supply current 300mA @ 24VDC For LOMT4 power supply: 12 VDC, 5W maximum (420mA) Operating ambient temperature ‐20 ˚C to 40 ˚C Operating relative humidity 10‐90% non condensing

Assembly Details of L0MT** Machine Mounted Transceiver : 1.

2.

Mounting Base is fitted with Cable Gland Stopping Plug M20.

Transceiver is assembled to Transceiver board using Button Head Cap Screws M3x6 along with Hex Nut M3 and crinkle washers, keeping F/M Hex Spacer M3x7 in the middle.

3. Antenna assembly is screwed onto Antenna Flange.

4. Transceiver Board assembly is fastened to Antenna Flange with Male /Female Hex Spacer M3x12.

5. Shield Plate is fastened to Transceiver assembly using Soc Head cap screws M3x6.

6. Teflon Cover is placed on the Antenna Flange and Clamping ring is placed on the top of the Teflon Cover. Antenna flange is fastened to the Clamping Ring with Soc head cap screws M6x30 long. Teflon Cover is held between Clamping Ring and Antenna Flange. These screws are torque tightened to 8N‐m.

7. O‐ring is placed into the Mounting Base inside the O‐ring groove.

8. Clamping Ring is fastened to Mounting Base with Soc Head cap screws M6x50.

These screws are torque tightened to 8N‐m.

9. Mounting Base is fitted with Cable assembly Transceiver consisting of Certified Cable gland M20 as required. Make sure that the threaded entry of the gland is fully inserted. This assembly is customer specific.

10. All the unused cable entries to be closed with certified blanking plugs. All OEM products are fitted with Redapt PD‐U M20 blanking plugs. These plugs can be substituted with other certified plugs in accordance with the regulation of country of use.

D0SL0100 Issue 01

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BI628443

INSTALLATION INSTRUCTIONS Information Technology Solutions

Instructions for maintenance: 1.

2.

3.

4.

STANDARDS

5.

COMPLIANCE

If the Oracle enclosure assembly need to be opened because of trouble shooting or maintenance, follow the assembly instructions as listed above.

Make sure O‐ring is kept back in O‐ring groove and M6 screws are tightened to the torque setting recommended.

All the washers should be assembled with screws as described and none should be discarded.

Inspect the Teflon Cover and note that no cracks are permitted on the Teflon Cover.

Make sure Cable Gland Stopping Plug and Cable Glands are fully inserted and tightened.

AS/IEC 60079.0 AS/IEC 60079.11

Installation Notes:

AS/IEC 61508

This flameproof apparatus should be installed prior to attempting electrical termination.

AS/IEC 62061 AS 4240

1.

2.

MSHA CFR 30 Part 18

3.

INFORM ATION For more information on any of our products or services please

4.

5.

6.

visit us on the Web at:

Remove the Antenna Flange to permit access to the internal electrical terminals.

Ensure any unused cable entries are fitted with certified M20 certified blanking plugs.

While Installing the M20 flameproof glands ensure that the threaded entry of the gland is fully inserted.

Tighten the gland’s compression assembly to ensure that the cable/cores are sufficiently restrained.

Terminate individual cores as per the prevailing electrical schematic.

Check the flame path seal with a calibrated feeler gauge. Any deviation from acceptable criteria shall result in removal of this apparatus from the explosive atmosphere.

www.pempek.com.au

Opening of the enclosure: 1. Opening time of an L0MT** enclosure has been measured to be approximately 3 minutes.

2. The energy level inside the enclosure measured after the opening time specified above shall to be discharged to a voltage lesser than allowable voltage under the capacitance ignition reference published in IEC 60079.11.

3. Temperature of any component inside the enclosure measured after the opening time specified above shall not exceed 150 ˚C for Ex d I and 80 ˚C for Ex d IIB.

