DOCUMENTS OF LONGWALL EQUIPMENT

SUPPLIED TO JHANJRA MINE, ECL

VOLUME 1: MG650/1630-GWD TYPE AC

ELECTRIC HAULAGE SHEARER

Book Two: The Maintenance Plan And Maintenance

Guide

Xi’An Coal Mining Machinery Co.,Ltd

China Coal Overseas Development Co. Ltd

JAN. 2015
 CONTENTS

Part I: Maintenance Plan

Part II: Maintenance Guide

PART I: Maintenance Plan
  

目录

CONTENT

1 机械单元维护 MECHANICAL UNIT MAINTENANCE .................. 1

1.1 采煤机注油 THE SHEARER OIL INJECTION ...................................................1

1.1.1 一般要求 GENERAL REQUIREMENTS......................................................1
1.1.2 工作液体 WORKING LIQUID ......................................................................2
1.1.3 注油指南 THE OILING GUIDE ....................................................................4
1.2 机械单元维护 MAINTENANCE FOR MECHANICAL UNIT .........................15
1.2.1 检查周期及检查内容 CHECK CYCLE AND CHECK CONTENT ...............15
1.2.2 机械单元关键部件的维护 MAINTENANCE FOR KEY COMPONENTS OF
MECHANICAL UNITS.............................................................................................18
1.3 常见故障及处理方法 COMMON FAULTS AND PROCESSING METHODS28
1.3.1 摇臂常见故障及处理方法 THE RANGING ARM COMMON FAULTS
AND PROCESSING METHODS..........................................................................28
1.3.2 牵引部常见故障及处理方法 COMMON FAULTS OF HAULAGE UNIT
AND SOLVING METHODS.................................................................................30
1.3.3 液压调高系统常见故障及处理方法 COMMON FAULTS OF
HYDRAULIC HEIGHT-ADJUSTMENT SYSTEM AND PROCESSING
METHODS .............................................................................................................32
1.3.4 行走箱常见故障及处理方法 COMMON FAULTS OF WALKING BOX
AND PROCESSING METHODS..........................................................................36

2 电气单元维护 ELECTRICAL UNIT MAINTENANCE.................. 39

2.1 每日维护 THE DAILY MAINTENANCE..........................................................39

2.2 每周维护 WEEKLY MAINTENANCE..............................................................40
2.3 每月维护 MONTHLY MAINTENANCE...........................................................41
2.4 维护工具 MAINTENANCE TOOLS..................................................................42
2.5 电气单元常见故障及处理方法 ELECTRICAL UNIT COMMON FAULTS
AND PROCESSING METHODS..............................................................................42
2.5.1 先导回路故障 PILOT CIRCUIT FAULT ....................................................42
2.5.2 端头站、遥控器故障 END STATION, REMOTE CONTROL FAULT....43
2.5.3 摇臂升降系统故障 RANGING ARM LIFT SYSTEM FAULTS ...............45
2.5.4 电机故障 THE MOTOR FAULTS ...............................................................46
2.5.5 漏电故障 LEAKAGE FAULT......................................................................48
2.5.6 开机后采煤机自动加速 SHEARER SPEED UP AUTOMATICALLY
AFTER TURNING ON..........................................................................................49
2.5.7 截割电机不能启动 CUTTING MACHINE CANNOT START..................49
I 
 
 2.5.8 变频器故障 INVERTER FAULT.................................................................49
2.5.9 显示屏故障 DISPLAY FAILURE................................................................56
2.5.10 PLC 故障 PLC FAILURE...........................................................................57

3 大修 OVERHAUL ................................................................................ 57

4 储存管理 STORAGE MANAGEMENT ............................................ 58

II 
 
  

1 机械单元维护 Mechanical unit maintenance

1.1 采煤机注油 The shearer oil injection

1.1.1 一般要求 General requirements
（1）必须按指定的油脂牌号加油，不允许混用。

（2） 油液存放、运输必须防水、防尘。

（3）盛、贮油容器必须洗净。

（4）井下检修开大盖时必须支蓬、洒水灭尘, 并严防煤块、岩渣、工具、手

套等杂物落入油池。

（5）严禁用纱布、普通布、棉纱等擦洗液压油池及液压元件，而应用泡沫塑

料或绸缎擦抹。

（6）各部分油位应在适当位置。

1.1.1 General requirements

(1) The inject oil brand must be specified, and not allowed to mix.

(2) The oil storage and transportation must be water-proof and dust-proof.

(3) Containers, storage equipment must be clean.

(4) Support and dust extinguishing sprinkler must be done when you overhaul the up

cover underground, and extremely protected the coal, slag, tools, gloves and other

debris drop into the oil pool.

(5) It is strictly prohibited to use gauze, ordinary cloth, cotton swab to clean the

hydraulic oil pool; it needs using foam plastic or silk to wipe it.

(6) Each part of the oil level should be in place.

注意：

当使用油液、润滑脂及其他化学物品时应遵守与产品有关的安全规则。

当处理很热的工作液体时要意识到烧伤和烫伤的危险。

Note:

When use the oil, grease and other chemical substances shall comply with the rules

related to product safety.

  1
When dealing with very hot working liquid should realize the danger of burns and

scalds.

1.1.2 工作液体 Working liquid

1）怎样处理工作液体的危害 Deal with the harm of working liquid

皮肤接触

尽可能避免扩大或重复接触。

接触后用肥皂和水来清洗身体的接触部位。

需要时可穿上耐油保护服。

不要用石油、溶剂及乳化剂洗手。

触及眼睛

用水彻底清洗眼睛。如眼睛有不适，应及时地看眼科医生。

环境危害

工作液将污染环境。故应避免其进入大气、土壤和水。

Skin contact

Avoid expand as far as possible or repeated contact.

After contact, use soap and water to wash the contact part of the body.

Put on the oil resistant protective cloth when it necessary.

Don't wash your hands with oil, solvent and emulsifier.

Do not contact with eyes.

Thoroughly use water to clean the eyes. If your eyes are discomfort, go to see a doctor

in a timely manner.

Environmental hazards

Working liquid will pollute the environment. Therefore avoid it go through into the

atmosphere, soil and water.

2）工作液体的特性具有良好的泵送性和耐极压性，用于轴承润滑 The
characteristics of the work liquid has good pumping and extreme pressure
resistance, it is used for bearing lubrication

  2
  

工作液体 型号 说明 规格

齿轮油 320# 加添加剂的抗氧化 N320#齿轮油

矿物油，具有极好 运动粘度 40 °C):
的抗磨损性能 288 mm²/s (min.) - 352mm²/s (max.)
密度(15 °C): 0.910g/cm³
闪点: ≥200°C (min)
凝点: ≤- 8 °C

液压油 100# 具有提高防腐和老 N100#液压油

化稳定特性添加剂 运动粘度(40 °C):
的矿物油 90 mm²/s (min.) - 110 mm²/s (max.)
密度(15 °C): 0.880 g/cm³
闪点: ≥180 °C
凝点: ≤- 8°C

润滑脂 3#极压锂基润 具有良好的泵送性 工作锥入度(0.1mm): 265-295

滑脂 和耐极压性，用于 滴点: ≥175°C
轴承润滑 密度(20 °C): 0.9g/cm³

Wor
Type instructions specifications
king fluid

Gear oil 320# the antioxidant N320 # gear oil

mineral oil, has

Kinematic viscosity 40 ° C) :
excellent wear

resistance 288 mm squared/s (min.) - 352 - mm

characteristics squared/s (Max.)

