CAT Shearer EL2000 Operation & Maintenance Manual BI628443 – PDF DOWNLOAD

Description

CAT Shearer EL2000 Operation & Maintenance Manual BI628443 – PDF DOWNLOAD

FILE DETAILS:

CAT Shearer EL2000 Operation & Maintenance Manual BI628443 – PDF DOWNLOAD

Language : English
Pages : 320
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

CAT Shearer EL2000 Operation & Maintenance Manual BI628443 – PDF DOWNLOAD

• 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 BI628443 – PDF DOWNLOAD

1 About this manual
Before starting work 1 3
Who is this operating manual intended for? 1 3
2 Introduction
Your safety 2 3
Personnel 2 4
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
Overview of the safety instructions 2 12
Starage and transport 2 12
Installation 2 14
Operation (Electrical) (Chapter 5) 2 16
Operation (Mechanical) (Chapter 5) 2 18
Technical Data (Chapter 6) 2 20
3 Storage and transport
Storage 3 3
Conditions for despatch 3 3
General instructions 3 3
Short-Term-Storage 3 4
Long-Term-Storage 3 4
Storing used equipment 3 4
Transport 3 6
Load Units, Dimensions and Weights 3 6
Before Transport 3 6
Transport of the Components 3 6
Transporting The Machine Underground 3 7
Cutting Drum Removal 3 10
Ranging Arm Hydraulic Cylinder Removal 3 12
EL58B Ranging Arm Motor Removal 3 13
EL62F Ranging Arm Removal 3 14
EL53A Haulage Downdrive Removal 3 15
Caterpillar Global Mining Europe GmbH, Lünen 2013E
BI628443
Table of content
Shearer EL 2000
EL55C Haulage Motor Removal 3 17
EL57B Haulage Unit Removal 3 18
EL56BN Hydraulic Pump Motor Removal 3 20
Hydraulic Reservoir Removal 3 21
Control Box (EL49A),
Power Box (EL48A) Removal 3 22
EL45A Mainframe 3 24
Face Side Shoe Removal 3 25
4 Installation
Installation of the machine underground 4 3
Greasing 4 4
Oil and Fluid filling 4 4
Commissioning the Haulage System 4 6
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
Pilot ‘TEST’ pushbutton 5 17
Machine ‘START/TEST’ pushbutton 5 17
Machine ‘START RUN’ pushbutton 5 17
Motor START / STOP pushbutton 5 18
Motors ‘STOP’ pushbutton 5 18
Stop / Emergency stop lever 5 18
Keypad 5 18
Radio control selection 5 18
Pilot circuit 5 19
General 5 19
Pilot circuit 5 20
Caterpillar Global Mining Europe GmbH, Lünen 2013E
BI628443
Table of content
Doc no : SHEL2000-034 BA 00 VPSP / 01
Electrical power distribution 5 23
General 5 23
Main power distribution 5 24
Control power distribution 5 25
EL58B Ranging Arm Motors 5 27
General 5 28
System operation 5 29
Motor start circuits 5 31
Quill Shaft Removal Procedure 5 32
Lubrication 5 32
EL56BN Pump Motor 5 33
General 5 33
System operation 5 34
Motor start circuit 5 35
Lubrication 5 36
EL55C Haulage Motor 5 37
General 5 37
Motor operation 5 38
Motor start circuit 5 38
Motor removal procedure 5 38
Quill Shaft 5 41
Removal Procedure 5 42
Assembly Procedure 5 46
Lubrication 5 48
Radio Control System 5 49
General 5 49
Key Features 5 49
System operation 5 49
Transmitter 5 50
Radio Receiver Unit 5 53
Hydraulic Functions (electrical control) 5 54
General 5 54
Haulage System (AC drive) 5 58
General Description 5 58
Basic System Operation 5 58
Haulage Circuit Description 5 59
Introduction To Inverter Drive 5 61