Tools required for the assembly:

D0SL0100 Issue 01

Set of Metric Hexagonal Wrenches (Allen keys) Torque wrench with 0‐100N‐m range

Page 5

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

Wiring L0MT01 PCA B0MT3005

STANDARDS

External Wiring

Item

PIN

LABEL

1

J1‐1

RS422‐Tx+

2

J1‐2

RS422‐Tx‐

3

J1‐3

RS422‐Rx+

4

J1‐4

RS422‐Rx‐

COMPLIANCE

5

J1‐5

0V Supply Input

AS/IEC 60079.0

6

J1‐6

24V Supply Input

AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

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14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

Wiring L0MT02 PCA B0TEK3005

External Wiring

Item

PIN

LABEL

1

1

24V Supply

2

2

0V Supply

PCA B0TEK3005

External Wiring

STANDARDS COMPLIANCE AS/IEC 60079.0

Item

PIN

LABEL

AS/IEC 60079.11

1

J2‐1

RS422‐Rx+

AS/IEC 61508

2

J2‐2

RS422‐Rx‐

3

J2‐3

RS422‐Tx+ RS422‐Tx‐

AS/IEC 62061

4

J2‐4

AS 4240

5

J2‐5

0V

MSHA CFR 30 Part 18

6

J2‐6

CAN‐High

7

J2‐7

CAN‐Low

8

J2‐8

0V

PCA B0TEK3005

External Wiring

INFORM ATION For more information on any of

Item

PIN

LABEL

our products or services please

1

J4‐1

Ethernet – Tx+

visit us on the Web at:

2

J4‐2

Ethernet – Tx‐

3

J4‐3

Ethernet – Rx+

4

J4‐4

5

J4‐5

6

J4‐6

7

J4‐7

8

J4‐8

www.pempek.com.au

D0SL0100 Issue 01

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Ethernet – Rx‐

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

Wiring L0MT03 PCA B0TEK3005

External Wiring

Item

PIN

LABEL

1

1

24V Supply

2

2

0V Supply

PCA B0TEK3005

External Wiring

STANDARDS COMPLIANCE

Item

PIN

LABEL

AS/IEC 60079.0

1

J2‐1

RS422‐Rx+

AS/IEC 60079.11

2

J2‐2

RS422‐Rx‐

3

J2‐3

RS422‐Tx+ RS422‐Tx‐

AS/IEC 61508

4

J2‐4

AS/IEC 62061

5

J2‐5

0V

AS 4240

6

J2‐6

CAN‐High

7

J2‐7

CAN‐Low

8

J2‐8

0V

PCA B0TEK3005

External Wiring

MSHA CFR 30 Part 18

INFORM ATION

Item

PIN

LABEL

For more information on any of

1

J4‐1

Ethernet – Tx+

our products or services please

2

J4‐2

Ethernet – Tx‐

3

J4‐3

Ethernet – Rx+

4

J4‐4

5

J4‐5

6

J4‐6

7

J4‐7

8

J4‐8

visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

Page 8

Ethernet – Rx‐

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

Wiring L0MT04 Wireless Module

External Wiring

Item

PIN

1

J1‐inner

24V Supply

LABEL

2

J1‐outer

0V Supply

Wireless Module

External Wiring

STANDARDS COMPLIANCE AS/IEC 60079.0

Item

PIN

LABEL

AS/IEC 60079.11

1

J2‐1

Ethernet – Tx+

AS/IEC 61508

2

J2‐2

Ethernet – Tx‐

3

J2‐3

Ethernet – Rx+

4

J2‐4

AS 4240

5

J2‐5

MSHA CFR 30 Part 18

6

J2‐6

7

J2‐7

8

J2‐8

AS/IEC 62061

Ethernet – Rx‐

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

Page 9

14 October 2009

BI628443

Information Technology Solutions INSTALLATION INSTRUCTIONS

Wiring L0MT08 PCA B0TEK3005

External Wiring

Item

PIN

LABEL

1

1

24V Supply

2

2

0V Supply

PCA B0TEK3005

External Wiring

STANDARDS COMPLIANCE

Item

PIN

LABEL

AS/IEC 60079.0

1

J2‐1

RS422‐Rx+

2

J2‐2

RS422‐Rx‐

AS/IEC 60079.11

3

J2‐3

RS422‐Tx+

AS/IEC 61508

4

J2‐4

RS422‐Tx‐

AS/IEC 62061

5

J2‐5

0V

6

J2‐6

CAN‐High

AS 4240

7

J2‐7

CAN‐Low

MSHA CFR 30 Part 18

8

J2‐8

0V

PCA B0TEK3005

External Wiring

INFORM ATION

Item

PIN

LABEL

1

J4‐1

Ethernet – Tx+

2

J4‐2

Ethernet – Tx‐

3

J4‐3

Ethernet – Rx+

visit us on the Web at:

