CAT Shearer EL3000 Operation & Maintenance Manual 4836780 BA - PDF DOWNLOAD

Media-ID: EM027495-00-EN Doc.-No.: 4836780 BA 00 May. 2017

Operating and Maintenance Manual EL3000 Shearer

Part-No.:

4836780

Serial-No.:

LSW30138

SAFETY.CAT.COM

© 2017 CATERPILLAR ALL RIGHTS RESERVED

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

Table of contents

Table of contents 1 About this manual ....................................................................................... 6 1.1 How to use this manual ........................................................................ 6 1.2 Signs and symbols used....................................................................... 7 2 Safety............................................................................................................ 8 2.1 Personnel.............................................................................................. 8 2.2 Operating Conditions ............................................................................ 9 2.2.1 Intended use .............................................................................. 9 2.2.2 Unauthorized use....................................................................... 9 2.2.3 Ambient conditions..................................................................... 9 2.2.4 Prerequisites for operation....................................................... 10 2.3 Operator requirements........................................................................ 10 Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

2.4 Using the machine and working on the machine ................................ 10 2.4.1 General principles .................................................................... 10 2.4.2 Storage and transport .............................................................. 12 2.4.3 Installation and commissioning ................................................ 12 2.4.4 Operation ................................................................................. 12 2.4.5 Maintenance and repair ........................................................... 13 2.5 Notes on the hydraulic system............................................................ 14 2.5.1 Recommended storage and use period................................... 15 3 Storage and transport ............................................................................... 17 3.1 Storage ............................................................................................... 17 3.1.1 Conditions for despatch ........................................................... 17 3.1.2 Storing the equipment.............................................................. 17 3.1.3 Storing used equipment ........................................................... 18 3.2 Transport ............................................................................................ 19 3.2.1 Load Units, Dimensions and Weights ...................................... 19 3.2.2 Before transport ....................................................................... 20 3.2.3 Transporting the components .................................................. 20 3.2.4 Dismantling of components...................................................... 21 3.2.5 Transporting the machine underground................................... 22 3.2.6 Moving the shearer onto the conveyor..................................... 22 4 Assembly.................................................................................................... 27 4.1 Notes on installation ........................................................................... 27 4.2 Overview - EL 3000 shearer ............................................................... 27 4.3 Installing the shearer .......................................................................... 28 4.4 Installing the shoe post on the mainframe .......................................... 29 4.5 Installing the lifting cylinders ............................................................... 32 4.6 Installing the downdrive on the mainframe ......................................... 36 4.7 Installing the ranging arm on the mainframe ...................................... 43 4.8 Installing the lifting cylinder on the ranging arm.................................. 47 4.9 Installing the shearer drum on the ranging arm .................................. 49 4.10 Connecting the shearer ...................................................................... 53 4.10.1 Electrical connection ................................................................ 53 4.10.2 Water connection ..................................................................... 53

EL3000 Shearer

Table of contents

4.11 Greases, oils and hydraulic fluids ....................................................... 53 4.12 Commissioning the shearer ................................................................ 53 4.12.1 Before commissioning.............................................................. 53 4.12.2 Adjusting the cable arm ........................................................... 54 4.12.3 Commissioning the shearer ..................................................... 54 4.12.4 Retightening bolted connections.............................................. 55 4.12.5 Changing oils and hydraulic fluid ............................................. 55 4.13 Dismantling and removing the shearer ............................................... 55 4.13.1 Important instructions for dismantling ...................................... 55 5 Operation.................................................................................................... 56 5.1 Start of work........................................................................................ 56 5.2 Control elements................................................................................. 56 5.4 Wireless remote control ...................................................................... 60 5.4.1 General operating elements..................................................... 61 5.4.2 Switching the wireless remote control on/off............................ 62 5.4.3 General control buttons............................................................ 64 5.4.4 Shift keys ................................................................................. 66 5.4.5 Numeric keypad ....................................................................... 66 5.4.6 Starting/stopping motors .......................................................... 67 5.4.7 Setup Mode.............................................................................. 68 5.5 Commissioning the shearer ................................................................ 70 5.6 What to observe during operation....................................................... 71 5.6.1 Operator's Report..................................................................... 71 5.6.2 Face conditions........................................................................ 72 5.7 Stopping the shearer .......................................................................... 72 5.8 Electrical isolation of the shearer........................................................ 72 5.9 Maintenance ....................................................................................... 73 5.9.1 Maintenance instructions ......................................................... 73 5.9.2 Important instructions............................................................... 74 5.9.3 Maintenance intervals (mechanical) ........................................ 74 5.9.4 Maintenance intervals (electrical) ............................................ 78 5.9.5 Oil and fluid analyses............................................................... 80 5.9.6 Filling oil and hydraulic fluid ..................................................... 81 5.9.7 Maintenance of the ranging arms ............................................ 86 5.9.8 Maintenance of the cutting drums............................................ 98 5.9.9 Maintenance of the haulage units ............................................ 99 5.9.10 Maintenance of the power pack ............................................. 111 5.9.11 Maintenance of the downdrives ............................................. 113 5.9.12 Replacing wearing parts ........................................................ 114 6 Technical data.......................................................................................... 127 6.1 Main components of the shearer ...................................................... 127 6.1.1 Technical data sheet.............................................................. 127 6.2 Identification...................................................................................... 128 6.3 Mechanical components ................................................................... 129 6.3.1 RA0750 ranging arm.............................................................. 129 6.3.2 HU150 haulage unit ............................................................... 130 6.3.3 Downdrive DC150-B .............................................................. 133 6.4 Hydraulic components ...................................................................... 136

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5.3 MMC/ Electrical Control Box............................................................... 58

Table of contents

6.4.1 Hydraulic system.................................................................... 136 6.4.2 Powerpack PP3 ..................................................................... 138 6.5 Electrical components....................................................................... 139 6.5.1 Electrical system .................................................................... 139 6.5.2 Electrical Control Box ECB 3 ................................................. 142 6.5.3 Haulage transformer box HTB3 ............................................. 146 6.5.4 Cutter motors ......................................................................... 149 6.5.5 Haulage motor ....................................................................... 150 6.5.6 Pump motor ........................................................................... 151 6.5.7 Electrical Diagrams ................................................................ 153 6.6 Water System ................................................................................... 153 6.6.1 Cooling system ...................................................................... 153

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6.7 Permissible media ............................................................................ 154 6.7.1 Gear Oil.................................................................................. 154 6.7.2 Hydraulic Fluid ....................................................................... 155 6.7.3 Quill Shaft Grease.................................................................. 156 6.7.4 All Other Grease Applications................................................ 156 6.8 Tightening torques ............................................................................ 157 6.8.1 Screws and bolts with ISO metric thread .............................. 157

EL3000 Shearer

About this manual

1

How to use this manual

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

1.1 How to use this manual applicable operating manual

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

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

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

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

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

Purpose of this operating manual Efficiency

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

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

Safety

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

Observe the information given and follow the instructions.

service partner

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

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new operating manual

About this manual

1

Signs and symbols used

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

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

1. Follow the described instructions.

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

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

1. Follow the described instructions.

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

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

1. Follow the described instructions.

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

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

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

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

1. Observe the provided tips and information.

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

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

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2

Safety Personnel

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

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

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

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

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

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

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

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

2.1 Personnel operation installation and repairs

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

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

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

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

Safety

2

Operating Conditions

qualification

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

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

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

2.2 Operating Conditions 2.2.1 Intended use Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

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

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

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

Unauthorized use includes the transport of persons.

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

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

That includes: adequate and consistent ventilation, water spraying systems.

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

It may only be restarted by an authorized person.

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

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

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2

Safety Operator requirements

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

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

The machine may be operated only if the safety requirements specified in national regulations are met. These include: equipment for preventing unauthorized startup,

water spraying systems in areas where there is a danger of explosion safe shutdown command systems, emergency stop systems, dust extraction systems, noise protection, warnings etc.

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

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

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

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

Become familiar with your working area.

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startup warning systems,

Safety Using the machine and working on the machine

noise emissions

2

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

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

safety components

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

Keep the signaling and lighting systems in good condition.

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

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

Observe the warning signs on the machine. emergency stop switch

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

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

electrical trips

Shut off the shearer completely for: maintenance work inspection work repair work Never carry out work on the shearer or walk on the conveyor if the shearer and conveyor have not been shut off. For information on the shutdown procedure for the shearer, see "Electrical isolation of the shearer" [} 72] If it is necessary to supply power to the shearer for the above-mentioned work, the operator must carry out a risk assessment that considers the individual risks in the mine. The manual operating mode must be activated when performing work while power is switched on in order to prevent unintentional activation of functions via the remote control that could endanger the personnel working on the machine.

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

automatic mode

danger of explosion

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

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

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

Observe the separate operating manuals for the components used.

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

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2

Safety Using the machine and working on the machine

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

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

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

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

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

Secure all moving parts.

means of attachment

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

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

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

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

mobile handling systems

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

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

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

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

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

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

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Never walk or stay under unsecured components or suspended loads.

Safety Using the machine and working on the machine

2

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

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

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

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

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Fig. 1: Go/no-go zones

radio mode

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

automation mode

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

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

Notify the responsible personnel of the following prior to working on the longwall: your exact location, the work you are carrying out how much time you will probably need You may only carry out work in the mining area if: the roof has been secured against falling rock,

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2

Safety Notes on the hydraulic system

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

When the shearer is in manual mode (e.g. for maintenance or repair) or the shearer is switched to manual mode motors might start and thus machine parts might move inadvertently. Beware of moving machine parts or flying rock from unexpected cutting action. A risk assessment has to be carried out taking into account the conditions in the mine when the machine is to be operated in manual mode.

hydraulic system protective devices

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

pressure relief valves

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

handling hydraulic fluids

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

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

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

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

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

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

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

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

Never use nails, wire or similar materials.

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

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2.5 Notes on the hydraulic system

Safety Notes on the hydraulic system

2

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

Never try to repair damaged hose lines.

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

Only use hose lines approved for the prevailing pressures.

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

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

installing hose lines

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

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

Australia

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID

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working pressure in [bar] date of manufacture (YY, MM) Caterpillar ID Additional writing on the label: manufacturer ID material number number of the test record, date of manufacture of the hose line, date of manufacture of the hose working pressure.

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

length of storage time for hose lines

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

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

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

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Safety Notes on the hydraulic system

service life/period of use of hose lines

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

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

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

Storage period

Storage period

Service life

max. 4 years (calculated from date of manufacture)

max. 2 years (calculated from date of manufacture)

max. 2 years

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Hydraulic hose

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Storage and transport Storage

3

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

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

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

3.1 Storage 3.1.1 Conditions for despatch

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

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

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

hydraulic components

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

3.1.2 Storing the equipment corrosion protection

avoid direct exposure to sunlight

dirt and moisture

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

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

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

short-term storage

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

long-term storage

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

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Storage and transport Storage

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

hydraulic Components

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

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

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

storage of motors

natural aging

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

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

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

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

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

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

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Then seal the ports with plastic or steel plugs.

Storage and transport Transport

3

NOTICE Important!

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

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

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

Notice on work safety Transport weights!

It may be necessary to divide the transport units differently because of the conditions in the mine. This can result in different dimensions and weights. Keep this in mind when planning transport of components. Information on the dimensions can be found in section "Overview - EL 3000 shearer" [} 27]

DANGER Suspended loads Not observing the rules for safely lifting or transporting may cause injury or death to your colleagues.

