CAT Shearer EL3000 Longwall System Operation & Maintenance Manual BI001777 - PDF DOWNLOAD

ID-Nr. BI001777_00_00_EN_CMPL May. 2013

Operation and Maintenance Manual EL3000 Typ: Shearer Doc-No.: SHEL3000-127 BA 00

SAFETY.CAT.COM SAFETY.CAT.COM

© 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.

Operating Manual

Original operating manual

Shearer EL3000 Doc. no.: SHEL3000-127 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

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

Table of content

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

Persons for whom the operating manual is intended . . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . . .

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4 1.4

2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.3 2.3 2.4

2.5 2.5 2.5 2.5 2.5

2.7

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the components . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the machine underground . . . . . . . .

Driving the shearer onto the AFC . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.3 3.4 3.4 3.4

3.6 3.6 3.6 3.6 3.8

3.9 3.9

4. Installation What you need to observe prior to installation . . .

Who is allowed to perform the installation? . . . . . . . . . . . . .

Which tools are required for installation? . . . . . . . . . . . . . . .

Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.3 4.3

Overview - Shearer EL3000-127/128 . . . . . . . . . . . .

4.4

How to install the shearer . . . . . . . . . . . . . . . . . . . . .

4.5

Fit shoe post to mainframe . . . . . . . . . . . . . . . . . . . . . . . . . .

Fit lifting cylinder to shoe post . . . . . . . . . . . . . . . . . . . . . . . .

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4.6 4.7

Table of content How to install the downdrive . . . . . . . . . . . . . . . . . . . . . . . . .

Fit ranging arm to mainframe . . . . . . . . . . . . . . . . . . . . . . . .

Connect ranging arm to lifting cylinder . . . . . . . . . . . . . . . . .

Fit spall guards to mainframe . . . . . . . . . . . . . . . . . . . . . . . .

Fit cutting drum to ranging arm . . . . . . . . . . . . . . . . . . . . . . .

How to connect the shearer . . . . . . . . . . . . . . . . . . . .

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 4.13 4.18 4.20 4.21

4.24 4.24 4.24

Greases, oils and hydraulic fluids . . . . . . . . . . . . . .

4.24

How to commission the shearer . . . . . . . . . . . . . . . .

4.25

Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning the shearer . . . . . . . . . . . . . . . . . . . . . . . . . .

Retightening bolted connections . . . . . . . . . . . . . . . . . . . . .

Replacement of oils and hydraulic fluid . . . . . . . . . . . . . . . .

How to dismantle and remove the shearer . . . . . . .

4.27 4.27

5. Operation Who is allowed to operate the shearer? . . . . . . . . . . . . . . . .

When is coal cutting allowed to be started? . . . . . . . . . . . .

What you have to observe before starting the shearer . . .

How to operate the shearer . . . . . . . . . . . . . . . . . . . .

Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control elements of control box ECB3 . . . . . . . . . . . . . . . . .

USB remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Taking shearer into use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to observe during operation . . . . . . . . . . . . . . . . . . . . .

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

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

How to maintain the shearer . . . . . . . . . . . . . . . . . . .

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

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

Oil and fluid condition monitoring . . . . . . . . . . . . . . . . . . . . .

Oil condition limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flash Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil contamination analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of the ranging arms . . . . . . . . . . . . . . . . . . . . .

Maintenance of the cutting drums . . . . . . . . . . . . . . . . . . . . .

Maintenance of the haulage units . . . . . . . . . . . . . . . . . . . . .

Maintenance of the powerpack . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of the downdrives . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3 5.3

5.4 5.5 5.6 5.7 5.9 5.18 5.19 5.19 5.20

5.21 5.22 5.24 5.27 5.27 5.28 5.28 5.29 5.31 5.33 5.34 5.36 5.38

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Who is authorized to dismantle and remove the shearer? .

4.25 4.25 4.26 4.26

Table of content How to replace wear parts . . . . . . . . . . . . . . . . . . . . .

Picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Skid shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Insert in trapping shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other replacement procedures . . . . . . . . . . . . . . . . .

Haulage motor quill shaft replacement . . . . . . . . . . . . . . . . .

Cutter motor quill shaft replacement . . . . . . . . . . . . . . . . . .

When faults occur . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault diagnosis - mechanical . . . . . . . . . . . . . . . . . . . . . . . . .

Fault diagnosis - electrical . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.40 5.40 5.41 5.43 5.46

5.51 5.51 5.59

5.65 5.65 5.69

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6. Technical data General information . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Mechanical Components . . . . . . . . . . . . . . . . . . . . . .

6.6

Ranging arm RA 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Haulage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downdrives DC150-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power pack PP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Test facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical control box ECB 3 . . . . . . . . . . . . . . . . . . . . . . . . .

Haulage Transformer Box HTB3 . . . . . . . . . . . . . . . . . . . . . .

Haulage Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Haulage motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shearer Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quill Shaft Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Motor Bearing Grease . . . . . . . . . . . . . . . . . . . . . . .

All Other Grease Applications . . . . . . . . . . . . . . . . . . . . . . . .

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6.6 6.8 6.10

6.12 6.12 6.14

6.16 6.16 6.20 6.20 6.21 6.24 6.25 6.29 6.31 6.32 6.34

6.35 6.35

6.38 6.38 6.39 6.39 6.39 6.40 6.41 6.41 6.42

Table of content Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolts with metric coarse pitch . . . . . . . . . . . . . . . . . . . . . . . .

Bolts with metric fine pitch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolts for flameproof covers . . . . . . . . . . . . . . . . . . . . . . . . . .

6.43 6.44 6.45

6.47

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Recommended Lubricants . . . . . . . . . . . . . . . . . . . .

6.43

Shearer EL3000

1

About this manual

Before starting work

About this manual This chapter contains important information that will make it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols and characters used in it.

Before starting work applicable operating manual

shearer type

Take care to ensure that the operating manual available to you is applicable for the type of shearer used. Failure to do so can result in a safety hazard for yourself and others.

Make sure the details on the shearer correspond to those given in the operating manual.

This operating manual is for: Shearer EL3000 ID No.: SHEL3000-127 and

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ID No.: SHEL3000-128 It is only permitted to be used for shearers of this type. category according to Atex directive

According to the European Directive 94/9/EC the shearer belongs to Equipment Group I, Category M2.

The operating manual must be available at all times to all persons working on or with the shearer.

If possible, there should always be an operating manual for the shearer available at the place of operation.

new operating manual

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

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shearer.

All persons working on the face, at the edge of the face or at the gate must read this operating manual.

This includes persons who: are in charge of transport, perform assembly/disassembly work, operate the shearer, correct malfunctions, carry out daily routine work on the face, perform maintenance work, perform repair work.

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

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1.3

Before starting work Purpose of this operating manual efficiency

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

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our Service Department.

safety

Read the chapter entitled “Your safety” closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

Characters and symbols used

Memorize the symbols and their meanings.

Danger!

Points in the text marked with this symbol inform you of an imminent danger. Possible consequences are very serious injury or even death.

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

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.

Important!

Points in the text marked with this symbol contain useful tips and information intended to make work easier for you. They do not warn about harmful or hazardous situations.

Items in lists are marked with bullets.

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

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

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The following characters and symbols are used for safety instructions and important information in the operating manual.

2

Your safety

Personnel

Your safety This chapter provides important 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 perform the necessary work as safely as possible. state-of-the-art technology

The shearer was manufactured in accordance with the latest technology 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.

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 requirements plus legislation and regulations of practice in the country where the machine is being used.

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Do not make any modifications or carry out conversions which could impair the safety of the shearer. All modifications and conversions must be approved by the manufacturer.

Only use original spare parts from Caterpillar. Note that using parts from other manufacturers will void the guarantee.

The European directives/standards referred to in this operating manual must be applied when using the shearer within the member states of the European Union (EU).

If the device is used outside the EU, the directives and standards which apply in those countries must be observed.

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

Observe the safety and accident prevention regulations of the following parties: of the mine, of the mines inspectorate and of the mining supervisory authorities. additional operating manuals

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

Personnel Operation training

The shearer may be operated by qualified personnel only who can provide proof of having undergone appropriate training.

Reading the operating manual, especially the chapter on safety, must constitute a part of this training.

The personnel must have sufficient knowledge of the mechanical system, the hydraulic system,

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2.3

Personnel the electrical system and the control technology and be able to provide proof of this.

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

Installation and repair work on: the safety components (pressure relief valves, extinguishers, etc.), the electrical systems (control systems, signaling devices, etc.), and the hydraulic system

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may only be carried out by Caterpillar service engineers or by specially trained personnel of the mining company.

2.4

Shearer EL 3000

Operating conditions 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.

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

Unauthorized use includes: the transport of persons, the lifting and pulling of objects

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

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

These include: sufficient and continuous ventilation, water spraying systems.

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

It may only be restarted by an authorized person.

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

The machine is to be shut down immediately and secured against being switched back on again if damage to the firedamp protection systems is detected.

Prerequisites for operation It is prohibited to put the shearer into service until it has been confirmed that the overall system in which the shearer is installed complies with the requirements of the European Directive 94/9/EC and the standard DIN EN 1710.

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

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2.5

Operating conditions The shearer may only be operated when the safety requirements according to DIN EN 1552 and EN 12321 have been met. These include: equipment for preventing unauthorized starting startup warning systems water spraying systems in areas where there is a danger of explosion safe shutdown command systems emergency-stop systems dust extraction systems noise protection warnings, etc.

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The electrical equipment required to operate the shearer must be identified according to the legal provisions applicable at the time of its placement on the market.

2.6

Shearer EL 3000

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear personal protective equipment. This includes wearing ear protection since the noise emitted by the shearer may at times exceed 85 dB(A).

Inform your colleagues of: your exact location, the work you are carrying out and the amount of time you will probably require.

safety equipment

Keep the signaling and lighting systems in proper working order.

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

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

Observe the symbol plates on the shearer.

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, so that necessary action can be taken immediately.

Also press the EMERGENCY STOP switch when safety equipment such as firedamp protection systems break down.

lock-out

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

moving parts

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

automatic mode

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In automatic mode, the shield units are controlled by an automatic program. When traveling along the face you should always keep in mind that the shield units may move automatically. It is vital that you observe the warnings at the face entries as well as the visual and acoustic signals emitted by the control unit in the shield unit currently operated. When you work in a shield, ensure your own safety by pressing the shield locking switch!

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2.7

Safety instructions danger of explosion

Make sure you observe the maintenance and inspection intervals for the shearer as explosive atmospheres (air) and dust can be ignited by hot surfaces.

Observe the separate operating manuals for the components used.

Storage and transport Observe the specified storage periods and the storage instructions.

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

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

transport safety device

Ensure that the transport safety devices have been correctly installed.

Secure all moving parts so that they are stationary.

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

Only use means of attachment which are in a good condition and have been designed for the loads concerned.

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

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

mobile handling systems

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

Installation and start-up

inclined face

On an inclined face secure all individual parts using chains, e.g. on the supports.

Secure the installed E-motors during assembly against unauthorized or unintentional start-up.

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

environmental acceptability

Dispose of auxiliary equipment which has been soiled with oil, grease or other chemical substances in an environmentally sound manner.

Operation You may operate the control system only if you have detailed knowledge of the operating controls and their method of operation.

You need to have been instructed on the control system concerned.

Before switching on the shearer, make sure that there are no persons on the conveyor.

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

Clean the control devices at regular intervals. Ensure that the operating symbols are clearly recognizable in order to avoid any operator errors and accidents that may result.

2.8

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

means of attachment

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Never stay under unsecured components or suspended loads.

Safety instructions Ensure that protection defeats are for service/fault finding purposes only and not to be defeated in production mode. It is to be made clear that the responsibility/authority is at mine level to run with thermal protection and health monitoring defeated.

Maintenance and repairs Make sure to comply with the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its probable duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

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 area

the roof has been secured against falling rock/coal,

E Caterpillar Global Mining Europe GmbH, Lünen 2013

You may only carry out work in the mining area if the coal face has been secured against collapsing and the shearer and conveyor have been shut down and secured against restarting.

replacing components

Before replacing defective parts, shut down the conveyor and shearer and secure it against restarting.

Remove any defective components from the face immediately to avoid hindering the face crew. In addition, this measure prevents any unintentional reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

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

original parts

Only use spare parts which meet the technical requirements. This is only ensured with original Caterpillar spare parts. Please refer to the spare parts lists for the order numbers.

To lift parts, only use: the intended lifting points, lifting tackle of adequate load-carrying capacity.

Only use the points of attachment intended for that purpose.

Under no circumstances should brackets of cylinders be used as they are not designed to withstand tensile loads.

protective devices

Refit any removed protective devices immediately after completing the work, and check that they work properly.

Hydraulic system

handling hydraulic fluids

Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective devices - hydraulic system

When removing protective devices which include hydraulic components, bear in mind that these hydraulic components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective devices.

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2.9

Safety instructions Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids pose a very serious danger to health. maintenance, repair

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

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 mistaken for low pressure circuits and vice-versa.

pressure relief valves

Make sure that pressure relief valves are always fitted with protective caps. Replace any defective protective caps without delay.

Carry out a visual inspection of all hydraulic components at regular intervals. Check, in particular, that: the hoses are not pinched. the hoses have no swollen parts or blisters.

the outer sheath of the hose is not damaged. the connectors are firmly inserted in the sockets. the connections are leak-tight.

Make sure no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage to the entire system. Backflush the hydraulic lines thoroughly before installing them.

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

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Make sure to depressurize the line.

Secure the connectors of the hydraulic elements with the proper staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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the hoses or the outer sheaths of the hoses are not abnormallyrigid or hard.

Safety instructions Fig. 1:

Example: hydraulic hose, identification 2

3

1

4

1 manufacturer 2 calendar week

3 year 4 max. working pressure

Never attempt to hold a hydraulic hose that is thrashing about. Immediately depressurize the section in question.

Never attempt to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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Observe the following recommendations for use, storage and assembly of hydraulic hoses and assembled hoses: Storage of hoses Storage of assembled hose

A hose should not be stored for more than four years before assembly.

An assembled hose should not be stored for more than 2 years (after assembly).

Observe the following storage conditions to minimize wear of hydraulic hoses and assembled hoses: The storage temperature should be between +15°C and +25°C with a max. humidity of 65%.

Avoid storage temperatures of below 10°C! Store horizontally in a dry and low-dust environment.

Avoid direct sunlight or UV rays.

Protect from sources of heat.

Do not store near ozone emitting lighting equipment or electrical appliances that might generate sparks.

Avoid contact with acids, bases or solvents.

When stored radially, observe the manufacturer´s bend radius.

Period of use assembled hoses

The period of use of assembled hoses should not exceed a maximum of 2 years.

Tab. 1: Period of use Hydraulic hose Period of storage Age max. 4 years

Assembled hose Period of use Storage

Use

max. 2 years

max. 2 years

Important!

Due to the cold flow (crawling expansion) of the hose after assembly, assembled hoses should only be stored for a short time.

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2.11

Safety instructions Important!

The inspection intervals of assembled hoses have to be adjusted to the working conditions in the mine.

Prolongation of use

The operating company may appoint a prolongation of the recommended values observing the following: A written risk assessment has to be carried out, taking into account preventive measures in case of a failure of an hydraulic hose.

Periodic checks for safe working conditions of the hoses have to be carried out by a specially trained person.

Periodic checks intervals

The operating company must reduce the inspection intervals if the following applies: checks show an increasing wear of assembled hoses which indicates a reduced life of the hose.

laying hydraulic hoses

Lay the hydraulic hoses correctly behind the brackets and clips provided for them.

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

Laying hydraulic hoses, slack CORRECT

WRONG

are not twisted, Fig. 3:

Laying a hydraulic hose, twisted CORRECT

2.12

WRONG

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

If hydraulic hoses fail during use or damages are being observed during periodic checks, investigate thoroughly the causes of the failures or damages and reduce the intervals of the periodic checks.

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Notice!

When prolonging the replacement intervals of hydraulic hoses, make sure no risks or dangerous situations are raised that might harm employees or other persons.