4

J4‐4

www.pempek.com.au

5

J4‐5

6

J4‐6

7

J4‐7

8

J4‐8

For more information on any of our products or services please

D0SL0100 Issue 01

Page 10

Ethernet – Rx‐

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

Detailed Technical Specification L0MT01

Power Supply Max Power consumption Power Method STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

12‐24VDC 5W Passive PoE (pairs 4,5+ ; 7,8 return)

Radio Frequency Transmit Power Receive Sensitivity Bit Rate Modulation Range MIN Range MAX Channel Spacing Antenna Classification

ISM 2.4GHz PLL SYNTHESIZED Programmable up to +26dBm ‐90dBm @ 1Mbps 1Mbit .. 54Mbps OFDM 200m Line of Sight 1000m Line of Sight 125kHz Internal Passive Transceiver

Electronics INFORM ATION For more information on any of

CPU Memory Interfaces

Atheros MIPS 4KC, 180MHz 32bit 50MIPS 16MB SDRAM, 4MB Flash 1x Ethernet 10/100 Base Tx (Cat.5, RJ45)

our products or services please

Mechanical

visit us on the Web at:

Material Width Height Depth Mass

www.pempek.com.au

Brass / Teflon / Stainless Steel 149mm 131mm 149mm 10.5kg

Environmental Operating Temperature Temperature Class Ingress Protection

‐20°C..+40°C T6 IP65

Approvals IEC Australia MA China MSHA USA ATEX Europe

D0SL0100 Issue 01

IECEx TSA 07.0016X Group I/IIB Pending 18‐XPA090007‐0 Pending

Page 11

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

L0MT02

Power Supply Max Power consumption

24VDC 5W

Radio STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

Frequency Transmit Power Receive Sensitivity Bit Rate Modulation MIN Range Range MAX Data Integrity Antenna Classification

Electronics CPU Data Storage Interfaces

ARM7 32bit 50MIPS 2GB Ethernet 10/100 UDP/TCP RS‐422 CAN 2.0B

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

ICM 5.8GHz PLL SYNTHESIZED Programmable up to +26dBm ‐97dBm 1Mbit .. 54Mbps OFDM Line of Sight 100m 500m Line of Sight CCITT CRC Internal Passive Transceiver

Mechanical Material Width Height Depth Mass

Brass / Teflon / Stainless Steel 149mm 131mm 149mm 10.5kg

Environmental Operating Temperature Temperature Class Ingress Protection

‐10°C..+50°C T6 IP65

Approvals IEC Australia MA China MSHA USA ATEX Europe

D0SL0100 Issue 01

IECEx TSA 07.0016X Group I/IIB Pending 18‐XPA090007‐0 Pending

Page 12

14 October 2009

BI628443

D0SL0100 Issue 01

Page 13

14 October 2009

INSTALLATION INSTRUCTIONS BI628443 INSTALLATION INSTRUCTIONS

L0MT03

Power Supply Max Power consumption

24VDC 5W

Radio STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

Frequency Deviation Receive Sensitivity Bit Rate Channels Modulation Range MIN Range MAX Data Integrity Channel Spacing Antenna Classification

UHF 458.5‐460.5MHz PLL SYNTHESIZED +‐2.5KHz ‐113dBm 1200bps 32 Simplex NRZ 100m Line of Sight 500m Line of Sight CCITT CRC 25kHz Internal Passive Receiver