Density (15 ° C) : 0.910 g/cm after

Flashing point: 200 ° C or higher (min)

Freezing point: 8 ° C or less

  3
 工作液体 型号 说明 规格

hydraulic 100# Has the improve N100 # hydraulic oil

oil
corrosion
Kinematic viscosity (40 ° C) :
resistance and

aging stability 90 mm squared/s (min.) - 110 - mm

characteristics squared/s (Max.)
additive mineral
Density (15 ° C) : 0.880 g/cm after
oil

Flashing point: 180 ° C or higher

Freezing point: - 8 ° C or less

grease 3#extreme It has good Work cone into the degrees (0.1 mm) :
pressure
pumping and 265-295
lithium
grease extreme pressure
Drop point: 175 ° C or higher
resistance, and it

is used for Density (20 ° C) : 0.9 g/cm after

bearing

lubrication

1.1.3 注油指南 The oiling Guide

注油点 注油部位 润滑油牌号 注油量
A1 左摇臂臂身 摇臂水平时，油池油位在摇臂惰轮轴中心线
A1 右摇臂臂身 以下 80～100mm
B1 左摇臂行星头
油位标尺规定的最高油面和最低油面之间
B2 右摇臂行星头
N320 工业
C1 左牵引部
齿轮油 油位至机壳上平面 380～400mm
C2 右牵引部
加油时，将油口 3 置于与滚筒回转中心相同
D 破碎机构 的水平位置，作为油位标志口，即溢出时，
加到位。（详见破碎机构注油）
N100 抗磨
E 调高泵箱 油位在较高油窗，注油量约 100L
液压油
F1 左摇臂回转中心销轴 3#极压锂基 适 量
F2 右摇臂回转中心销轴 润滑脂

  4
  

G1 左行走箱销轴
G2 右行走箱销轴
H1 左行走箱驱动轮轴承

H2 右行走箱驱动轮轴承

I1 右行走箱驱动轮轴承

I2 右行走箱驱动轮轴承

J 破碎机构转动轴承
Oil
injec Lubricating oil
Oil section Oil amount
t brand
point
A1 Left ranging arm N320 When ranging arm is balanced,
industrial gear
oil oil level in oil tank should

below the center line of the

A1 Right ranging arm
radial idler shaft 80 ~ 100 mm

Left ranging arm

B1 planetary head The oil level gauge is between

the maximum oil level and the

right ranging arm minimum oil level

B2 planetary head

C1 Left haulage section Oil level up to the shell level

380 ~ 400 mm
C2 Right haulage section

  5
 During the oil injection, put the

oil mouth 3 at the same level as

the drum slewing center, as the

oil level mark, when it

Broken body
D overflows, it show that oil is in

place. (see the details of oil

injection of broken

mechanism)

Oil level at the higher oil

window, oil injection rate is

height-adjustment N100Anti-wea
E
pump tank r hydraulic oil about 100 L

3 # extreme
The left arm slewing
pressure
F1 center pin moderate amount
lithium grease

The right arm slewing

F2 center pin

The left walking tank

G1
pin shaft
The right walking tank
G2
pin shaft

  6
  

Left walking tank

H1 driving wheel bearing

Right walking tank

H2 driving wheel bearing

Right walking tank

I1 driving wheel bearing

Right walking tank

I2 driving wheel bearing

Broken body rotation

J
bearing

牵引机构注油 Oil injection of haulage mechanism

牵引机构分为牵引部和行走箱。牵引部齿轮传动分为直齿轮系的传动腔与行星轮

系的传动腔相互连通，行走箱是一个开式齿轮减速箱。Haulage section is divided

into haulage and walking box. The haulage section transmission part has divide into

straight gear train transmission cavity and planetary gear train cavity and both

connected with each other, walking box is a open gear reducer.

a．牵引部注油（如图 1-1）haulage oil injection (shown as figure 1-1)

  7
 图 1-1 牵引部注油位置 Figure 1-1 haulage oil position

1 电机泄油孔（底部） 2 泄油孔（背面） 3 加油孔

4 油位探尺 5 空气滤清器 6 泵箱检修孔

1 motor oil drain hole (bottom) 2 drain holes (on the back) 3 oil inject hole

4 oil level gage rod 5 air filter 6 pump box manhole

牵引减速机的油位可通过安装在齿轮箱上的油位探尺进行检查，油位应该位于油

位探尺允许的最大油位跟最小油位间。如图 1-2 The oil level of haulage reducer can

be checked by oil level gage rod that installed on the gear box, oil level should

between the maximum and the minimum oil level that under the oil level gage rod

allowance. Shown as the figure 1-2

在进行油位检查时煤机必须处于平放及关闭状态。The shearer must be in the

flat and closed state during the oil level check.

  8
  

图 1-2 油位探尺

Figure1-2 oil level gage rod

行走箱注油（如图 1-5）

图 1-3 行走箱注油位置 Figure1-3 walking tank oil level

1 驱动轮前轴承注油 2 驱动轮后轴承注油

3 惰轮轴承注油 4、5、6 齿轨轮组轴承注油

1 driving wheel front bearing grease injection

  9
2 driving wheels back bearing grease injection 3 Idler wheel bearing grease injection

4、5、6 Rack wheel bearing grease injection.

注：行走箱注油牌号为 3#极压锂基润滑脂（见表 1.1.3 注油指南）Note: walking

tank oil brand is 3 # extreme pressure lithium grease (see table 1.1.3 filling guide)

截割机构注油（如图 1-5）Cutting institutions oil (shown as figure 1-5)

摇臂齿轮传动分为直齿轮系的传动腔与行星轮系的传动腔为二个独立的油

腔。The ranging arm gear transmission divide into gear train of transmission cavity and

planetary gear train cavity as two separate oil cavity.

摇臂行星减速机构通过安装在行星头上

的油位探尺进行检查，油位应该位于油位探

尺允许的最高油位跟最底油位间。如图 1-4。

在进行油位检查时煤机摇臂必须处于水平位

置及关闭状态。 图 1-4 油位探尺

Figure 1-4 Oil level gage rod

Ranging arm planetary reduction mechanism is checked by oil level gage rod that

installing on the planet's head, the oil level should be located in between the maximum

and the minimum oil level of oil level gage rod allowance. Shown as in figure 1-4, the

machine ranging arm must be in a horizontal position and closed state during oil level

check.

  10
  

图 1-5 摇臂注油位置 Figure 1-5 Ranging arm oil position

1 行星机构油位尺 2 行星机构透气塞（油位探尺）

3 行星机构加油口 4 行星机构放油口

5 摇臂身加油口 6 摇臂身放油口

7 摇臂身油位尺 8 摇臂身放油孔
9 摇臂身透气塞 10 截割电机和摇臂腔检查口
1 Planetary mechanism oil level ruler 2 planetary mechanism vent plug

(oil level gage rod)

3 Refueling planetary mechanism 4 planetary mechanism oil drain port

  11
5 The ranging arm body filler 6 the ranging arm body oil drain port

7 The ranging arm body oil level ruler 8 the ranging arm oil drain port

9 Radial vent plug 10 Cutting motor and ranging arm cavity check port

破碎机构注油（如图 1-6）Oiling for crushing unit (shown as in figure 1-6)

油口Ⅰ、Ⅱ、Ⅲ均可作为放油口；加油时，将油口 3 置于与滚筒回转中心相

同的水平位置，作 为油位标志口（油溢出时即加油到位），油口Ⅰ为加油口，油

口Ⅱ为透气口。Oil port Ⅰ, Ⅱ, Ⅲ all can be used as oil drain mouth; When you are

refueling, the oil mouth 3 is at the same level of drum slewing center , as oil level mark

mouth (oil spill means the oil is in place), oil mouth Ⅰ is filler, oil mouth Ⅱ is

breathe mouth.

序号 4 油杯给轴承加油。Use the serial number 4 oil cup to oil in bearing.

  12
  

图 1-6 破碎机构注油位置 Figure 1-6 oil broken mechanism

1 油口Ⅰ 2 油口Ⅱ 3 油口Ⅲ 4 油杯

1 oil mouth Ⅰ 2 oil mouth Ⅱ 3 oil mouth Ⅲ 4 oil cup

调高泵箱注油（如图1-7）Oiling for height-adjustment pump box

(shown as figure 1-7)

当摇臂处于最高位置及关闭状态。油位不得低于最低油标位置。

通过调高泵箱的放油孔(3) 和 (4) 放掉液压油， 在这之前必须拧下 M33×2

螺塞。

通过调高泵箱的加油口(1) 加液压油， 在这之前必须拆卸下油口上的空气滤清器

EF2-32。

  13
When the ranging arm is in the highest and closed position, oil level shall not be less

than the minimum oil standard position.

Release the hydraulic oil through height-adjustment pump box drain hole (3) and (4),

before this the plug M33 x 2 must be unscrewed.

Fill the hydraulic oil through oiling port (1) of height-adjustment pump box, before this the

air filter EF2-32 at the oil port must be removed.