Multiple Drives And Motors 5 65
COMPACT Display Module and Keypad 5 67
Configuration Switches 5 69
Component Location (quick reference guide) 5 71
General 5 71
Maintenance (electrical) 5 77
Fault diagnosis (electrical) 5 82
Diagnosis Guide 1 5 82
Diagnostic Guide 2 5 82
Caterpillar Global Mining Europe GmbH, Lünen 2013E
BI628443
Table of content
Shearer EL 2000
General machine specification 5 83
Hoses 5 85
Abbreviations 5 85
Operator controls (mechanical & electrical) 5 86
Electrical Supply 5 86
Machine controls 5 86
Control mode selector switch 5 86
Cooling supply 5 86
Emergency stop switch and buttons 5 86
Face conditions 5 87
Stopping the shearer 5 87
Electrical trips 5 87
Shearer Operators Report 5 88
Mainframe (EL45A) 5 89
Tollok locking assemblies 5 94
Installation 5 94
Dismantling 5 99
Haulage unit (EL57B) 5 102
General 5 102
Downdrive system (EL53A) 5 110
Drive Quill Shaft Removal/Assembly 5 113
Lubrication 5 115
Ranging arm EL62F 5 116
Introduction 5 116
General 5 116
High speed section 5 116
Drum speed 5 116
Seals 5 116
Cooler 5 116
Ranging arm lifting cylinder 5 120
Face seal fitting instructions 5 121
Arm position monitoring set-up procedure 5 122
Lubrication 5 123
Power pack EL50A & hydraulic system 5 124
Introduction 5 124
General 5 124
Hydraulic Reservoir (Fig 125) 5 125
Reservoir Fluid Filling 5 126
Hydraulic Fluid Cooling 5 126
Manifold Block 5 126
Hydraulic Pump (Fig 128) 5 127
Directional Control Valve Bank (Fig 129) 5 128
Solenoid Valve (Fig 130) 5 130
Ranging Arm Lifting Cylinder (Fig 132) 5 132
Pilot Operated Check Valve (Fig 133) 5 134
Cowl Float Valve (Fig 134) 5 135
Hydraulic System Technical Data 5 137
Lubrication 5 139
Caterpillar Global Mining Europe GmbH, Lünen 2013E
BI628443
Table of content
Doc no : SHEL2000-034 BA 00 VPSP / 01
Water System 5 140
Introduction 5 140
Shearer Cooling System (Fig 140) 5 140
Dust Suppression System (Fig 140) 5 141
Fire Deluge System (Fig 140) 5 141
Cowl Flush System 5 141
Ranging Arm Motor Cooling (Fig 140) 5 142
Ranging Arm Internal Cooler (Fig 141) 5 142
Haulage Motor Cooling (Fig 142) 5 143
Haulage Unit Cooler (Fig 143) 5 143
Power Box Cooling (Fig 144) 5 144
Pump Motor Cooling (Fig 145) 5 144
Hydraulic Fluid Cooler (Fig 146) 5 145
Maintenance (mechanical) 5 147
Introduction 5 147
Oil and Fluid Condition Monitoring 5 148
Fault diagnosis (mechanical) 5 158
Introduction 5 158
General 5 158
Diagnostic Guide 1 5 159
Diagnostic Guide 2 5 159
Diagnostic Guide 3 5 160
Diagnostic Guide 4 5 161
Diagnostic Guide 5 5 161
Diagnostic Guide 6 5 162
Diagnostic Guide 7 5 162
Diagnostic Guide 8 5 163
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
Caterpillar Global Mining Europe GmbH, Lünen 2013E
BI628443
Table of content
Shearer EL 2000
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 17
Hydraulic & water diagrams 6 17
7 For your information
Our service 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
Electrical, Hydraulic, Water and Lubrication Diagrams
SUPERNUT (Downdrive)
P & S Expansion Bolt System (Shoepost)
Clampex clamping set
AmerCable Trailing Cable
Pempek Radio System
Rocol DryMoly Paste
ACT Cable Handler

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