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

2. Only attach the loads to the provided lifting points.

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

4. Never stand under suspended loads.

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3

Storage and transport Transport Fig. 2: Lifting eye and load ring example

A

B

b

c

a

a

A

Lifting eye

B

Load ring

a

Load capacity 5000 kg

b

Eye

c

Welded onto component

d

Screwed onto component

3.2.2 Before transport temperatures below freezing

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

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

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

electrical and electronic components

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

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

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

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

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d

Storage and transport Transport

3

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Fig. 3: Correct transport of machine parts

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

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

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

Protect the transport boxes from moisture.

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

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

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

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

WARNING Switch off and support the machine!

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

For more information, see also 2 Overview - EL 3000 shearer [} 27]

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Storage and transport Transport

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

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

NOTICE Protect the machine!

after transport

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

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

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

WARNING Dangers when moving the shearer!

Dangerous situations may arise due to unforeseen movements of the machine and other incidents when moving the shearer onto the face conveyor. Note the space available in your mine and plan the procedure with this in mind. Conduct a risk assessment if the planning shows that the operation cannot be carried out safely without assessing the risks.

Tip Plan the installation steps!

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

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

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

Storage and transport Transport

3

Fig. 4: Moving the shearer on to the conveyor

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1

3

4

2

5

6

1

Coal face

4

Mainframe

2

Entry to tail gate end

5

Trapping shoe

3

Conveyor

6

Rack bar

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

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

2. Remove the circlip (2).

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3

Storage and transport Transport

Fig. 5: Removing the circlip

2

1 Coupling housing

2

Retaining ring

Tip Important!

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

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

Fig. 6: Removing the plug

3

4

3

Plug

4

T-key

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

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1

Storage and transport Transport

3

Fig. 7: Installing the adapter

5

6

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5

Hydraulic motor

6

Adapter

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

Fig. 8: Installing the O-ring

7

5

5

EL3000 Shearer

Hydraulic motor

7

O-ring

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3

Storage and transport Transport

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

Fig. 9: Installing the hydraulic motor

5

1

Coupling housing

5

Hydraulic motor

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

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

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

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Assembly

4

Notes on installation

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

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

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tools

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

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

installation plan

tightening torques

handling instructions connection points

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

For tightening torques not specified for the installation of the components, please refer to the list in chapter 6.

Pins, holes, screws and securing devices must be lubricated with grease (see "All Other Grease Applications" [} 156]) prior to installation.

4.2 Overview - EL 3000 shearer Fig. 10: EL3000 Shearer

10

21

80 82

30

84

92

90

21 30

82

80

10

61

61 5

EL3000 Shearer

1 40

2

3

5

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Assembly Installing the shearer

item

Quantity

Description

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

1

1

Mainframe

9840

1769

1152

21621

2

1

Shoe post SP B-LH

1363

425

830

1096

3

1

Shoe post SP B-RH

1363

425

830

1096

5

2

Skid shoe

900

165

346

152

10

2

Ranging arm RA 0750-WP-R2

3393

1960

900

6618

21

2

Haulage unit HU 150-PN-EN-MC-R1

1217

1073

510

2023

30

2

Downdrive DD-150-B-NH

1500

615

1023

3349

40

1

Powerpack PP3-200-75-E0 AUS TX

1590

1519

550

2015

61

2

Lifting cylinder

1730

400

450

830

80

2

Cutter motor CM 750 MBM

See separate operating manual

2300

82

2

Haulage motor HM150MF

See separate operating manual

700

84

1

Pump motor PM75M

See separate operating manual

575

90

1

Electrical Control Box ECB3

2461

1509

595

2502

92

1

Haulage transformer box HTB3-33-AU-RN

2061

1233

595

3560

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

WARNING Falling material!

This could cause you serious injuries! Ensure that the installation area is adequately supported during installation.

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

WARNING Danger from unsecured loads!

You can be seriously injured! Make sure that the units are supported sufficiently during installation and only use approved lifting devices.

The machine should be installed, hosed and cabled in the following order: Attach face-side shoe post (incl. skid shoes) to the mainframe (if required) Attach lifting cylinders to the shoe posts (if required) Attach downdrives to the mainframe (if required) Attach ranging arms to the mainframe Connect cables and hoses between the mainframe and ranging arms Connect lifting cylinders to the ranging arms. To do so, power up the powerpack of the machine and first carry out the necessary safety checks or use a separate powerpack to extend the cylinders to the required length.

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Tab. 2: EL 3000 shearer - Main components, dimensions and weights

Assembly Installing the shoe post on the mainframe

4

Ensure all covers and guards are in position and secured Install spall guards on the mainframe (If they were 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 first carry out the necessary safety checks or use a separate powerpack Attach the cutting drums to the ranging arms Attach the picks and water spraying devices to the cutting drums Commission the shearer. To do so, refer to the documents on mechanical, electrical and electronic commissioning You will find detailed descriptions of the steps listed in the following chapters.

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4.4 Installing the shoe post on the mainframe The shoe posts are installed on the shearer by means of two tapered pins (1).

The two pins are secured by means of sockets with a tapered bush (2). These are pressed onto the pins (1) with the aid of a hex. head screw (4) and hex. nut (5), creating a friction fit between the shoe post and mainframe. Covers (6) protect the fastening elements.

overview

Fig. 11: Overview of installation material for shoe post

7, 8

6

5

3

assembly

2

3, 4

2

1

1

Tapered pin

5

Hex. nut

2

Tapered bush

6

Cover

3

Washer

7

Hex. head screw

4

Hex. head screw

8

Lockwasher set

6

7, 8

1. Support the mainframe with suitable lifting or supporting devices.

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

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4

Assembly Installing the shoe post on the mainframe

3. Clean and degrease the tapered pins (1) and insert into the holes. Make sure the pin is centered. The distance from the pin to the ring around the hole in the shoe post should be approx. 58 mm (face side).

Fig. 13: Inserting the pin

58 mm

1

1

Tapered pin

4. Clean and degrease the tapered bushes (2) and place on the tapered pins (1).

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Fig. 12: Positioning the shoe post under the mainframe

Assembly Installing the shoe post on the mainframe

4

Fig. 14: Installing the bushes

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2

1

Tapered pin

1

2

2

Tapered bush

5. Insert the hex. head screw (4) with washer (3) through the pin from the face side and secure with washer (3) and hex. nut (5) from the gob side.

Fig. 15: Installing the bolts

5

3 3, 4

3

Washer

4

Hex. head screw

5

Hex. nut

6. Grease the surfaces of the tapered bushes (2) and fasten cover (6) to shoe post using hex. head screws (7) and lockwasher sets (8).

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4

Assembly Installing the lifting cylinders Fig. 16: Installing the covers

6

6

2

Tapered bush

7

Hex. head screw

6

Cover

8

Lockwasher set

7, 8

4.5 Installing the lifting cylinders The lifting cylinders are installed on the shearer by means of a tapered pin (1).

The pin is secured by means of tapered bushes (2). These are pressed onto the pins (1) with the aid of a hex. head screw (4) and hex. nut (5). Covers (6) protect the fastening elements.

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7, 8

Assembly Installing the lifting cylinders

4

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Fig. 17: Overview of installation material for lifting cylinder

7, 8

6

3, 4

2

3

1

5

1

Tapered pin

5

Hex. nut

2

Tapered bush

6

Cover

3

Spring washer

7

Hex. head screw

4

Hex. head screw

8

Retaining washer (set)

6

7, 8

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: 1. Position the lifting cylinder (A) under the mainframe (B).

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

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4

Assembly Installing the lifting cylinders Fig. 18: Positioning the lifting cylinder

B

A

Lifting cylinder

B

Mainframe

3. Clean and degrease the tapered pin (1) and insert in the through hole.

Center the pin.

Fig. 19: Centering the pin

1

1

Tapered pin

2

4. Clean and degrease the tapered bushes (2) and place on the tapered pins (1).

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A

Assembly

4

Installing the lifting cylinders Fig. 20: Installing the bushes

2

2

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1

1

Tapered pin

2

Tapered bush

5. Insert the hex. head screw (4) with spring washer (3) through the pin from the face side and secure with spring washer (3) and hex. nut (5) from the gob side.

Fig. 21: Securing the bush

5 3

3, 4

3

Spring washer

4

Hex. head screw

5

Hex. nut

6. Fill the ends of the tapered bushes (2) with grease and fasten cover (6) to shoe post using hex. head screws (7) and lockwasher sets (8).

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4

Assembly Installing the downdrive on the mainframe Fig. 22: Installing the covers

7, 8

6

Cover

7

Hex. head screw

8

Retaining washer (set)

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

4.6 Installing the downdrive on the mainframe fastening elements

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The downdrives are fastened to the mainframe by means of 8 threaded pins (4, 5). The threaded pins are screwed into threaded plates (6, 7) and secured with tensioning nuts (3).

EL3000 Shearer

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6

Assembly Installing the downdrive on the mainframe

4

Fig. 23: Overview of installation material for downdrive

3

7

4

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2

5 6

provisional installation

2

Protective cap

5

Threaded pin, 700 mm

3

Tensioning nut

6

Threaded plate, 3 holes

4

Threaded pin, 590 mm

7

Threaded plate

The initial fastening of the downdrive is done in a provisional manner to position the downdrive for installation of the Superbolt fasteners.

Tip Danger of damage to machine parts!

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 threaded pins, washers and standard nuts.

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

NOTICE Crushing hazard!

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

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

3. Insert threaded plates (7) for the 2 upper studbolts of the downdrive into the pockets at the top of the mainframe.

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4

Assembly Installing the downdrive on the mainframe Fig. 24: Positioning the downdrive

7

Threaded plate

4. Push provisional threaded pins (8) with an appropriate length through the 2 upper through holes and screw into the threaded plates (7) in the mainframe.

5. Push provisional threaded pins with an appropriate length through the 2 lower, outer through holes and screw into the threaded plates (6) in the mainframe.

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7

Assembly Installing the downdrive on the mainframe

4

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Fig. 25: Installing provisional threaded pins

6 6

Threaded plate, 3 holes

6. Screw suitable threaded plates/nuts (9) onto the provisional threaded pins (8) until the downdrive is fully mated with the mainframe. Tighten the threaded plates/nuts using a crisscross pattern.

Fig. 26: Pulling the downdrive to the mainframe

9 8

8

EL3000 Shearer

Provisional threaded pin

9

Threaded plate/nut

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4

Assembly Installing the downdrive on the mainframe

final installation

When the downdrive is fully mated to the mainframe, you can exchange the provisional fastening elements: 1. Remove threaded plate/nut (9) and threaded pin (8) at one of the upper through holes and replace with appropriate threaded pin (4) and tensioning nut (3).

2. Tighten tensioning nut (3) in accordance with separate manual for tensioning nuts.

3. Remove threaded plate/nut (9) and threaded pin (8) at one of the lower through holes diagonally opposite the upper through hole and replace with appropriate threaded pin (4) and tensioning nut (3).

4. Tighten tensioning nuts (3) in accordance with separate manual for tensioning nuts.

Fig. 27: Replacing provisional fastening elements

4

5

3

3

Tensioning nut

4

Threaded pin, 590 mm

5

Threaded pin, 700 mm

5. Replace the remaining two fastening elements and tighten tensioning nuts (3) in accordance with separate manual for tensioning nuts.