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

Laying hydraulic hoses, bending CORRECT

WRONG

cannot chafe, Fig. 5:

Laying hydraulic hoses, crossing WRONG

Caterpillar Global Mining Europe GmbH, Lünen 2013

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CORRECT

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

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

When installing the hydraulic hoses, make sure they cannot be: torn out, kinked, crushed, driven over or twisted as a result of moving equipment. (Fig. 6).

Fig. 6:

Laying hydraulic hoses, connections on moving parts CORRECT

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WRONG

2.13

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Safety instructions

2.14

Shearer EL 3000

3

Storage and transport

Storage

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

The service life of the shearer will be increased if you observe the instructions and notes. You will be able to carry out transport work more safely and quickly.

Paying careful attention to the points in this chapter will also 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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3.3

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.

Shearer EL 3000

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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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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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3.5

Transport Transport Load units; dimensions and weights It is imperative that you observe the transport sheets. They include information on: dimensions, weight, lifting points and centers of gravity, etc.

The load units are provided with suitable lifting points for transport and installation as far as technically feasible.

Before transport freezing temperature

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

During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

At very low temperatures and on roads in bad condition, the transport vehicle's speed must therefore be limited to a maximum of 25 km/h for truck transport.

electrical and electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the entire equipment are protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully against transport damage and the connectors must be protected against dirt.

Transporting the components machine parts

Mainframe, ranging arms and other machine parts are equipped with lifting eyes or load rings. In some cases you will have to screw the lifting eyes into the holes provided before transport and remove them again immediately after transport. The lifting points and the corresponding load capacities are specified further on in the document for the respective machine parts.

Warning!

Only use load handling devices that comply with the technical and legal regulations to transport loads.

Observe the permissible load capacities of the lifting points and keep a safe distance from suspended loads.

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Important!

The transport units might have to be altered due to conditions in the mine. This may result in different sizes and weight distributions of parts. Make sure to consider this when planning the transport of parts. Further information concerning the size and the weight of the main parts can be obtained in chapter 4, “Installation”.

Transport Fig. 7:

Lifting eye and load ring example

Lifting eye

eye

load capacity (5000 kg)

Load ring

welded onto component

load capacity (5000 kg)

screwed onto component

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Danger!

To transport loads, always use all lifting points provided. Components may come loose due to incorrectly or insufficiently attached loads. Falling components can cause serious injury or even death.

Fig. 8:

Correct transport of machine parts

CORRECT

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WRONG

3.7

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. Important!

Also observe the separate operating manuals for machine parts not specified here, such as motors, gearboxes etc.

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.

Dismantling of parts In many occasions it will be necessary to dismantle parts of the machine for underground transportation.

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. 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 table contained in this Chapter for unit dimensions and weights.

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.

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Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

IN SOME CASES, THE MACHINE IS TRANSPORTED WITH ALL UNITS DRAINED OF HYDRAULIC FLUID AND GEAR OIL. 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.

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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.

Transporting the machine underground It is suggested that the units are dismantled in the following order: Cutting Drums Ranging Arms Haulage Downdrives (if necessary) Mainframe (if necessary) 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 Important!

Observe the installation procedures in chapter 4. They will give you detailed information on how to install and dismantle machine parts.

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Transporting the machine underground Caterpillar Global Mining Europe GmbH, Lünen 2013

Transporting the machine underground is highly dependant on the conditions in the mine. In many cases the shearer can be transported with purpose made vehicles that can transport the whole mainframe to the AFC. Carefully plan the transport of the shearer observing the conditions in your mine and the sizes and weights of the transport units.

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. after underground transport

After underground transport first unpack all electronic and electric equipment to allow ventilation around the components before installing and applying power. Otherwise condensed water might damage the electric equipment and cause machine failure.

Driving the shearer onto the AFC Driving the mainframe onto the shearer depends on the conditions in the mine. In most cases the transport units are brought in from the tailgate end and are then assembled on the face conveyor.

Important!

Consider the assembly steps of the shearer before bringing the transport units to the face. Place the machine parts on the face conveyor in a manner that guarantees an easy way of installation (eg. left hand parts on the left hand side).

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

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3.9

Transporting the machine underground Fig. 9:

Driving the mainframe onto the conveyor

4

3

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1

2

5

6

1 face 2 tail gate 3 conveyor

4 mainframe 5 trapping shoe 6 rack bar

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

Important!

Observe the separate manual of the hydraulic motor!

3.10

Shearer EL 3000

Transporting the machine underground To fit the hydraulic motor to the haulage unit, proceed as follows:

. Remove the cover of the bell housing which is located on the first motion shaft of the haulage gear box.

. Remove the circlip.

Fig. 10:

Remove circlip

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1 1 bell housing

2 circlip

Important!

Oil can drop out of the bell housing when you pull out the plug.

Make sure to use a suitable container to collect the oil.

. Use a T key (4) to pull the plug (3) from the first motion shaft.

The plug has an internal thread of 12 mm.

Fig. 11:

Remove plug

3

4

3 plug

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4 T key

3.11

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

Fig. 12:

Fit adapter

5

6

. Grease the o-ring (7) and place it around the base of the motion shaft of the motor (5).

Fig. 13:

Install o-ring

7

5

5 hydraulic motor

3.12

7 o-ring

Shearer EL 3000

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6 adapter

Caterpillar Global Mining Europe GmbH, Lünen 2013

5 hydraulic motor

Transporting the machine underground . Insert the motion shaft of the hydraulic motor (5) into the bell housing (1) on the haulage unit.

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

Fig. 14:

Install hydraulic motor

Caterpillar Global Mining Europe GmbH, Lünen 2013

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1

5

1 bell housing

5 hydraulic motor

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

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Transporting the machine underground

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Shearer EL 3000

4

Installation

What you need to observe prior to installation

Installation What you need to observe prior to installation Who is allowed to perform the installation?

Installation work may only be carried out by persons who have been adequately trained for these specific requirements.

Work on: safety components (pressure relief valves, extinguishers etc.), the electrical system (controls, signaling devices, etc.), the hydraulic system (cylinders, directional control valves, hoses etc.) may only be carried out by service engineers from Caterpillar or by specially trained personnel.

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Which tools are required for installation? tool box

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

We recommend that you use the tool box and special tools supplied.

Furthermore, various items of auxiliary equipment and machines are required at the installation points. These include: lifting equipment with sufficient load capacity means of attachment with sufficient load capacity impact wrenches incl. accessories

Notes on installation Caution!

Serious damage can be caused to the shearer as a result of incorrect installation.

The shearer should therefore only be installed under the instructions of specialists from Caterpillar.

Caution!

Please take care to observe the corresponding separate operating manuals (e.g. for motors, superbolts, etc.). installation plan

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

tightening torques

For tightening torques not listed in the installation instructions for the components, please refer to the list in chapter 6. Please also observe the tightening torques specified in the spare parts lists provided.

instructions for handling - connection points

Doc. no.: SHEL3000-127 BA 00

Pins, holes, screws and securing elements must be lubricated with grease.

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4.3

Overview - Shearer EL3000-127/128 Overview - Shearer EL3000-127/128 Fig. 15:

Shearer overview

82

80

21

61

40

120

84

30

1

92

22

90

5

2

61

10

Amount

1

Part

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

1

Mainframe MF3-1

9840

1769

1152

21621

2

2

Shoe post B-NH

1343

550

1128

1544

5

2

Skid shoe SKS-SN

900

165

290

154

10

2

Ranging arm RA 750

3393

900

1960

6516

21

1

Haulage unit HU150 with encoder

1217

1091

510

2100

22

1

Haulage unit HU150 with CSIRO encoder

1217

1091

510

2095

30

2

Downdrive DC 150-B-NH-JT2

1500

615

1023

3349

40

1

Power pack PP3

1590

1519

550

2511

61

2

Lifting cylinder

2142

400

450

1173

80

1

Cutter motor 750 kW, type EL68B-006

see separate manual

2300

81

1

Cutter motor 750 kW, type EL68B-007

see separate manual

2300

82

2

Haulage motor 150 kW , type EL55F

see separate manual

600

84

1

Pump motor 75 kW, type EL63B

90

1

Electrical control box ECB3

2461

1509

595

2429

92

1

Haulage transformer box HTB3

2061

1233

595

6349

120

1

Spall guards

10682

1700

254

4149

4.4

see separate manual

575

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Tab. 2: Main components

How to install the shearer How to install the shearer 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.

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

. Fit the face side shoe posts (incl. skid shoes) to the mainframe (if necessary)

. Fit the lifting cylinders to the shoe post (if necessary). . Fit the downdrives to the mainframe (if necessary). . Install the ranging arms to the mainframe. . Connect cables and hoses between mainframe and ranging arms.

. Connect ranging arms to lifting cylinders. To do so power up the power pack of the machine and do preliminary checks or use a separate power pack to expand the cylinders to the required length.

. Ensure all covers and guards are in position and secured. . Install spall guards onto the mainframe (if they have been removed before).

. Fill machine with oil, hydraulic fluid and grease it. . Position the ranging arms to fit the cutting drums. To do so power up the machine and do preliminary checks or use separate power pack

. Fit the cutting drums to the ranging arms. . Fit picks and sprays to the cutting drums.

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4.5

How to install the shearer . Comission the shearer. To do so refer to the documents on mechanical, electrical and electronic comissioning.

You will find detailed descriptions of the steps listed in the following chapters.

Fit shoe post to mainframe The shoe posts are installed to the shearer using three expansion bolts. The two outer expansion bolts are endowed with a tapered sleeve. Tightening the jackbolts the tapered sleeve expands, locks the bore and tensions radially.

Important!

You will find important notes on how to tighten the expansion bolts in the separate manual of P+S. Read those instructions carefully before you start the installation work. Make sure to observe the installation and safety advices.

Fit shoe post to mainframe

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Fig. 16:

a

c b a expansion bolt b shoe post

4.6

c mainframe

Shearer EL 3000

How to install the shearer Fit lifting cylinder to shoe post The lifting cylinders are fitted to the shoe post using ram anchor pins. The ram anchor pins are secured by a hex. head bolt and a retaining plate.

Important!

Do not grease the anchor pins before you install them! Degrease anchor pins in case they have been greased before. holding the cylinder in place

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

. Lift the cylinder (1) into position under the mainframe (a). . Carefully align the bores of the shoe post and the lifting cylinder.

Installation of lifting cylinder to shoe post

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Fig. 17:

a

b

1

2 1 lifting cylinder ZE-325/180-640 2 valve block

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a mainframe b lifting eye links

4.7

How to install the shearer . Insert the ram anchor pin (1) through the bores (do not grease the ram anchor pin). You might have to use a hydraulic hollow cylinder or a soft mallet to push the anchor pin into position.

. Attach the nord-lock washer (3) to the hex. head bolt (4). Push the bolt through the anchor pin (1) and screw the bolt into the retaining plate (2).

. Torque the hex. head bolt to 1300 Nm. . Secure the lifting cylinder to the mainframe to protect it from falling down.

The cylinder is now installed to the shoe post und can be connected to the hoses of the hydraulic power pack.

Fig. 18:

Secure lifting cylinder on shoe post

Caterpillar Global Mining Europe GmbH, Lünen 2013

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a

1

3

4

2

1 ram anchor pin 2 retaining plate

4.8

3 nord-lock washer 4 hex. head bolt M 30x380-8.8

Shearer EL 3000

How to install the shearer How to install the downdrive fastening elements

The downdrives are fitted to the mainframe using 8 studbolts.

(Pos.4+5). The two upper studbolts are secured by tapped plates (7) in the mainframe and supernuts (3) on the ouside of the downdrive. Two tapped plates with 3 holes (6) on the inside of the mainframe secure 3 of the lower studbolts (5) each. Supernuts (3) are used to to secure the lower studbolts on the downdrive side.

Fig. 19:

Overview downdrive, example 7 3

4

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5

6

a

3 supernut 4 studbolt 5 studbolt, long provisional installation

6 tapped plate 3 holes 7 tapped plate 1 hole a downdrive

The initial fitment of the downdrive is done in a provisional manner to position the downdrive for the installation of the supernuts.

Important!

The fastening elements can be damaged during the initial installation due to misalignment or faulty gripping. The initial installation should therefore be carried out using spare studbolts, washers and standard nuts.

For a provisional installation, proceed as follows:

. Clean and grease mating faces of the downdrive and mainframe locations using a general purpose anti seize type grease (eg. Copaslip or similar ).

Caution!

Danger of Squeezing! Hydraulic hoses near the site of installation can be damaged during an inobservant installation.

Make sure not to damage any of the surrounding machine parts when fitting the downdrive to the mainframe.

. Use appropriate lifting devices to position downdrive at mainframe and align the bores of the downdrive and the mainframe.

. Position the two tapped plates (7) for the 2 top studbolts of the downdrive into the location pockets on the top face of the mainframe.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

4.9

How to install the shearer Fig. 20:

Position downdrive, example 7

a

. Insert 2 studbolts of appropriate length through the 2 top bores and screw them into the tapped plates (7) in the mainframe.

. Insert 2 studbolts of appropriate length through the 2 bottom outer bores and screw them into the tapped plates (6) at the inner side of the mainframe.

Fig. 21:

Inserting provisional studbolts, example 4

7

5

6

4 studbolt 5 studbolt, long

6 tapped plate 3 hole 7 tapped plate 1 hole

. Using suitable washer plates and standard nuts for the 4 -off retaining studs start to pull the downdrive unit into the mainframe location by tightening in a sequential manner (opposite to opposite).

4.10

Shearer EL 3000

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a downdrive

Caterpillar Global Mining Europe GmbH, Lünen 2013

7 tapped plate 1 hole

How to install the shearer Fig. 22:

Secure with standard washers and nuts, example

a

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a Standard washer and nut Final installation

When the downdrive is fully mated to the mainframe you can exchange the provisional fastening elements. To do so, proceed as follows:

. Remove washer plate, standard nut and studbolt on one top location hole and fit the appropriate studbolt and super nut.

. Tighten the super nut in accordance with the separate manual of P+S. Fig. 23:

Tighten first super nut

3

3 super nut M 42

. Remove washer plate, standard nut and studbolt on one of the lower location holes diagonally opposite to the top hole that has a supernut now fitted and fit the appropriate studbolt and supernut.

. Tighten the supernut in accordance with the P+S manual.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

4.11

How to install the shearer . Repeat the exchange of the fastening elements and the tightening of the supernut for the remaining fixing points (diagonally).

Fig. 24:

Fit remaining supernuts, example 4

5

5

5 studbolt, long

. Insert the remaining 4 studbolts (5) into the lower bores, fit the supernuts to the studbolts and tighten the supernuts in accordance with the P+S manual.

Fig. 25:

Fitment of remaining studbolts and supernuts, example

5

3 3 supernut M 42

5 studbolt, long

. When all supernuts have been fitted and tightened in accordance with the supernut manual a final check should be carried out to ensure even bolt loading. To do so use a torque wrench and tighten all jackbolts to the recommended value.

. Provide all supernuts with protective caps.

4.12

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

3 supernut M 42 4 studbolt

E

3

How to install the shearer Fit ranging arm to mainframe Each ranging arm is being fitted to the mainframe using 2 hinge pins and 4 clamping sets that are inserted into the bores of the hinge brackets of the mainframe and the ranging arm.

Important!

Carefully read the separate mounting instructions of the clamping sets before you start the installation and make sure you are familiar with the mounting steps.

Fig. 26:

Hinge pin with clamping set and thrust washer 2

1

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3

1 hinge pin 2 thrust washer

3 clamping set KTR 401

To fit the ranging arm to the mainframe, proceed as follows:

. Use appropriate lifting equipment or a special vehicle to position the ranging arm at the mainframe.

. Make sure the ranging arm is level.

Fig. 27:

Position and align ranging arm

1

10 a

1 mainframe 10 ranging arm

Doc. no.: SHEL3000-127 BA 00

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a lifting eye (max. load capacity = 8000 kg)

4.13

How to install the shearer . Insert the thrust washers (2) into the bores of the hinge bracket. Grease thrust washers to prevent them from falling out.