Electronics INFORM ATION For more information on any of

CPU Data Storage Interfaces

ARM7 32bit 50MIPS 2GB Ethernet 10/100 UDP/TCP RS‐422 CAN 2.0B

our products or services please visit us on the Web at: www.pempek.com.au

Mechanical Material Width Height Depth Mass

Brass / Teflon / Stainless Steel 149mm 131mm 149mm 10.5kg

Environmental Operating Temperature Temperature Class Ingress Protection

‐20°C..+40°C T6 IP65

Approvals IEC Australia MA China MSHA USA ATEX Europe

D0SL0100 Issue 01

IECEx TSA 07.0016X Group I/IIB Pending 18‐XPA090007‐0 Pending

Page 14

14 October 2009

BI628443

INSTALLATION INSTRUCTIONS

L0MT04

Power Supply Max Power consumption Power Method

12‐24VDC 5W Passive PoE (pairs 4,5+ ; 7,8 return)

Radio STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

INFORM ATION For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

Frequency Deviation Transmit Power Receive Sensitivity Bit Rate Modulation Range MIN Range MAX Channel Spacing Antenna Classification

ISM 2.4GHz +‐20KHz Programmable up to +26dBm ‐97dBm @ 1Mbps 1Mbit .. 54Mbps OFDM 200m Line of Sight 1000m Line of Sight 125kHz Internal Passive Transceiver

Electronics CPU Memory Interfaces

Atheros MIPS 4KC, 180MHz 32bit 50MIPS 16MB SDRAM, 4MB Flash 1x Ethernet 10/100 Base Tx (Cat.5, RJ45)

Mechanical Material Width Height Depth Mass

Brass / Teflon / Stainless Steel 149mm 131mm 149mm 10.5kg

Environmental Operating Temperature Temperature Class Ingress Protection

‐20°C..+40°C T6 IP65

Approvals IEC Australia MA China MSHA USA ATEX Europe

D0SL0100 Issue 01

IECEx TSA 07.0016X Group I/IIB Pending 18‐XPA090007‐0 Pending

Page 15

14 October 2009

INSTALLATION INSTRUCTIONS BI628443

INSTALLATION INSTRUCTIONS

L0MT0801

Power Supply Max Power consumption

24VDC 5W

Radio STANDARDS COMPLIANCE AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508 AS/IEC 62061 AS 4240 MSHA CFR 30 Part 18

Frequency Deviation Transmit Power Receive Sensitivity Bit Rate Channels Modulation Range MIN Range MAX Data Integrity Channel Spacing Antenna Classification

UHF 902‐928MHz PLL SYNTHESIZED +‐20KHz +18dBm ±2 ‐107dBm @ 40kbps 2.5Kbits .. 80Kbits 40Kbits Default 26 Half Duplex NRZ 100m Line of Sight 500m Line of Sight CCITT CRC 1MHz Internal Passive Transceiver

Electronics INFORM ATION

CPU Data Storage Interfaces

ARM7 32bit 50MIPS 2GB Ethernet 10/100 UDP/TCP RS‐422 CAN 2.0B

For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

Mechanical Material Width Height Depth Mass

Brass / Teflon / Stainless Steel 149mm 131mm 149mm 10.5kg

Environmental Operating Temperature Temperature Class Ingress Protection

‐20°C..+40°C T6 IP65

Approvals IEC Australia MA China MSHA USA ATEX Europe

D0SL0100 Issue 01

IECEx TSA 07.0016X Group I/IIB Pending 18‐XPA090007‐0 Pending

Page 16

14 October 2009

INSTALLATION INSTRUCTIONS BI628443

INSTALLATION INSTRUCTIONS

Sales and After Sales Service

Service of equipment shall be carried out by the manufacturer or their certified agent.

All spare parts shall be supplied by the manufacturer or their certified agent.