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3

Assembly Installing the downdrive on the mainframe

4

Fig. 28: Replacing the remaining fastening elements

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3

3

3

Tensioning nut

6. Insert the remaining four threaded pins (5) into the lower through holes and install tensioning nuts (3).

7. Tighten tensioning nuts (3) in accordance with separate manual for tensioning nuts.

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4

Assembly Installing the downdrive on the mainframe

3 5

3

Tensioning nut

5

Threaded pin, 700 mm

8. When all tensioning nuts have been installed and tightened in accordance with the manual, carry out a final check to ensure even pin loading. To do so, use a torque wrench and tighten all clamping screws to the recommended value.

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

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Fig. 29: Installing the remaining threaded pins and tensioning nuts

Assembly Installing the ranging arm on the mainframe

4

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Fig. 30: Installing the protective caps

2

2

Protective cap

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

Tip Risk of machine damage from improper installation!

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.

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

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

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4

Assembly Installing the ranging arm on the mainframe

Fig. 31: Positioning the ranging arm

1

Mainframe

2

Ranging arm

2

3

3

Lifting eye 8 load capacity = 8000 kg

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

Fig. 32: Inserting contact washers

1 4 2

4

1

Mainframe

2

Ranging arm

4

Contact washer

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

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

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1

Assembly Installing the ranging arm on the mainframe

4

Fig. 33: Inserting the hinge pin

5 2

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1

5

1

Mainframe

2

Ranging arm

5

Hinge pin

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

7. Align the hinge pins horizontally (cover must lie flat on the mainframe).

Fig. 34: Aligning the hinge pin with cover

7 8, 9

EL3000 Shearer

7

Cover

8

Hex. head screw

9

Washer

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4

Assembly Installing the ranging arm on the mainframe

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

Fig. 35: Installing the inner clamping sets

5

Hinge pin

5

10

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10

Clamping set KTR 401

9. Remove the covers from the hinge pins.

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

Fig. 36: Installing the outer clamping sets

10

5 10

5

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Hinge pin

10

Clamping set KTR 401

EL3000 Shearer

Assembly Installing the lifting cylinder on the ranging arm

4

11. Further installation (e.g. tightening the clamping screws) must be done in accordance with the mounting instructions for the clamping sets. Make sure to tighten the clamping screws to the required torque.

12. Reinstall the two covers on the joint brackets.

13. Support the ranging arm with appropriate material so that it cannot move during the subsequent installation steps.

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

4.8 Installing the lifting cylinder on the ranging arm Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

The lifting cylinders are fastened to the ranging arm by means of pins. The pins are secured by a retaining ring and a hex. head screw.

Tip Do not grease the pins before you install them!

Degrease pins in case they were greased before. moving the cylinder into position

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

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

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

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4

Assembly Installing the lifting cylinder on the ranging arm

a

b

1

Pin

a

Lifting cylinder

1

b

Lifting eye

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

4. Tighten the hex. head screw (4) to a torque of 1332 Nm. Fig. 38: Tightening the pin

3, 4

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1

2

1

Pin

3

Nord-Lock washer

2

Retaining ring

4

Hex. head screw

EL3000 Shearer

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Fig. 37: Inserting the pin

Assembly Installing the shearer drum on the ranging arm

4

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

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

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Fig. 39: Preparing the working area

1

3

2

4

1

Coal face

3

Cutting drum

2

Working area

4

Shearer

3. Align the ranging arm horizontally.

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

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

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

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

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4

Assembly Installing the shearer drum on the ranging arm Fig. 40: Installing the cutting drum

2

3

4

1

Ranging arm

3

Square hub

2

Cutting drum

4

Bolt

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

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

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

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1

Assembly Installing the shearer drum on the ranging arm

4

Fig. 41: Installing the water distribution plate

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2

3

5

4

2

Cutting drum

4

Cylinder head screw

3

Square hub

5

Water distribution plate

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

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

13. Insert the spray nozzles and secure with staples.

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

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4

Assembly Installing the shearer drum on the ranging arm Fig. 42: 41_Installing the spray nozzles

1 2

4 1

Ranging arm

6

Spray nozzle

2

Cutting drum

7

Pick holder

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

Fig. 43: Installing a pick

2

7

8

2

Cutting drum

7

Pick holder

8

Picks

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

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3

Assembly Connecting the shearer

4

4.10 Connecting the shearer 4.10.1 Electrical connection The shearer must be connected to a suitable electrical power supply cable. For further information see "Electrical components" [} 139] and the electrical diagrams.

4.10.2 Water connection The shearer has to be connected to an appropriate water supply. The water system of the shearer has the following functions: to provide cooling for the shearer units to provide dust suppression Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

The inlet for the water supply is located near the power pack and is clearly identified. For further information on the water system, see "Water System" [} 153] and the diagrams for the water supply.

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

For additional information, see "Maintenance" [} 73] and "Permissible media" [} 154].

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

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

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

4.12.1 Before commissioning The following work has to be performed before starting up the shearer: align conveyor remove all tools, auxiliary equipment, etc. from the shearer, the conveyor and your working area

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4

Assembly Commissioning the shearer

check that all bolted connections are tightened to the correct torque check the hydraulic connections and lines for leakage or damage check that all supply lines are installed properly check the hydraulic connectors. In particular, check that the staples are completely pushed in

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

2. If staple retainers are used, ensure that when working on hose connections the staple retainers are reinstalled on completion of the work. check the oil level and the cooling of the gearboxes check that the hydraulic reservoir is filled to the correct level check the cooling of the electric motors check the rotational direction of the electric motors check the electrical connections

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

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

4.12.3 Commissioning the shearer commissioning document

The shearer is commissioned under the instruction of Caterpillar technicians.

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

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

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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.

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

Assembly Dismantling and removing the shearer

4

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

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

4.12.5 Changing oils and hydraulic fluid

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It is recommended that all oils be replaced after the first two weeks of production. After the first replacement, oil and hydraulic fluid are monitored by taking samples and contamination analysis (see "Oil and fluid analyses" [} 80]).

4.13 Dismantling and removing the shearer drawing up a removal plan

personnel

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

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

4.13.1 Important instructions for dismantling handling sensitive components

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

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

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

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5

Operation Start of work

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

Please read this chapter carefully and thoroughly. Make sure you observe the safety instructions in the "Safety" chapter.

5.1 Start of work Carefully perform the daily maintenance activities listed in the maintenance tables when you start the shift. This will ensure a better reliability and performance of the shearer:

2. check the shearer for any visible defects, e.g. cracks, leakages, broken or missing parts or wear. This includes hoses and cables, wear of the picks on the cutting drums, wear of the skid shoes as well as wear of the inserts in the trapping shoes (gobside). Additional information on wear measurements can be found in the "Replacing worn parts" section of this chapter 3. check oil and hydraulic fluid levels. Fill up if necessary. Grease the grease nipples as stated in the maintenance tables. Further information can be found in the section “Maintenance” 4. check that the cutting drums can rotate freely 5. check all flameproof covers, cable inlets, safety equipment, controls and inspection covers for damage 6. check that the water supply is correct to all parts of the shearer 7. check that the emergency stop is working correctly 8. check if further maintenance is necessary in accordance with the maintenance tables (e.g. weekly, monthly, quarterly) Work may not be started until the perfect condition and proper functioning of the shearer and the entire conveyor system have been checked and the daily maintenance activities have been performed.

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

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

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1. clean the shearer from any debris that might obstruct the operation of the shearer

Operation Control elements

5

Fig. 44: Control elements

5

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1

2

4

3

6

11

10

9

8

7

12

13

14

EL3000 Shearer

1

LH end display

8

Motor start/stop button

2

Reset button

9

RH transceiver

3

Circuit breaker for LH frequency converter

10

LH wireless remote control

4

Circuit breaker for RH frequency converter

11

Main disconnect switch

5

RH end display

12

Cutter motor isolation switch

6

LH transceiver

13

RH wireless remote control

7

Main display

14

USB remote control

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5

Operation MMC/ Electrical Control Box

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

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

Tip Important!

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

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Operation

5

MMC/ Electrical Control Box Fig. 45: ECB3 control elements - low-voltage area

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18

15

16

17

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

Headlights on/off (if headlights are installed)

10

Stop pump motor and haulage motor

2

Start machine

11

Start coal sizer (if coal sizer is installed)

3

Start motors in sequence

12

Stop coal sizer (if coal sizer is installed)

4

Stop motors in sequence

13

Test ground-fault electrical circuits

5

Start LH cutter motor

14

Reset ground-fault circuits

6

Stop LH cutter motor

15

Emergency stop

7

Start RH cutter motor

16

Control circuit test points

8

Stop RH cutter motor

17

Reset low-voltage circuit breaker

9

Start pump motor and haulage motor

18

MMC display

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

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5

Operation Wireless remote control

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

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

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

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Fig. 46: USB remote control

Operation Wireless remote control

5

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Fig. 47: Wireless remote control

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

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

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

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5

Operation Wireless remote control

1

Display

3

"Back" key

2

Symbol on the display

4

"Input" key

a

Keystroke/synchronization

5

"Page up" key

b

Active wireless connection

6

"Page down" key

c

Charging status

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

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

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

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

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

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

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

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Fig. 48: General control elements and display

Operation Wireless remote control

5

Fig. 49: Switching on the remote control

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1

1

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

There are two possible ways to turn off the wireless remote control: press and hold the "STOP" (2) key Press and hold the "SHIFT/ON" (1) and "HAUL/HALT" (3) keys

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5

Operation Wireless remote control Fig. 50: Switching off the remote control

2

3

1

"SHIFT/ON" key

2

"STOP" key

3

"HAUL/HALT" key

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

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1

Operation Wireless remote control

5

Fig. 51: General control buttons

3

1 2 4

6

5 9

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7 8

12

10 11

15

13 14

18

16 17 19

21

20 1

Slowly raise LH ranging arm

12

Start/stop motors

2

Stop all motors/ turn off remote control

13

Rotate LH cowl counterclockwise (if installed)

3

Slowly raise RH ranging arm

14

Programming on/off

4

Slowly lower LH ranging arm

15

Rotate RH cowl counterclockwise (if installed)

5

Shift (for blue buttons)/switch on remote control/

16

Rotate LH cowl counterclockwise (if installed)

synchronize (press and hold >5 sec.)

6

Slowly lower RH ranging arm

17

Automatic mode on/off

7

Increase LH feed rate (when going left)/

18

Rotate RH cowl counterclockwise (if installed)

8

Activate (in combination with button 7/9)/ 19 deactivate haulage unit

LH ranging arm: switch from automatic mode to manual mode

9

Increase RH feed rate (when going right)/

20

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

21

RH ranging arm: switch from automatic mode to manual mode

reduce RH feed rate (when going right)

reduce LH feed rate (when going left)

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End of display: open next page

11

Activate keypad mode

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Operation Wireless remote control

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

Fig. 52: Shift buttons

2

3

4

5

6

7

8

9

10

11

1

SHIFT key (press and hold)

7

RH cutting drum: water on/off

2

Rapidly raise LH ranging arm

8

Programming key (MMC, setup mode)

3

Rapidly raise RH ranging arm

9

Programming key (MMC, setup mode)

4

Rapidly lower LH ranging arm

10

Programming key (MMC, setup mode)

5

Rapidly lower RH ranging arm

11

Programming key (MMC, setup mode)

6

LH cutting drum: water on/off

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

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1

Operation Wireless remote control

5

Fig. 53: Numeric keypad

3

4 6

5

7

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1 1

2

3

4

5

6

7

8

9

*

0

#

2

9 8

10

1

Activate numeric keypad

6

TAB (jump to next input field)

2

Numeric keypad (numbers 0-9)

7

ENTF (delete entry left of cursor)

3

F1 (reset function, machine mode)

8

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

4

F3 (confirm page number)

9

Open fault list

5

Open previous page

10

ENTER key

5.4.6 Starting/stopping motors To start a motor, proceed as follows: After pressing “MOTOR STOP/START”, you can start individual motors or a sequence of motors. The following keys serve to start motors:

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5

Operation Wireless remote control Fig. 54: Start/stop motors

1 4 6

5

7

1

Activate motor stop/start function

5

Motor selection: pump motor

2

Motor selection: LH cutter motor

6

Motor selection: haulage frequency converter

3

Motor selection: RH cutter motor

7

Motor selection: motor sequence

4

Motor selection: coal sizer (if installed)

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

5.4.7 Setup Mode Tip Important!

Additional information on the setup mode can be found in the operating manual for the wireless remote control.