Fig. 28:

Insert thrust washers a

2 b

2 thrust washer a mainframe

b ranging arm

. Enter the ranging arm into the hinge points of the mainframe and align the bores of the hinge brackets of the ranging arm with the bores of the mainframe.

. Slide the two hinge pins (1) loosely into the bores.

Fig. 29:

Insert hinge pins 1

a b

1

1 hinge pins a mainframe

4.14

b ranging arm

Shearer EL 3000

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2

How to install the shearer . Fit the two covers of the hinge brackets.

Fig. 30:

Fit covers a 1

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b

1

1 cover a mainframe

b ranging arm

. Insert three hex. head screws and washers into the covers and screw the hex. head screws into the three inner bores of the hinge pins.

Fig. 31:

Position hinge pins with hex. head screws 2, 3

5 1 cover 2 Nord-Lock washer DNL 20 3 hex. head screw M 20x50-8.8

Doc. no.: SHEL3000-127 BA 00

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1

4 4 Nord-Lock washer DNL 16 5 hex. head screw M 16x45-8.8

4.15

How to install the shearer . Fit the inner clamping sets (3) between hinge pin and hinge bracket. Adjust the position of the hinge pin and tighten the cap screws loosely to secure the hinge pin in its position.

Fig. 32:

Fit inner clamping sets

3 clamping set KTR 401

. Remove the hinge pin covers.

Fig. 33:

Remove hinge pin covers 1 b

a

1 1 cover a mainframe

4.16

b ranging arm

Shearer EL 3000

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3

How to install the shearer . Fit the outer clamping sets (3) between hinge pin (1) and hinge bracket.

Fig. 34:

Fit outer clamping sets

3

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1

3

1 hinge pin

3 clamping set KTR 401

. Further installation (eg. tightening of the cap screws) has to be done in accordance with the mounting instructions of the clamping sets. Make sure to observe the required torque value.

. Refit the two covers of the hinge brackets.

Fig. 35:

Refit covers

1 b

a 1 1 cover a mainframe

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

b ranging arm

4.17

How to install the shearer . Support the ranging arm by suitable packaging material, so that it cannot move during the following installation steps.

. Connect all necessary cables and hoses (eg. electrics, sensor systems, cooling water, spraying, hydraulics ) to the ranging arm. Further information can be obtained in the respective diagrams.

Connect ranging arm to lifting cylinder The lifting cylinders are fitted to the ranging arm using clevis pins.

The clevis pins are secured by a hex. head bolt and a retaining plate.

Important!

Do not grease the anchor pins before you install them! Degrease clevis pins in case they have been greased before.

. Extend the lifting cylinder until the bores of the cylinder and the lifting bracket align. To do so start the power pack of the shearer or use a separate power pack to extend the cylinder to the required length.

. Insert the clevis pins (1) into the bores (do not grease clevis pin). You might have to use a hydraulic hollow cylinder or a soft mallet to push the clevis anchor pin into position.

Fig. 36:

Insert clevis pin

b

1 a 1 clevis pin a lifting cylinder

b lifting eye link

. Insert the hex. head screw (4) and nord-lock washer (3) into clevis pin and the retaining plate (2).

. Tighten the hex. head screw (4) to 1300 Nm.

4.18

Shearer EL 3000

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There are lifting eye links (b) on the underside of the mainframe which can be used to hold the cylinders in place during the installation. To install the cylinders, proceed as follows: Caterpillar Global Mining Europe GmbH, Lünen 2013

holding the cylinder in place

How to install the shearer Fig. 37:

Secure clevis pin

2

3

4

3 nord-lock washer 4 hex. head screw

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1 clevis pin 2 retaining plate

1

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4.19

How to install the shearer Fit spall guards to mainframe The spall guards consist of 8 steel segments (Pos. 3 - 10) that are being fitted to the mainframe. Rubber mats (25) on either side of the spall guards protect the ranging arms and spall guards. The spall guards are fastened to hinge brackets (1) that are attached to the mainframe. Cylinders (a) lift and lower the spall guards and are connected to the mainframe by a clevis pin.

Fig. 38: 10

Spall guard assembly 8

7

6 4

3

9

25

1 40

a 40

39

39 35 36 33 31 2 32 1 hinge bracket spall guards 2 hinge bracket cylinder 3 spall guard 1 4 spall guard 2 5 spall guard 3 6 spall guard 4 7 spall guard 5 8 spall guard 6 9 spall guard plate rh

4.20

10 spall guard plate lh 25 rubber mat 31 clevis pin 33 lynch pin 35 hex. head screw M20x75-8.8 36 hex. head screw M20x50-8.8 39 nord-lock washer 40 hex. nut M 20-8 a cylinder

Shearer EL 3000

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5

How to install the shearer Fit cutting drum to ranging arm To fit the cutting drum to the ranging arm, proceed as follows:

. Prepare a working area of suitable dimension safely secured for fitting the drums.

. Place the cutting drum in the working area and drive the shearer into position.

Prepare working area

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Fig. 39:

1

3

2

4

1 coal face 2 working area

3 cutting drum 4 shearer

. Align the ranging arm horizontally. . Isolate power from the shearer and secure it to prevent unauthorized and unintentional restarting.

. Use appropriate lifting equipment to lift the cutting drum. . Manoeuver the cutting drum onto the square hub of the ranging arm using appropriate tools.

. Once entered insert appropriate bolts (4) through the bores of the cutting drum and the square hub.

. Tighten the bolts to pull the drum fully into position onto the square hub.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

4.21

How to install the shearer Fig. 40:

Fitting the cutting drum

1

2 3

1 ranging arm 2 cutting drum

3 square hub 4 bolt

. Fit all the correct drum retaining bolts and tighten (star pattern) to the correct torque value (see torque table, chapter 6).

. Fit water distribution plate ensuring seals are fitted with grease before fitting the plate. Torque the bolts up to the appropriate figure.

Fig. 41:

Fitting water distribution plate 3 2

5 2 cutting drum 3 square hub

4 4 cylinder screw 5 water distribution plate

. Ensure the drum can rotate freely. . Remove all spray blanks and flush the drum with water.

4.22

Shearer EL 3000

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4

How to install the shearer . Fit the sprays and secure the sprays with the staples. Test all sprays are operational.

Fig. 42:

Fitting sprays

1 2

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3

1 ranging arm 2 cutting drum

3 spray 4 pick retainer

4

. Fit the picks. Make sure not to strike the Tungsten tip. . Fit cover plate if supplied.

Fig. 43:

Fitting picks

2

3

4

1 ranging arm 2 cutting drum

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3 pick 4 pick retainer

4.23

How to connect the shearer How to connect the shearer Electrical connection The shearer has to be connected to an appropriate towing cable.

For further information refer to chapter 6, “Electrical System” and the electrical diagrams.

Connection to towing cable

1

2

1 towing cable

2 electrical control box

Water connection The shearer has to be connected to an appropriate water supply.

The functions of the shearer water system are: To provide cooling for the shearer units.

To provide dust suppression.

The inlet for the water hose is clearly labelled. For further information concerning the water system refer to “Water system” (chapter 6).

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

For further information please refer to “maintenance” (chapter 5) and “lubrication” (chapter 6).

4.24

Shearer EL 3000

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Fig. 44:

How to commission the shearer How to commission the shearer The shearer must be commissioned under the instructions of Caterpillar technicians or qualified mine personnel.

Warning!

Make sure that nobody is present in the hazardous area of the shearer and the conveyor system when you start operating the shearer.

The first time you put the shearer into service, hazards may occur which would not occur during normal operation, e.g. due to installation errors.

Keep a safe distance from the shearer and the conveyor!

Notice!

Furthermore, observe the instructions in the separate operating manuals for the shearer components, such as E-motors, etc.

Before commissioning The following work has to be performed before starting up the shearer: Caterpillar Global Mining Europe GmbH, Lünen 2013

E

. Align the conveyor. . Remove all tools, auxiliary equipment, etc. from the shearer, the conveyor and your working area.

. Check that all bolted connections are tightened to the correct torque.

. Check the hydraulic connections and lines for leaks and damage.

. Check that all supply lines are installed properly. . Check the hydraulic connectors. In particular, check that the staples are completely pushed in.

Danger!

You could be seriously injured or even killed by a hydraulic hose that is thrashing about!

Secure the connectors of the hydraulic elements with the proper staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials.

. Check the oil level and the cooling of the gearboxes. . Check that the hydraulic reservoir is filled to the correct level. . Check the cooling of the E-motors. . Check the direction of rotation of the E-motors. . Check the electrical connections.

Commissioning the shearer commissioning sheet

Doc. no.: SHEL3000-127 BA 00

The shearer is commissioned under the instruction of Caterpillar technicians. During commissioning all functions of the machine are tested, the machine settings are adjusted and the machine control is set up. All commissioning steps, settings and, as may be the case, problems will be documented in a commissioning sheet for the shearer.

VSSP / 02

4.25

How to commission the shearer after commissioning

After commissioning, observe the following points before releasing the shearer:

. Inspect the shearer once again thoroughly for installation errors, damage or other faults.

. Check the functions of the shearer and the safety systems once again. releasing the shearer for operation

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

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

This is why you have to retighten the following bolted connections of the shearer after an initial operating time of approximately 60 hours. In doing so, observe the respective torque required or the required tensioning force.

Connections of the E-Motors Superbolt connections of the downdrives selecting the tightening torque

Refer to the appropriate spare parts drawing for the tightening torque of the respective bolted connection. If the spare parts drawing does not contain any other information, the tightening torques in chapter 6, “Technical data” apply.

Replacement of oils and hydraulic fluid All oils are recommeneded to be replaced after the first two weeks of production. After the first replacement oil and hydraulic fluid is montitored by taking samples and contamination analysis (see chapter 5, “Oil and fluid condition monitoring”).

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Shearer EL 3000

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Bolted connections of the cutting drums

How to dismantle and remove the shearer How to dismantle and remove the shearer drawing up a removal plan

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

Who is authorized to dismantle and remove the shearer?

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

Important instructions for dismantling handling sensitive components

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

. Seal all open lines and separation points with protective caps Caterpillar Global Mining Europe GmbH, Lünen 2013

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or plugs.

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

Doc. no.: SHEL3000-127 BA 00

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4.27

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How to dismantle and remove the shearer

4.28

Shearer EL 3000

5

Operation

Operation This chapter contains important information on the operation and maintenance of the shearer. It also includes instructions on the replacement of wear parts, etc.

Please read this chapter carefully and thoroughly. Make sure you observe the safety instructions in chapter 2, “Your safety”.

Who is allowed to operate the shearer?

The shearer may only be operated by persons with sufficient knowledge of the shearer and the entire conveyor system.

This includes knowledge of: what safety equipment is installed on the system, where this safety equipment is located, how this safety equipment is to be operated.

When is coal cutting allowed to be started?

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Coal cutting may not be started until the perfect condition and proper function of the shearer and the entire conveyor system has been checked and the daily maintenance operations have been performed.

Danger!

When you start up the shearer ensure that nobody is present in the shearer's hazardous area.

What you have to observe before starting the shearer Carefully observe the procedures for daily maintenance stated in the maintenance tables when you start the shift. This will ensure a better reliability and performance of the shearer:

. Clean the shearer from any debris that might obstruct the operation of the shearer.

. Check the shearer for any visible defects, eg. cracks, leakages, broken or missing parts or wear. That includes: – wear of the picks on the cutting drums – wear of the skid shoes (face side) – wear of the insert in the trapping shoes (goaf side) – hoses and cables For further information concerning the wear measurement please refer to “How to replace wear parts” in this chapter.

. Check oil and hydaulic fluid levels. Fill up if necessary. Grease the grease nipples as stated in the maintenance tables. Further information can be obtained in the section “Maintenance”.

. Check if the cutting drums can rotate freely. . Check all flameproof covers, cable inlets, safety equipment, controls and inspection covers for damage.

. Check that the water supply is correct to all parts of the shearer.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.3

How to operate the shearer . Check that electrical power is available. . Check if the emergency stop is working correctly. . Check if further maintenance is necessary in accordance with the maintenance tables (eg. weekly, monthly, quarterly).

How to operate the shearer

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Danger!

Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of severe accidents.

Operate the shearer only if you have been sufficiently trained on the existing control systems and have read and understood all the operating instructions for the shearer.

Should anything be unclear, please contact your supervisor.

5.4

Shearer EL 3000

How to operate the shearer Control elements The main control and monitoring elements are situated on the goaf side of the shearer. The following image will give you an overview of the control and monitoring elements.

Fig. 45:

Control elements 8

7

12

13

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14

11

1

6

5

9

10

2

4

1 main display 2 remote I.S. keypad 3 radio transmitter rh 4 radio transmitter lh 5 transceiver lh

Doc. no.: SHEL3000-127 BA 00

3

6 transceiver rh 7 end display rh 8 end display lh 9 main high voltage switch 10 main high voltage switch cutting elements

VSSP / 02

11 pushbuttons (motor and machine start) 12 reset pushbuttons 13 lh inverter drive circuit breaker 14 rh inverter drive circuit breaker

5.5

How to operate the shearer MMC The machine has a mobile machine control (MMC) that processes the operator´s control commands and gives detailed information of the status of various machine components.

Important!

Further information concerning the MMC control system can be obtained in the separate MMC manual.

A display in the electrical control box ECB3 serves to show the information of the machine control and can be used to change settings.

Control elements of control box ECB3 Control box ECB3: Control elements low voltage compartment 15

16 1

2

3

4

5

6

7

8

9

10

11

12

13

14

17

5.6

Nr.

Control elements low voltage compartment ECB3

1

Headlight Toggle

2

Machine start

3

Sequence start

4

Sequence stop

5

Left cutter motor start

6

Left cutter motor stop

7

Right cutter motor start

8

Right cutter motor stop

Shearer EL 3000

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18

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 46:

How to operate the shearer Nr.

Control elements low voltage compartment ECB3

9

Pump motor and haulage motor start

10

Pump motor and haulage motor stop

11

Coalsizer start (if fitted)

12

Coalsizer stop (if fitted)

13

Earth leakage: Circuits test

14

Earth leakage: Reset

15

Emergency stop

16

Control pilot test points (under cover)

17

Low voltage circuit breaker resets

18

MMC display

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

Intrinsically safe USB remote control

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Fig. 47:

The remote control is intrisically safe and thus suitable for use in potentially explosive areas. It has 21 keys with 28 functions.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.7

How to operate the shearer Keyboard protective cover for the USB remote control

1 keypad supply on LED indication 2 button operation LED indication 3 quick access menu 4 currently not assigned 5 alternative page number navigation page 6 return to previous page 7 tabulator 8 delete 9 digit 1 / beginning of line 10 digit 2 / up

11 digit 3 / end of line 12 digit 4 / to the left 13 digit 6 / to the right 14 digit 8 / down 15 decimal / page up 16 minus / page down 17 mode change input of digits / navigation 18 error list 19 enter (entry / selection confirmation)

Two LEDs in the header indicate ready for operation (1) and button operation (2).

Keys with single assignments: With function key F1 (3), you get quick access to reset functions and the machine mode. Function key F2 is currently not assigned.

Function key F3 (5) will lead you to a quick display where you can enter a page number.

The “home” key (6), will backstep one page at a time. The tabulator key (7) allows you to jump from input field to input field in a defined order. With the “delete” key (8), you can delete entries to the left of the cursor position.

You can switch back and forth between the two keyboard layouts with the “change” key (17). The green LED on the key lights up when navigation mode is active and goes out when digit mode is active.

5.8

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Fig. 48:

How to operate the shearer The key with the warning symbol calls up a list with errors.

Keys with double assignments: If, after pressing the “change” key (17), the LED on the key is illuminated, the remote control is in navigation mode. The keys then have the following functions: With the POS 1 (9) and END (11) keys, you jump to the beginning and end of the current line.

The “up” (10) and “down” (14) keys are for scrolling the lines.

The “to the left” (12) and “to the right” (13) keys are for scrolling the columns.

With the “decimal” / “page up" (15) and “minus” / “page down” (16) keys, you can enter a decimal and “-” in input mode. In navigation mode, they scroll up and down in long lists. In this case, there is an arrow below or above the list range to indicate there are additional lines in the list.

