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CAT Shearer EL2000 Operation & Maintenance Manual BI001780 – PDF DOWNLOAD
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CAT Shearer EL2000 Operation & Maintenance Manual BI001780 – PDF DOWNLOAD
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Description
CAT Shearer EL2000 Operation & Maintenance Manual BI001780 – PDF DOWNLOAD
FILE DETAILS:
CAT Shearer EL2000 Operation & Maintenance Manual BI001780 – PDF DOWNLOAD
Language : English
Pages : 356
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Shearer EL2000 Operation & Maintenance Manual BI001780 – PDF DOWNLOAD
About this manual:
This chapter contains important information which will simplify the use of this manual for you. In addition it includes information about the structure of the manual and on the characters and symbols used.
Before starting work:
This chapter contains important information which will simplify the use of this manual for you. In addition it includes information about the structure of the manual and on the characters and symbols used.
Before starting work:
correct operating manual:
If you use an operating manual which has not been written for your machine type, you will endanger yourself and others.
Ensure that the serial number on you machine corresponds with the following :
If you use an operating manual which has not been written for your machine type, you will endanger yourself and others.
Ensure that the serial number on you machine corresponds with the following :
machine type:
Electra® EL2000 Shearer
Ident. no.: EL2000-021
The operating manual must be accessible at all times to all persons
working on, or with, this shearer.
Ident. no.: EL2000-021
The operating manual must be accessible at all times to all persons
working on, or with, this shearer.
new operating manual:
If your manual is no longer complete, has become illegible or damaged,
send for a replacement immediately.
Who is this operating manual intended for?
This operating manual is intended for all persons working with or on the shearer.
All persons working with the shearer must have read this manual.
This includes persons:
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 BI001780 – PDF DOWNLOAD
EL2000-014 Electra 2000............................................... 3 Contents.......................................................... 5 1. About this manual.............................................. 11 Before starting work.......................................... 13 Who is this operating manual for?............................. 13 Characters and symbols used................................... 14 2. Your safety.................................................... 15 Your safety................................................... 17 Observe the safety & accident prevention rules................ 17 Personnel..................................................... 18 Operating conditions.......................................... 18 Unauthorised use.............................................. 18 Safety instructions........................................... 19 Storage and transport......................................... 20 To electrically isolate the shearer........................... 25 Overview of safety instructions............................... 26 3. Storage and transport.......................................... 39 Storage....................................................... 41 Transport..................................................... 42 Unit weights.................................................. 42 Cutting drum removal.......................................... 46 Ranging arm hydraulic cylinder removal........................ 48 EL68A Ranging arm motor removal............................... 49 RA750 Ranging arm removal..................................... 50 EL53A Haulage downdrive removal............................... 51 EL55A Haulage motor removal................................... 53 EL57B Haulage unit removal.................................... 54 EL56BN Hydraulic power pack motor removal..................... 56 Hydraulic reservoir removal................................... 57 EL49A Control box & EL48A power box removal................... 58 EL45A Mainframe............................................... 60 Face side skid shoe removal................................... 61 4. Installation................................................... 62 Installation of machine underground........................... 64 Greasing...................................................... 65 Oil and fluid filling......................................... 65 Commissioning the haulage system.............................. 66 Fault diagnosis and repair.................................... 67 5. Operation...................................................... 68 Introduction to electrical equipment.......................... 70 General................................................... 70 Electrical control boxes.................................. 71 Electric motor driven units............................... 71 Hydraulic actuated units.................................. 72 Other electrical equipment................................ 73 Electrical circuits....................................... 74 EL49A Control box............................................. 76 General................................................... 76 Unit contents............................................. 77 EL48A Power box............................................... 80 General................................................... 80 Component location........................................ 81 Operator controls (electrical)................................ 82 Main switch handle........................................ 84 Machine 'START' pushbutton................................ 84 Motors 'START' / 'STOP' pushbutton........................ 84 Motor 'STOP' pushbutton................................... 84 Control circuit earth leakage test pushbutton............. 84 Haulage circuit earth leakage test pushbutton............. 85 Earth leakage circuits reset pushbutton................... 85 Stop/emergency stop lever................................. 85 Keypad.................................................... 85 Radio control selection................................... 85 Haulage system circuit breaker handle..................... 85 Electrical pilot circuit...................................... 86 General................................................... 86 Pilot circuit............................................. 87 Electrical power distribution................................. 90 General................................................... 90 Main power distribution................................... 91 Control power distribution................................ 92 EL68A Ranging arm motor....................................... 94 General................................................... 95 System operation.......................................... 96 Quill shaft removal procedures............................ 99 Quill shaft lubrication...................................104 EL56BN Hydraulic power pack motor.............................106 General...................................................106 System operation..........................................107 Motor start circuit.......................................108 Lubrication...............................................109 EL55A Haulage motor...........................................110 General...................................................110 Motor operation...........................................111 Motor start circuit.......................................111 Motor removal procedure...................................111 Quill shaft removal and assembly..........................114 Lubrication...............................................121 Pempek radio control system...................................122 General...................................................122 Transceiver...............................................124 Hydraulic functions (electric control)........................126 General...................................................126 Haulage system (AC drive).....................................130 General...................................................130 Basic system operation....................................130 Haulage circuit description...............................131 Main circuit..............................................131 Monitoring circuits.......................................131 Radio control circuits....................................132 Transmitter control circuit...............................132 Double drive operation....................................132 Introduction to inverter drives...........................133 Drive configuration.......................................134 Multiple drives and motors................................138 Frequency slaving.........................................138 Current slaving...........................................138 Electrical paralleling....................................138 COMPACT display module and keypad.........................140 Configuration switches....................................142 Switch positions and modes................................143 Component location (quick reference guide)....................144 General...................................................144 Electrical component location (general)...................145 EL48A Left and right hand covers..........................146 EL48A Component