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

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3

2

Operation Wireless remote control

5

Fig. 55: Activating the setup mode

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1

1

Activate setup mode (4 buttons)

Five buttons serve to navigate through the setup mode:

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5

Operation Commissioning the shearer Fig. 56: Navigation in the setup mode

1

2

5

4

1

Up

4

Selection/enter

2

Down

5

Right

3

Left

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

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

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

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

NOTICE Risk of overheating!

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

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Operation What to observe during operation

5

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

Notice on work safety Important!

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

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Fig. 57: Main switches on the electronic control unit

1

1

Main switch for shearer

2

2

Main switch for cutting elements

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

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

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

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5

Operation Stopping the shearer

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

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

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

NOTICE Danger from different gradients!

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

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

NOTICE Deviation from cutting horizon!

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

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

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

Notice on work safety Notice!

The emergency stop should be used in emergencies only.

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

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

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

Operation Maintenance

5

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

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

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

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

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

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

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4. Switch `ON' the shearer main switch.

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

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

7. Select the desired control mode.

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

9. Switch on the motors.

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

5.9 Maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the shearer. Be sure to follow the safety instructions in chapter "Safety" [} 8] 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. The information is divided into mechanical and electrical maintenance tasks. The tables contain references to detailed information on the individual maintenance items. Follow these references in case you need further information.

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

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

Only use suitable and approved tools for maintenance work.

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Operation Maintenance

Only use original Caterpillar spare parts when replacing components.

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

DANGER Risk of electric shock!

DANGER Danger due to moving parts!

Moving or falling parts can cause serious injury. The shearer must be immobilized before you carry out maintenance on moving parts. When work needs to be carried out over or on the face side of the shearer, both the shearer and conveyor (AFC) must be immobilized. In addition, adequate roof and face support must be provided.

WARNING Danger from hot fluids under pressure!

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

5.9.3 Maintenance intervals (mechanical) Tab. 3: Maintenance intervals (mechanical) No.

Maintenance point

daily

weekly

monthly

every three months

Comment/ Reference

General M10

Contamination

Clean

M20

Missing/damaged parts

Check

M30

Skid shoe wear

M35

Cable arm

M40

Cover plates secured?

M45

Check gearbox oil filling filter

Visual inspection Check

Lubricate

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

Ranging arms

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

Operation

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Maintenance

weekly

monthly

every three months

5

No.

Maintenance point

daily

M50

Oil levels

Check

"Maintenance of the ranging arms" [} 86]

M60

Lifting cylinder operation

Check

"Maintenance of the ranging arms" [} 86]

M80

Water supply tight?

Check

"Maintenance of the ranging arms" [} 86]

M90

Cover plates secured?

Check

"Maintenance of the ranging arms" [} 86]

M95

Motor quill shaft

Check, lubricate

Comment/ Reference

"Lubricating/replacing the quill shaft" [} 88]

M100 Oil leaks?

Check

"Maintenance of the ranging arms" [} 86]

M110 Hinge pins in drive frame

Lubricate

"Maintenance of the ranging arms" [} 86]

M120 Pin connection on lifting cylinder

Check

"Maintenance of the ranging arms" [} 86]

M130 Lifting cylinder damage?

Check

"Maintenance of the ranging arms" [} 86]

M140 Fluid sample for analysis

Check

"Maintenance of the ranging arms" [} 86]

M150 Motor bracket tight?

Check

"Maintenance of the ranging arms" [} 86]

M160 Wear and correct positioning of hinge pins

Check

"Maintenance of the ranging arms" [} 86]

M170 Oil change (If no analysis was carried out)

Change

"Maintenance of the ranging arms" [} 86]

M180 Cover plate on high-speed section

Check

"Maintenance of the ranging arms" [} 86]

M190 Water pipe seals

Lubricate

"Maintenance of the ranging arms" [} 86]

M200 Cowls (if installed)

Lubricate

"Maintenance of the ranging arms" [} 86]

Check

"Maintenance of the cutting drums" [} 98]

Cutting drums M210 Picks and pick holders

M220 Connecting pins tight?

EL3000 Shearer

Check

"Maintenance of the cutting drums" [} 98]

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Operation

No.

Maintenance point

daily

M230 Can rotate freely?

Check

"Maintenance of the cutting drums" [} 98]

M240 Damaged?

Check

"Maintenance of the cutting drums" [} 98]

M250 Oil leakage (from ranging arm)?

Check

"Maintenance of the cutting drums" [} 98]

M260 Dust suppression nozzles

Check

"Maintenance of the cutting drums" [} 98]

Check

"Maintenance of the haulage units" [} 99]

Maintenance

weekly

monthly

every three months

Comment/ Reference

M270 Oil level

M280 Motor bracket tight?

Check

"Maintenance of the haulage units" [} 99]

M290 Motor quill shaft

Check, lubricate

"Lubricating/replacing the quill shaft" [} 100]

M300 Fluid sample for analysis

Check

"Maintenance of the haulage units" [} 99]

M310 Brake wear (if brake installed)

Check

"Maintenance of the haulage units" [} 99]

M320 Oil change (If no analysis was carried out)

Change

"Maintenance of the haulage units" [} 99]

Powerpack M330 Fluid level

Check

"Maintenance of the power pack" [} 111]

M340 Working pressure

Check

"Maintenance of the power pack" [} 111]

M350 Leakage?

Check

"Maintenance of the power pack" [} 111]

M360 Filter condition

Check

"Maintenance of the power pack" [} 111]

M370 Hoses and connections

Check

"Maintenance of the power pack" [} 111]

M390 Fluid sample for analysis

Check

"Maintenance of the power pack" [} 111]

M400 Pressure and return filter

Check/ replace

"Maintenance of the power pack" [} 111]

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Haulage unit

Operation Maintenance

No.

Maintenance point

daily

weekly

monthly

Comment/ Reference

M405 Tank breather filter

Change

"Maintenance of the power pack" [} 111]

M410 Pump bracket tight?

Check

"Maintenance of the power pack" [} 111]

M420 Motor bracket tight?

Check

"Maintenance of the power pack" [} 111]

M430 Control valves tight?

Check

"Maintenance of the power pack" [} 111]

M440 Hydraulic Fluid

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every three months

5

Change

"Maintenance of the power pack" [} 111]

Water System M450 Valves operate?

Check

M460 Visible hoses and connections

Check

M470 Flow and pressure values (MMC)

Check + note

Downdrives M480 Oil level

Check

"Maintenance of the downdrives" [} 113]

M490 Bearings

Lubricate

"Maintenance of the downdrives" [} 113]

M495 Drive shaft

Lubricate

"Maintenance of the downdrives" [} 113]

M500 Trapping shoe pin connection

Check

"Maintenance of the downdrives" [} 113]

M505 Trapping shoe lubrication points

Lubricate

"Maintenance of the downdrives" [} 113]

M510 Gear condition

Check

"Maintenance of the downdrives" [} 113]

M520 Gear lubrication

Check

"Maintenance of the downdrives" [} 113]

M530 Trapping shoe wear part

M540 Tensioning nut torque

EL3000 Shearer

Check

"Insert on trapping shoe" [} 116] Check

"Maintenance of the downdrives" [} 113]

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Operation Maintenance

5.9.4 Maintenance intervals (electrical) Tab. 4: Maintenance intervals (electrical) No.

Maintenance point

daily

weekly

monthly

every three months

Comment/ Reference

General E10

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

Visual inspection

E20

Correct operation of the main switch, buttons, keyboard…

Check

Also by operator at start of shift

E30

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

Check

Also by operator at start of shift

E40

Trailing cable: Connection to ECB3 and monitoring unit

Visual inspection

E50

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

E60

Methane concentration

E70

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

Check Visual inspection/ knocking test

Wireless remote controls E90

Contamination and moisture

Remove

E100

Wireless remote control defective?

Check/ replace

E110

Rechargeable batteries charged?

Check

E120

Can all operating functions be executed?

Check

By operator at start of shift

Control system (MMC) E130

Does the MMC control system function correctly?

Check

E140

Motor parameters, start-up operating parameters

Note

E150

Haulage system parameters

Check/ record

E155

CIOS modules and brackets tight?

Check

E160

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

Record

E170

Motor winding insulation and consistency values for all motors

By connecting to control station above ground

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

If necessary, tighten by hand

Record

Ranging arm motor E180

Connection of main and sensor cables. Cable and feedthrough points

Check

E190

Cable entry housing dry and clean?

Check

E200

Connection of motor transmitter unit

Check

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Check

Operation Maintenance

No.

Maintenance point

E210

Explosion protection cover plates damaged?

Gap dimensions for explosion protection correct?

daily

weekly

monthly

every three months

5

Comment/ Reference

Check

Electrical Control Box ECB 3 E215

All ground fault and shutdown devices

Trigger/ check

E220

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

Check

E230

Gap dimensions for explosion protection correct?

Check

Visual inspection/ knocking test

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Main transformer unit HTB3 E235

Ground fault test unit and LEDs

Trigger/ check

E240

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

Check

E250

Gap dimensions for explosion protection correct?

Check

Visual inspection/ knocking test

Pump motor E255

Connection of motor transmitter unit

Check

E260

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

Check

E270

Gap dimensions for explosion protection correct?

Check

Visual inspections/ knocking test, Check strength of bolted connections

Haulage motors E275

Connection of motor transmitter unit

Check

E280

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

Check

E290

Gap dimensions for explosion protection correct?

Check

Visual inspections/ knocking test, Check strength of bolted connections

Electro-hydraulic control valves E300

Control valves functioning correctly?

Check

Start-up warning sirens E310

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

Check

Visual inspection of the flashing light

Motor of coal sizer (if installed) E320

Connection of motor transmitter unit

EL3000 Shearer

Check

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Operation

No.

Maintenance point

E330

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

Check

E340

Gap dimensions for explosion protection correct?

Check

Maintenance

daily

weekly

monthly

every three months

Comment/ Reference Visual inspections/ knocking test, Check strength of bolted connections

5.9.5 Oil and fluid analyses Notice on work safety Replace all oils and the hydraulic fluid after the first two weeks of production.

Then continue routine oil sampling as stated in the maintenance tables.

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

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

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

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

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

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

CAUTION Hot oil!

Hot oil can cause burns. If the oil is sufficiently hot, take great care.

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Notice!