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Transmitter With the certified, intrinsically safe wireless radio frequency remote control, you can directly control individual devices of the machine.

The remote control is supplied with energy by a rechargeable battery. This is charged in a special charging station.

Important!

Further information concerning the charging station can be obtained in the separate MMC control system manual.

Fig. 49:

Transmitter

Important!

Site safe working controls need to be applied for functional testing and verification at the machine when a new transceiver is introduced for operation.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.9

How to operate the shearer General operating elements The following figure shows the top part of the device with general operating elements and display.

Important!

Apply recommended 12 monthly manufacturer servicing and inspection of handset to reduce potential for membrane failure.

It is recommended that membrane switch pads be replaced annually.

Wireless remote control: general operating elements and display

1 display 2 symbol on the display a registered keystroke/synchronising

3 ESCAPE key 4 ENTER / Return key 5 “page up“ key

b wireless connection active

6 “page down“ key

c charging status

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

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

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

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

The ESC and ENT keys (ESC = cancel/back, ENT = enter/confirmation) are equivalent to those on a computer keyboard.

They are not activated on every machine, however.

You can scroll page-by-page on the display with the “page up” (5) and “page down” (6) keys.

5.10

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Fig. 50:

How to operate the shearer Turning on/off transmitter You can turn on the transmitter by pressing the “SHIFT/ON” button and keeping it pressed for more than 5 seconds.

There are two possible ways to turn off the transmitter: Press the “STOP” button and keep it pressed Press the “SHIFT/ON” button and the “HAUL/HALT” button and keep them pressed Turning on/off the transmitter

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Fig. 51:

or

Turning on

Doc. no.: SHEL3000-127 BA 00

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Turning off

5.11

How to operate the shearer General control buttons The following image shows the general buttons for the control of the shearer.

Fig. 52:

Transmitter: Control buttons

3

1 2

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6

4 5 7

1

2

3

4

5

6

7

8

9

*

0

#

9

8 10

12

11 13

15

14 16

18

17 21

19 20 No.

Function

1

Slow boom raise left arm

2

Stop all motors/ turn off transmitter

3

Slow arm raise right arm

4

Slow arm lower left arm

5

Shift (for blue buttons)/turn on transmitter/synchronize (keep pressed >5 seconds)

6

Slow boom lower right arm

7

Increase left haulage speed/ decrease right haulage speed

8

Traction haulage request

9

Increase right haulage speed/ decrease left haulage speed

10

End display page change

5.12

11

Keypad mode (see explanation below)

12

Motor stop/start (see explanation below)

13

Left cowl clockwise

Shearer EL 3000

How to operate the shearer No.

Function

14

Program on/off

15

Right cowl clockwise

16

Left cowl counter clockwise

17

Auto mode on/off

18

Right cowl counter clockwise

19

Left arm: change from auto mode to manual operation

20

Cooling water on/off (programmable in MMC, Setup mode)

21

Right arm: change from auto mode to manual operation

Shift buttons The following image shows the buttons that can be activated after pressing and holding the SHIFT button.

Transmitter: Shift buttons

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 53:

1

3

2 4

5

1

2

3

4

5

6

7

8

9

*

0

#

7

6

8

11

10

No.

Function

1

Shift button (keep pressed)

2

Left arm raise fast

3

Right arm raise fast

4

Left arm lower fast

5

Right arm lower fast

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VSSP / 02

9

5.13

How to operate the shearer No.

Function

6

Left drum: water on/off

7

Right drum: water on/off

8

Programmable button (MMC, Setup mode)

9

Programmable button (MMC, Setup mode)

10

Programmable button (MMC, Setup mode)

11

Programmable button (MMC, Setup mode)

Keypad Operation The keypad buttons of the transmitter can be used to simulate the USB keypad and navigate through the pages of the mobile machine control (MMC). The Keypad mode ist activated by pressing the SHIFT and the KEYPAD button together (> 0.3 seconds).You can then choose between the numbers 0-9.

Transmitter: Keypad Operation

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 54:

1 1

2

3

4

5

6

7

8

9

*

0

#

2

No.

Function

1

Activate keypad mode (press ”SHIFT” and “KEYPAD” together, > 0,3 seconds)

2

Keypad (numbers 0-9)

5.14

Shearer EL 3000

How to operate the shearer Start/Stop Motor With Transmitter To start a motor proceed as follows: After pressing the “MOTOR STOP/START” you can start single motors or a sequence of motors. The following buttons serve to start motors: Transmitter: Motor Start/Stop

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 55:

2

1

2

3

4

5

6

5

7

8

9

7

*

0

#

3

1

4

No.

Function

1

Activate Motor Stop/Start function

2

Motor selection: left cutter motor

3

Motor selection: right cutter motor

4

Motor selection:coalsizer (if fitted)

5

Motor selection: pump motor

6

Motor selection: haulage transformer

7

Motor selection:sequence of motors

6

Important!

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

Doc. no.: SHEL3000-127 BA 00

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5.15

How to operate the shearer Setup Mode Important!

Further information concerning the setup mode can be obtained in the separate manual of the transmitter.

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 56:

5.16

Shearer EL 3000

How to operate the shearer Five buttons serve to navigate through the setup mode: Fig. 57:

Transmitter: Setup mode navigation

1 2 3

5

Caterpillar Global Mining Europe GmbH, Lünen 2013

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4

1 Up 2 Down 3 Left

4 Selection/Enter 5 Right

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

Doc. no.: SHEL3000-127 BA 00

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5.17

How to operate the shearer Taking shearer into use Starting procedure If you have observed all the points listed in the section “how to operate the shearer” you can continue with the starting procedure:

. Make sure that there are no persons on the conveyor or close to the shearer.

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

. Turn on the cooling water supply for the shearer motors and units before you start the shearer

trical control box (position “I”).

Important!

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

Fig. 58:

Main switches electrical control box

1 1 main switch shearer

2 2 main switch cutting elements

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

5.18

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Switch on both main switches (visible disconnects) on the elec-

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Caution!

DO NOT ATTEMPT TO ISOLATE THE COOLING SUPPLY AT ANY TIME WHILST THE SHEARER MOTORS ARE RUNNING, AS DAMAGE TO THE MOTOR SEALING ARRANGEMENTS WILL OCCUR.

How to operate the shearer . Start the motors of the shearer. To do so you can use the control elements of the low voltage compartment of the ECB3 (see Fig. 46) or the transmitter (see Fig. 52).

What to observe during operation Shearer Operators Report The shearer operator 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.

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.

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

Rapid changes of gradient along the face should be graded out to an acceptable value for the 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. Then select 'Haul Stop', 'Cutter Stop' and power down the shearer.

Notice!

The emergency stop should be used in emergencies only.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.19

How to operate the shearer Electrical isolation of the shearer To electrically isolate the shearer, proceed as follows:

. If the shearer is hauling, reduce the haulage speed to zero. . Stop the ranging arm, coal sizer (if fitted) and pump motor. . Operate the `MACHINE STOP' pushbutton (see transmitter) to stop all motors. If a transmitter control mode is not selected, use the emergency stop lever to remove power from the shearer.

. Switch the shearer main switch handles to the `0' position.

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

. Switch the gate end panel isolating switch to the `OFF' position

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 (if fitted) motors.

Operate the haulage and hydraulic functions using the selected controls.

5.20

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Un-plug the trailing cable at the gate end panel and at the

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and secure it in this position using `YOUR' personal safety lock.

How to maintain the shearer How to maintain the shearer Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

Make sure you also observe the safety instructions in chapter 2, “Your safety”. danger of explosion

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

maintenance charts

You can use the maintenance charts on the following pages to get an overview of the necessary maintenance. There is a chart for mechanical and electrical maintenance.

Following the maintenance charts you can obtain detailed information on the maintenance procedures for the various machine parts, if necessary. There you will find further information on the exact location of maintenance points and procedures.

maintenance of machine parts

Please observe the following instructions:

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

Only use suitable and approved tools for maintenance work.

Only use original Caterpillar spare parts when replacing components.

Warning!

Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties.

Ensure the shearer is isolated at the gate end or panel or by removal of the trailing cable, prior to carrying out electrical maintenance, unless power is required to carry out the checks!

Warning!

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.

Warning!

Ensure all hydraulic and water systems are isolated and depressurised 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.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.21

How to maintain the shearer Maintenance intervals (mechanical) Comment

Maintenance interval

No.

Subject

Daily

Weekly

Monthly

Quarterly

/ Reference

General M10

Debris

clean

M20

Missing/damaged parts

check

M30

Wear skid shoe

check

see Fig. 67

M40

Mechanical covers secure

check

Knocking test

visual insp.

Oil level

check

see Fig. 60

M60

Correct functioning lifting cylinder

check

see Fig. 60

M80

Water leaks on inlet distributor?

check

see Fig. 60

M90

All covers tight?

check

see Fig. 60

M100

Oil leaks

check

see Fig. 60

M110

Hinge pins mainframe

grease

see Fig. 60

M120

Pin connection lifting cylinder

check

see Fig. 60

M130

Lifting cylinder damaged?

M140

Oil sample for analysis

check

see Fig. 60

M150

Security of cutter motor retaining fasteners

check

see Fig. 60

M160

Wear and correct location of hinge pins

check

see Fig. 60

M170

Change oil (if no contamination analysis is being carried out)

change

see Fig. 60

M180

Covers high speed section

check

see Fig. 60

M190

Wet cutting shaft seals

grease

see Fig. 60

M200

Cowls (if fitted)

grease

see Fig. 60

check

see Fig. 61

check

see Fig. 60

Cutting drums M210

Picks and pick boxes

M220

Retaining and shaft bolts

M230

Can rotate freely

check

see Fig. 61

M240

Damages?

check

see Fig. 61

M250

Oil leakage

check

see Fig. 61

M260

Dust suppression sprays

check

see Fig. 61

5.22

check

see Fig. 61

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

M50

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Ranging arms

How to maintain the shearer Comment

Maintenance interval

No.

Subject

Daily

Weekly

Monthly

Quarterly

/ Reference

Haulage units M270

Oil level

check

see Fig. 62

M280

Motor attachment screws

check

see Fig. 62

M290

Motor quill shafts

check, grease

see p. 5.51

M300

Oil sample for analysis

check

see Fig. 62

M310

Brake wear (if brake is fitted)

check

see Fig. 62

M320

Change oil (if no contamination analysis is being carried out)

change

see Fig. 62

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Powerpack M330

Fluid level

check

see Fig. 63

M340

Nominal pressure value

check

see Fig. 63

M350

Leakages?

check

see Fig. 63

M360

Filter conditions

check

see Fig. 63

M370

Hoses and connections

check

see Fig. 63

M380

Functioning of control handles

check

see Fig. 63

M390

Oil sample for analysis

check

see Fig. 63

M400

Pressure and return filter

check/ replace

see Fig. 63/ filter manual

M410

Hydraulic pump fasteners

check

see Fig. 63

M420

Pump motor fasteners

check

see Fig. 63

M430

Control valve fasteners

check

see Fig. 63

M440

Hydraulic fluid

change

see Fig. 63

Water system M450

Functioning of all valves

check

see Fig. 128

M460

All visible hoses and connections

check

see Fig. 128

M470

Waterflow and pressure values (MMC)

check + record

see MMC manual

Downdrives M480

Oil level

check

see Fig. 64

M490

Bearings

grease

see Fig. 64

M500

Pin connection trapping shoe

check

see Fig. 64

M505

Grease nipples trapping shoe

grease

see Fig. 64

M510

Condition of gears

check

see Fig. 64

M520

Lubrication of gears

check

see Fig. 64

M530

Wear of trapping shoe inserts

M540

Supernut torque values

Doc. no.: SHEL3000-127 BA 00

check

see Fig. 64 check

VSSP / 02

see Fig. 64

5.23

How to maintain the shearer Maintenance intervals (electrical) Maintenance interval

No.

Subject

Daily

Weekly

Comment/ Monthly

Quarterly

Reference

General E10

Damage to all flameproof covers, cable entries, protective guards, control handles, and inspection windows

visual check

E20

Correct functioning of main switch, pushbuttons, keypad...

check

Also by operator at start of shift

E30

Correct functioning of emergency stop button and radio transmitter stop

check

Also by operator at start of shift

E40

Trailing cable, connection to ECB3 and monitoring device

visual check

E50

Prestart warnings haulage, pump and cutter motors

E60

Methane level

E70

All flameproof covers, cable entry devices, blanking elements and fixings of correct type, in position and secure?

check visual check/ knocking test

Radio Transmitter E90

Dirt and moisture

remove

E100

Transmitters damaged?

check/ exchange

E110

Batteries loaded?

check

E120

All operator functions can be activated?

check

By the operator before the start of a shift

MMC module E130

Correct functioning MMC module

check

E140

Motor parameters, start-up operational values

document

E150

Parameter values haulage systems

check/document

E160

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

E170

Motor winding insulation and continuity values of all motors

5.24

via connections to surface communications

record

record

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

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check

How to maintain the shearer Maintenance interval

No.

Subject

Daily

Weekly

Comment/ Monthly

Quarterly Reference

Ranging Arm Motors E180

Connections of main and transducer cables. Cables and cable insertion points

check

E190

Cable entry chamber dry and clean

check

E200

Motor Transmitter Unit connectors

check

E210

Flameproof covers damaged?

Flameproof gaps correct?

check

Covers disassembled

Control Box (ECB3) All earth leakage and lockout facilities

E220

Condition of all flameproof flanges, studs, threads, dowel pins and washers ok (outside only)?

check

E230

Flameproof gaps correct?

check

Caterpillar Global Mining Europe GmbH, Lünen 2013

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E215

operate/ check Visual inspection/ Knocking test

Haulage Transformer Box (HTB3) E235

“Earth Fault” test device and LED´s

activate/ check

E240

Condition of all flameproof flanges, studs, threads, dowel pins and washers ok (outside only)?

check

E250

Flameproof gaps correct?

check

Visual inspection/ Knocking test

Pump Motor E255

Motor Transmitter Unit connectors

E260

Flameproof covers, cable entries protective guards damaged?

check

Visual inspection/ Knocking test, check tightness of bolt connections

E270

Flameproof gaps correct?

check

Visual inspection/ Knocking test, check tightness of bolt connections

Doc. no.: SHEL3000-127 BA 00

check

VSSP / 02

5.25

How to maintain the shearer Maintenance interval

No.

Subject

Daily

Weekly

Comment/ Monthly

Quarterly Reference

Haulage Motors check

E280

Flameproof covers, cable entries protective guards damaged?

check

Visual inspection/ Knocking test, check tightness of bolt connections

E290

Flameproof gaps correct?

check

Visual inspection/ Knocking test, check tightness of bolt connections

E290

Flameproof gaps correct?

check

Visual inspection/ Knocking test, check tightness of bolt connections

check

Visual check of beacons

Electro Hydraulic Control Valves E300

Correct operation of control valves

check

Siren Pre-start Alarms E310

5.26

Cleanliness and damage of the pre-start alarm on right and left machine ends

Shearer EL 3000

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Motor Transmitter Unit connectors

Caterpillar Global Mining Europe GmbH, Lünen 2013

E275

How to maintain the shearer Oil and fluid condition monitoring Introduction Important!

All oils and the hydraulic fluid are recommended to be replaced after the first two weeks of production. Then conduct routine oil sampling as stated below.

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.

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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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

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

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

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.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.27

How to maintain the shearer Where possible the cause of the change should be established.

Additives 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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Cognisance should be taken of the legal minimum flash point.

5.28

Shearer EL 3000

How to maintain the shearer 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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.

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.

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.

If the normal wear causes the level of iron to rise to 500 parts per million the oil should be changed.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.29

How to maintain the shearer Fig. 59:

Debris graph (Example)

Possible Cycle

Fe Concentration

100 hrs

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.

* Some methods of analysis give an empirical number rather than ppm.

Refer to instrument manufacturer for guidance in such cases.

Frequency of sampling 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.