location..................................147 EL49A Control cover.......................................151 Control compartment chassis...............................152 Maintenance (electrical)......................................154 Maintenance schedules.....................................155 Introduction to mechanical equipment..........................160 General machine specification.............................160 Hoses.....................................................162 Abbreviations.............................................162 Operator controls (mechanical & electrical)...................164 Electrical supply.........................................164 Machine controls..........................................164 Control mode selector switch..............................164 Cooling supply............................................164 Emergency stop switch and buttons.........................164 Face conditions...........................................165 Stopping the shearer......................................165 Electrical trips..........................................165 Shearer operators report..................................166 EL45A Mainframe...............................................168 Waste side and plan.......................................169 Face side view............................................170 Hinge pin arrangement.....................................171 Ranging arm cylinder anchor...............................171 Face side skid shoe.......................................172 Face side skid shoe wear limit............................172 Ranging arm hinge points lubrication......................173 EL57B Haulage unit............................................174 General...................................................174 Haulage system location...................................175 Outside views.............................................176 General arrangement.......................................177 Encoder...................................................178 Dipstick..................................................179 Cooler arrangement........................................179 Haulage unit lubrication..................................180 EL53A Downdrive...............................................182 Downdrive system..........................................182 Front and rear views......................................183 Component location........................................184 Trapping shoe wear limits.................................184 Drive quill shaft removal/assembly........................185 Lubrication...............................................187 RA750 Ranging arm.............................................188 Introduction..............................................188 General...................................................188 High speed section........................................188 Drum speed................................................188 Seals.....................................................188 Coolers...................................................188 Ranging arm lifting cylinder..............................192 Fit ranging arm to mainframe..............................193 Lubrication...............................................199 Power pack EL50A & hydraulic system...........................200 Introduction..............................................200 General...................................................200 Hydraulic reservoir.......................................201 Hydraulic fluid cooling...................................202 Pressure filter...........................................202 Return line filter........................................202 Safety relief valve.......................................202 Hydraulic pump............................................203 Directional control valve bank............................204 Ranging arm lifting cylinder..............................208 Cylinder valve block......................................208 Low pressure solenoid valve...............................210 Hydraulic system technical data...........................211 Hydraulic symbolic diagram................................212 Lubrication...............................................213 Water system..................................................214 Introduction..............................................214 Fire fighting.............................................214 Reverse flush filter......................................214 Main water pilot valve....................................215 Dust suppression..........................................217 Water circuit interlocking and monitoring.................219 Pre-start warning / PBF circuit...........................220 Cooling system............................................221 Pressure reducing valve...................................221 Relief valve..............................................221 Flow regulator assemblies.................................222 Ranging arm motor cooler..................................223 Ranging arm internal coolers..............................223 Haulage motor cooler......................................224 Haulage unit cooler.......................................224 Power box cooling.........................................225 Pump motor cooler.........................................225 Hydraulic fluid cooler....................................226 Water symbolic diagram....................................227 Maintenance (mechanical)......................................228 Introduction..............................................228 Oil and fluid condition monitoring........................229 Maintenance schedules.....................................232 Fault diagnosis (mechanical)..................................238 Introduction..............................................238 Guide 1...................................................239 Guide 2...................................................239 Guide 3...................................................240 Guide 4...................................................241 Guide 5...................................................241 Guide 6...................................................242 Guide 7...................................................242 Guide 8...................................................243 6. Technical data.................................................244 Permissible media.............................................246 Gear oil..................................................248 Hydraulic fluid...........................................249 Quill shaft grease........................................250 Electric motor bearing grease.............................251 All other grease applications.............................252 Lubricants chart..........................................277 Tightening torques (coarse pitch).............................253 Bolts grade 8.8 & nuts grade 8............................253 Bolts grade 10.9 & nuts grade 12..........................254 Tightening torques (special applications only)................254 Bolts grade 12.9 & nuts grade 12..........................254 Tightening torques (fine pitch)...............................255 Bolts and set screws grade 8.8............................255 Bolts and set screws grade 10.9...........................256 Bolts and set screws grade 12.9...........................257 SUPERNUT tensioning system....................................258 Electrical diagrams...........................................259 Diagram identification....................................259 Balloon mapping instructions..............................259 Relay mapping instructions................................259 Wire number colour code...................................259 Wire numbering and colour coding..........................260 Standing instructions.....................................260 Plug and socket details...................................260 Electrical diagrams.......................................261 Shearer schematic.....................................261 EL2000-S-21-A (general information)...............264 EL2000-S-21-B (power system and drive circuit)....265 EL2000-S-21-C (COMPACT)...........................266 EL2000-S-21-D (motors)............................267 EL2000-S-21-E (SMART & auxiliaries)...............268 Shearer wiring........................................261 EL2000-W-21-A (HV box isolator/contactor area)....270 EL2000-W-21-B (HV box drive area).................271 EL2000-W-21-C (LV box side wall area).............272 EL2000-W-21-D (LV box radio chassis)..............273 EL2000-W-21-E (motor control circuit).............274 EL2000-W-21-F (SMART & auxiliaries)...............275 EL2000-W-21-G (COMPACT connections)...............276 7. For your information...........................................278 Our service...................................................280 Standards and guidelines......................................283 Annexe........................................................284 Hydraulic, Water and Lubrication diagrams.................288 Supernut..................................................305 P & S Expansion bolt system...............................308 Clampex clamping set......................................321 Amercable trailing cable..................................326 Pempek radio system.......................................336 Rocol dry moly paste......................................353
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