Operation Maintenance

5

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

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

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

5.9.6 Filling oil and hydraulic fluid The shearer has a special system for filling oil and hydraulic fluid. With this system, it is possible to fill all units by means of an off-board pump or by means of the shearer's onboard pump. In either case, filling takes place at a central point on the right-hand downdrive, where the onboard pump is located. The procedures for both filling methods are explained in greater detail in the following.

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Filling procedure with off-board pump Filling with gear oil by means of an off-board pump takes place for all components (ranging arms, haulage units, downdrives) at a central filling point (1). To fill a certain unit, the corresponding valve (3, 4, 5, 6) for the unit must be opened so that oil can enter. Filling the power pack with hydraulic fluid also takes place at a central filling point (2).

NOTICE Risk of machine damage due to incorrect filling!

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

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

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5

Operation Maintenance Fig. 58: Overview of filling with off-board pump

4

3

5

6

1

Gear oil filling point

4

Ranging arm valve, high-speed section

2

Hydraulic fluid filling point

5

Ranging arm valve, epicyclic section

3

Downdrive oil reservoir valve

6

Haulage unit valve

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

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

3. When filling with gear oil: Completely open valve for the unit to be filled (3, 4, 5, 6).

4. Connect filling hose to the correct filling point (1, 2).

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

6. Shut off the pump once filling is complete and disconnect the filling hose from the filling point (1, 2).

7. Bleed the filled unit for 4 minutes.

8. Completely close the valve of the filled unit (3, 4, 5, 6).

Filling procedure with on-board pump Filling with gear oil by means of the on-board pump takes place for all components (ranging arms, haulage units, downdrives) at a central filling point (7). To fill a certain unit, the corresponding valve (3, 4, 5, 6) for the unit must be opened so that oil can enter. To open the valve, pull the control lever (2) towards the

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2

1

Operation Maintenance

5

front.

Filling the power pack with hydraulic fluid also takes place at the central filling point (7). In this case, push the control lever (2) towards the back.

NOTICE Risk of machine damage due to incorrect filling!

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

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

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5

Operation Maintenance

Fig. 59: Overview of filling with on-board pump

7

3 4 5

6

2

Control lever

5

Ranging arm valve, epicyclic section

3

Downdrive oil reservoir valve

6

Haulage unit valve

4

Ranging arm valve, high-speed section

6

Filling point

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

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

3. When filling with gear oil: Completely open valve for the unit to be filled (3, 4, 5, 6).

4. Remove plug at the filling point (7) (DN 25 staple lock). Connect filling hose to the filling point (7).

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2

Operation Maintenance

5

5. When filling with gear oil: Pull control lever (2) towards the front. When filling with hydraulic fluid: push control lever (2) towards the back.

6. Start the filling process with the aid of the wireless remote control (press and hold the "SHIFT"+ "S4" buttons). Observe the fill level at the corresponding oil-level gauge. Do not overfill the unit. If you noticed that too much oil has been filled, drain oil until the desired fill level is reached (as a rule: to the halfway mark in the oil-level gauge).

7. Shut off the pump once filling is complete (release the "SHIFT"+ "S4" buttons) and disconnect the filling hose from the filling point (7). Insert plug at the filling point (DN 25 staple lock).

8. Bleed the filled unit for 4 minutes.

9. Completely close the valve of the filled unit (3, 4, 5, 6).

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

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

The oil filter is fouled.

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

The factory setting of the throttle valve (3) is the fully open position. If it is observed during operation that the pressure relief valve opens too early or too late, the throttle valve (3) must be readjusted. To do this, the bolt (4) above the throttle valve must be removed. The throttle valve can then be readjusted with a square socket wrench.

NOTICE Risk from closing the throttle valve!

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

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5

Operation Maintenance Fig. 60: Adjusting the pressure limiter

4

2

2

1

Pressure relief valve

3

Throttle valve

2

Oil outlet

4

Bolt

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

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1

Operation

5

Maintenance Fig. 61: Maintenance points on ranging arm RA0750

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A, M170

M110, M160 M150

M80

M190

M180 M90

C, M140 M50

M100 D, M140

B, M170 M95

B, M170 M60, M130 M120

Tab. 5: Maintenance of the ranging arm Ranging arms

EL3000 Shearer

M50

Oil levels

Ranging arms horizontal, machine shut down, check oil levels

M60

Lifting cylinder operation

Raise and lower both ranging arms

M80

Water supply tight?

Visual inspection

M90

Cover plates secured?

Visual inspection

M95

Check/lubricate shear shaft

"Lubricating/replacing the quill shaft" [} 88]

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Operation Maintenance

M100

Oil leaks?

Visual inspection

M110

Hinge pins in drive frame

Hinge pins are connected to a central lubrication supply.

Before lubricating, ensure that the weight of the ranging arm is fully supported (e.g.: cutting drum resting on the floor or ranging arm is resting on support) For lubricants: see "Permissible media" [} 154]

M120

Pin connection on lifting cylinder

Visual inspection

M130

Lifting cylinder damage?

Visual inspection, machine shut down (see "Electrical isolation of the shearer" [} 72])

M140

Fluid sample for analysis

The oil change interval depends on the result of the analysis

M150

Motor bracket tight?

Acoustic emission testing

M160

Wear and correct positioning Visual inspection for "play" between hinge pin and mountof hinge pins ing hole

M170

Oil change (If no analysis was carried out)

Drain oil (high-speed section and epicyclic section) and refill. For details of the filling process, see .

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

M180

Cover plate on high-speed section

Visual inspection of whether cover plate is fastened securely.

Check for oil leaks.

Check the tightening torques of all bolts.

M190

Water pipe seals

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

M200

Cowls (if installed)

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

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

Notice on work safety Correct working height!

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

Notice on work safety Important!

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

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 72]) 2. Remove hex. head screws (7) and Nordlock washers from the motor housing cover (8) and then remove motor housing cover (8).

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5

Operation

5

Maintenance

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Fig. 62: Removing the motor housing cover

8

7

Hex. head screw

7

8

Motor housing cover

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

Fig. 63: Removing the quill shaft cover

2

1

4

3

1

Cylinder head screw

3

Shaft plug

2

Quill shaft cover

4

Quill shaft

4. Remove the retaining ring (6).

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5

Operation Maintenance

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Fig. 64: Removing the retaining ring

6

3 3

Shaft plug

6

Retaining ring

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

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Operation Maintenance

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Fig. 65: Screwing the puller into the shaft plug

3

3

Shaft plug

6. Pull out the shaft plug (3).

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5

Operation Maintenance

3

3

Shaft plug

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

Tip Broken quill shaft!

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

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Fig. 66: Removing the shaft plug

Operation Maintenance

5

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Fig. 67: Pulling out the quill shaft

4

4

Quill shaft

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

Fig. 68: Inspecting the quill shaft

4 4

Quill shaft

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

Tip Insert the quill shaft correctly!

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

10. Push the quill shaft (4) into the motor with the aid of the puller (M16). If you have difficulty pushing the quill shaft gearing into the ranging arm gearing, proceed as follows:

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5

Operation Maintenance

11. Slowly rotate the quill shaft by hand while at the same time pushing it into the motor. If the above does not work, then the cutting drum may need to be turned slowly by hand, but only if the conditions (roof, etc.) are safe.

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

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

9

4

Quill shaft

4

9

Shear point

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

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

15. Lubricate the shaft plug (3) (see "Quill Shaft Grease" [} 156]).

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

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

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Fig. 69: Installing the quill shaft

Operation Maintenance

5

Fig. 70: Install the shaft plug.

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3

5

3

Shaft plug

5

O-ring

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

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5

Operation Maintenance

6

3 3

Shaft plug

6

Retaining ring

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

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

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Fig. 71: Installing the retaining ring

Operation

5

Maintenance Fig. 72: Installing the quill shaft cover

2

4

3

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6

1

1

Cylinder head screw

4

Shear shaft

2

Quill shaft cover

6

Retaining ring

3

Shaft plug

21. Install the motor housing cover.

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Operation Maintenance

5.9.8 Maintenance of the cutting drums Fig. 73: Cutting drum maintenance points

M220

M260

M230

M250

M240

Tab. 6: Cutting drum maintenance

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No.

Maintenance point

Notes

M210

Picks and pick holders

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

M220

Connecting pins tight?

Raise and lower both ranging arms

M230

Can rotate freely?

Visual inspection

M240

Damaged?

Visual inspection

M250

Oil leakage (from ranging arm)?

Visual inspection

M260

Dust suppression nozzles

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

EL3000 Shearer

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M210

Operation Maintenance

5

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

Fig. 74: Haulage unit maintenance points

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M310

M290

M270

M280

M320

M300

Tab. 7: Haulage unit maintenance

EL3000 Shearer

No.

Maintenance point

Notes

M270

Oil level

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

M280

Motor bracket tight?

Check bolted connection on motor bracket

M290

Motor quill shaft

See "Lubricating/replacing the quill shaft" [} 100] for details of removal, inspection and installation of the quill shaft

M300

Fluid sample for analysis

Taken oil sample from both haulage units at the oil drain point. See "Sampling" [} 80] for additional information. If the analysis indicates that the oil must be changed, drain the oil and refill to the correct oil level.

Oil capacity: 28 l Oil grade: see "Gear Oil" [} 154]

M310

Brake wear (if brake installed)

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

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Operation Maintenance

M320

Oil change (If no analysis was carried out)

Drain the oil and refill to the correct oil level. For details of the filling process see "Filling oil and hydraulic fluid" [} 81] .

Oil capacity: 28 l Oil grade: see "Gear Oil" [} 154]

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

Notice on work safety Important!

1. Shut down the shearer (see "Electrical isolation of the shearer" [} 72] ).

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

CAUTION Risk of injury from pressurized hose lines!

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

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

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

Operation Maintenance

5

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Fig. 75: Removing the cover

1

2

1

Cylinder head screw

4

Short quill shaft

2

Cover

5

Long quill shaft

3

Shaft plug

4. Remove the retaining ring (6).

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5

Operation Maintenance

6

3

3

Shaft plug

6

Retaining ring

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

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Fig. 76: Removing the retaining ring

Operation Maintenance

5

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Fig. 77: Removing the shaft plug

3

3

Shaft plug

6. Screw the puller (M12) into the short shear shaft (4).

Tip Broken quill shaft!

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

7. Screw the puller (M12) farther through the short quill shaft so that the puller pushes the short quill shaft out of the gearing of the long quill shaft. Pull the short quill shaft out of the motor.

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5

Operation Maintenance

5

4 4

Short quill shaft

5

Long quill shaft

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

Fig. 79: Inspecting the short quill shaft

4 4

Short quill shaft

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

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EL3000 Shearer

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Fig. 78: Removing the short quill shaft

Operation Maintenance

5

Fig. 80: Removing the long quill shaft

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5 5

Long quill shaft

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

Fig. 81: Inspecting the long quill shaft

6

5

5

EL3000 Shearer

Long quill shaft

6

O-ring

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5

Operation Maintenance

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

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

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

5 5

Long quill shaft

14. Lubricate the short quill shaft (4) (see "Quill Shaft Grease" [} 156]).

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

Tip Lock the puller!