5.30

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

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0-1

How to maintain the shearer Maintenance of the ranging arms Fig. 60:

Maintenance Points Ranging Arm RA 750

M110 E, M170

Caterpillar Global Mining Europe GmbH, Lünen 2013

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D, M170

C, M140

A, M170

M180 M150

M160 M80 B, M170 M100

M90 B, M170

M190

M120

M60

M130

C, M140 M50

A oil fill B oil drain C oil sample

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D oil inlet valve High Speed Section E oil inlet valve Double Epicyclic

5.31

How to maintain the shearer Ranging arms Subject

Remarks

M50

Oil level

Arms horizontal, machine not powered, check oil levels

M60

Correct functioning lifting cylinder

Raise and lower both ranging arms

M80

Water leaks on inlet distributor?

Visual inspection

M90

All covers tight?

Visual inspection

M100

Oil leaks

Visual inspection

M110

Hinge pins mainframe

Hinge pins are connected to remote greasing stations located on the waste side of the machine. Prior to applying lubricant, ensure that the weight of the ranging arm is fully supported (e.g. drum rests on the floor or arm rests on support). Lubricant: Caterpillar Grade GR3

M120

Pin connection lifting cylinder

Visual inspection

M130

Lifting cylinder damaged?

Visual inspection, machine isolated

M140

Oil sample for analysis

Oil changes to be determined based upon results of oil sample analysis

M150

Security of cutter motor retaining fasteners

Knocking test

M160

Wear and correct location of hinge pins

Visual inspection for “play” between the pins and drilled (bore) holes

M170

Change oil (if no contamination analysis is being carried out)

Drain oil (both high speed and epicyclic section) and refill with new oil up to prescribed oil level. Oil fill inlet on top of machine lh side.

Oil capacity High Speed Section: 28 l Oil capacity Epicyclic Section: 30 l

M180

Covers high speed section

Check positioning of covers for security, check for oil loss, check all screws are torqued correctly

M190

Wet cutting shaft seals

Inject grease, Lubricant: Caterpillar Grade GR3

M200

Cowls (if fitted)

Inject grease

5.32

Shearer EL 3000

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No.

How to maintain the shearer Maintenance of the cutting drums The following image shows the RH cutting drum.The cutting drum on the LH side is laterally reversed.

Fig. 61:

Maintenance points cutting drum

M220

M210

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M250

M260

M230

M240

Maintenance of the cutting drums No.

Subject

Remarks

M210

Picks and pick boxes

Check for blunt od damaged picks (bits). Check the pick boxes (bit holders) for damage. Ranging arms out of gear, machine isolated.

M220

Retaining and shaft bolts

Remove the cover of the cutting drums and use a torque wrench to check bolts for correct torque.

M230

Can rotate freely

Check if drums can rotate freely before starting. Remove any obstacles.

M240

Damages?

Check cutting drums for damage.

M250

Oil leakage

Check cutting drums for oil leakage.

M260

Dust suppression sprays

Turn water spray system on and check if all nozzles work correctly.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

5.33

How to maintain the shearer Maintenance of the haulage units The following image shows the RH haulage unit. The haulage unit on the LH side is laterally reversed.

Fig. 62:

Maintenance points haulage unit A, M320

C B M300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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M320

E

M290 D

M300 M270

M320 M280

A oil fill haulage unit B oil drain haulage unit C oil sample haulage unit

5.34

D valve rh haulage unit E valve lh haulage unit

Shearer EL 3000

How to maintain the shearer

No.

Subject

Remarks

M270

Oil level

Check oil level. Machine powered but not hauling.

M280

Motor attachment screws

Check positioning of haulage motor attachment screws for security.

M290

Motor quill shafts

Refer to “Haulage motor quill shaft replacement” in this chapter for details on how to remove, inspect and install quill shaft.

M300

Oil sample for analysis

Take oil sample from both haulage units at sample point (C). Oil changes to be determined based upon results of oil sample analysis (see “Oil and fluid condition monitoring“ in this chapter).

If analysis suggests oil to be replaced, drain oil (B) and refill (A) up to prescribed oil level.

Oil capacity: 28 l Oil: G3 (see chapter 6)

M310

Brake wear (if brake is fitted)

Open face side cover of haulage unit and check wear indicator pin. Brake is worn if the wear indicator pin is flush with the cover.

M320

Change oil (if no contamination analysis is being carried out)

Drain oil at drain point (B) on waste side of the machine and refill with new oil at oil filling point (A) up to prescribed oil level.

Oil capacity: 28 l Oil: Caterpillar Grade G3 (see chapter 6)

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Maintenance of the haulage units

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5.35

How to maintain the shearer Maintenance of the powerpack Fig. 63:

Maintenance points powerpack

2

1

3, M340

4, M340

5

9

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14 Caterpillar Global Mining Europe GmbH, Lünen 2013

6 10, M400

7, M420 15, M390 M440

13, M330 16, M440

11, M400 12, M410

8, M380, M430

1 cooling water pressure 2 inlet water pressure 3 main hydraulic pressure 4 hydraulic pilot pressure 5 spare gauge (low pressure) 6 hydraulic reservoir

5.36

7 pump motor

12 hydraulic pump

8 valve block

13 oil level sightglass

9 oil cooler

14 breather

10 return filter

15 oil drain

11 pressure filter

16 oil fill

Shearer EL 3000

How to maintain the shearer

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Maintenance of the powerpack and hydraulic system No.

Subject

Remarks

M330

Fluid level

Machine powered but not hauling. Check MMC display & reservoir sight glass Refill to prescribed oil level as necessary.

M340

Nominal pressure value

Ceck pressure values on gauge and pressure transducer readings (MMC).

M350

Leakages?

Check system for leakages where practical. Visual examination.

M360

Filter conditions

Visual check of filters. Check pressures.

M370

Hoses and connections

Check hydraulic hoses and couplings for damage and leaks where practical.

M380

Functioning of valve control handles

Machine powered. Open and close valves.

M390

Oil sample for analysis

Take oil sample. Oil changes to be determined based upon results of oil sample analysis (see “Oil and fluid condition monitoring“ in this chapter). If analysis suggests oil to be replaced, drain oil (15) and refill (16) up to prescribed oil level.

Oil: Caterpillar Grade H2 (see chapter 6)

M400

Pressure and return filter

Compare readings on manual pressure gauges versus pressure transducer readings. Replace pressure and/or return filter if necessary. For further information refer to separate manuals for filters.

M410

Hydraulic pump fasteners

Physical check of accessible fasteners

M420

Pump motor fasteners

Physical check of accessible fasteners

M430

Control valve fasteners

Physical check

M440

Hydraulic fluid

Drain oil at drain point (15) and refill with new oil at oil filling point (16) up to prescribed oil level.

Fluid: Caterpillar Grade H2 (see chapter 6)

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How to maintain the shearer Maintenance of the downdrives Fig. 64:

Maintenance points downdrives DC150-B 9, M480

10, M480

M480 8

1, M490

7, M490

6, M490

2, M490

M510

3

M540

M505 M500

M530

1 grease nipple pinion bearing faceside 2 grease nipple pinion bearing waste side 3 telltale pinion 6 grease nipple drive wheel bearing waste side

5.38

7 grease nipple drive wheel bearing faceside 8 telltale drive wheel 9 oil fill lubrication reservoir 10 valve lh lubrication reservoir 11 valve rh lubrication reservoir

Shearer EL 3000

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11, M480

How to maintain the shearer Maintenance of downdrives Subject

Remarks

M480

Oil level

Check oil level in lubrication reservoir. Fill up if necessary.

M490

Bearings

Grease at the indicated lubrication points. Inject grease until grease is visible at the telltale point.

M500

Pin connection trapping shoe

Visual check

M505

Grease nipples trapping shoe

Grease at the indicated lubrication points. Inject grease until grease is visible at the telltale point.

M510

Condition of gears

Remove top drive gear guard /inspection covers and allow to run for at least 1 complete rotation for full inspection, refit guard

M520

Lubrication of gears

see M510

M530

Wear of trapping shoe inserts

Measure wear and replace if necessary. For further information see “How to replace wear parts” in this chapter.

M540

Supernut torque values

Random checks of and “Knock”-test (mechanical test)

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No.

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How to replace wear parts How to replace wear parts It is essential to replace wear parts before they reach the lowest wear limit otherwise damage can be caused to other parts of the machine. Inspect the wear parts at regular intervals.

The following wear parts need to be replaced on a regular basis: Picks of the cutting drums Face side skid shoes Inserts in the waste side trapping shoes Drive sprocket of downdrives

Picks Picks on both cutting drums need to be inspected daily.

. Replace the picks if they are blunt or worn.

Replacement of picks

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Fig. 65:

2

3

4

2 cutting drum 3 pick

5.40

4 pick retainer

Shearer EL 3000

How to replace wear parts Skid shoes The maximum wear of the face side skid shoes is 10 mm. The skid shoe needs to be replaced if the wear exceeds 10 mm.

Fig. 66:

Wear limit skid shoe

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10 mm maximum wear

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

The gauge is placed into the bores on each side of the skid shoe as shown below. The wear limit is reached when the gauge touches the toe plate of the conveyor or cannot be placed into the bores.

Fig. 67:

Skid shoe wear measurement 1 2

Skid shoe not worn >0 3

1

2

Skid shoe worn =0 3 1 skid shoe 2 wear gauge

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3 toe plate conveyor

5.41

How to replace wear parts Skid shoe replacement To replace a worn skid shoe, lift up the shoe post so that the tension in the skid shoe pin (1) is released. Then remove the bolt (4), the covers (2, 3) and the skid shoe pin and replace the skid shoe.

Fig. 68:

Skid shoe replacement

1 skid shoe pin 2 cover 3 cover

5.42

2 5

4

4 hex. head bolt M24x190-8.8 5 nord-lock washer a skid shoe

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1 a

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3

How to replace wear parts Insert in trapping shoes Wear measurement The wear of the inserts of the waste side trapping shoes is measured by means of feeler gauge plates which are supplied with the special tools for the shearer.

Fig. 69:

Feeler gauge for trapping shoe inserts

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3 2 1 1 feeler gauge plate 4 mm 2 feeler gauge plate 5 mm 3 feeler gauge plate 6 mm

4 feeler gauge plate 7 mm 5 feeler gauge plate 8 mm

Important!

To measure the wear correctly, set machine to a level position and raise ranging arms in line with safety instructions!

To measure the wear, a combination of appropriate plates are inserted between the insert and the rack bar of the conveyor as shown below.

Fig. 70:

Measuring wear of trapping shoe inserts

1

3

2

1 trapping shoe 2 rack bar

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3 combination of feeler gauge plates

5.43

How to replace wear parts The maximum wear of the inserts in the trapping shoe is reached when the distance between the rack bar and the insert exceeds: 20 mm on both sides of the rack bar (addition of values a and b as shown below) or 18 mm under the rack bar Fig. 71:

Wear limit inserts

max. (a+b)=20 mm b

18 mm max.

Insert replacement procedure To replace an insert of a trapping shoe, proceed as follows:

. Isolate the shearer . Remove a rack bar. . Power up the shearer . Drive the shearer so that the insert to be replaced is in the area where the rack bar has been removed.

5.44

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a

How to replace wear parts Fig. 72:

Drive shearer into position

3

2

1

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1 trapping shoe 2 insert (wear part)

3 rack bar

. Isolate the shearer. . Remove the insert from the trapping shoe by removing the outer retaining screws and the key. If the key is hard to remove, a threaded bolt can be screwed into the center hole to drive the key out of the trapping shoe.

Fig. 73:

Remove key and insert

6

1

5

3

4

2

1 trapping shoe 2 insert 3 key

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4 nord-lock washer 5 hex. head screw M24x60-8.8 6 grease nipple

5.45

How to replace wear parts . Use a tapped bolt to lift the new insert into the trapping shoe and secure the insert with the key, the washers and the screws.

. Power up the shearer and drive it out of the working area. . Re-fit the rack bar that has been removed previously.

Drive sprocket The drive sprocket is inspected visually during the weekly check of the gears of the downdrive. In case the sprocket is damaged or worn, it needs to be replaced as shown below.

Sprocket replacement To replace a sprocket of a downdrive, proceed as follows:

. Remove the capscrews (11), the plate (7) and the O-rings (20).

Remove cover plate

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Fig. 74:

7

11

7 plate 11 cap screw M16x40-12.9

5.46

20 20 O-ring a trapping shoe

a

Shearer EL 3000

How to replace wear parts . Remove the inner (4) and outer (6) pivot pin retainer. . Remove the pivot pin (3).

Fig. 75:

Remove pivot pin

4

5

1

6

11

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3

a

1 downdrive 3 pivot pin

6 pivot pin retainer, outer 11 cap screw M24x50-10.9

4 pivot pin retainer, inner 5 cap screw M24x50-10.9

a trapping shoe

. Remove the trapping shoe and the drive sprocket.

Fig. 76:

Remove trapping shoe and drive sprocket

1

3

2

1 downdrive 2 trapping shoe

3 drive sprocket

Important!

Special tools for the exact alignment of the drive sprocket and the trapping shoe are needed for the next steps. These tools are supplied with the shearer.

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5.47

How to replace wear parts . Replace the damaged or worn drive sprocket, grease it and place the sprocket lifting brace (4) around it as shown below.

. Place drive sprocket and lifting brace into the trapping shoe. . Insert to the hex. head screws (5) into the bores under the trapping shoe (for later alignment of drive sprocket).

Fig. 77:

Place new drive sprocket into trapping shoe

3

5 2 trapping shoe 3 drive sprocket

5.48

4

4 sprocket lifting brace 5 hex. head screw M20x80-8.8

Shearer EL 3000

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2

How to replace wear parts . Position the trapping shoe under the downdrive. . Insert the studbolt with the adjustment collar through the bores in the downdrive and into the tapped bores of the trapping shoe to keep the trapping shoe in place.

Fig. 78:

Fit trapping shoe

6

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7

2

3 2 trapping shoe 3 drive sprocket

6 studbolt M24 7 adjustment collar

. Adjust trapping shoe and drive sprocket with the help of the adjustment collar (7) and the hex. head screws (5) under the trapping shoe.

Fig. 79:

Trapping shoe and drive sprocket adjustment

7

6 2

3 2 trapping shoe 3 drive sprocket 4 sprocket lifting brace

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4

5 5 hex. head screw M20x80-8.8 6 studbolt M24 7 adjustment collar

5.49

How to replace wear parts . When the bores of the downdrive housing and the trapping shoe are perfectly aligned, re-fit pivot pin (3) and inner (4) and outer (6) retainer.

. Torque the cap screw (11) to 942 Nm. Fig. 80:

Re-fit pivot pin

5

4 1

6

11 E

a

1 downdrive 3 pivot pin 4 pivot pin retainer, inner

6 pivot pin retainer, outer 11 cap screw M24x50-10.9 a trapping shoe

5 cap screw M24x50-10.9

. Check if O-rings (20) are in good condition. Replace if necessary.

. Grease O-rings. . Re-fit the O-rings (20), the plate (7) and the capscrews (11). . Torque the cap screws (11) to 942 Nm. Fig. 81:

7

Re-fit cover plate

11

7 plate 11 cap screw M16x40-12.9

5.50

20 20 O-ring a trapping shoe

a

Shearer EL 3000

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Other replacement procedures Other replacement procedures This section provides information for replacing some of the parts of the shearer other than the wear parts listed above. Please note that this information is not exhaustive, i.e. it can not cover every possible replacement work needed.

Haulage motor quill shaft replacement Danger!

Prior to starting this work, make sure to observe the general safety notes in chapter 2. Isolate the shearer and the conveyor and secure them against unintentional restart!

Important!

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

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Warning!

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

To replace the quill shaft, proceed as follows:

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5.51

Other replacement procedures . Remove the cap screws and lock washers from the quill shaft access cover then remove the cover.

Fig. 82:

Remove quill shaft access cover

1

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a

2

5

3 1 cap screw 2 quill shaft access cover 3 shaft plug

5.52

4

4 short quill shaft 5 long quill shaft

Shearer EL 3000

Other replacement procedures . Remove the circlip.