图 1-7 调高泵箱油的更换 Figure 1-7 height-adjusting pump box oil

replacement

1 加油口 2 加油阀 3 左放油口 4 右放油口 5 油标

1 oiling port 2 oiling valve 3 left oil drain port

4 right oil drain port 5 oil leveler

  14
  

1.2 机械单元维护 Maintenance for mechanical unit

1.2.1 检查周期及检查内容 Check cycle and check content

维护周期
维护 维护点 每次换 每隔 300 至 500 半年 备注
项目 班后 小时或 1 个月
检查 牵引部油箱 　　
工作 调高泵箱 　　
油液 摇臂 摇臂身油箱 　　
行星头油箱 　　
更换工 牵引部油箱 第一次更换 　
作油液 调高泵箱 　
摇臂 摇臂身油箱 第一次更换 　
行星头油箱 第一次更换 　
换过滤 调高泵 吸油滤芯 80μm 检查 半个月
器滤芯 箱
压油滤芯 10μm检查 每周
检查液 整 液压拉杠（联接） 　 3～6 个班第一次
压拉杠 机 后每 3 月一次
的松紧 全部紧固
检查螺 行走 螺栓 　 每周一次
栓的张 机构 全部紧固
紧力
检查螺 摇臂铰 螺钉 　 每周一次
钉 接轴 全部紧固
检查制 牵引部 牵引制动闸 　 磨损超过 4 毫米
动闸 更换磨擦片
测量磨 行走机 导向滑靴 　 按需要
损 构等 齿轨轮 　 按需要

平滑靴 　 按需要
重型润 行走机 齿轨轮轴承 　
滑 构 驱动轮、惰轮 每周
轴承
检查截齿、齿套 　 每天
和齿座的外部损
伤
检查喷嘴 　 每天
其 滚 检查滚筒联接 　 每周
他 筒 检查水分配阀及 　 每周
管子的漏损

  15
 Maintenance cycle
Maintenance Maintenance points after each 300 half Remarks
program every year
shift - 500

hours or

one

month

check haulage oil tank 　　

working height-adjustment pump 　　
oil box
ranging oil tank of 　　
arm ranging arm
body
oil tank of 　　
planetary
head
change oil tank of haulage unit primary 　
working change
oil height-adjustment pump 　
box
ranging oil tank of primary 　
arm ranging arm change
body
oil tank of primary 　
planetary change
head
change the height- oil suction half month
adjustment
filter element pump box filter 80μm

pressure oil each week

filter 10μm

  16
  

check the whole hydraulic after 3 ~ 6

machine pull-bar shifts for
elasticity of the first
hydraulic time,
every three
pull-bar months
afterwards

check the walking bolt every

mechanism week
bolt

tensioning

force

check the ranging screw every

screw arm joint week
shaft
check the haulage haulage need to
brake unit brake
replace if

friction

wear is

more than

4 mm

measurement walking guide shoes According

mechanism to need
of grinding wheel rack According
damage to need
slide shoes According
to need
relubrication walking rack wheel weekly
mechanism bearing
driving weekly
wheel
bearing

  17
 check to see daily

if there is

external
others drum
damage of

cutting

tooth, tooth

sleeve and

tooth set

check the daily

spraying

performance

check the weekly

drum linking

check the weekly

water

distributing

valve and

pipe leakage

 润滑油的寿命：机器大修时，润滑油应更换。The service life of the

lubricating oil: when machine is overhauled, lubricating oil should be replaced.

1.2.2 机械单元关键部件的维护 Maintenance for key components

of mechanical units
1.浮动油封的安装（如图 1-8）The installation of floating oil seal (shown as
figure 1-8)

  18
  

按照以下步骤安装 GOETZE 金属面密封。According to the following steps to

install GOETZE metal facing seal.

（1）确认要安装的密封件匹配。切勿将新旧密封件安装在一起或使用两个以

前就不匹配的旧金属密封件。Confirm that the installed seal is matched. Do not

install the old and the new seal together or use two old metal seals that do not match

before.

（2）去除密封座上的粗糙污点和碎屑并清洗。Remove the rough stain and

debris in sealing seat , then clean it up.

（3）用溶剂清洁金属密封面、密封座（圈）和橡胶圈，去除保护层或油。不

要划伤密封面或复曲面环。如果金属密封面受损，更换整个密封件。Use the solvent

to clean metal sealing surface, sealing seat (circle) and rubber ring, remove the

protective coating or oil. Do not scratch sealing surface or complex curved surface.

Replace the seal if the metal sealing surface is damaged.

（4）安装前用溶剂弄湿橡胶圈。要遵循溶剂容器标签上的使用说明。Wet

solvent rubber ring before installing it. Follow instructions on the solvent container

labels should be complied.

（5）将复曲面环安装到金属面密封上，确保其无扭曲。Install the complex

curved surface on the metal surface seal ring, make sure it has no distortion.

（6）将复曲面环和密封件置于密封止动唇上。Put complex curved surface and

seal components on the sealing stopper lip.

（7）用安装工具边缘均匀施压将橡胶圈置入密封唇下。Use the installation

tools to press the rubber ring under the sealing lip generally

提示：切勿为了便于安装给橡胶圈涂油。不要使用改锥或尖状物安装橡胶圈，

因为这可能造成永久损坏和泄露。Tip: Do not paint oil on rubber ring just for easy

installation. Do not use a screwdriver or sharp pick to install rubber ring, because it

may cause permanent damage and leakage.

  19
 （8）安装好密封一面后，清洁金属密封表面，然后薄薄涂上一层油。该步骤

要在组装部件之前进行。不要把油弄到密封座和密封唇内。After installing one

sealing side, clean the metal sealing surface, then coat it with a thin layer of oil. This

step needs to be done before assembling the parts. Do not let the oil enter into of the

sealing and sealing lip.

图 1-8 浮动油封

Figure 1-8 Floating oil seal

1 橡胶密封圈 2 金属密封环 3 密封表面 4 密封唇

5 密封座 6 方法兰 7 安装工具

1 rubber sealing ring 2 metal sealing ring 3 sealing surface

4 sealing lip 5 seal seat 6 square flange 7 installation tools

注意：行星减速器调整间隙 The clearance of planetary gear reducer should

be adjusted if needed.

第一步

（1）轴承到 B 轴承座的尺寸 z 与单独测量 B 轴承座的尺寸 z 进行对比。

  20
  

（2）将上述两个测量值进行对比，如不符对 B 轴承座进行返修。

第二步

（1）先测绘 x 值，再测绘 y 值。

（2）将 x 与 y 值的差值算出。

（3）浮动油封值为 50，与 x、y 的差值进行对比，如差值不符，需返修 A 方法兰。

The first step

(1) Compare the size Z which is between bearing to bearing seat B with the value

measuring the size z of the bearing seat B alone.

(2) Compare these two measurements, if there is a discrepancy, B bearing-seat should

be repaired.

The second step

(1) Surveying value x, then value y.

(2) Calculate the difference between the x and y.

(3) The value of floating oil seal is 50, then compare it with the difference between x

and y, if they disaccords, the square flange need to be repaired

2.滚筒 Drum
更换截割滚筒时将采煤机停在巷道端头，如果需要更换前滚筒，需将滚筒放置在

巷道端头有空间的地方以便拔出滚筒。如果需更换尾滚筒，则需割掉滚筒之间的

煤壁。尽可能远离液压支架。拆除滚筒时，需将采煤机从工作面撤出，并在采煤

机和工作面间留足够的空间。When replacing cutting drum, stop shearer at the end of

the tunnel first, if need to replace the front drum, drum must be placed at the end of

roadway so that there is space to pull it out. If need to change the tail drum, it need to

cut coal wall between the drum. And also as far as possible away from the hydraulic

supports. When removing drum, the shearer must be moved away from working face,

and enough space between the shearer and coal face should be kept.

由于滚筒以及截齿、 喷嘴均属易损件，正确维护和使用滚筒，对延长其工作

寿命，提高截割效率是十分重要的，所以开机前必须做到如下几点：Because the

drum and cut teeth, nozzle are all wearing parts, proper maintenance and use of drum

  21
will be good for prolonging its service life, and improving the cutting efficiency is very

important, therefore the following points must be checked before starting:

a. 检查滚筒上截齿和喷嘴是否处于良好状态，若发现截齿刀头严重磨钝，应

及时更换，若喷嘴被堵，亦应及时更换。换下的喷嘴经清洗后可复用。

b. 检查滚筒上的截齿和喷嘴是否齐全，若发现丢失，则应及时补上。

c. 截齿和喷嘴的固定必须牢靠。

d. 检查喷嘴及系统管路是否漏水，水量、水压是否合乎要求。

A. Check to see if the cutting teeth on the drum and the nozzle are in good condition,

if the degree of wear of cutting blades is serious, it should be replaced in time, if the

nozzle is blocked, it also should be replaced timely. The nozzle could be reusable after

washing up.

