CAT Shearer EL2000 Operation & Maintenance Manual BI628601 – PDF DOWNLOAD
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CAT Shearer EL2000 Operation & Maintenance Manual BI628601 – PDF DOWNLOAD
Language : English
Pages : 323
Downloadable : Yes
File Type : PDF
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CAT Shearer EL2000 Operation & Maintenance Manual BI628601 – PDF DOWNLOAD
This chapter contains important information which will simplify the
use of this manual for you. In addition it includes information about
the structure of the manual and on the characters and symbols
used.
Before starting work:
If you use an operating manual which has not been written for your
machine type, you will endanger yourself and others.
Ensure that the serial number on you machine corresponds with the
following :
Electra® EL2000 Shearer
Ident. no.: EL2000-027
The operating manual must be accessible at all times to all persons
working on, or with, this shearer.
If your manual is no longer complete, has become illegible or damaged,
send for a replacement immediately.
Who is this operating manual intended for?
This operating manual is intended for all persons working with or on
the shearer.
All persons working with the shearer must have read this manual.
This includes persons:
- responsible for transport
- carrying out the drivage
- carrying out erection / dismantling
- operating the shearer
- eliminating faults
- carrying out routine work on the face
- carrying out maintenance operations
- carrying out repairs
TABLE OF CONTENTS:
CAT Shearer EL2000 Operation & Maintenance Manual BI628601 – PDF DOWNLOAD
1 About this manual
Before starting work 1 3
Who is this operating manual intended for? 1 3
Purpose of this operating manual 1 4
Signs and symbols used 1 4
2 Your safety
Safety 2 3
Personnel 2 4
Operation 2 4
Installation and repair 2 4
Operating conditions 2 4
Unauthorised use 2 4
Safety instructions 2 5
General rules 2 5
Electrical isolation of the shearer 2 11
To electrically isolate the shearer: 2 11
3 Storage and transport
Storage 3 3
Storage of the equipment 3 3
Transport 3 4
Load Units, Dimensions and Weights 3 4
Before Transport 3 4
Transport of the Components 3 4
Transporting The Machine Underground 3 5
Cutting Drum Removal 3 8
Ranging Arm Hydraulic Cylinder Removal 3 10
EL68A Ranging Arm Motor Removal 3 11
RA750 Ranging Arm Removal 3 12
EL53A Haulage Downdrive Removal 3 14
EL55A Haulage Motor Removal 3 16
EL57B Haulage Unit Removal 3 17
EL56BN Hydraulic Power Pack Motor Removal 3 19
Hydraulic Reservoir Removal 3 20
Control Box (EL49A), Power Box (EL48A) Removal 3 21
Caterpillar Global Mining Europe GmbH, Lünen 2012E
Table of content
EL2000 Shearer
EL45A Mainframe 3 23
Face Side Shoe Removal 3 24
4 Installation
Installation of the machine underground 4 3
Greasing 4 4
Oil and Fluid filling 4 4
Commissioning the Haulage System 4 5
Fault Diagnosis and Repair 4 6
5 Operation
Introduction To Electrical Equipment 5 3
General 5 3
Electrical control boxes 5 4
Electric motor driven units 5 4
Hydraulically actuated units 5 5
Other electrical equipment 5 6
EL49A Control box 5 9
General 5 9
EL48A Power box 5 13
General 5 13
Operator Controls (electrical) 5 15
Main Switch Handle 5 17
Machine ‘START’ pushbutton 5 17
Motors START / STOP pushbutton 5 17
Motors “STOP” pushbutton 5 17
Control circuit earth leakage test pushbutton 5 17
Haulage circuit earth leakage test pushbutton 5 18
Earth leakage circuits reset pushbutton 5 18
Stop / Emergency stop lever 5 18
Keypad 5 18
Radio control selection 5 18
Haulage system circuit breaker handle 5 18
Pilot circuit 5 19
General 5 19
Pilot circuit 5 20
Electrical power distribution 5 23
General 5 23
Main power distribution 5 24
Control power distribution 5 25
EL68A Ranging Arm Motors 5 27
General 5 28
System operation 5 29
Motor start circuits 5 30
Quill Shaft 5 32
Caterpillar Global Mining Europe GmbH, Lünen 2012E
Table of content
Doc no : SHEL2000-027 SVSU / 01
Removal Procedure 5 33
Assembly Procedure 5 36
Quill Shaft Lubrication 5 39
Motor Bearings Lubrication 5 39
EL56BN Power Pack Motor 5 41
General 5 41
System operation 5 42
Motor start circuit 5 43
Lubrication 5 44
EL55A Haulage Motor 5 45
General 5 45
Motor operation 5 46
Motor start circuit 5 46
Motor removal procedure 5 46
Quill Shaft 5 49
Removal Procedure 5 50