Fig. 83:

Remove circlip

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6

3

3 shaft plug

6 circlip

. Insert the M16 T bar into the shaft plug and withdraw the plug.

Fig. 84:

Remove shaft plug

3

3 shaft plug

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5.53

Other replacement procedures . Insert the M12 T bar into the short quill shaft.

Important!

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

. Keep screwing the M12 T bar into the short quill shaft until it is jacked out of the splines in the long quill shaft and the splines in the motor.

Remove short quill shaft

5

4 4 short quill shaft

5 long quill shaft

. Remove the T bar from the quill shaft and examine the splines for wear and damage. Replace if necessary.

Fig. 86:

Examine short quill shaft

4 4 short quill shaft

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Fig. 85:

Other replacement procedures . Insert M8 T bar into the long quill shaft. . Pull the long quill shaft out of the motor.

Fig. 87:

Remove long quill shaft

E

5 Caterpillar Global Mining Europe GmbH, Lünen 2013

5 long quill shaft

. Inspect the long quill shaft for damage and replace if necessary. Check the condition of the internal splines and the external splines. Check the condition of the “O” Ring on the gearbox end of the quill shaft and replace if damaged.

Fig. 88:

Inspect long quill shaft

5 5 long quill shaft

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6 6 “O” Ring

5.55

Other replacement procedures Important!

Ensure that grease of the correct grade is applied to the splines before assembly (Caterpillar GR5, see chapter 6 for further information)!

. Grease the “O” ring of the long quill shaft and re-fit the quill shaft into the motor.

. Ensure that the quill shaft is fully pushed home then remove the T bar.

Insert long quill shaft

5 5 long quill shaft

Important!

Ensure that grease of the correct grade is applied to the short quill shaft before assembly (Caterpillar GR5, see chapter 6 for further information)!

. Insert M16 T bar into large diameter side of the quill shaft as shown below.

Note Ensure that the T bar is locked up in the quill shaft so that the quill shaft can be turned when entering into the splines. A lock nut may have to be screwed onto the T bar first.

Fig. 90:

Insert T bar into short quill shaft

4 4 short quill shaft

5.56

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Fig. 89:

Other replacement procedures . Insert the short quill shaft into the long quill shaft. The splines in the long quill shaft will engage before the motor splines. The quill shaft will need to be rotated to align the splines up in the long quill shaft and then the motor. Ensure that the short quill shaft is pushed fully into the long one.

Fig. 91:

Insert short quill shaft into long quill shaft

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5

4 4 short quill shaft

5 long quill shaft

. Remove the M16 T bar from the short quill shaft. . Examine the “O” ring on the shaft plug for damage and replace if necessary.

. Apply FLP grease to the shaft plug. Ensure that the “O” ring is lubricated.

. Insert the M16 T bar into the shaft plug and fit the shaft plug.

Ensure the “O” ring is not damaged when fitting the shaft plug.

Fig. 92:

Insert shaft plug

7

3 shaft plug

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3

7 “O” ring

5.57

Other replacement procedures . Fit the circlip into the groove in front of the shaft plug.

Fig. 93:

Fit circlip

3

3 shaft plug

6 circlip

. Re-fit the quill shaft access cover. Fit the four cap studs and washers. Torque the studs to 77 Nm (57Ibf.ft).

Fig. 94:

Fit access cover

1

2 3 1 cap screw 2 quill shaft access cover

5.58

3 shaft plug

Shearer EL 3000

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6

Other replacement procedures Cutter motor quill shaft replacement Important!

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

Danger!

Prior to starting this work, make sure to observe the general safety notes in chapter 2. Isolate the shearer and the conveyor and secure them against unintentional restart!

Important!

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

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Warning!

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

To replace the quill shaft, proceed as follows:

. Remove the M16 hex. head screws and the Nordlock washers. . Remove the motor shroud access cover.

Fig. 95:

Remove motor shroud access cover

1

2

1 ranging arm 2 motor shroud access cover

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3

3 hex. head screw M16

5.59

Other replacement procedures . Remove the M10 cap screws and washers from the quill shaft access cover then remove the cover.

Fig. 96:

Remove quill shaft access cover 2

1

4

1 cap screw M10 2 quill shaft access cover

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3

3 shaft plug 4 quill shaft

. Remove the circlip.

Fig. 97:

Remove circlip

3

6

3 shaft plug

5.60

6 circlip

Shearer EL 3000

Other replacement procedures . Insert the M10 puller bar into the shaft plug.

Fig. 98:

Insert puller bar

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3

3 shaft plug

. Withdraw the plug.

Fig. 99:

Remove shaft plug

3

3 shaft plug

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5.61

Other replacement procedures . Insert the M16 Puller bar into the quill shaft and withdraw the quill shaft.

Important!

If the quill shaft has failed, then two parts need to be pulled out of the motor!

Fig. 100: Remove quill shaft

4 quill shaft

. Inspect the quill shaft for damage and replace if necessary.

Fig. 101: Inspect quill shaft

4 4 quill shaft

. Apply Caterpillar grade GR5 grease to the splines before assembly.

Important!

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

. Insert the M16 puller bar into the quill shaft to assist fitting.

If it is difficult to align the splines in the motor and the ranging arm, then proceed as below:

5.62

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4

Other replacement procedures . Slowly rotate the quill shaft by hand in the motor and at the same time push the quill shaft into the motor.

. If the above does not work then the drum may need to be turned slowly by hand but only if the roof and rib conditions are safe. At the same time as the drum is being rotated keep weight on the quill shaft. This will assist to engaging the splines in the motor and 1st motion shaft.

Fig. 102: Insert quill shaft

4

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7

4 quill shaft

7 shear point

. Ensure that the quill shaft is fully engaged in the splines and remove the M16 puller bar.

Important!

Examine the ‘O’ Ring of the shaft plug for damage and replace if necessary. Lubricate the ‘O’ Ring and ensure that it is not damaged when fitting the shaft plug.

. Fit the shaft plug using the M10 puller bar.

Fig. 103: Insert shaft plug

3

5

3 shaft plug

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5 “O” ring

5.63

Other replacement procedures . Ensure that the blind plug is fully engaged and the circlip groove is visible.

. Remove the M10 Puller bar. Secure the shaft plug by fitting the circlip.

Fig. 104: Fit circlip

6

3 shaft plug

6 circlip

. Re-fit the quill shaft access cover, the M10 cap screws and washers. Torque the cap screws to 77 Nm (57lbf.ft.).

Fig. 105: Re-fit quill shaft access cover 2

1

4 3

6

1 cap screw M10 2 quill shaft access cover 3 shaft plug

4 quill shaft 6 circlip

. Re-fit the motor shroud access cover.

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3

When faults occur When faults occur This 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 a memory jogger 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.

If you do not find the cause of a fault, please contact our after-sales service personnel.

Fault diagnosis - mechanical The guides included are: Guide 1 - No response of any Hydraulic Functions from the Radio Transmitter.

Guide 2 - From Step 3 GUIDE No. 1.

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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.

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 MMC above normal?

– YES: Refer to Mechanical Diagnostic Guide No. 2.

NO: Move to Step 4.

. STEP 4. Is the pilot pressure reading normal on MMC? – 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.

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When faults occur . 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 MMC? – 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.

. 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 MMC? – YES: Clean or replace suction hose arrangement.

NO: Move to Step 4.

. STEP 4. Stall a function.

Does the pressure indicate 3500 PSI/ 241 BAR on MMC? – NO: Adjust relief valve and secure with lock-nut.

YES: Move to Step 6.

. STEP 5. Are flow rate settings correct at the Danfoss Directional Control 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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Symptom: All functions are responding slowly from all modes of control.

E

Diagnostic guide 3:

When faults occur Diagnostic guide 4: Symptom: Ranging Arm will not raise or lower from 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/ 241 BAR on MMC? Caterpillar Global Mining Europe GmbH, Lünen 2013

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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 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 Gide No. 4 Action: Check the other Ranging Arm

. STEP 1. Is the system pressure reading normal on MMC? – 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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When faults occur 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 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:

When faults occur . 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?

– NO: Fault in slow speed gearing, renew L.H. haulage unit.

YES: Move to Step 10.

E

. STEP 10. Refit L.H. output quill shaft. Move to R.H. haulage Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

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 MMC. Diagnostic 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.

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5.69

When faults occur . STEP 2. Is the main switch handle at the `ON' position?

– NO: Rectify this and try again to start the shearer.

YES: Move to Step 3.

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 more than 1 second?

– NO: Operate the machine `START' pushbutton and release after 1 second.

YES: Move to Step 2.

. STEP 2. Check the wiring to the pilot retaining contact within

Caterpillar Global Mining Europe GmbH, Lünen 2013

When the shearer has been successfully powered up the MMC display unit will detect any other fault or alarm condition.

(Refer to the `MMC fault diagnosis', of the MMC manual).

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MMC.

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6

Technical data

General information

Technical data This chapter contains the most important technical data for the shearer. Further information is given in the spare parts lists and in the separate operating manuals for the individual components such as e.g. the E-motors. Information about tightening torques, greases etc. can be found at the end of this chapter.

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

General information

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Important!

No modifications may be made to the components listed unless they have been inspected and approved by the manufacturer.

General

Shearer type: . . . . . . . . . . . . . .

Noise level: . . . . . . . . . . . . . . . .

EL 3000 > 85 dB(A) 1)

Mainframe

Type: . . . . . . . . . . . . . . . . . . . . .

Construction: . . . . . . . . . . . . . .

MF 3-1 single frame

Ranging Arms

Type: . . . . . . . . . . . . . . . . . . . . .

Gear ratio: . . . . . . . . . . . . . . . . .

Oil capacity High Speed Section: . . . . . . . . . . . . . . . . . . . . . .

Oil capacity Epicyclic Section:

RA 750-WP-R2 24/44 at 37 rpm output speed 28 l 30 l

Ranging Arm motors

Type: . . . . . . . . . . . . . . . . . . . . .

Manufacturer: . . . . . . . . . . . . . .

Power rating: . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

EL 68B ATB Morley 2) 750 kW 3300 V

Haulage Unit LH side

Type: . . . . . . . . . . . . . . . . . . . . .

HU150-PN-EY-MC-R1 (with standard encoder) 137:1 28 l

Gear ratio: . . . . . . . . . . . . . . . . .

Oil capacity: . . . . . . . . . . . . . . .

Haulage Unit RH side

Haulage motor

Type: . . . . . . . . . . . . . . . . . . . . .

Gear ratio: . . . . . . . . . . . . . . . . .

Oil capacity: . . . . . . . . . . . . . . .

HU150-PN-EY-MC-R1 (CSIRO encoder) 137:1 28 l

Type: . . . . . . . . . . . . . . . . . . . . .

Manufacturer: . . . . . . . . . . . . . .

Power rating: . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

EL 55F ATB Morley 2) 150 kW 0 - 600 V

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

2) Further information can be found in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

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6.3

General information Type: . . . . . . . . . . . . . . . . . . . . .

Height of machine: . . . . . . . . . .

Track system: . . . . . . . . . . . . . .

Lubrication: . . . . . . . . . . . . . . . .

DC150-B-NH-JT2 1690 mm Jumbotrack 2000 12 l reservoir for each downdrive

Power pack

Type: . . . . . . . . . . . . . . . . . . . . .

Pump: . . . . . . . . . . . . . . . . . . . .

Motor power rating: . . . . . . . . .

Fluid reservoir capacity:: . . . . .

PP3-200-75-T4 - AUS 200 l/m 75 kW 300 l

Pump motor

Type: . . . . . . . . . . . . . . . . . . . . .

Manufacturer: . . . . . . . . . . . . . .

Power rating: . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

EL 63B ATB Morley 2) 75 kW 3300-4160 V

Lifting cylinders

Type: . . . . . . . . . . . . . . . . . . . . .

Stroke: . . . . . . . . . . . . . . . . . . . .

ZE-325/180-640-SO-CR 640 mm

Electrical control box

Type: . . . . . . . . . . . . . . . . . . . . .

ECB-3

Haulage Transformer

Type: . . . . . . . . . . . . . . . . . . . . .

Input voltage: . . . . . . . . . . . . . .

Output voltage: . . . . . . . . . . . . .

Haulage drives: . . . . . . . . . . . .

HTB3-33-AU 3300 V 600 V 2 x D2-100-600 ENCF

Accessories

Tools: . . . . . . . . . . . . . . . . . . . . .

Others:

Tool box Fire extinguisher

Further information concerning the machine parts can be obtained in the following chapters.

2) Further information can be found in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

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Downdrives

Identification Identification Manufacturer: . . . . . . . . . Caterpillar Global Mining Europe GmbH Type: . . . . . . . . . . . . . . . . EL 3000 Year of manufacturing: . . MM/YY (e.g.: 06/12 ≙ June 2012) ID No.: . . . . . . . . . . . . . . . SHEL3000-127 The shearer is marked with the following information.

Fig. 106: Nameplate and CE-marking, example Nameplate

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X

1

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

2

4

5 1 company name & address 2 material record number 3 month & year of manufacture

4 unit status R=repair, blank=new 5 serial number X company logo

CE-marking

The design of the shearer meets the requirements of European Directives 94/9/EC and DIN EN1710. It is suitable for use in potentially explosive atmospheres.

Information on the shearer components subject to identification, but not included here, can be found in the corresponding operating manuals.

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6.5

Mechanical Components Mechanical Components Ranging arm RA 750 The ranging arm is divided into three sections. high speed section idlers double epicyclic section In the high speed section, the 1st motion shaft is driven by a splined quill shaft (powered by the motor) which can be fitted or withdrawn from the waste side of the shearer.

The drive from the 1st motion shaft continues through a 2nd and 3rd motion shaft, a set of three idler gears, before reaching the double epicyclic and final drive. The final drive is by means of a square hub at the cutting drum.

Fig. 107: Overview ranging arm rh side

4

5 8

b

12 7 13 6

a 2

1

11

9 1 ranging arm 2 high speed section 3 3rd motion shaft 4 idler 5 final spur gear

6.6

6 double epicyclic section 7 covers 8 spray material 9 throughshaft 10 hoses and fittings

11 high speed section cooler 12 oil level sight glass epicyclic 13 oil level sight glass highspeed a lifting eye, 8000 kg b motor shroud

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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10

Mechanical Components The drum speed can be varied by replacement of the 1st motion shaft assembly and 2nd motion shaft assembly with varying gear teeth numbers to suit the desired drum speed. These shaft assemblies are accessed via the covers on the faceside of the ranging arm. type: . . . . . . . . . . . . . . . . . . . . . . water system: . . . . . . . . . . . . . . gear ratio: . . . . . . . . . . . . . . . . .

Oil capacity High Speed Section: . . . . . . . . . . . . . . . . . . . . . .

Oil capacity Epicyclic Section:

RA 750-WP-R2 PFF 24/44 at 37 RpM 28 l 30 l

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technical data

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6.7

Mechanical Components Haulage Unit The handable haulage unit is driven by a water cooled ac electric motor.

The gear transmission of the haulage unit consists of a high-speed section and a slow-speed section.

High speed section

The high speed section 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 an `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 further reduction gears.

A set of change speed gears are also located in this section.

Cooler

This cooler requires a minimum flow of 15 litres per minute at a maximum pressure of 30 bar. (Refer to Water system section for further information).

Slow speed section

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.

Oil monitoring

An oil level and temperature transducer is fitted into the slow speed section of the haulage unit. This transducer is monitored by the MMC shearer control system.

Recommended lubricants and their specifications can be found in 'Permissible Media' in this Chapter.

Oil level gauge

An oil level gauge is fitted on the waste side of the haulage unit and is visible from the waste side of the machine.

Unit to mainframe retention

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 eight (8) M24 bolts and Nord lock washers.

Torque settings for these bolts can be found in the chapter “torque settings”.

The following image shows the RH Haulage unit. The LH haulage unit is laterally inversed.