B. Check to see if cutting teeth and the nozzle of the drum are complete, if any lose

is found, they should be timely fixed.

C. Cutting teeth and nozzle must be fixed firmly.

D. Examine Nozzle to see whether there is a leakage of the system pipeline, and the

water quantity, water pressure complies with requirements or not.

警告：在检修滚筒期间，应在工作面裸露区域进行临时支护，以保证工作区域的

安全。否则顶板冒落会造成严重的伤亡事故。

Warning: During overhaul of drum, it should have temporary supports in uncovered

area of working face, ensure the safety. Otherwise, it will cause serious casualty

accidents caused by roof caving.

滚筒的内喷雾装置包括内喷雾供水水路、 喷嘴座、喷嘴等。内喷雾供水水路

由连接方法兰盘中的通水孔槽、端盘板和叶片内缘的环形水槽、U 形管和端盘板、

叶片中的径向孔等组成。The inner spraying device includes drum inner spraying

water supply system, spray nozzle set, nozzle, etc. The inner spray water supply

system consists of water hole which connects flange limbers trough, the end plate and

the annular sink of the inner edge of blade, U tube and end plate, radial holes in blade,

etc.

  22
  

3.液压拉杠 Hydraulic pull-bar

（1）采煤机在井下开始使用后 7-10 天内，应第一次检查液压拉杠的松紧（即

重新紧固）。在使用满一个月后应进行第二次检查液压拉杠的松紧（即重新紧固）。

以后每 3 个月应检查一次液压拉杠的松紧（即重新紧固）。

（2）用于机身联结的四条液压拉杠是一个整体，在进行第“Ⅰ”条检查液压拉

杠松紧（即重新紧固）时，四条液压拉杠都需按要求进行检查和紧固。

（3） 在检修采煤机中，当发现某条液压拉杠拉紧力不足时，应视为四条拉杠

拉紧力不足，对所有四条液压拉杠都需按要求进行检查和紧固。

（4）当需要更换某条液压拉杠时，请注意在更换操作过程中，应对所有四条液压

拉杠都按要求进行检查和紧固(1) When shearer is in the mine for 7 to 10 days after

starting using, elasticity of hydraulic pull-bar should be checked first (namely

retightened). After a full month of use, it should take the second check (namely

retightened). After every 3 months need to check the tightness of a hydraulic pull-bar

(namely retightened).

(2) The four hydraulic pull-bars that are used for is a whole, when use article "Ⅰ" to

check elasticity (i.e. retightened), four hydraulic pull-bar need to check and tighten as

required.

(3) During the repairing, when the tensioning force of one hydraulic pull-bar is found

insufficient, it should be taken as the four pull-bar tensioning force are all insufficient,

and need to check and tighten all as required.

(4) When replacing one hydraulic pull-bar, please pay attention in the process of

operation, all four hydraulic pull-bar should be checked and tighten as required

  23
 图 1-9 液压拉紧装置 Figure 1-9 The hydraulic tension device

1 拉紧头 2 活塞 3 缸体 4 支撑套 5 螺杆 6 螺母

1 tensioning head 2 piston 3 cylinder block

4 supporting sleeve 5 screw stem 6 nut

注意事项： 液压拉杠在紧固之前，高强度螺母在液压拉杠的端头螺纹上必

须转动灵活。 紧固分两步进行，先用 50％的压力使四条液压拉杠将三段箱体联

成整体，然后再用接近所要求的压力紧固，并防止压力超限。拆卸液压拉杠时，

瞬时压力可达到所要求的压力值，防止压力严重超限。

Note: Before fastening the hydraulic pull-bar, high strength nuts on the end of the

hydraulic pull-bar thread need to flexibly rotates. Tighten process is divided into two

steps, firstly use 50% pressure to combine three cabinets as a whole with four

hydraulic pull-bar, and then use the pressure that closes to the required to tighten, and

prevent the pressure overrunning. When removing hydraulic pull-bar, the

instantaneous pressure can reach the required pressure value, the serious pressure

overrun must be avoided.

4.液压螺母 Hydraulic nut
液压螺母由螺母、活塞、密封圈、油堵、紧圈组成。其工作原理和使用方法

如下：The hydraulic nut consists of nut, piston, sealing ring, oil plug, clamping ring. Its

working principle and using method are shown as follows:

  24
  

由超高压泵提供高压油，通过超高压软管、快速接头注入液压螺母油腔，缓

慢拉伸高强度螺栓，达到规定压力后，用紧圈机械锁紧，使螺栓始终处于拉伸状

态，以达到防松的目的。本机选用两种规格的液压螺母 M72×4，机身联接用，配

液压拉杠； M36×3，行走箱与牵引部连接用。The high pressure oil provided by the

ultra-high pressure pump , inject oil through quick connector into hydraulic nut oil

cavity through the ultra high pressure hose, slowly drawing high strength bolt, when it

reaches the specified pressure, lock it with mechanical lock, keep the bolt in tensile

state, so it can achieve the locking purpose. The machine adopts two specifications of

hydraulic nut M72 x 4, used for machine body connecting, combine with hydraulic

pull-bar. M36 x3, used for walking box and haulage connection.

操作步骤 Steps：

（1）检查液压螺母紧圈端与活塞端距离如图 1-10，在 B 结合面无间隙情况下，

距离 A 不得大于 2mm；

（2）把液压螺母和高强度螺母与高强度螺栓

安装就位；

（3）取掉液压螺母上的黄色螺堵，装上快速

接头座；

（4）接上超高压泵软管，接通超高压泵，关

闭（拧紧）超高压泵的截止阀； 图 1-10 液压螺母

Figure 1-10 hydraulic nut

（5）确定超高压泵油箱油量充足，开始打压，直到规定压力；

（6）拧紧圈，使其贴紧螺母端面，使得结合面 B 无间隙；

（7）缓慢转动油泵截止阀，卸去压力；

（8）拆下液压螺母上的快速接头座，并拧入螺堵。(1) Check the distance between

hydraulic nut end and piston ring end, shown as figure 1-10, if combining with the

surface without clearance, the distance A shall not be more than 2 mm.

(2) Install the hydraulic nuts, high strength nuts and high strength bolts in place;

(3) Take out the yellow screw on hydraulic nut, install the fast connection device,

  25
(4) The hose connected to ultra-high pressure pump, through to ultra-high pressure

pump, closed (tight) ultra-high pressure pump valve;

(5) Make sure the ultra-high pressure of pump oil tank is sufficient, fill it until the

specified pressure is achieved;

(6) Tight the ring, and make it stick to the nut face, make no clearance with

combination surface B ;

(7) Slowly turn the pump valve, discharge the pressure.

(8) Remove the hydraulic quick connector on the nut, and screw in the screw plug.

拆卸液压螺母步骤与安装相反，即打压后转动紧圈使其与螺母脱离即可。

Remove the hydraulic nut steps are in contrast to the installation, namely rotating ring

with the nut out away of the can .

注意事项：Note:

（1）36×3， 72×4 四种液压螺母打压到 150-180Mpa 左右为宜；

（2）超高压设备需专人保管和负责，培训合格后方能上岗。确保手压泵有足

够的稳定性，工作范围内的垫板水平并稳固，在工作过程中不能移动；

（3）超高压泵使用专用油 L-AN10（GB443－89），需保护油液和接头的清

洁；

（4）液压螺母的行程较小，使用时不得超过 5mm；

（5）安装前要清除对接面上的毛刺等；

（6）液压螺母不得用作移距，对接面接触后再用液压螺母锁紧。

(1) Suppression the 36 x 3, 72 x 4 four hydraulic nut down to 150-180 mpa;

(2) The extra high pressure equipment responsible to specified person and served, after

pass the training can go to work,make sure the pressure pump has sufficient stability.

The plate of working area must be balanced and stable,it cannot move during the

working process.

(3) The ultra-high pressure pump used oil - AN10 L (GB443-89), to protect the oil and

joint clean;

  26
  

(4) Hydraulic nut relatively smaller of working distance and use no more than 5 mm;

(5) Before installation it is needed to remove burrs on the surface of the docking, etc.;

(6) Hydraulic nut shall not be used as the shift, reoccupy using the hydraulic nut to

lock after surface contact .