Manufacturer Pempek Systems Pty Ltd

STANDARDS COMPLIANCE

Unit 3/13 Hoyle Ave Castle Hill NSW 2154 Australia Phone +612.8853.4800 Fax +612.9894.0379 Web www.pempek.com.au

AS/IEC 60079.0 AS/IEC 60079.11 AS/IEC 61508

Service agents Forced Potato Incorporated

MSHA CFR 30 Part 18

United States of America 640 Bizzell Drive Lexington KY 40510 USA Phone +859.252.4439 Fax +859.252.4641 Web www.forcedpotato.com

INFORM ATION

Pempek China

AS/IEC 62061 AS 4240

For more information on any of our products or services please visit us on the Web at: www.pempek.com.au

D0SL0100 Issue 01

KhaiShun Centre ChunYangGong No21 TaiYuan City ShanXi Province P.R.C. 030001 China Phone +86.13413883932 Web www.pempek.com.au

Page 17

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BI628443

SAFETY DATA SHEET 安全数据表 DRY MOLY PASTE 干性二硫化钼抗磨软膏 1.

Page 1 Issued: 30/05/2008 Revision No: 4

DENTIFICATION OF THE SUBSTANCE / PREPARATION AND OF THE COMPANY / UNDERTAKING 产品/配制品及相应公司/企业鉴定 Product name: DRY MOLY PASTE 产品名称: 干性二硫化钼抗磨软膏 Company name: ROCOL 公司名称：罗哥 ROCOL House Swillington Leeds West Yorkshire LS26 8BS ENGLAND Tel: +44 (0) 113 232 2700 Fax: +44 (0) 113 232 2740 Emergency tel: +44 (0) 113 232 2600 Email: customer-service@rocol.com

2. HAZARDS IDENTIFICATION 危害鉴定 Main hazards: No significant hazard. 主要危害：无重大危害

3. COMPOSITION / INFORMATION ON INGREDIENTS 成份组成/信息 Hazardous ingredients: MOLYBDENUM DISULPHIDE 30-60% EINECS: 215-263-9 CAS: 1317-33-5 • MINERAL OIL 30-60% EINECS: 265-090-8 CAS: 64741-88-4 危害成份：二硫化钼30-60%

化合物目录数据库： 215-263-9 CAS: 1317-33-5 • 矿物油 30-60%

化合物目录数据库：265-090-8 CAS: 64741-88-4 4. FIRST AID MEASURES (SYMPTOMS) 急救措施（症状） Skin contact: There may be mild irritation at the site of contact. 接触皮肤：接触部分可能有中度刺激 Eye contact: There may be irritation and redness. 接触眼睛：可能有刺激，发红 Ingestion: There may be irritation of the throat. 咽下：咽喉可能有刺激 Inhalation: No symptoms. 吸入：无症状

4. FIRST AID MEASURES (ACTION) 急救措施（行动） Skin contact: Wash immediately with plenty of soap and water. 接触皮肤：立即用大量肥皂水清洗 Eye contact: Bathe the eye with running water for 15 minutes. 接触眼睛：流水冲洗眼睛15分钟 Ingestion: Wash out mouth with water. 咽下：用水清晰口腔

[cont…]

BI628443

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SAFETY DATA SHEET 安全数据表 DRY MOLY PASTE 干性二硫化钼抗磨软膏

Page 2

5. FIRE-FIGHTING MEASURES 救火措施 Extinguishing media: Use water spray to cool containers. Suitable extinguishing media for the surrounding fire should be used. 灭火工具：喷水以冷却容器。应使用适当灭火工具扑灭周围的火 Exposure hazards: In combustion emits toxic fumes. 暴露危害：燃烧时产生有毒的烟 Protection of fire-fighters: Wear self-contained breathing apparatus. Wear protective clothing to prevent contact with skin and eyes. 消防人员防护：佩戴全套呼吸设备。穿防护服以防止接触皮肤和眼睛。

6. ACCIDENTAL RELEASE MEASURES 意外泄漏处理 Personal precautions: Refer to section 8 of SDS for personal protection details. 个人防护：参见第8节SDS的个人防护细节 Environmental precautions: Do not discharge into drains or rivers. 环境保护：不要排放到排水系统或河流中 Clean-up procedures: Transfer to a closable, labelled salvage container for disposal by an appropriate method. 清洁方法：转移到贴有标签的可封闭容器中，以待采用适当方法处理。