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Shearer EL 3000

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An encoder drive facility is provided on the 4th motion shaft of the LH haulage unit (Fig. 108, b). The RH haulage unit is endowed with a CSIRO encoder. The purpose of the encoder units is to provide machine position monitoring. A gear reduction is incorporated in the drive to the encoder from the 4th motion shaft. This ensures the total number of turns of the encoder will cater for the full face length.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Encoder drive

Mechanical Components Fig. 108: Haulage unit HU 150 (RH side), shown with standard encoder

8 a

d

e

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9 c

1 7

12

2

b 3

1 frame 2 cooler 3 first motion shaft 4 final spur gear 5 double epicyclic and output 7 oil level transducer technical data

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14

8 breather 9 oil drain 12 quill shaft 14 second motion shaft 15 third motion shaft a haulage motor

Gear ratio: . . . . . . . . . . . . . . . . .

Oil capacity: . . . . . . . . . . . . . . .

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15

4

b encoder c oil level sight glass d oil fill e oil sample

137:1 28 l

6.9

Mechanical Components Downdrives DC150-B general information

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

assembly

The complete downdrive is bolted and keyed to the mainframe on the waste side. The bolt retention is by means of Supernuts (see chapter 4, “Assembly”).

oil tank

From an oil tank on the inner side of each haulage unit oil is dripped onto the pinion gear of the downdrive. The oil level can be checked from the waste side of the shearer.

Fig. 109: Downdrives

5

1

5

2

3

6

4

1

3 6

1 downdrive 2 mainframe 3 haulage motor

6.10

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1

6

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3

4 haulage unit 5 oil tank downdrive 6 trapping shoe

Shearer EL 3000

Mechanical Components Fig. 110: Downdrive DC150-B-NH-JT2 exploded view

1 3 2 4

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5

10 8 6

9

1 3

4

5

2

10

7

1 downdrive housing 2 pionion gear, z=22 3 pinion cartridge, inner housing 4 pinion cartridge, outer housing

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8

5 roller bearing SPH 220x300x60 6 drive sprocket, z=11 7 wheel gear, z=31 8 trapping shoe

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9 trapping shoe insert 10 pivot pin

6.11

6.12

/

Oil filling

MA1MA2

A

2,3:1 3:1

A1

a b

MB1

280bar 248bar

- 1 - 0 bar

IP

MB1

MA1MA2

265 bar

0-- 400 bar

300 l

2x100 l/min

I P

MB1

A B

1

A B

DOWN DRIVE LUB

2

2 1

A B

3

1

A B

2

3

1 1

LUBRICATION TANK

1

A B A B

DOWN DRIVE LUB

2

V

P

A B

SPARE

PILOT PRESSURE 0-- 40 bar

I

C

LS

210 bar

24 bar

E

25 bar

Pp P Pg T0

PP MANIFOLD

V

S

Caterpillar Global Mining Europe GmbH, Lünen 2013

MAIN VALVE BANK

C

S

HP MANIFOLD

RH RA HIGH SPEED LH RA HIGH SPEED SPALL GUARD SPRAY BOOM LH RA LOW SPEED RH RA LOW SPEED LUBRICATION TANK

T A B

350bar

B1 MB2

275bar B

3:1

SYSTEM PRESSURE 0-- 400 bar

A

A1

a b

RH RANGING ARM

350bar 280bar 248bar

B1 MB2

275bar B

3:1

280 bar

A

A1

a b

LH RANGING ARM

MA1MA2

POWER PACK

B

B1 MB2

SPRAY BAR C

S V

V

S C

S V

V

S

LH Drum Water

C

SPALL GUARD C

S V

V

S C

RH Drum Water

PILOT VALVE BANK

C

Hydraulic Components Hydraulic Components

Hydraulic System

Fig. 111: Overview hydraulic system

Shearer EL 3000

1 hydraulic reservoir 2 return ilter 3 solenoid valve 4 valve bank

2

1

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5 pressure filter 6 pump 7 cylinder valve 8 pilot valve bank

3

7

5

6

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Hydraulic Components

Fig. 112: Hydraulic system - item location

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6.13

Hydraulic Components Power pack PP3 Fig. 113: Overview power pack 4 15

e

14 22 25, 29, 30

27, 28 a g

Caterpillar Global Mining Europe GmbH, Lünen 2013

25, 26

d

h

b 11, 13

3, 32

11, 12

21

c 5 17, 18, 19, 20

f 2 1 4 1 hydraulic reservoir 2 pump motor 3 valve block 4 oil cooler 5 hose DN 32 11 male stud connector G 3/4 “ 12 fitting port A 13 fitting port B 14 hose DN6ST/STX1350 15 hose DN6ST/STX1050 17 washer

6.14

18 hex head screw M 20x50-8.8 19 nord-lock washer 20 hex nut M 20-8 21 hose DN 6 22 hose DN 20x1200 25 nord-lock washer 26 hex head screw M12x25-8.8 27 dowty seal G 1/4 “ 28 hex head plug 29 hose retainer

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2

30 hex head screw M12x16-8.8 32 solenoid cable a return filter b pressure filter c hydraulic pump d fluid level sight glass e breather f lifting eye, 1500 kg g oil drain h oil fill

Shearer EL 3000

Hydraulic Components general information

The power pack unit provides the hydraulic system power for the shearer auxiliary functions.

The components of the power pack unit are bench assembled and the complete assembly slides into the mainframe. All are accessible from the goaf side of the shearer. The hydraulic pump is driven by a dedicated electric motor, also housed in the power pack area.

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filters

The hydraulic fluid is filtered by a pressure filter and a return line filter. 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.

technical data power pack

designation: . . . . . . . . . . . . . . . hydraulic pump: . . . . . . . . . . . . operating pressure: . . . . . . . . . system relief valve setting: . . . hydraulic reservoir: . . . . . . . . .

PP3-200-75-T4 - AUS 200 l/m, fixed displacement up to 210 bar 280 bar 300 l

pump motor

motor power rating: . . . . . . . . .

75 kW

valve bank

number of valves: . . . . . . . . . . number of spare valves: . . . . . safety relief valve setting: . . . . shock pressure valve setting: . low pressure pilot setting: . . . .

8 1 210 bar 265 bar 24 bar

return filter

filter size: . . . . . . . . . . . . . . . . . .

12 m

pressure filter

filter size: . . . . . . . . . . . . . . . . . .

22 m

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6.15

Electrical components Electrical components 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. It also shows the motors and the boxes that incorporate most of the electrical parts mentioned, these being the Haulage Transformer Box (HTB) and the Electrical Control Box (ECB3).

Electrical system The electrical system of the shearer consists of three main circuits, these being: The `Pilot Power System' The `Main Power Distribution' system The `Control Power Distribution' system All three systems are introduced in basic form in the diagram below.

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

Control Circuits Pilot Circuits

MAIN POWER SYSTEM

CONTROL POWER SYSTEM PILOT POWER SYSTEM

Earth Core

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

The diagrams of the electrical system of the shearer serve for a deeper understanding and are attached to this manual. You can find a list of the diagrams attached at the end of the chapter “electrical components”.

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Gate End Panel

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Fig. 114: Typical power distribution diagram

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

A typical pilot circuit 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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6.17

Electrical components Main power distribution The main power distribution system is illustrated in the block diagram included as Fig. 115.

Fig. 115: Main power distribution block diagram Pumpmotor

Contactor

AC Drive

LH HaulageMotor

Circuit Breaker

AC Drive

RH HaulageMotor

Main Transformer

Gate EndPanel

Line Side Main Isolating Switch Load Side

H.V. Fuses

Line Side Cutter Isolating Switch Load Side

Contactor

LH Cutter Motor

Contactor

RH Cutter 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 ECB3 box via the incoming cable entry, is initially connected to the `LINE' side of the main switch (via a three phase termination point on the LH side wall of the HV compartment).

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 CHAPTER 5 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').

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Contactor

Circuit Breaker

Electrical components The `LOAD' side of the main switch is connected to the primary windings of the Haulage Transformer and Pump Motor (via a pushbutton controlled contactor), the Haulage Transformer steps down the voltage to a value suitable for the Haulage System. The ‘LOAD’ side of the main switch is also connected to the ‘LINE’ side of an isolating switch for the cutting elements.

The ‘LOAD’ side of this isolating switch is connected to the Cutter Motors and Coal Sizer (if fitted) via pushbutton controlled contactors.

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

Doc. no.: SHEL3000-127 BA 00

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6.19

Electrical components Control power distribution The control power distribution system is illustrated in the block diagram included as Fig. 116.

Fig. 116: Control power distribution block diagram 3300 V Supply H.V. Fuses Power Line Modem

Control Transformer 110V 110V 24V 16A

10A 5A

PLC

Headlights

Headlights AC/DC PSU

Machine Encoder

Ethernet Switch ECB3 N Tron Switch

Monitoring Transducers

24V

110V AC/DC PSU 12V

Methane I/Face Circuit

Ethernet Switch HTB3

CIOS Block HTB3

110V

I.S. Power Supply

B.P. LM

Ethernet Switch ECB3

L.H. Display L.H. Transceiver

I.S. Ethernet Switch IPC

CIOS Block LH Mainframe

Monitoring Transducers

CIOS Block RH Mainframe

Monitoring Transducers

CIOS Block Powerpack

Monitoring Transducers

CIOS Block Powerpack

Hydraulic Solenoids

IMU

WiFi Antenna

R.H. Display R.H. Transceiver

CIOS Block ECB3

Monitoring Transducers

Test facilities Pilot circuit test points By referring to the pilot circuit diagram within the electrical diagrams, 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 ECB3 control box provides a useful method of carrying out pilot circuit point to point testing.

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110V Contactor Supply (via CISOS module)

Electrical components Electrical control box ECB 3 The ECB3 control box is designed to accommodate a combination of both HV and LV components.

The box is divided into two main sections: High Voltage Section (a) Low Voltage Section (b) Figure 117 shows the operating elements on the waste side of the ECB3.

Fig. 117: Overview Electrical Control Box ECB3 9

a

b

8

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10

1 2

3

1 main isolating switch shearer 2 main isolating switch cutting elements 3 display control unit (MMC) 4 low voltage circuit breakers reset pushbuttons 5 cover pilot-test points 6 emergency stop

4

5

6

7

7 pushbuttons 8 displayVisual Disconnect cutting elements 9 displayVisual Disconnect shearer 10 entry trailing cable a high voltage section b low voltage section

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

High Voltage Section HV section general

The HV section contains the HV cable entries for the cutter, coalsizer (if fitted) and pump motors as well as the supply cable to the HTB3 enclosure. These entries are on the face side. The HV section also houses the following components: Control Transformer Incoming Voltage Monitor HV Earth Leakage/Lockout Monitor Control Voltage Earth Leakage Monitor The HV section of the ECB3 is divided into two sub-sections accessible via two separate access covers.

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6.21

Electrical components The LH HV Section houses the following components:

LH HV section

HV Contactor Chassis (Coalsizer/Haulage/Pump motor) Machine Main Isolation (Visible Disconnect) Live Line Indication Unit Data Transmission Inductive Coupler RH HV section

The RH HV Section houses the following components: HV Contactor Chassis (Cutter motors) Cutter Motor Isolation (Visible Disconnect) Pl4 Indication Unit HV Insulation Test Point (accessible via small access cover) Main Control Transformer Fuse Fig. 118: Overview High Voltage Section 4

Caterpillar Global Mining Europe GmbH, Lünen 2013

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3 7 6 8

1 2

10

2 11 5

9

1 haulage contactors 2 pump contactors 3 right cutter motor contactors 4 left cutter motor contactors

6.22

5 coal sizer(if fitted)/haulage/pump contactors connections 6 right and left cutter motor contactors connection 7 control transformer

8 interface Box 9 main isolating switch 10 cutting elements isolating switch 11 high voltage test points

Shearer EL 3000

Electrical components Low Voltage Section LV section

The LV section is designed to accomodate the machine control components as follows: PLC Chassis Power Supply Chassis Ethernet Power Switch Units (2 off) 11 Way CIOS Block Main PLC Display Control System Circuit Breakers Pushbutton Chassis Pl28 Indicator Unit Sockets for the connection of all external control cables are located on the face side of the LV section.

Fig. 119: Overview Low Voltage Section

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11 10 9

1 2

8

3

7

4 5 6

1 power supply 12V 2 power supply 24 V 3 multiple power supply (IS) 8x12V DC

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4 INS/ IMU unit 5 PLC 6 ethernet switch 7 ethernet Switch

VSSP / 02

8 CIOS modul 9 CIOS backplane 10 IPC 11 interface box

6.23

Electrical components Haulage Transformer Box HTB3 The haulage transformer box accommodates the electrical components related to the haulage of the shearer.

All electrical components are accessible by removing the flameproof covers from the waste side of the unit.The haulage drives (5) and the transformer (2) are cooled by passing a cooling supply through an internal cooling path, embedded inside the box.

Fig. 120: Haulage transformer box HTB3

16

4

6

15

10

a

1 HTB3 box 2 transformer (350 kVA) 3 HLG 600V connection chassis 4 auxilary transformer 5 drives 6 earth leakage monitoring

9

3

8

2

8 pilot circuit connections (door switches) 9 CIOS switch 10 low voltage connector interface 15 circuit breaker 16 high voltage connection with ingress barrier a ethernet switch

Fig. 121: Operating elements

1

2

3

4 1 low voltage circuit breakers reset pushbuttons 2 window

6.24

3 left haulage circuit breaker 4 right haulage circuit breaker

Shearer EL 3000

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5

Electrical components Haulage Drive System Main Circuit The secondary side of the haulage transformer provides a 600V supply output (via circuit breaker) to the haulage drive system. As well as the main power to the drive, there is a 110V supply from the auxiliary transformer.

The haulage transformer has internal temperature transducers that are used by the MMC system to provide temperature protection and monitoring.

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.

Monitoring Circuits Both the Drive and MMC can monitor temperatures, currents and haulage motor speeds using transducers whose outputs can be connected via the relevant inputs.

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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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temperature monitoring

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 MMC display.

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.

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.

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6.25

Electrical components Fig. 122: 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

M

Two or more mechanically-coupled motors in master/slave operation by current-slaving.

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. 123: Appearance of configuration switches for “MASTER” drive

LEFT

ENABLE

MASTER

RIGHT

ENABLE

MASTER

Fig. 124: Appearance of configuration switches for “SLAVE” drive

LEFT

ENABLE

6.26

MASTER

RIGHT

ENABLE

MASTER

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Torque reference input 4 CON2

Electrical components 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.

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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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6.27

Electrical components

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

6.28

MASTER

MASTER

MASTER

MASTER

MASTER

X

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

MODE

E

Tab. 3: Switch positions and modes

Electrical components Ranging Arm Motors The ranging arm motors (cutter motors) are incorporated to drive the cutting drums. One cutter motor is attached to each ranging arm and covered by a protective casing.

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 earth lockout, 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 ‘Motor Transmitter Unit (MTU)’.

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

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A ranging arm angle transducer (inclinometer) is located in the terminal chamber enclosure at the waste side of each motor.

Fig. 125: Ranging arm motor (waste side view) 3 4

4

6 5

1 fixing hole 2 extraction hole 3 lifting shackle

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1

2

4 cooling water entry 5 cooling water exit 6 terminal chamber

6.29

Electrical components Technical data Ranging arm motor

Motor type: . . . . . . . . . . . . . . . . kW: . . . . . . . . . . . . . . . . . . . . . . .

Rating: . . . . . . . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

Frequency/Cycles: . . . . . . . . . .

Insulation Class: . . . . . . . . . . . .

Amps: . . . . . . . . . . . . . . . . . . . .

Voltage Range: . . . . . . . . . . . . .

Starting Current: . . . . . . . . . . . .

Starting Torque: . . . . . . . . . . . .

No of Phases: . . . . . . . . . . . . . .

Connection: . . . . . . . . . . . . . . . .

Cooling water temperature.: . .

EL 68 B 750 cont.

3300 V 50 Hz H 154 2640 - 3630 V (7.3 x FLC) (1.4 x FLT) 3 Star max. 30° C

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Further information can be be found in the separate operating manual or spare parts documentation from the respective manufacturer or supplier.

6.30

Shearer EL 3000

Electrical components Haulage motor 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 monitored to provide earth leakage, over temperature and over current protection.

Warning!