5.反冲洗过滤器 Anti-flush filter
（1）定期检查喷雾泵站至采煤机的输水胶管连接是否密封，不得有渗漏水现

象。

（2）定期检查和清洗采煤机水阀内的过滤器。

（3）注意内喷雾供水装置的外壳泄漏孔。如果发生线状漏水现象，应及时检

查原因，必要时更换水密封件。

（4）加强对滚筒喷雾系统的日常维护，随时注意各喷嘴的运行情况，如有堵

塞和丢失，应及时疏通和安装喷嘴。

（5）采煤机运行时，随时注意冷却水路中的安全阀，如产生释放现象，应及

时检查原因，进行处理。

（6）采煤机开机前必须先通水，当喷雾泵站停止供水时，采煤机应立即停止

运行。

(1) Periodically check the spray pump station to shearer water hose connection is

sealed, can not have leakage phenomenon.

(2)Regular inspection and cleaning of shearer filter in the water valve.

(3) Pay attention to shell leakage hole of the spray water supply mechanism. If there is

a linear leakage phenomenon, it should timely check the reason, replace the water seal

if necessary.

(4) Strengthen the daily maintenance of drum spray system, pay attention to the

operating condition of the nozzle at any time if the nozzle has any blockage and lost,

take timely dredging and installation of nozzle.

(5) During mining, always pay attention to the safety valve of cooling water, if release

phenomenon occur, take timely check for the reason, processing it.

(6) Starting water before shearer operate, when the spray pump station stop supply

water, shearer should immediately stop running.

  27
1.3 常见故障及处理方法 Common faults and processing methods

1.3.1 摇臂常见故障及处理方法 The ranging arm common faults and

processing methods
序号 故障现象 故障分析及排除方法

1 电动机腔有 电机齿轮轴后的骨架油封容易漏油（320#极压齿轮油），此油漏出
油、且量大 后应该流到下方的溢油口，但是由于机身下运输机过煤常将此溢油眼堵
塞，严重的情况下此油可进入截割电动机。
处理方法一：将电动机拆掉更换密封，更换新油封时可将旧油封垫
在新油封上敲击旧油封同时将新油封安装到位，这样安装不会损坏新油
封。
处理方法二：将电机齿轮轴从煤墙处拆掉，第二步将轴承处的套拆
掉即可更换油封。但是一些小的机型采煤机还得将摇臂二轴，也就是惰
轮轴拆掉后才能够更换，在安装惰轮轴时注意两轴承中间的距离环，因
为由于自重这个距离环在侧面安装时容易掉下来，此时安装需讲求方
法。
2 离合器在脱 更换铜套
开的状态下 将铜套更换一个方向，因铜套中孔是等径通孔，故两端都可以用。
发出哒哒的
响声

3 滑动密封漏 由于行星减速器出轴轴承长时间的工作，圆锥磙子轴承的滚珠磨
油问题及处 损，造成行星架轴向窜动，滑动密封的间隙曾大，超出了滑动密封“O”
理方法 型密封圈的弹性范围，此时就要更换轴承来解决漏油问题。

对于行星减速器两端用圆锥磙子轴承的情况，在安装时就要调整端
盖与轴承外环的间隙，一般为 0.15mm～0.3mm。对于采用调心轴承的，
间隙应该为零。
测量间隙的方法是压铅丝法：此法就是将端盖拆掉把保险丝放在轴
承外环上将端盖安装上，将螺栓压紧，然后再拆掉，铅丝被压薄后就是
间隙的实际尺寸。此时用减法减掉后余下的间隙就是你要的间隙。

行星头上固定定心座的螺栓是用铁丝串联防松，如果此螺栓松动会
造成漏油，严重时滚筒和方法兰盘会掉下来，要求此螺栓应经常检查。
滑动密封“O”型密封圈失去弹性，也是造成漏的原因之一。原因是
由于常时间煤尘的积累，使滑动密封“O”型圈失去弹性。此时要更换滑
动密封“O”型圈并清理周边的煤尘。

  28
  

No. The fault Failure analysis and elimination method

phenome

non
1 large Skeleton oil seal is easy to leak (320 # extreme pressure gear oil),
after leak, the oil should flow to the bottom of the oil spill, but
amount of coal often blocked up oil spill hole when it goes through the under

oil in the conveyor, in bad situation, the oil may enter into the cutting motor.

Motor

cavity Processing method 1: Dismantle the motor and replace the seal,
when replacing the new seal, the old one can be padded on the
new one, keep knocking it and install the new one in place, this
installation would not damage the new oil seal.

Processing method 2: Take the motor gear shaft away from coal
wall, the second step is to remove the bearing sleeve to replace the
oil seal. But for several small models of shearers, the second shaft
of ranging arm, namely idler shaft should be removed first, pay
attention to the distance between two bearing rings, because of the
weight, this distance ring in side is easy to fall down when
installation, so the installation method should be emphasized.

2 Clutch Replace copper sleeve

under the

release
Change the copper sleeve to another direction, because the copper
conditions
sleeve hole is diameter hole, so it can be used on both ends.
have dada

sound

3 Sliding Due to the long time working of planetary gear reducer shaft, balls
of tapered roller bearing wear, cause the planet carrier axial
seal oil
channeling, sliding sealing gap was increased to surpass the elastic
leakage range of sliding sealing "O" type sealing ring, at this moment,
replace the bearing to solve the leaking problem.

  29
 problems For planetary reducer with tapered roller bearings on both ends,
when installation the clearance between the bearing outer ring and
and
end cover will be adjusted, usually from 0.15 mm to 0.3 mm, for
solutions self-aligning bearing, clearance should be zero.

Clearance measurement method is lead wire method: this method

is to remove the end cover, put the fuse on the bearing outer ring
end cover, install the end cover again, press the bolt, then remove
down, after being pressed thin, lead wire is the gap of actual size.
At this time after subtracting the value, the rest of the space is the
space that you want.

Planet head fixed centering of bolt is in series with wire locking, if

the bolts loose, it can cause leakage, in more serious situation , it
can cause the drum and square flange falling down, so it should be
checked regularly.
The elasticity lose of sliding sealing "O" type sealing ring, it is
also one of the reason to cause leakage. Because the coal dust
would accumulate during a long time, it may cause "O" type circle
loss elasticity. If that happens, replace the sliding sealing "O" ring
and clean up the dust around.

1.3.2 牵引部常见故障及处理方法 Common faults of haulage unit and solving

methods
序号 故障现象 故障分析及排除方法

1 牵引电动机后部积油太多 （此方法与摇臂电机齿轮轴的处理是一样的）

2 检查摩擦片是否磨损严重，超出 4 毫米时要更换摩

擦片，安装时如果是 YZQ-700，就先将制动活塞提起，

制动器故障 提起时用 M8×25 的螺栓。

是否在牵引时管路不来油，查电磁阀不动作，或低

压低于 1.3Mpa。

密封圈处严重漏油,释放行程不足，更换密封圈。

  30
  

3 由于牵引部减速箱内第二级行星机构处的油封损

牵引部与行走箱结合 坏，导致行走箱老塘端面渗油，因为行走箱属于开式齿

面漏油 轮箱，其内的轴承是靠油脂润滑，所以判断不可能有齿

轮油渗出。故判断是牵引部与行走箱结合面漏油，需更

换其处油封。

No. The fault phenomenon Failure analysis and elimination method

1 Too much oil at the back of the (this method is the same solution for the

haulage motor. ranging arm motor gear shaft)

2 Check whether the friction plate is badly worn,

when it is more than 4 mm, it needs to replace

friction plate, if the YZQ - 700 is installed, pull

Brake failure
out the brake piston first by the M8 x 25bolt.

If the haulage line can not get oil, check the

electromagnetic valve to see if it is active or if

low pressure is lower than 1.3 MPa.

If there is serious leakage of sealing ring, or

stroke release is not enough, replace the seal

ring.

  31
 Due to oil seal of the secondary planet

mechanism inside haulage reduction box is

Oil leakage in combined surface
damaged, and as walking box belongs to open
between haulage unit and walking
gear box, inside bearings rely on grease
box
3 lubrication, so there must be no gear oil

leakage. So the problem should be there must

be oil leakage in combined faces between

haulage unit and walking box, it needs to

change the oil seal then.

1.3.3 液压调高系统常见故障及处理方法 Common faults of hydraulic
height-adjustment system and processing methods
1、判断的基本方法 The basic judging methods：

如果液压系统出现问题，首先应判断是机械的问题还是电气的问题，其方法是，

操作手动阀杆来判断阀杆的随动情况。If problems appear in hydraulic system, the

first judgment should be mechanical or electrical problem happening, the method is

operating manually to judge the follow-up situation of valve handle.