7. HANDLING AND STORAGE 操作与储存 Handling requirements: Avoid direct contact with the substance. 操作要求：避免直接接触。 Storage conditions: Store in cool, well ventilated area. 存储条件：存放在冷却通风良好处 Suitable packaging: Must only be kept in original packaging. 适用包装：只可使用原包装。

8. EXPOSURE CONTROLS / PERSONAL PROTECTION 暴露控制/个人防护 Hazardous ingredients: MOLYBDENUM DISULPHIDE WEL (8 hr TWA): 15mg/m3 WEL (15 min STEL): 10mg/m3 • MINERAL OIL WEL (8 hr TWA): 5mg/m3 WEL (15 min STEL): 10mg/m3 危害成份： 二硫化钼

工作场所暴露时限（平均8小时）：15mg/m3工作场所暴露时限(15 min 短期暴露时限): 10mg/m3 • 矿物油

工作场所暴露时限(平均8 hr ): 5mg/m3工作场所暴露时限(15 min短期暴露时限): 10mg/m3 Respirable dust: MOLYBDENUM DISULPHIDE 可吸入粉尘：二硫化钼 WEL (8 hr TWA): 15mg/m3 WEL (15 min STEL): 10mg/m3 工作场所暴露时限(平均8 hr ): 15mg/m3工作场所暴露时限(15 min短期暴露时限): 10mg/m3 Respiratory protection: Respiratory protection not normally required. 呼吸防护：一般不需要呼吸防护 Hand protection: Protective gloves. 手防护：防护手套 Eye protection: Safety glasses with side-shields. 眼睛防护：有护翼的安全眼镜 Skin protection: Protective clothing. 皮肤防护：防护服

[cont…]

BI628443

Issued: 30/05/2008

SAFETY DATA SHEET 安全数据表 DRY MOLY PASTE 干性二硫化钼抗磨软膏

Page 3

9. PHYSICAL AND CHEMICAL PROPERTIES 理化性质 State: Paste 外观：膏体 Colour: Blue-black 颜色：蓝黑 Odour: Barely perceptible odour 气味：几乎无气味 Evaporation rate: Negligible 挥发速度：可以忽略 Oxidising: Non-oxidising (by EC criteria) 氧化：无氧化作用（按照欧盟标准） Solubility in water: Insoluble 在水中的溶解度：不可溶 Viscosity: Highly viscous 粘性：高粘度 Melting point/range °C: > 100 熔点/范围 °C: > 100 Flash point°C: > 150 闪点 °C: > 150 Autoflammability°C: > 200 自燃性 °C: > 200 Relative density: 1.5 相对密度：1.5

10. STABILITY AND REACTIVITY 稳定性与反应活性 Stability: Stable under normal conditions. 稳定性：在一般条件下稳定 Conditions to avoid: Heat. 应避免的条件：热 Materials to avoid: Strong oxidising agents. Strong reducing agents. 应避免的物质：强氧化剂，强还原剂 Haz. decomp. products: In combustion emits toxic fumes of carbon dioxide / carbon monoxide. 危害分解产物：燃烧中发出有毒的烟，含一氧化碳和二氧化碳

11. TOXICOLOGICAL INFORMATION 毒物学信息 Routes of exposure: Refer to section 4 of SDS for routes of exposure and corresponding symptoms. 暴露途径:参见第4节SDS中有关暴露途径和相应症状

12. ECOLOGICAL INFORMATION 生态学信息 Mobility: Non-volatile. Absorbed only slowly into soil. 活性：非挥发，在土壤中仅能缓慢被吸收 Persistence and degradability: Only slightly biodegradable. 持久性和可解性：仅可轻度生物分解 Bioaccumulative potential: Slightly bioaccumulable. 生物积累：轻度生物积累

[cont…]

BI628443

Issued: 30/05/2008

SAFETY DATA SHEET 安全数据表 DRY MOLY PASTE 干性二硫化钼抗磨软膏

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13. DISPOSAL CONSIDERATIONS 废弃处理 Disposal of packaging: Dispose of in a regulated landfill site or other method for hazardous or toxic wastes. 包装处理：在有管理的垃圾填埋场处理，或其他危险或有毒废物处理方法 NB: The user's attention is drawn to the possible existence of regional or national regulations regarding disposal. 说明：用户应注意可能现有一些地区或国家规定。