Assembly Procedure 5 53
Lubrication 5 55
Radio Control System (Pempek) 5 57
General 5 57
Hydraulic Functions (electrical control) 5 61
General 5 61
Haulage System (AC drive) 5 65
General Description 5 65
Basic System Operation 5 65
AC Haulage Drive(s) 5 66
Configuration Switches 5 67
Double Drive Operation 5 69
Parameters 5 69
Regeneration 5 69
Haulage Circuit Description 5 69
Component Location (quick reference guide) 5 73
General 5 73
Maintenance (electrical) 5 82
Maintence schedules 5 83
General machine specification 5 87
Hoses 5 89
Abbreviations 5 89
Operator controls (mechanical & electrical) 5 91
Electrical Supply 5 91
Machine controls 5 91
Control mode selector switch 5 91
Cooling supply 5 91
Emergency stop switch and buttons 5 91
Face conditions 5 92
Stopping the shearer 5 92
Electrical trips 5 92
Caterpillar Global Mining Europe GmbH, Lünen 2012E
Table of content
EL2000 Shearer
Shearer Operators Report 5 93
Mainframe (EL45A) 5 95
Lubrication 5 100
Haulage unit (EL57B) 5 101
General 5 101
Downdrive system (EL53A) 5 109
Trapping Shoe Measuring Procedure 5 112
Trapping Shoe Insert Removal Procedure 5 112
Drive Quill Shaft Removal/Assembly 5 115
Lubrication 5 117
Ranging arm RA0750 5 119
Introduction 5 119
General 5 119
Drum speed 5 119
Seals 5 119
Coolers 5 119
Ranging arm lifting cylinder (Fig 129) 5 123
Fit ranging arm to mainframe 5 124
Lubrication 5 129
Power pack EL50A & hydraulic system 5 131
Introduction 5 131
General 5 131
Hydraulic reservoir (Fig 143) 5 132
Reservoir fluid filling 5 133
Hydraulic fluid cooling 5 133
Manifold block 5 133
Hydraulic pump (Fig 146) 5 134
Directional control valve bank (Fig 147) 5 135
Solenoid valve (Fig 148) 5 137
Ranging arm lifting cylinder (Fig 150) 5 139
Low pressure solenoid valve (Fig 151) 5 141
Oil Filling Pump (Fig 152) 5 142
Hydraulic system technical data 5 142
Lubrication 5 143
Water System 5 145
Introduction 5 145
Reverse Flush Filter (Fig 154) 5 145
Washdown Facility 5 146
Dust Suppression 5 146
Water Circuit Interlocking and Monitoring 5 148
Pre-Start Warning/PBF circuit 5 150
SHEARER COOLING SYSTEM 5 150
Flow Regulators 5 151
Maintenance (mechanical) 5 157
Introduction 5 157
Oil and Fluid Condition Monitoring 5 158
Maintenance schedules 5 161
Caterpillar Global Mining Europe GmbH, Lünen 2012E
Table of content
Doc no : SHEL2000-027 SVSU / 01
6 Technical data
Permissible Media 6 3
General 6 3
Shearer lubrication 6 4
Gear oil filling 6 4
Lubricants (Gear Oil) 6 5
Lubricants (Hydraulic Fluid) 6 6
Lubricants (Quill Shaft Grease) 6 7
Lubricants (Electric Motor Bearing Grease) 6 8
Lubricants (All Other Grease Applications) 6 9
Torque table 6 10
Torque table 6 11
SPECIAL APPLICATIONS ONLY 6 11
Torque table 6 12
Torque table 6 13
Torque table 6 14
SUPERNUT tensioning system 6 15
Electrical diagrams 6 16
Diagram Identification 6 16
Balloon Mapping Instructions 6 16
Relay Mapping Instructions 6 16
Wire Number Color Code 6 16
Wire Numbering and Color Coding 6 17
Standing Instructions 6 17
Plug and Socket Details 6 17
Electrical Diagrams 6 18
Hydraulic & water diagrams 6 20
Electrical diagrams -schematic- EL2000-S-27-A 6 21
Electrical diagrams -schematic- EL2000-S-27-B 6 22
Electrical diagrams -schematic- EL2000-S-27-C 6 23
Electrical diagrams -schematic- EL2000-S-27-D 6 24
Electrical diagrams -schematic- EL2000-S-27-E 6 25
Electrical diagrams -schematic- EL2000-S-27-F 6 26
Electrical diagrams -wiring- EL2000-W-27-A 6 27
Electrical diagrams -wiring- EL2000-W-27-B 6 28
Electrical diagrams -wiring- EL2000-W-27-C 6 29
Electrical diagrams -wiring- EL2000-W-27-D 6 30
Electrical diagrams -wiring- EL2000-W-27-E 6 31
Electrical diagrams -wiring- EL2000-W-27-F 6 32
Electrical diagrams -wiring- EL2000-W-27-G 6 33
Electrical diagrams -wiring- EL2000-W 6 21
Caterpillar Global Mining Europe GmbH, Lünen 2012E
Table of content
EL2000 Shearer
7 For your information
Our service 7 3
Service addresses 7 3
Europe 7 3
Standards and guidelines 7 4
Referenced European standards and guidelines 7 4
Referenced USA standards and guidelines 7 4
Referenced Australian standards and guidelines 7 4
ANNEXE 7 5
Hydraulic, Water and Lubrication Diagrams 7 5
P & S SUPERNUTS (Downdrive) 7 5
Clampex clamping set 7 5
AmerCable Trailing Cable 7 5
Pempek Radio System 7 5
Rocol Dry Moly Paste 7 5
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