首先将油泵的排油口打开，再开机使油泵开始工作，观察排油量以及压力的

大小；如果没有压力，则可断定是齿轮泵到油池的部分出了问题。如果压力很大

而油也能连续流出，则需检查阀组到油缸的部分。这样以来可以事半功倍。

按顺序分步检查：第一步检查油箱是否有油，吸油滤油器滤网是否需清洗；

第二步检查吸油管路的密封状况，看是否漏气；第三步检查齿轮泵的排油压力是

否不足；第四步检查配油块，看配油块中的油路是不是有贯通或者堵塞现象，没

有进行工作就直接回到油池了；第五步考虑低压溢流阀和高压安全阀的可靠性，

第六步检查手动调高阀的进、回油的情况；因为有的中位为 H 型的三位四通阀回

油不畅，会使油直接进入油缸而使油缸动作。第七步检查油缸，在确定低压溢流

阀和高压安全阀没有问题的前提下，检查油缸的活塞是否漏油而不调高，还是油

缸的前后腔串油导致油直接回油池。

  32
  

你如果对液压系统比较熟悉，便可以根据现象大概判断问题部位。检查齿轮泵的

排油是否正常，看管路是否漏油，根据压力表的数值判断低压阀和高压阀是否有

问题。

Open oil discharge port of the oil pump first, then start machine to make the pump

work, observe the oil discharge volume and pressure amount; if there is no pressure, it

could be concluded that the parts from the gear pump to oil pool is out of question. If

pressure is high and oil can also flow out continuously, it needs to check the parts from

valve group to cylinder, that would be more effective. Check components step by step

in sequence: Step 1, check whether there is oil tank and oil suction filter is clean or not;

Step 2, check the seal condition of suction pipe line to see if there is air leakage; Step 3,

check oil discharge pressure of gear pump is enough or not; Step 4, check oil

distribution block to see if it has occlusion or jam phenomenon, and oil goes back to

oil pool directly without work; Step 5, consider the reliability of the low pressure

overflow valve and high pressure relief valve; Step 6, check the oil feeding and

returning situation of hand-operated valve ; Because oil returning of some median H

three-position four-way valve is not smooth, makes the oil directly goes into the

cylinder and make cylinder act; Step 7, check the oil cylinder , if the low pressure

relief valve and pressure relief valve has any problems, check if height-adjustment is

not acted because the oil cylinder piston is not raised, or cylinder oil is intermingled

between front and back cavities leads oil flow back into pool directly.

If you have been familiar with the hydraulic system, judge the problem area

according to the phenomenon. Check the discharge of oil pump whether it is normal,

watch the pipe if it is leakage, according to the value of pressure gauge whether low

pressure and high pressure valves have problem.

序号 故 障 现 象 故障分析及排除方法

1 检查油箱是否有油，油量有多少。
油缸是否漏油，前后腔是否串油，需修理或更换油缸。

  33
 手动能够调高，电控不能控制，说明手动和电控脱节，
需检查相应电气控制回路或更换调高电磁阀。
系统不调高 齿轮泵损坏。判断齿轮泵的好坏首先保证油池有油,泵
坏了出现的现象是:排油管路无力,吸油的滤芯干净无
脏东西。
高压安全阀内有杂物影响阀芯，阀芯不能复位，压力
油直接回油箱。进行清洗或更换高压安全阀。

2 吸油过滤器铜网堵塞， 清洗过滤网。
会造成不能正常吸油，高低
压表均无显示

3 调高速度慢，齿轮泵的来油 检查高压阀，如果高压阀开启不能复位,液体全回油池，
有力，高低压表不显示 可能出现此问题。
观察低压表，看压力值是否低于要求压力，调节低压
阀即可。

4 摇臂有慢慢下降的现象 说明双锁阀不起作用,可将双锁阀拆下来清洗重新安装
即可,原因是阀的封油区有脏东西黏附在封油线上,如
果怕耽误生产可更换新的双锁阀,将旧的清洗备用。

5 调高出现自动升的象 检查端头站内部是否短路。需修理或更换端头站。
三位四通阀是否卡死。需修理或更换三位四通阀。

6 调高油缸在下降过程中出 液压系统有空气进入。需进行系统排空。
现“点头”现象 双向液压锁内有杂物影响工作。进行清洗或更换。

No. The fault phenomenon Failure analysis and elimination method

1 Height-adjusting system does Check whether there is oil in tank and how much.

not work

Check whether the front and back cavities of the oil

cylinder leak oil, if have, it needs to repair or replace the

oil cylinder.

  34
  

Do height-adjusting manually, electric control is not

functional, it means the manual and electric control is

disconnected, so that needs to check the corresponding

electrical control circuit or replace higher electromagnetic

valve.

Gear pump is damaged. Check gear pump is good or not,

it needs to ensure there is oil in oil pool first, and the

following phenomenon showing pump is broken: the

discharge of oil pipe lacks strength and oil suction filter is

clean without dirty things inside.

The inside debris in high-pressure relief valve effects

valve core, valve core cannot be reset, pressure oil

directly goes back to the tank. Then clean or replace high

pressure relief valve.

2 Oil suction filter copper Wash up the filter.

network is blocked, causing

abnormal soil absorption,

high and low pressure meter

cannot display.

3 Height-adjusting speed is Check if the high pressure valve, high pressure valve

slow, gear pump incoming opening button cannot be reset, oil get back to oil pool,

oil is strong, high and low the problem may arise.

  35
 pressure meter cannot display Observe low pressure meter to see if pressure value is
lower than the required value, adjust the low pressure
valve.

4 Ranging arm slowly decline Double lock valve doesn't work, double lock valve can be

phenomenon removed to clean and re-installed, the reason was that the

valve seal oil dirt adhesion on the oil seal line, in case of

delaying production , double lock valve can be replaced,

clean the old one and make it standby.

5 Automatic arising Check whether short circuit happens in internal end

phenomenon in station. Need to repair or replace the end station.

height-adjusting

Three four-way valve is stuck. Need to repair or replace

the three-position four-way valve.

6 Higher oil cylinder "nod" Air enters into the hydraulic system. Need to drain the

phenomena appeared in the system.

process of falling

The sundry inside two-way hydraulic lock affects its

work, clean or replace it.

1.3.4 行走箱常见故障及处理方法 Common faults of walking box and processing

methods
序号 故障现象 故障分析及排除方法

1 当实际载荷大于额定 将弹性挡圈拆掉，再将小盖拆掉，更换扭矩轴即可。

载荷时，扭矩轴从剪切 如果是液压牵引采煤机出现不牵引的现象。原因是力量都从

槽处折断，不能传递到 扭矩轴断的这个液压马达上损失掉了。

齿轨轮上

2 采煤机开到机头或机尾时，挑顶到位 处理方法：

  36
  

后、卧底后，采煤机倒退使运输机推 首先将采煤机导

进，此时采煤机的位置应该 26m 以 向滑靴和销轨吻

上，如果在 26m 以内会造成导向靴断 合住，再将齿条

裂，因为运输机的弯度较大。 销拆掉两个，再

齿轨轮和导向滑靴损 导向滑靴磨损严重，齿轨轮在和齿条 将挡煤板拆掉，

咬合发生变化，齿轨轮的平咬在齿条
坏 接下来将齿轨轮
的间隔挡处，齿轨轮容易断牙掉齿，
导向滑靴磨损时要及早的更换。 轴拆掉（拆齿轨

损 由于平滑靴的磨损严重会使采煤机 轮轴有专用工
向煤壁侧倾斜，由于重心的偏斜导向
坏 具），此时将摇
滑靴抬起，不仅磨损勾起齿条的部
的 臂头垫住，再使
分，还影响齿轨轮的啮合，严重时会
原 使采煤机掉道，这时齿轨轮的轴承也 摇臂下降。使采

因 易损坏。 煤机的机身升
注意经常检查，齿轨销是否出来
起，即可更换损

坏的零件，换好

的时候将摇臂上

升，使齿轨轮的

孔、导向滑靴的

孔对齐，安装齿

轨轮轴就可以

了。

No. The fault Failure analysis and elimination method

Phenomenon

1 When the actual Pull down the elastic ring, and then remove the small

load is greater than cover, replace the torque axis.

the rated load and

the torque shaft is

If hydraulic haulage shearer cannot haulage. The reason
broken from the
is the power lost from the torque on the shaft of broken
shear slot, it cannot

  37
 be passed on to the hydraulic motor.

wheel rack

2 When Shearer drives to head or Processing

tail of machine, if roof ripping
is in place, after dinting, method:
shearer get back to propel the
First shearer
conveyor, shearer's position
guide sliding
should more than 20m, if
boots and pin
within 20m, it could cause
rail match
breaking of guiding shoe due to
Rack rail wheels together, then
large conveyor curvature.
and guide shoes remove two
broken rack pin ,And
If guide sliding shoes wear then coal
seriously, engagement between eliminators
Dama rack wheel and rack changes, can be
ge flat engagement in interval remove,
shift, rack wheel is easy to be remove rack
reason broken and lose teeth, then wheel axle
guide sliding shoes should be (remove rack
early replaced. wheel axle
with special
tool), then
Due to the fact that bad wear of insert the
drum head
flat sliding shoes will make the gasket, let
shearer Lateral tilt towards the drum
declined.
coal wall, due to the center of When
gravity deflection direction Shearer's body
rises, you can
slippery boots up, triggering replace the
rack part not only wear, also damaged
parts, when
affect the mesh of rack wheel, it's down, rise
seriously when they make the the
drum,make
shearer off, then the rack wheel the guiding
bearing is easy to damage. sliding shoes
rack wheel
hole aligned,

  38
  

Pay attention to check, whether install the rack

wheel axle.
the rack pin can pull out or not.