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

Fig. 83: Screwing in the puller

4 4

Short quill shaft

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

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Fig. 82: Installing the long quill shaft

Operation

5

Maintenance

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

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Fig. 84: Installing the short shear shaft

5

4 4

Short shear shaft

5

Long shear shaft

18. Unscrew the puller from the short shear shaft.

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

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

21. Lubricate the shaft plug (3) (see "Quill Shaft Grease" [} 156]).

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

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5

Operation Maintenance

3

3

Shaft plug

7

O-ring

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

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Fig. 85: Installing the shaft plug

Operation Maintenance

5

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Fig. 86: Installing the retaining ring

6

3

3

Shaft plug

6

Retaining ring

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

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

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5

Operation Maintenance Fig. 87: Installing the covers

3 2

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1

Cylinder head screw

2

Cover

3

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1

Shaft plug

EL3000 Shearer

Operation Maintenance

5

5.9.10 Maintenance of the power pack Fig. 88: Power pack maintenance points

1

3, M340

2

5

4, M340

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9 14, M405

6

10

7, M420

15, M390 M440

16, M440

11, M400

13, M330 8, M380 M430

12, M410

1

Cooling water pressure

9

Oil cooler

2

Inlet water pressure

10

Return filter

3

Hydraulic system pressure

11

Pressure filter

4

Hydraulic control pressure

12

Hydraulic pump

5

Unused pressure gauge (0-40 bar)

13

Oil level gauge

6

Hydraulic reservoir

14

Breather

7

Pump motor

15

Oil drain

8

Valve block

16

Oil filling valve (for separate oil filling system)

Tab. 8: Haulage unit maintenance No.

EL3000 Shearer

Maintenance point

Notes

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Operation Maintenance

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M330

Fluid level

Electricity still supplied to the machine, but haulage motor isolated. Check the fill level with the aid of the MMC system and at the oil-level gauge on the power pack. Add hydraulic fluid, if necessary. For information on the filling procedure, see "Filling oil and hydraulic fluid" [} 81].

M340

Working pressure

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

M350

Leakage?

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

M360

Filter condition

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

M370

Hoses and connections

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

M390

Fluid sample for analysis

Remove a sample of hydraulic fluid. See "Sampling" [} 80] for additional information. If the analysis indicates that the hydraulic fluid must be changed, drain the hydraulic fluid and refill to the correct fill level.

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

M400

Pressure and return filter

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

M405

Tank breather filter

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

M410

Pump bracket tight?

Check accessible bolted connections

M420

Motor bracket tight?

Check accessible bolted connections

M430

Control valves tight?

Check accessible bolted connections

M440

Hydraulic Fluid

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

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

EL3000 Shearer

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5

Operation Maintenance

5

5.9.11 Maintenance of the downdrives Fig. 89: Downdrive maintenance points

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9, M480

6, M490

1, M490

8

7, M490

M510

2, M490 3

M495

M540

M505 M530 M500

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5

Operation Maintenance

1

Spur gear bearing lubrication point, face side

7

Drive gear bearing lubrication point, face side

2

Spur gear bearing lubrication point, gob side

8

Tell tale drive gear

3

Telltale spur gear section

9

Oil filling point

6

Drive gear bearing lubrication point, gob side

No.

Maintenance point

Notes

M480

Oil level

Check oil level at the oil-level gauge. Add oil, if necessary.

See "Filling oil and hydraulic fluid" [} 81] for details of the oil filling procedure.

M490

Bearings

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

M495

Drive shaft

Open cover over drive shaft and lubricate drive shaft

M500

Trapping shoe pin connection

Visual inspection

M505

Trapping shoe lubrication points

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

M510

Gear condition

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

M520

Gear lubrication

see M510

M530

Trapping shoe insert wear

Measure wear and replace insert, if necessary. See "Insert on trapping shoe" [} 116] for details.

M540

Tensioning nut torque

Random check and knocking test.

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

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

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

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

To measure the wear, proceed as follows: 1. Insert the pin of the wear gauge into the through hole of the skid shoe.

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Tab. 9: Downdrive maintenance

Operation Maintenance

5

Fig. 90: Placing the wear gauge

2

3

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1

1

Skid shoe

2

Wear gauge

3

Conveyor track

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

Fig. 91: Measure wear

>0 = OK <0=not OK

1

1

Skid shoe

2

Wear gauge

2

3

3

Conveyor track

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

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5

Operation Maintenance

Replacing a skid shoe To replace a worn skid shoe, raise the shoe post so that the weight of the machine is taken off the pin (1). Then remove the bolt (4), the cover (2) and the pin, and replace the skid shoe.

Fig. 92: Replacing a skid shoe

2

1

Pin

4

Hex. head screw

2

Cover

a

Skid shoe

3

Nord-Lock washer

2

3

4

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

Fig. 93: Trapping shoe wear gauges

5 4 3 2 1

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1

Wear gauge 4 mm

4

Wear gauge 7 mm

2

Wear gauge 5 mm

5

Wear gauge 8 mm

3

Wear gauge 6 mm

EL3000 Shearer

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1

a

Operation Maintenance

5

Tip Important!

Bring the machine to a level position and raise the ranging arm to measure the wear. Follow the safety instructions for working under the ranging arm!

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

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Fig. 94: Trapping shoe wear measurement

1 1

Trapping shoe

2

Rack bar

3

2

3

Combination of wear gauges

The wear limit of the inserts in the tracking shoe is reached when the distance between the rack bar and insert exceeds the following values: 20 mm on both sides of the rack bar (addition of values a and b as shown below) or 17 mm under the rack bar

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5

Operation Maintenance Fig. 95: Trapping shoe wear limits

max.(a+b)=20 mm a

b

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

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

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

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

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

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

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17 mm max.

Operation Maintenance

5

Fig. 96: Removing the rack bars

1

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7

1

Trapping shoe

7

Rack bar

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

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Operation

5

Maintenance

Fig. 97: Removing the wear part

1 4

3

5 2

1

Trapping shoe

4

Nord-Lock washer

2

Insert

5

Hex. head screw

3

Key

6

Lubricating nipple

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

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

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

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

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6

Operation Maintenance

5

Fig. 98: Installing the rack bars

1

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7

1

Trapping shoe

7

Rack bar

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

13. Shut down the shearer.

14. Fasten the rack bars (7).

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

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

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

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

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

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

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

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5

Operation Maintenance Fig. 99: Removing the rack bars

2

1

1

Downdrive

2

Trapping shoe

4

Rack bar

7. Remove the cylinder head screws (15), metal sheet (12), and O-rings (16).

Fig. 100: Removing the plate and O-rings

12

15 12

Plate

15

Cylinder head screw

16 16

O-ring

8. Remove the cylinder head screws (14, 15) from the inner pin retainer (9) and the outer pin retainer (10).

9. Remove inner (9) and outer pin retainer (10).

10. Remove pin (11).

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4

Operation Maintenance

5

Fig. 101: Removing the pin retainers and pin

9 1

10 14

15

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11

2

1

Downdrive

11

Pin

2

Trapping shoe

14

Cylinder head screw

9

Inner pin retainer

15

Cylinder head screw

10

Outer pin retainer

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

Fig. 102: Removing the trapping shoe with drive gear

1 3

2

1

Downdrive

2

Trapping shoe

3

Drive gear

12. Replace damaged or worn drive gear (3) and lubricate.

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5

Operation Maintenance

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

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

Fig. 103: Lowering the shearer

3

2

1

Downdrive

2

Trapping shoe

3

Drive gear

15. Align the trapping shoe and drive gear. Once the through holes in the downdrive housing and the unit consisting of trapping shoe and drive gear are aligned perfectly, install pin (11), inner (9) and outer (10) pin retainer.

16. Tighten the cylinder head screw (15) to a torque of 942 Nm.

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1

Operation Maintenance

5

Fig. 104: Installing the pin and pin retainers

9 1

10 14

15

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11

2

1

Downdrive

11

Pin

2

Trapping shoe

14

Cylinder head screw

9

Inner pin retainer

15

Cylinder head screw

10

Outer pin retainer

17. Check whether the O-rings (16) are in good condition. Replace the O-rings, if necessary.

18. Lubricate the O-rings (16).

19. Install the O-rings (16), plate (12) and cylinder head screws (15).

20. Tighten the cylinder head screws (15) to a torque of 942 Nm. Fig. 105: Removing the metal sheet and O-rings

12

15 12

Sheet

15

Cylinder head screw

16 16

O-ring

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

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5

Operation Maintenance

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

Fig. 106: Installing the rack bars

1

1

Trapping shoe

7

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7

Rack bar

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

24. Shut down the shearer.

25. Fasten the rack bars (7).

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Technical data Main components of the shearer

6

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

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

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

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

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

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

3. Modifications or changes must be approved by Caterpillar.

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

General Shearer type:

EL 3000

Noise level:

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

Mainframe Type:

MF 3-1

Construction:

One-piece frame

Ranging arms Type:

RA 750-WP-R2 (2x)

Gear ratio:

24/44 at 37 rpm

Oil capacity, high-speed stage:

28 l

Oil capacity, planetary stage:

30 l

Cutter motors Type:

CM750 MBM (2x)

Rated power:

750 kW

Voltage:

3300 V

Haulage unit

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6

Technical data Identification

Type:

HU150-MC-R1 (2x)

gear ratio:

137:1

Oil capacity:

28 l

Haulage motor Type:

HM150 MF (2x)

Rated power:

150 kW

Voltage:

0-600 V

Downdrives Type:

DC150-B-NH-JT2 (2x)

Height of machine:

1690 mm

Rack bar system:

Jumbotrack 2000

Lubrication:

Oil tank 12 l

Type:

PP3-200-75-E2 AUS TX

Pump rating:

200 l/min

Hydraulic fluid capacity:

300 l

Pump motor, type:

PM75 M

Pump motor power rating:

75 kW

Pump motor voltage:

3300 V

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Powerpack

Lifting cylinder Type:

ZE-250/150-670 (2x)

Stroke:

670 mm

Electrical Control Box Type:

ECB 3

Haulage transformer box Type:

HTB-33-AU-RN

Input voltage:

3300 V

Output voltage:

600 V

Frequency converter, type:

D2-100-600 ENCDS (2x)

Accessories Tools:

Tool box

Miscellaneous:

Fire extinguisher

6.2 Identification The identification of the shearer is specified below.

The shearer is identified with a serial number name plate.

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Technical data Mechanical components

6

Fig. 107: Type plate serial number

1

Serial number

2

Model designation

3

Object number

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

Components requiring special types of protection as a result of the ignition hazard assessment are identified with the classification on the name plate.

6.3 Mechanical components 6.3.1 RA0750 ranging arm The ranging arm is divided into three sections: high-speed section idlers section with double epicyclic stage In the high-speed section, the 1st motion shaft is driven by a splined shear shaft which can be fitted or withdrawn from the gob side of the shearer. The drive from the 1st motion shaft continues through a 2nd and 3rd motion shaft, a set of three idler gears, before reaching the planetary and output stage. The output is designed as a rectangular hub on the cutting drum.

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

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Technical data

6

Mechanical components

Fig. 108: RA0750 ranging arm

3 4 5

12 13 6 a 2

1

11 9

1

Ranging arm

9

Water spraying system pipe

2

High-speed section

11

Cooler, high-speed section

3

3rd motion shaft

12

Oil-level gauge, double epicyclic stage

4

Idler

13

Oil-level gauge, high-speed section

5

Spur gear

a

Lifting eye, 8000 kg

6

Double epicyclic stage

b

Motor housing

6.3.2 HU150 haulage unit The haulage unit is driven by a water-cooled electric motor. It consists of a highspeed section and a low-speed section.