THE OVER CURRENT AND OVER TEMPERATURE PROTECTION FOR THIS MOTOR IS SET VIA THE `MMC' 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. A view of a typical EL55F haulage motor is shown in Fig. 126.

Fig. 126: Typical haulage motor

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1

3

1 water connection 2 terminal chamber

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3 cable entry (600V AC)

6.31

Motor type: . . . . . . . . . . . . . . . . kW: . . . . . . . . . . . . . . . . . . . . . . .

Rating: . . . . . . . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

Frequency/Cycles: . . . . . . . . . .

Insulation Class: . . . . . . . . . . . .

Amps: . . . . . . . . . . . . . . . . . . . .

RPM: . . . . . . . . . . . . . . . . . . . . .

Starting Current: . . . . . . . . . . . .

Starting Torque: . . . . . . . . . . . .

No of Phases: . . . . . . . . . . . . . .

Connection: . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . .

Cooling water: . . . . . . . . . . . . . .

Cooling water temperature.: . .

Winding Temp. Alarm: . . . . . . .

Winding Temp. Trip: . . . . . . . .

Bearing Temp. Setting: . . . . . .

EL 55 F 150 cont.

0 - 600 V 0 - 60 - 120 Hz H 182 1767@ 60 Hz (5.77 x FLC) (1.02 x FLT) 3 Star 700 kg 15 l/min max. 30° C 160° C N/A 75° C Alarm, 85° C Trip

Further information can be be found in the separate operating manual or spare parts documentation from the respective manufacturer or supplier.

Pump motor 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.

Warning!

THE OVER CURRENT AND OVER TEMPERATURE PROTECTION FOR THIS MOTOR IS SET VIA THE `MMC' 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. The over temperature protection facility is provided by means of four (4) thermostats and six (6) resistance temperature detectors (RTD's) which are located within the motor, connected to a `Motor Transmitter Unit (MTU)' and monitored by the MMC unit.

The over current protection is provided by means of a three phase current monitor assembly located within the ECB3 control box.

A view of a typical pump motor is shown in Fig. 127.

6.32

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Technical data haulage motor

E

Electrical components

Electrical components Fig. 127: Typical pump motor 2 1

Caterpillar Global Mining Europe GmbH, Lünen 2013

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3

1 water connections 2 terminal chamber

3 power pack

The over temperature protection facility is provided by means of four (4) thermostats and six (6) resistance temperature detectors (RTD's) which are located within the motor, connected to a `Motor Transmitter Unit (MTU)' and monitored by the MMC unit.

Technical data haulage motor

Motor type: . . . . . . . . . . . . . . . . kW: . . . . . . . . . . . . . . . . . . . . . . .

Rating: . . . . . . . . . . . . . . . . . . . .

Voltage: . . . . . . . . . . . . . . . . . . .

Frequency/Cycles: . . . . . . . . . .

Insulation Class: . . . . . . . . . . . .

Amps: . . . . . . . . . . . . . . . . . . . .

Voltage Range: . . . . . . . . . . . . .

RPM: . . . . . . . . . . . . . . . . . . . . .

Starting Current: . . . . . . . . . . . .

Starting Torque: . . . . . . . . . . . .

No of Phases: . . . . . . . . . . . . . .

Connection: . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . .

Water Inlet Temperature: . . . .

Cooling Water Quantity: . . . . .

Winding Temp. Alarm: . . . . . . .

Winding Temp. Trip: . . . . . . . .

EL 63B 75 MCR 3300 V 50 Hz H 18 2300/3300/4160 V 1475 (5.96 x FLC) (1.2 x FLT) 3 Star 575 kg 35° C max.

15 l/min 160° C 180° C

Further information can be be found in the seperate operating manual or spare parts documentation from the respective manufacturer or supplier.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

6.33

Electrical components Electrical Diagrams The electrical diagrams have been constructed using E-Plan and Standard IEC 61346. A PDF document is available that gives instruction on how to navigate through the diagrams, plus a Powerpoint presentation is available to demonstrate the navigation process.

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A complete set of all diagrams will be supplied with this manual.

6.34

Shearer EL 3000

Water System Water System The functions of the shearer water system are: To provide cooling for the shearer units.

To provide dust suppression.

The Water circuit diagrams are contained within the drawing package accompanying this manual.

Shearer Cooling System The cooling circuit comprises of coolers for the following: Ranging Arms (High Speed Section and Epicyclic) Ranging Arm Motors Haulage Units Haulage Motors Power Pack Motor Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Hydraulic Circuit Coalsizer Motor/Coalsizer Gearbox (if fitted) Haulage Drive Box (transformer & AC drive) Restrictor Valve The supply to each cooler is regulated by a restrictor valve giving the following values (these are adjustable to vary flowrate): L.H. Ranging Arm - High Speed Section

15 lpm

L.H. Ranging Arm - Epicyclic

8 lpm

R.H. Ranging Arm - High Speed Section

15 lpm

R.H. Ranging Arm - Epicyclic

8 lpm

L.H. Ranging Arm Motor

20 lpm

R.H. Ranging Arm Motor

20 lpm

L.H. Haulage Motor/Unit

20 lpm

R.H. Haulage Motor/Unit/Transformer Box

20 lpm

Hydraulic Oil Cooler/Pump Motor

15 lpm

The exhaust flow from all coolers exhaust via manifolds to atmosphere.

Fig. 128 will give you an overview of the parts of the water system.

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

6.35

6.36

EXHAUST

20 bar

DN12 BALL VALVE

0-100 bar

EXHAUST

DRUM FLUSH CONNECTION

105 l/min

E

20 L/min

35 bar

E

20 l/min

23 l/min

20 l/min

30 bar

DN12 BALL VALVE

BRETBY SPRAY

15 l/min

20 l/min

20 l/min

23 l/min

E

Caterpillar Global Mining Europe GmbH, Lünen 2013

Cutter Motor LH

COWL SPRAY RING LH

8 l/min

Ranging Arm Epic

DRUM SPRAYS LH

15 l/min

Ranging Arm

Water supply 357 l/min min. 30 BAR

DN50 LOCKABLE BALL VALVE

”Y-STRAINER” 200 μm

DN50

Haulage Motor

Haulage Unit

E

20 L/min

15 l/min

Cutter Motor RH Ranging Arm

DRUM FLUSH CONNECTION

105 l/min

DRUM SPRAYS RH

COWL SPRAY RING RH

0-100 bar

8 l/min

Ranging Arm Epic.

2

3

6

7

1

4

5

8

Haulage Motor

Haulage Unit Hydraulic Oil

Hydraulic Motor

Water System

Fig. 128: Layout Water System

Shearer EL 3000

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Y-STRAINER

E

RELIEF VALVE

RESTRICTOR (DRUM VALVE BYPASS)

COOLING WATER FLOW METER

MMAIN WATER PILOT OPERATED VALVE

WATER PILOT VALVE

INLINE-FLOWMETER

LH DRUM FLOW METER

BRETBY SPRAY VALVE

LOCKABLE BALL VALVE

PRESSURE REDUCER

Caterpillar Global Mining Europe GmbH, Lünen 2013

FLOW METER

RH DRUM FLOW METER

RESTRICTOR (COOLERS)

DRUM WATER PILOT OPERATED VALVE

Water System

Fig. 129: Water System - Item Location

6.37

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

Notice!

Use only hydraulic fluids and gear oils approved by the manufacturer!

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

General 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.

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.

6.38

Shearer EL 3000

Caterpillar Global Mining Europe GmbH, Lünen 2013

Inspection of lubricants taken from the machine can often reveal problems before breakdowns occur.

E

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.

Permissible media Shearer lubrication Shearer lubrication includes gear oil and hydraulic fluid filling. Gear oil is used to fill the ranging arms and the traction 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 traction units and down drive lubrication reservoirs.

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.

Gear Oil

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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 corrosion inhibition 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 7.

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VSSP / 02

6.39

Permissible media 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 7.

6.40

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air release ) anti foaming ) with good balance between these

Permissible media 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 7.

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 corrosion inhibition compatibility and miscibility with lithium complex base mineral oil grease (initial charge) compatibility with mineral oil based grease seals wear resistance water washout resistance Lubricants in compliance are shown in table 7.

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6.41

Permissible media 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

load carrying Lubricants in compliance are shown in table 7.

6.42

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compatibility with lithium soap based mineral oil grease

E

shear stability

Tightening torques Tightening torques Recommended tightening torques for lubricated bolts These figures provide an induced stress equal to 90% of minimum yield stress.

Bolts with metric coarse pitch Tab. 4: Tightening torques, coefficient of friction . = 0,14

Tightening Torque Thread Size

M8

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M10

M12

M16

M20

M24

M30

M36

Bolt Grade

ν = 0,9 for shank bolts

ν = 0,9 for necked-down bolts

8.8

27.3

18.9

10.9

40.1

27.8

12.9

46.9

32.5

8.8

54

38

10.9

79

55

12.9

93

65

8.8

93

65

10.9

137

96

12.9

160

112

8.8

230

165

10.9

338

242

12.9

395

283

8.8

464

332

10.9

661

473

12.9

773

554

8.8

798

572

10.9

1136

814

12.9

1329

953

8.8

1597

1154

10.9

2274

1643

12.9

2662

1923

8.8

2778

2019

10.9

3957

2875

12.9

4631

3364

With metric standard / fine thread according to DIN ISO 262; head dimensions of hexagonal bolts according to DIN EN ISO 4014-4018, hexalobular external driven head bolts according to DIN 34800, cylindrical bolts according to DIN EN ISO 4762 and hole "medium" according to DIN EN 20273.

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6.43

Tightening torques Bolts with metric fine pitch Tab. 5: Tightening torques, coefficient of friction . = 0,14

Tightening Torque

M10 x 1

M10 x 1,5

M12 x 1,25

M12 x 1,5

M16 x 1,5

M20 x 1,5

M24 x 1,5

M24 x 2

M30 x 2

M36 x 2

6.44

ν = 0,9 for shank bolts

ν = 0,9 for neck-down bolts

8.8

29.2

20.9

10.9

42.8

30.7

12.9

50.1

35.9

8.8

60

44

10.9

88

64

12.9

103

75

8.8

57

41

10.9

83

60

12.9

98

70

8.8

101

74

10.9

149

109

12.9

174

127

8.8

97

70

10.9

143

102

12.9

167

120

8.8

244

181

10.9

359

265

12.9

420

310

8.8

511

384

10.9

728

547

12.9

852

640

8.8

899

682

10.9

1280

972

12.9

1498

1137

8.8

865

645

10.9

1232

919

12.9

1442

1075

8.8

1756

1329

10.9

2502

1892

12.9

2927

2214

8.8

3082

2353

10.9

4390

3352

12.9

5137

3922

E

M8 x 1

Bolt Grade

Caterpillar Global Mining Europe GmbH, Lünen 2013

Thread Size

Shearer EL 3000

Tightening torques With metric standard / fine thread according to DIN ISO 262; head dimensions of hexagonal bolts according to DIN EN ISO 4014-4018, hexalobular external driven head bolts according to DIN 34800, cylindrical bolts according to DIN EN ISO 4762 and hole "medium" according to DIN EN 20273.

The above tables are in accordance with VDI 2230 Part1 - 2003

Bolts for flameproof covers Tab. 6: FLP Torque table (metric pitch) Thread Size (HEX or CAP)

Tightening Torque MA in Nm

M8

18

M10

30

M12

50

M16

55

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Danger!

Make sure to observe the stated torque values for FLP covers!

Incorrect tightening torques might affect FLP integrity of the enclosure and lead to an explosion!

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

6.45

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Tightening torques

6.46

Shearer EL 3000

Doc. no.: SHEL3000-127 BA 00

VSSP / 02

6.47

NLGI grade 1

NLGI grade 1

NLGI grade 1-2

NLGI grade 1

NLGI grade 1

NLGI grade 1-2

NLGI grade 1-2

NLGI grade 1

NLGI grade 2

NLGI grade 2

NLGI grade 2

Ranging arm cowl mechanism

Ranging arm pivot pins

Haulage gearbox / motor quill shaft

Quill shafts: Haulage drive/ Coalsizer

Haulage downdrive bearings

Haulage downdrive wheel bearings

Hydraulic pump drive couplings

Pump motor bearings

Haulage motor bearings

Cutter motor bearings

On Application

On Application

On Application

Mobiltemp 78

Mobilgrease HTS

Mobilgrease HTS

Mobiltemp 78

Mobiltemp 78

Mobiltemp 78 Mobilgrease HTS

Mobiltemp 78

Mobiltemp 78

MOBIL SPECIFICATION Mobilgrease HTS NLGI grade 1-2

Ranging arm / motor quill shaft

Ranging arm water tube seals

Lubrication Areas

Tab. 7: Recommended Lubricants

Luplex M2 Renolit High Temp 2

Luplex M2 Renolit High Temp 2

Luplex M2 Renolit High Temp 2

Moreplex 2HV

Renolit Extreme Load 2 Renolit LX2

Renolit Extreme Load 2 Renolit LX2

Moreplex 2HV

Moreplex 2HV

Renolit Extreme Load 2 Renolit LX2

Moreplex 2HV

Moreplex 2HV

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

Gadus S3 V460D2

Gadus S3 V460D2

SHELL

On Application

On Application

On Application

Drill Rod Grease

Energrease LM EP 680

Energrease LM EP 680

Drill Rod Grease

Drill Rod Grease

Energrease LM EP 680

Drill Rod Grease

Drill Rod Grease

Energrease LM EP 680

BP

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

---

---

Wear Protect HTP2 Longlife Grease HP2

ADDINOL

CATERPILLAR SHEARER LUBRICANTS FUCHS

CALTEX

On Application

On Application

On Application

Mine Grease Premium

RPM Grease SRI

RPM Grease SRI

Mine Grease Premium

Mine Grease Premium

Mine Grease Premium Rockdrill grease

Mine Grease Premium

Mine Grease Premium

Mine Grease Premium Rockdrill grease

OTHERS

(EL 58) Kluber Asonic HQ 72-102 (EL58C) Klubersynth BEP72-82

On Application

(EL 56) Kluberquiet BHQ 72-102

Castrol Molub-Alloy 860/460-1 Castrol Molub-Alloy 777-1

Quaker Mine Tech Synlith EP-220 Castrol Molub-Alloy 777-2 & 777-1

Quaker Mine Tech Synlith EP-220 Castrol Molub-Alloy 777-2 & 777-1

Castrol Molub-Alloy 860/460-1 Castrol Molub-Alloy 777-1

Castrol Molub-Alloy 860/460-1 Castrol Molub-Alloy 777-1

Quaker Mine Tech Synlith EP-220 Castrol Molub-Alloy 777-2 & 777-1

Castrol Molub-Alloy 860/460-1 Castrol Molub-Alloy 777-1

Castrol Molub-Alloy 860/460-1 Castrol Molub-Alloy 777-1

Quaker Mine Tech Synlith EP-220 Castrol Molub-Alloy 777-2 & 777-1

6.48

Shearer EL 3000

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

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

Mobilgear 634 Mobil SHC 634 Mobil SHC Gear 320

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

Luplex M2 Renolit High Temp 2

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

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)

Bartan 100 Bartan 68

Molygear 07 GR-XP 460

Molygear 07 GR-XP 460

Molygear 07 GR-XP 460

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

EP Mehrbereichsfett LM 2 EP Hightemp EK 2

Oils listed in the ranging arm or haulage (above).

Rando HD 68 or 100

Meropa 460 Meropa Synthetic 320 EP

Meropa 460 Meropa Synthetic 320 EP

Meropa 460 Meropa Synthetic 320 EP

On Application

Any oils listed in the ranging arm or haulage (above)

Castrol Hyspin AWH-M 100

Quaker Mine Tech Synthetic gear oil EP460 Castrol Tribol 1710 320 & 460 Castrol Optigear Synthetic X320

Quaker Mine Tech Synthetic gear oil EP460 Castrol Tribol 1710 320 & 460 Castrol Optigear Synthetic X320

Castrol Optigear Synthetic X320 Quaker Mine Tech Synthetic gear oil EP460 Castrol Tribol 1710 320 & 460

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