2 电气单元维护 Electrical unit maintenance

正确的维护和检修，对提高机器的可靠性，减少事故率，延长使用寿命十分

重要。其主要内容一般分日检、周检、月检。The correct maintenance and overhaul

can improve the reliability of the machine, reduce the accident rate and prolong the

service life, all of those are very important. The main content can be divided into daily

inspection, weekly inspection and monthly inspection.

2.1 每日维护 The daily maintenance

(1) 检查各电缆是否有损坏，确保无明显破损。

(2) 检查各盖板看是否有松动。

(3) 检查端头站引线，确保无明显破损。

(4) 检查所有电器元件，确保正常。

(5) 检查冷却水是否畅通，压力是否正常，确保冷却系统正常。

(6) 检查两边遥控器、端头站与机身按钮，确保各指令可靠执行。

(7) 观察机组上中文显示屏上显示数据，并作各电机温度，电流、速度数据的记

录，观察数据变化规律。

(1) Check if the cable was damaged; ensure that there is no significant damage of the

cable.

(2) Check the cover plate to see whether it is loosed.

(3) Check the end station leads to ensure that there is no obvious damaged.

(4) Check all electrical components and please ensure it is at good condition.

(5) Check whether the cooling water is clear, the pressure is normal; and also ensure

that the cooling system is in normal state.

(6) Check on both sides of the remote control device, end station and the fuselage

  39
button; ensure each instruction is reliable executed.

(7) Check the data that set on a Chinese screen display, and make the records of

temperature, the motor current, speed data for the machine, observe data variation.

2.2 每周维护 Weekly maintenance

(1)检查电控箱各箱体内是否潮湿，若潮湿，一定要放入干燥剂，并观察干燥

剂变化，以及时更换，进行干燥处理。

(2)检查电控箱隔爆面是否有锈迹，电控箱盖板密封条是否完好。

(3)检查电控箱各箱体内各个接线、插头、器件固定是否牢靠。

(4)检查电控箱内高压保险，低压保险，及保险座接触是否牢靠。

(5)检查电控箱各箱体内各线头绝缘胶布是否老化。

(6)检查电控箱各箱体内接线是否牢靠，确保控制线与高压线之间的间隙。

(7)检查左右截割电机、左右牵引电机、泵电机接线腔是否潮湿，若潮湿，一

定要放入干燥剂，并观察干燥剂变化，以及时更换，进行干燥处理。

(8)检查左右截割电机、左右牵引电机、泵电机接线是否牢靠，确保 PT100 温

度控制线与高压线之间的间隙。

(9)检查瓦斯探头确保其正常工作。

(10)检查各个冷却水道，保持畅通。

(1) Check whether the electric cabinet is in the moisture circumstance, if it is wet, it

must put the desiccant into it, and observe if there is any changes of desiccant, replace

it timely and take the dry processing.

(2) Check the electric control box flameproof surface whether it is rust or not, and

whether the electric control box cover plate is in good condition or not.

(3) Check each wiring, plugs and other components whether it is fixed of each cabinet

of electric control box.

(4) Check the high pressure electric insurance, low-pressure insurance and insurance

seat whether it is contact good or not.

  40
  

(5) You should check whether the thrum insulating tape that inside of each the electric

cabinet is aging.

(6) check whether the wiring is good that inside of each box of the electric cabinet,

ensure the gap between the control line and the high voltage wire

(7) Check the left and right cutting motor, haulage motor, pump motor wiring cavity is

damp, if it is wet, please be sure to put the desiccant inside, and be aware of the

changes of desiccant, change it in time and also the drying process must be taken.

(8) Check around left and right cutting motor, haulage motor, pump motor wiring is

secure, ensure that the PT100 temperature control line and the gap between the high

voltage wire is ok.

(9) Check the gas detectors ensure it is working properly.

(10) Check the cooling water channel, it needs to remain opening.

2.3 每月维护 Monthly maintenance

(1)检查牵引电机、截割电机、泵电机接线腔是否潮湿，应保持干燥。

(2)检查电控箱盖板、电机、电缆密封圈是否松动、老化。

(3)检查牵引电机、截割电机、泵电机接线腔接线情况是否松动，确保接线良

好。用 2500V/1000V 摇表对截割电机、泵电机进行绝缘测试，阻值应大于 3M。

(4)用 500V 摇表对牵引电机进行绝缘测试，阻值应大于 3M。此时一定要注意

与变频器拖开，否则会导致变频器损坏。

(5)检查绝缘材料有没有变质和破坏，必要时更换。

(1) Check haulage machine, cutting machine, pump motor wiring cavity whether it is

damped, it should be kept in dry condition.

(2) Check whether the electronic control box cover plate, motor, cables sealing ring are

loosed or aged.

(3) Check whether the cutting motor, haulage motor, pump motor wiring cavity’s wire

is loosed, ensure that it is wiring good. Use 2500V/1000V Megger to test the insulation

of cutting motor and pump motor, the resistance value should be greater than 3M.

  41
(4) Use a 500V Megger to test the insulation of the haulage motors, the resistance

should be greater than 3M. It is important to note that pull it away from inverter at this

time, or it would cause damage to the inverter.

(5) Check whether the insulation material is deteriorated and damaged, and replace it if

necessary.

2.4 维护工具 Maintenance tools

（1）内六方：5，6，8，10，12。

（2）绝缘胶布。

（3）万用表，摇表（2500V/1000V）、500V。

（4）活动扳手。

（5）螺丝刀（平口，梅花，大小，各两把）。

（6）套筒一套。

(1) The inner hexagon: 5,6,8,10,12.

(2) The insulating tape.

(3) The multimeter, Megger (2500 v / 2500 v), the 500 v.

(4) Adjustable wrench.

(5) Screwdriver (flat mouth, plum blossom, big and small, each needs two).

(6) One set of socket.

2.5 电气单元常见故障及处理方法 Electrical unit common faults

and processing methods

2.5.1 先导回路故障 Pilot circuit fault
1）按下总起按钮，采煤机送不上电 Shearer can not be powered up, when press the

general starting buttons,

首先判断是顺槽开关的问题还是采煤机先导回路的问题，可以用万用表在采

煤机接线腔检查主电缆先导线是否有交流电压，如果有电压则说明采煤机先导回

路有故障，分别检查温度接点、启动按钮是否损坏，急停按钮是否没有拔上来，

二极管是否被击穿；如果没有电压，先检查主电缆先导线是否断线或接地，如果

  42
  

主电缆先导线完好，检查顺槽开关是否有故障。The first judgment would be

problems with crossheading switch or it has mining machine pilot circuit problem, it

can use multimeter in mining machine wiring cavity to check the main cable pilot line

whether it has exchange voltage, if it has voltage, it means it has fault on mining

machine pilot circuit, respectively check the temperature contact and starting button

whether they are damaged, is that due to urgent stopped button does not pull up, or

whether the diode is breakdown; if there is no voltage supply, first to check the main

cable pilot line to see whether it is disconnected to the ground, if main cable pilot line

is intact, check the pilot circuit switch whether has fault .