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b

Technical data

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Mechanical components

6

high speed section

The high-speed section is driven by a shear shaft. The first motion shaft has a lip seal. This seal and an O-ring located on the end of the long shear shaft prevent oil contamination of the electric motor. The high-speed section has two further reduction gears and a set of idlers.

encoder

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

cooling

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

low-speed section

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

oil monitoring

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

oil level gauge

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

fastening in the mainframe

The haulage unit can be placed in the mainframe horizontally from the face side as a complete module. The unit is fastened in the mainframe by means of eight M24 bolts and Nord-Lock washers.

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

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6

Technical data Mechanical components

Fig. 109: HU150 haulage unit (RH gearbox)

f d a

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e

5 7

c

g 1 6

h

2

b 3

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9

4 10

EL3000 Shearer

Technical data Mechanical components

6

1

Housing

10

Shaft, third stage

2

Cooler

a

Haulage motor

3

Shaft, first stage

b

Encoder

4

Spur gear

c

Oil-level gauge

5

Double epicyclic stage

d

Oil filling connection (via hose or oil filling valve subassembly)

6

Oil level/temperature sensor

e

Oil sampling point (via hose)

7

Motor fastener

f

Breather (via hose or oil filling valve subassembly)

9

Shaft, second stage

g

Oil drain (via hose)

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6.3.3 Downdrive DC150-B

EL3000 Shearer

general

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

assembly

The entire downdrive is bolted to the gob side of the mainframe. It is attached by means of Superbolt fasteners (see chapter 4 "Assembly").

lubrication

Oil is dripped onto the pinion gear of the downdrive from a 12 l oil tank on the inner side of each haulage unit. The oil level can be checked from the gob side of the shearer.

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6

Technical data Mechanical components

Fig. 110: Downdrive DC150-B

1

2

5

2

5

5

4

1

3

3

1

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6

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3

6

1

Downdrive

4

Haulage unit

2

Mainframe

5

Oil tank

3

Haulage motor

6

Trapping shoe

EL3000 Shearer

Technical data Mechanical components

6

Fig. 111: Downdrive DC150-B, exploded view

1 2

3

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2

10 8 6

9

1 4

5

3

2

10

7 9

8

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1

Downdrive housing

6

Cylindrical lantern gear, z=11

2

Spur gear, z=22

7

Gear, z=31

3

Bearing housing, inner

8

Trapping shoe

4

Bearing housing, outer

9

Wear part

5

Swivel-joint roller bearing

10

Shaft

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Technical data Hydraulic components

6.4 Hydraulic components 6.4.1 Hydraulic system tank/motor area

The hydraulic system is fed from a 300 l tank (1). The hydraulic fluid is pumped through a connection block (4) by a tandem pump (2) powered by an electric motor (3). This block contains a pressure relief valve (240 bar) (5) as well as a pressure sensor (6) that is connected to the control system of the shearer. The hydraulic fluid is pumped into the valve block (8) through a pressure filter (22 µm) (7).

Fig. 112: Tank/motor area

3

4 7

valve block

5

2

6

1

Tank

5

Pressure relief valve

2

Tandem pump

6

Pressure sensor

3

Electric motor

7

Pressure filter

4

Connection block

Eight 4/3-way valves (9) can be controlled in the valve block; in addition, the pilot line system for the hydraulics is supplied via a 3-way pressure regulator (24 bar). A pressure relief valve maintains the idling pressure at 20 bar. The pilot line pressure is needed to actuate the 4/3-way valves. Solenoid valves connected to the control system of the shearer regulate the flow for the pilot line pressure to the 4/3-way valves. Each 4/3-way valve has an A port and a B port.

The ports on the 4/3-way valves are assigned as follows: 1st valve, A port: not used 1st valve, B port: not used 2nd valve, A port: slow raising of the LH ranging arm 2nd valve, B port: slow lowering of the LH ranging arm 3rd valve, A port: fast raising of the LH ranging arm 3rd valve, B port: fast lowering of the LH ranging arm 4th valve, A port: slow raising of the RH ranging arm 4th valve, B port: slow lowering of the RH ranging arm

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6

5th valve, A port: fast raising of the RH ranging arm 5th valve, B port: fast lowering of the RH ranging arm 6th valve, A port: not used 6th valve, B port: lubrication of the downdrive 7th valve, A port: not used 7th valve, B port: not used 8th valve, A port: oil filling pump 8th valve, B port: not used

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Fig. 113: Valve block

8 9

8 distributor block

Valve block

9

4/3-way valve

A valve block for the pilot line pressure and main pressure is located on the rear of the powerpack. The distributor block is connected to the port for the pilot line pressure and the main pressure port for the valve bank. A sensor for the pilot line pressure and a sensor for the main pressure, both of which are connected to the control system for the shearer, are installed on the distributor block. A difference between the main pressure sensor on this valve block and the pressure sensor on the connection block (see above) indicates dirt buildup in the pressure filter.

pressure gauge bank

A bank of pressure gauges that indicate the main hydraulic pressure (from the connection block) and the pilot pressure (from the pilot pressure distributor) as well as a spare pressure gauge on which a pressure of 0 to 40 bar can be displayed if necessary is located above the valve bank.

external powerpack

The hoses of ports A and B of the 3rd and 5th valve of the valve bank (fast raising and lowering of the ranging arms) are each connected to a T-fitting. The Tfitting permits connection of an external powerpack for raising and lowering the ranging arms.

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Technical data Hydraulic components

lifting cylinder

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

On the piston side, the lifting cylinders have a check valve (190 bar) which ensures that the ranging arm remains in its position when no longer pressurized. If the pressure on the piston side exceeds 190 bar, the valve opens and the excess pressure is relieved slowly. If the pressure on the piston side increases to over 300 bar, the excess pressure is relieved by a pressure relief valve (300 bar) and fed to the ring side of the lifting cylinder so that the pressure can equalize between the two sides of the lifting cylinder.

The ring side of the lifting cylinder also has a check valve (275 bar). If the pressure on the ring side exceeds 350 bar, the excess pressure is fed to the piston side of the lifting cylinder via a pressure relief valve (350 bar) so that the pressure can equalize between the two sides of the lifting cylinder. The maximum stroke of the cylinder is 670 mm.

6.4.2 Powerpack PP3 The powerpack supplies the hydraulic pressure to the hydraulic components of the shearer.

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

The hydraulic fluid is filtered by a pressure filter and a return line filter. The return filter assembly contains a bypass valve which will open if the filter element becomes blocked. In this case, no filtering of the fluid takes place. Prior to the bypass valve opening, an indication of the filter becoming dirty is provided by the control system (MMC).

Tab. 10: Table title Technical data – Powerpack PP3 Type:

PP3-200-75-E2 AUS TX

Hydraulic pump:

200 l/min, constant

Working pressure:

up to 210 bar

Pressure relief valve setting:

240 bar

Hydraulic tank capacity

300 l

Pump motor Rated power:

75 kW

Valve bank Number of valves:

8

Number of spare valves:

2

Safety relief valve setting:

210 bar

Shock pressure valve setting (tank side module PVT):

270 bar

Pilot pressure valve setting:

24 bar

Return filter Filter size:

12 µm

Pressure filter

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Filter size:

6

22 µm

6.5 Electrical components 6.5.1 Electrical system The electrical system of the shearer consists of three main circuits, namely: the pilot power system the main power distribution system the power system for the control components All three systems are introduced in basic form in the diagram below.

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Fig. 114: Typical power distribution system

Gate End Panel

Trailing Cable

Shearer

Main Contactor 3 Phase

Main

Power

Cores

Fuses

Main

Main Power

Circuits

System

Control

Control Power

Circuits

System

Pilot Pilot Circuit

Core

Pilot Power

Control Relay Low Voltage Transformer

Pilot Circuits

Earth

System

Core

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

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

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

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Technical data Electrical components

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

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

NOTICE 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.

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

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Danger from incorrect operation

Technical data Electrical components

6

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Fig. 115: Main power distribution system

After entering the Electrical Control Box ECB3 via the incoming cable entry, the 3-phase power from the gate end panel is initially connected to the "LINE" side of the main switch (via a three-phase termination point on the LH sidewall of the HV compartment).

WARNING Risk of electric shock!

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

The "LOAD" side of the main switch is connected to the control transformer.

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

The `LOAD' side of the main switch is also 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 secondary windings of this transformer are connected (via circuit breakers) to the frequency converters used to control the haulage motors. The "LOAD" side of the main switch is also connected to the "LINE’"side of

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Technical data Electrical components

an isolating switch for the cutter motors.

The "LOAD" side of this isolating switch is connected to the cutter motors and coal sizer (if installed) via pushbutton-controlled contactors.

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

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Fig. 116: Power distribution for control components

6.5.2 Electrical Control Box ECB 3 The Electrical Control Box ECB3 is designed to accommodate a combination of both HV and LV components.

The unit is divided into two main sections:

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high-voltage (HV) section (a) low-voltage (LV) section (b) The following figure shows the operating elements on the gob side of the ECB3.

Fig. 117: Control unit ECB3 - Overview

9

a

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10

1

b

8

2

3

5

4

6

7

1

Main disconnect switch

7

Motor start and stop buttons

2

Cutter motor isolation switch

8

Cutter motor isolation switch check window

3

Monitor

9

Main disconnect switch check window

4

Reset buttons for LV safety switch

10

Inlet for power supply trailing cable

5

Cover for pilot circuit test points

a

High-voltage (HV) section

6

Emergency stop

b

Low-voltage (LV) section

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

High-voltage (HV) section The high-voltage (HV) section contains the high-voltage cable entries for the cutter motors, coal sizer (if present) and pump motors as well as the supplied cable to the HTB3 housing. These entries are located on the gob side. The following components are also located in the high-voltage section: control transformer input voltage monitoring high-voltage ground fault monitoring (if installed) control voltage ground fault monitoring (if installed) The high-voltage section of the ECB3 is divided into two subsections that are accessible via two separate covers. high-voltage (HV) section - LH side

The LH HV Section houses the following components: High-voltage chassis (coal sizer/haulage/pump motor) main disconnect switch live line indication unit

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Technical data Electrical components

data transmission inductive coupler (if installed) high-voltage (HV) section - RH

The RH HV Section houses the following components:

side

high-voltage chassis (cutter motors) cutter motor isolation switch Pl4 Indication Unit high-voltage isolation test point (behind small cover) main control transformer fuse

Fig. 118: ECB3 high-voltage section

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3

3

4 11

12

9 7 5 1 2

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1

Contactor for haulage motors/pump motor

7

Control transformer

2

Contactor for optional coal sizer

8

Connection box to low voltage section

3

Contactor for RH cutter motor

9

Main isolation switch

4

Contactor for LH cutter motor

10

Cutter motor isolation switch

5

Connection terminals for haulage motors 11 and pump motor

High-voltage fuse

6

Connection terminals for LH and RH cut- 12 ter motor

Incoming voltage monitoring

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Technical data Electrical components

6

Low-voltage (LV) section The low-voltage section houses the components for controlling the machine: PLC chassis power supply chassis Ethernet power switch (2x) 11-way CIOS block PLC monitor control system circuit breakers pushbutton unit for motors PI28 indicator unit Connections for external cables are located on the rear side (face side) of the low-voltage section.