14. TRANSPORT INFORMATION 运输信息 ADR / RID 公路/铁路（欧洲内陆危险品运输协议） UN no: Not Classified. 联合国编码:未归类

IMDG / IMO 国际海运危险品协议/国际海运组织 UN no: Not Classified. 联合国编码:未归类

IATA / ICAO 国际空运危险品协议/国际民航组织 UN no: Not Classified. 联合国编码:未归类

15. REGULATORY INFORMATION 法规信息 Hazard symbols: No significant hazard. 危险符号：无重大危险 Note: The regulatory information given above only indicates the principal regulations specifically applicable to the product described in the safety data sheet. The user's attention is drawn to the possible existence of additional provisions which complete these regulations. Refer to all applicable national, international and local regulations or provisions. 说明：以上法规信息仅指出特别适用于安全数据表所述产品的基本规范。用户应注意这些规范可能存在补充条例。 参照适用的国家、国际和当地规范或条例

16. OTHER INFORMATION 其他信息 Other information: EC Directive 1999/45/EC relating to the classification, packaging and labelling of dangerous preparations. 其他信息：EC Directive 1999/45/EC 有关危险配制品的分类、包装和标识。 EC Directive 91/155/EEC defining the laying down and detailed arrangements for the system of specific information relating to dangerous preparations EC Directive 91/155/EEC定义了有关危险配制品的具体信息系统的制定和详细设置。 Legal disclaimer: The above information is believed to be correct but does not purport to be all inclusive and shall be used only as a guide. This company shall not be held liable for any damage resulting from handling or from contact with the above product. 法律声明: 本公司认为以上信息是正确的，但并不声明其含盖一切方面，以上仅用于指导。本公司对由于处理或接触上述产品造 成的危害不承担责任。

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ADVANCED CHAIN TECHNOLOGIES

INSTALLATION PROCEDURE FOR HEAVY DUTY (HD) SCORPION TWIN – PULL CABLE HANDLER 1. The cable handling system will be delivered on pallets and consisting of Bodies and End Caps in 1.6Mtr. lengths plus Separators.

2. Starting at the Shearer, place the 1.6 meter lengths of Bodies above the spillplate (Cable Handler Troughs) or on a convenient surface on the coalface and assemble them together.

3. Ensure handler is of correct orientation,(Usually the cable is fitted in the face side of the handler) The white link is always anchored to the towing bracket on the machine.

4. When assembling the 1.6 m. Body sections together, use the body shoulder bolts supplied. (These bolts are retained in the last body link) Apply a full ring of Loctite 638 around the threads and tighten to a torque of 60 ft./lbs (80 Nm) 5. Once sufficient bodies have been assembled together, it is recommended that the electric cable is installed by laying the cable at the side of the assembled bodies.

The cable is then lubricated with a solution of soapy water or dish washing liquid and then with the loading tool set correctly (see notes on the setting up of loading tools) and the cable touching the cable handler body side. The loading tool is used to squeeze the cable in to the handler (see Fig. 2). Starting at the machine end and then working towards the turn over point.

Do not use oil or any other such lubricant to aid insertion.

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Loading Tool

6)

Fig 2

Once the cable is installed into the bodies, this is then followed up with the installation of the separator (fig. 3). Insert the bottom pegs of the separator into the holes provided in the body (fig 4) and then push the top of the separator until the top pegs click into the top half of the body. (Fig 5)

Fig. 3

Fig. 4 Bottom pegs into Body holes

Fig 5 2

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7)

Once the cable and the separators are in the handler the hose is inserted in similar fashion into the handler starting at the machine end and working to the turn over point. (Fig 6).

Fig 6

8)

Starting at the Machine end, a minimum of three lengths of 1.6 m of End Caps are bolted together, using the End Cap shoulder bolts supplied. (Again these bolts are retained in the Last End Cap Link) Apply a full ring of Loctite 638 around the threads and tighten to a torque of 60 ft./lbs.(81 Nm)

9)

Ensure the End Cap links are assembled in the correct direction, with the white link to the machine and the arrow head pointing to the machine. (Fig 7.)

Fig 7 3

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10)

Once the minimum three lengths have been assembled together, align

the nibs of the End Caps up with the recess in the bodies (Fig 8). Then using the Loading tool (set at the correct setting required) from the end nearest the machine squeeze the end caps onto the cable handler (Fig 9).

Fig 8

11)

Fig 9

After approximately 16 End Cap links have been squeezed into place, (one1.6mtr. length) add further lengths of end caps to the original three lengths that have been bolted together, then continue to squeeze on the next set of 16 end caps. (one 1.6m length) Continue this process until all the end caps are fitted to the cable side of the handler (Fig 10).

Fig 10 4

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12)

After any of the lengths of end caps have been fitted, the location of the end cap link needs to be checked to ensure that full engagement has been achieved. (Fig 11)

Fig 11 Full engagement of end cap.

13)

If any of the end caps have not totally engaged, a slight amount of

upward pressure should be applied to the end cap clip with a screw driver or equivalent (Fig. 12)

Fig. 12

13)

Fig 13

Continue this process until all the required lengths are installed (Fig 13) 5

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14)

Attach the shearer end to the Towing Arm and connect the other end to the Midpoint Anchorage.

15)

Ensure that when the shearer is at the Loader Gate end of the face, the Scorpion is lying flat with no loop at the mid point and that the cable is no under any tension.

16)

Station a person at the mid-point of the face to observe the Scorpion as the shearer travels into the other end of the Longwall Face. (Return End) Adjust the Scorpion length to ensure that there is no tension on the cable with the shearer at either end of the face.

17)

Regularly check the mid-point area and adjust the number of links as required. Wear will occur in the pivot points, as with any chain link system. An indication that the links may require removal is jack-knifing at the mid point and consequent, noisy and jerky operation.

N.B. Before removing any links, ensure that by removing links with the shearer at one end of the face this does not put the scorpion / cable in tension when the shearer is at the other end of the face.

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ADVANCED CHAIN TECHNOLOGIES

Cable and Hose Removal Procedure for Scorpion HD Twin Pull 1. Remove the appropriate bolts in both the end cap and the body at the section to be removed. (Fig1 & Fig 2)

Fig1 (remove bolt in end cap)

Fig 2 (remove bolt in the body)

2. Push the two loose components apart (Fig 3) until the female end is clear of the male end (Fig 4).

Fig 4

Fig 3

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3.

Insert the un clipping tool between the body and the end cap but ensure that this is over two links. (The angle created on the body and the end cap will determine the angle of the un clipping tool). Fig 5

4.

Once the un clipping tool is in position strike same with a hand hammer and lever forward on the tool this will release the end cap clip out of the body clip. (Fig 6)

5.

Continue along all the length that requires to be removed

Fig 5

Fig 6

6. Once the complete length that is required to be removed is un clipped on the top, take a movable spanner (Wrench) and place over the end caps (Fig 7), at an appropriate distance from the start of the section to be removed and lever downwards. (Fig 8)

Fig 7

Fig 8

7. NOTE:- Under no circumstances should excessive side force be exerted onto the lengths of end caps or permanent bending will take place and maybe replacement difficult if not impossible.

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8. Then take the hose/cable unloading tool and insert the three legs between the gaps in the links and also at the same time between the hose and the cable (Fig 9) then pull the centre of the tool backwards to release the hose out of the handler. (Fig 10).

Fig 9

Fig 10

9. Once the hose has been removed the separators need to be removed (Fig 11 & 12) before you can get access to remove the cable.

Fig 11

10.

Fig 12

Once the required separators have been removed the cable can then be removed if required.

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11.

To assemble the handler back together after access to either the hose or the cable follow the installation procedure until you get this handler back to the situation as Fig 13.

Fig 13 12.

The two halves of the handler have to be pulled back together until the retention bolts can be refitted. (Fig 14)

Fig 14

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