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Fig. 119: ECB3 low-voltage section

8

9

10

12

11

1 2 3 7

EL3000 Shearer

6

5

4

1

Multipurpose power supply (IS)

7

Ethernet switch

2

12 V power supply

8

CIOS module

3

24 V power supply

9

CIOS backplane

4

IMU unit

10

IPC

5

PLC

11

Interface box

6

Ethernet switch

12

Relay chassis

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Technical data

6

Electrical components

6.5.3 Haulage transformer box HTB3 The haulage transformer box contains the components for supplying electric power to the drive system.

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

Fig. 120: Haulage transformer box

16

4 1 2 6 15a

15b

25

3

9

8

10

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1

HTB3 housing

9

CIOS switch module

2

350 kVA transformer

10

Low-voltage connection means

3

HLG 600 V connection housing

15a

Circuit breaker for LH frequency converter

4

Auxiliary transformer

15b

Circuit breaker for RH frequency converter

5

Frequency converter

16

High-voltage connection

6

Ground fault monitoring

25

Ethernet switch

8

Control circuit subassembly (door switch)

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Technical data Electrical components

6

Fig. 121: Control elements

2

1

3

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1

Reset buttons for low-voltage circuit breakers

3

Circuit breaker for RH frequency converter

(ground fault, F1, F2, F3) 2

Circuit breaker for LH frequency converter

Drive system Main Circuit The secondary side of the haulage transformer supplies 600 V (via circuit breaker) to the frequency converters. In addition to this main power supply for the drive, the control transformer provides 110 V as an auxiliary supply.

The haulage transformer has a built-in temperature transmitter that is connected to the control system (MMC) of the shearer.

The frequency converters supply power at a variable voltage and frequency that is used to control the speed of the haulage motors.

Monitoring Circuits Both the drive system and the control system (MMC) of the shearer monitor the temperature, the power supply and the speed of the haulage motors. temperature monitoring

current monitoring

The drive system continuously monitors its own operating temperatures. If safety limits are exceeded, operation is interrupted until the values are once again within the permissible limits.

The main power supply for each cutter motor passes 3-phase current monitoring devices. These feed the measured current values back to the master frequency converter, which then uses this information to reduce and control the drive speed and thus the shearer load if one of the cutter motors exceeds the set overload limits.

Additionally, the frequency converter inhibits operation if preset overload limits are exceeded by one of the cutter motors for an extended or brief period of time.

The system response to whichever cutter motor load is the greater. The current values are displayed on the MMC display.

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Technical data Electrical components

Operation with two frequency converters In applications configured to operate with two frequency converters (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.

All command and load control operations are executed 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.

Configuration Switches The configuration switches are located at the extreme right of the electronics module.

The four slide switches are used to determine the configuration of the inverter bridges. The top position of the slide switch corresponds to OFF, the bottom position to ON. The following figure shows the configuration of the slide switches for the "Master" and "Slave" frequency converters.

Fig. 122: Configuration for the "Master" frequency converter

Fig. 123: Configuration for the "Slave" frequency converter

The individual slide switches have the following function: "LEFT ENABLE": This switch controls the LH bridge of the frequency converter (outputs T1, T2 and T3). The LH bridge is deactivated when the switch is in the top position.

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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".

Assignment of the frequency converters as "Master" or "Slave" can be changed via these configuration switches.

Technical data Electrical components

6

"LEFT MASTER": This switch determines whether the LH control card functions as "MASTER" or as "SLAVE". The bottom switch position corresponds to "MASTER", the top to "SLAVE".

"RIGHT ENABLE": This switch controls the RH bridge of the frequency converter (outputs T4, T5 and T6). The RH bridge is deactivated when the switch is in the top position.

"RIGHT MASTER": This switch determines whether the RH control card functions as "MASTER" or as "SLAVE". The bottom switch position corresponds to "MASTER", the top to "SLAVE". If this configuration setting is the same as that of the LH control card the converter functions with both bridges in parallel under the control of the LH card. Control by the RH card is deactivated.

NOTICE Risk of machine damage from power surges!

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Changing the switch position while the frequency converter is in use can cause large power surges at the output. This can damage the frequency converter and cause unforeseeable motor response. Never change the switch position while the frequency converter is in use.

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

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

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

The overcurrent protection is provided by means of a three-phase current monitor assembly located within the shearer contactor section. The inclinometer for the ranging arm is located in the terminal compartment on the gob side of each motor.

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Technical data Electrical components Fig. 124: Cutter motor on ranging arm

4

5

6

3

Load ring

5

Cooling water connection

4

Cooling water connection

6

Terminal compartment

Tab. 11: Technical data – Cutter motor Motor type:

CM750MBM

Rated power:

750 kW

Voltage:

3300 V

Frequency/Cycles:

50 Hz

Insulation class:

H

Amps:

154 A

Starting current:

7.3 x full-load current

Starting torque:

1.4 x full-load torque

No of phases:

3

Circuit type:

Star

Cooling water temperature:

max. 30 °C

Additional data on the motor can be found in the separate operating manual from the manufacture.

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

CAUTION Risk of overheating!

Overcurrent and overheating protection for this motor is set in the machine control system (MMC). This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user. Failure to comply with this may result in damage to the motor.

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Fig. 125: Haulage motor

2 1

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3

1

Cooling water connection

2

Terminal compartment

3

Cable entry (600 V AC)

Tab. 12: Technical data - Haulage motor Motor type:

HM150MF

Rated power:

150 kW

Voltage:

0-600 V

Frequency/Cycles:

0 - 60 - 120 Hz

Insulation class:

H

Amps:

182 A

RPM:

1472

Starting current:

5.77x full-load current

Starting torque:

1.02x full-load torque

No of phases:

3

Circuit type:

Star

Weight:

700 kg

Cooling water flow rate:

15 l/min

Cooling water temperature:

max. 30 °C

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

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

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CAUTION Risk of motor damage from overheating!

Overcurrent and overheating protection for this motor is set in the machine control system (MMC). This protection is set by the manufacturer during commissioning and should not subsequently be altered by the user. Failure to comply with this may result in damage to the motor.

Fig. 126: Pump motor

2

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1

3

1

Cooling water connection

2

Terminal compartment

3

Powerpack

Tab. 13: Technical data - Pump motor Motor type:

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Rated power:

75 kW

Voltage:

3300 V

Frequency/Cycles:

50 Hz

Insulation class:

H

Amps:

18 A

RPM:

1475

Starting current:

5.96x full-load current

Starting torque:

1.2x full-load torque

No of phases:

3

Circuit type:

Star

Weight:

575 kg

Cooling water temperature.:

max. 35° C

Cooling water flow rate:

15 l/min

EL3000 Shearer

Technical data Water System

6

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

6.5.7 Electrical Diagrams The electrical diagrams have been constructed using E-Plan and Standard IEC 61346. A PDF document that shows how to navigate through the diagrams is available. In addition, a PowerPoint presentation is available to demonstrate the navigation process.

A complete set of all electrical diagrams is included with the operating manual.

6.6 Water System The functions of the shearer water system are: to provide cooling for the shearer units Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

to provide dust suppression The diagrams for the shearer's water system are contained in the drawing package accompanying this manual.

6.6.1 Cooling system The cooling circuit comprises of coolers for the following: ranging arms (high-speed section and epicyclic) cutter motors haulage unit haulage motors pump motor hydraulic system coal sizer motor/coal sizer gearbox (if installed) electric haulage drive unit HTB3 (transformer & frequency converter)

Flow Valve The supply to each cooler is regulated by a flow valve giving the following values (these are not adjustable): Tab. 14: Cooling water system flow rates

EL3000 Shearer

LH ranging arm - High-speed section

15 l/min

LH ranging arm - Epicyclic section

8 l/min

RH ranging arm - High-speed section

15 l/min

RH ranging arm - Epicyclic section

8 l/min

LH cutter motor

36 l/min

RH cutter motor

36 l/min

LH haulage motor/gearbox

15 l/min

RH haulage motor/gearbox

15 l/min

Transformer unit

20 l/min

Hydraulic oil cooler/pump motor

20 l/min

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Technical data Permissible media

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

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

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

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

1. Only use lubricants approved by Caterpillar!

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

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

On startup of a new machine, or when a new unit is installed, it is imperative that the gear oil or hydraulic fluid is drained from the unit after working a maximum of ten shifts. The unit should be flushed and replenished with the recommended grade of oil or fluid to the correct level. After a further ten shifts of operation, this process must be repeated. Thereafter, if `debris monitoring/oil or fluid analysis' is being performed, this should dictate the periods of lubricant replacement. If, however, no monitoring/analysis is used, the lubricant in the units should generally be changed in accordance with the table in the "Maintenance" chapter.

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

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

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Technical data Permissible media

6

WARNING Handling operating materials and consumables Handling operating materials and consumables (such as grease or oil) can pose numerous hazards to your health.

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

Tab. 15: Gear Oil Use:

Ranging arms, haulage units, down drive lubrication reservoirs

Specification:

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

Approved brand:

Castrol Optigear PD 320 Synth

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

WARNING Handling operating materials and consumables Handling operating materials and consumables (such as grease or oil) can pose numerous hazards to your health.

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

A highly refined fluid or synthetic olefin oligomers should serve as the base of the hydraulic fluid. In addition, it must have a balanced additive system providing a high viscosity index and good performance when judged against industry standards for the following properties: thermal stability oxidation resistance and stability corrosion inhibition air release/anti foaming, with a good balance of these shear stability compatibility with mineral oil seals filterability anti-wear compatibility and miscibility with other mineral hydraulic oils The properties should not be significantly affected by modest amounts of contamination in the form of water or particulate matter. In particular, there must be no plating out of zinc-based anti-wear additives in the presence of water.

Tab. 16: Hydraulic Fluid Use:

EL3000 Shearer

Hydraulic reservoir in powerpack

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Technical data Permissible media

Specification:

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

Approved brands (examples):

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

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

Handling operating materials and consumables Handling operating materials and consumables (such as grease or oil) can pose numerous hazards to your health.

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

The grease, which must be suited to gear coupling application, should contain a highly refined base oil or synthetic hydrocarbon of very high viscosity with a balanced additive system, including molybdenum disulfide, providing good performance when judged against industry standards for the following properties: shear stability oxidation resistance and stability fretting inhibition very high operating temperature Tab. 17: Quill Shaft Grease Use:

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

Specification:

NLGI 1

Approved brands (examples):

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

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

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WARNING

Technical data

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Tightening torques

WARNING Handling operating materials and consumables Handling operating materials and consumables (such as grease or oil) can pose numerous hazards to your health.

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

The grease must be suited for use in heavily loaded slow moving plain and rolling element bearings subjected to vibration and shock loading. The base should be a highly refined oil or synthetic hydrocarbon. In addition, it must have a balanced additive system providing good performance when judged against industry standards for the following properties: water washout resistance corrosion inhibition Media-ID: EM027495-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

wear resistance shear stability compatibility with lithium soap-based mineral oil grease load carrying Tab. 18: Grease Use:

Other lubrication points as indicated in the "Maintenance" chapter

Specification:

NLGI 1-2

Approved brands (examples):

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

6.8 Tightening torques 6.8.1 Screws and bolts with ISO metric thread Tab. 19: Tightening torques at µtot. = 0.14 Thread (mm)

EL3000 Shearer

Pitch P (mm)

d

Coarse thread

M8

Tightening torque MA (Nm) Fine thread

8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

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Technical data Tightening torques

Thread (mm)

Pitch P (mm)

Tightening torque MA (Nm)

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

2

DM 24

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27)

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

NOTICE Tightening torques Incorrect torque may cause considerable machine damage.

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

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EL3000 Shearer

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