2）启动后，机组不能自保 After starting, the unit cannot implement self-protection

首先按住总起按钮观察中文显示屏有没有亮，如果没有亮检查高低压保险是

否损坏，如果中文显示屏正常显示观察 PLC 自保输出指示灯亮否，如果自保输出

灯亮，则检查自保继电器是否损坏，如果自保输出灯不亮检查总停信号是否有输

入，如果总停信号有输入，检查端头站、遥控器是否误发总停信号，12V 继电器

是否有粘连现象；观察中文显示屏上有没有出现瓦斯超限故障，如果有检查瓦斯

是否超限，检查瓦斯断电仪是否损坏。First press the total start up button to see if

Chinese display is bright, if not please check high voltage insurance whether is

damaged, if Chinese display is normal displayed, observe whether the PLC captive

output indicates lamp is bright , if captive output lamp is bright, check the captive

electrical relay whether it is damaged, if captive output lamp is not bright check the

final stopping signal whether it is input, if final stopping signal is input, check the end

head station and remote controller whether it sends the mistake final stopped signal,

check the 12V electrical relay whether it has adhesion phenomenon, and observe if

there is any gas concentration exceeding limitation failure that is shown on the Chinese

display, if there is, check the gas circuit breaker whether it is damaged.
2.5.2 端头站、遥控器故障 End station, remote control fault
1）遥控接收控制器、遥控器不动作 The remote control and end station receiver do

not work

  43
A、端头站不动作先检查端头站 12V 电源是否正常，如果电源正常再检查相对应

的 12V 继电器回路是否工作正常，端头站按钮是否损坏。如果端头站没有 12V 电

源，检查端头站电缆的连接头是否紧凑、牢固，端头站电缆是否损坏，本安电源

是否损坏。A, End station receiver doesn't move means it needs to check if the 12V

power supply of the end station is functioning properly, check the corresponding 12V

relay circuit is working correctly if the power supply is normal, check whether the end

station button is damaged. If end station does not have 12V power supply, check to see

whether the end station cable connecting head is compact and firm, whether end cable

is damaged and whether the intrinsically safe power supply is damaged.

B、遥控器不动作先检查遥控器电池开关是否闭合，遥控器电池电量是否耗

尽，再检查遥控接收装置是否损坏，可通过端头站上的遥控指示灯来判断遥控接

收装置是否动作。B, No action of the remote control need to be checked for the

remote control battery switch is closed, whether the battery is exhausted, and then

checks whether it has damage of the remote control receiver, it can judge through the

remote control indicator light on the end station to determine if the remote control

receiver is moving.

2）遥控器、遥控接收控制器误动作 Remote control, remote control receiving

controller malfunction

首先判断是哪个遥控器、遥控接收控制器误动作，可以先将左右遥控器的电

池开关断开来判断是哪个遥控器误动作，如果左右遥控器的电池开关都断开后还

有动作，就可以排除遥控器误动作，再分别将左右端头站的电缆接头拔掉，来判

断是哪个端头站误动作。端头站和遥控器都排除后再检查端头站电缆是否破损造

成线路粘连或者是 12V 继电器接点粘连。First determine is remote control is causing

the fault or it is causing by remote control receiver controller malfunction, you can first

cut off the battery of the left and right remote control switch to determine which

remote control malfunction, if after the switch of left and right remote control

disconnects, it still can move, you can exclude the remote control malfunction, then

pull the cable connector of left and right ends out separately, to determine which end

  44
  

station malfunction. After both end station and remote control were excluded, then

check the cable whether is damaged causing the line adhesion or a 12V relay contact

adhesion.
2.5.3 摇臂升降系统故障 Ranging arm lift system faults
1）开机后摇臂自动上升或下降 Ranging arm automatic increases or decreases after

turning on

首先判断造成摇臂上升或下降的是机械故障还是电气故障，可以先将电磁阀

线摘掉，如果摘掉电磁阀线之后还有升降故障说明是机械故障，这时需要检查电

磁阀阀芯是否卡堵，以致不能回到中位；如果摘掉之后没有升降故障，这说明是

电气故障造成的，首先检查 PLC 是否有输入如果有输入，检查 PLC 输入部分是

否有误动作，如遥控接收控制器、遥控器误动作或 12V 继电器接点有粘连现象。

如果 PLC 没有输入有输出则是 PLC 故障，如果输入输出均正常，检查 PLC 输出

继电器是否有粘连现象。First to judge the reason that caused shake arm rose or

declined is mechanical fault or it is the electrical fault, you can remove electromagnetic

valve line at first, if after removed electromagnetic valve line, it also has lifting fault, it

means it is the mechanical fault, then you need to check the electromagnetic valve core

whether is blocked that leads to it cannot returned back to the center; if after remove,

there is no lifting fault, it shows that it is the electrical fault , then first check PLC

whether it has input, check PLC input part whether it has errors action, for example the

remote control receive controller, and remote control is malfunctioning or the 12V

relay contact has stick phenomenon. If the PLC has no input but has output is PLC

failed, if the input and output are properly, check that PLC output relays have

adhesions.

2）开机后摇臂上升或下降不动作 After booting the ranging arm up or down doesn't

work

首先检查 PLC 是否有输入，如果没有输入检查遥控接收控制器、遥控器等输入信

号是否正常，如果 PLC 有输入没有输出则是 PLC 故障，如果 PLC 输入、输出均

正常，检查电磁阀工作电源是否正常，检查液压系统压力，管路等是否正常，检

查电磁阀线圈是否短路、开路，可用正常的一路来“替换”查找。First check PLC

  45
whether it has input, if it is not, please check the remote control receive controller, and

remote control input signal whether it is normal, if PLC has input but has no output it

shows that it is the PLC fault, if PLC input and output are working properly, the check

the electromagnetic valve working power whether it is normal, check hydraulic system

pressure, pipeline whether those are normal, check the electromagnetic valve coil

whether it has short-circuit or open, it is available for using a normal way that

"replaces" finding.
2.5.4 电机故障 The motor faults
序号 故障现象 分析及处理方法

温度接点断开,采煤
1 为保证不影响正常生产，将其短接。
机送不上电。

电机 PT100 损坏， 为保证不影响正常生产，可以先用 110Ω～120Ω、1/4W 电阻

2
电机过温故障 来代替恢复生产。

检查电机电缆、电机接线腔接线是否牢靠；检查电流互感器
3 电机缺相
及其接线是否正常。

检查电机接线腔是否潮湿，用摇表检测电机绝缘层是否损
4 电机漏电
坏；检查绝缘闭锁模块是否损坏。

5 电机过载 截割电机、牵引电机负载过重，减小牵引速度。

No. The fault Failure analysis and elimination method

phenomenon

Temperature In order to guarantee it does not affect the normal

contact disconnect, production, short-circuit it.
1
shearer has no

electric.

  46
  

The motor PT100

In order to guarantee it does not affect the normal
is damaged,
2 production, can first use 110 Ω to 120 Ω, 1/4Ww resist
breakdown by
or instead of resuming production.
overheated

Check the motor cable, connect line cavity is connect

3 Motor open phase well; Check the current transformer and its wiring are
in normal condition.

Check whether motor line cavity is wet, use megger

4 Electric leakage test motor insulation whether it is damaged; Check

whether insulated locking module is damaged.

Cutting motor, haulage motor is overload, the drawing

speed need to be reduce.

5 Motor overload

注意：

（1）条件允许时，每周对电机进行一次绝缘测试，3300V 的用 2500V 的摇表

测试，1140V 的用 1000V 摇表测试，380V 的用 500V 摇表测试。

（2）对于牵引电机摇绝缘时应与变频器断开，这点切记，否则会损坏变频器。

（3）用万用表检查是否缺相。

Note:

(1) If the conditions permit, the motor insulation test should be done once a week, use

2500V megger to test the 3300V, use 1100V megger to test the 1140V, use 500V

megger to test the 380V

(2) According to the haulage motor insulation should be with inverter disconnect,

  47
please remember this fact, otherwise it will damage the inverter.

(3) Use the multimeter to check whether it is lack.

2.5.5 漏电故障 Leakage fault
（1）采煤机一按总起按钮，顺槽开关就跳闸 The tripping phenomenon is

happening when press the shearer a total startup button, or switch the trough switch

a.将隔离开关断开，将超前断电接点短接，在隔离开关绝缘正常的情况下，

按总起按钮，如果前级开关继续跳闸，可确定不是采煤机内部的接地故障造成开

关跳闸，主要检查主电源供电电缆。

b.如果前级开关不跳闸可确定是采煤机内部接地故障造成开关跳闸，用 1000V 摇

表测主回路单相对地绝缘，检查牵引变压器、控制变压器进线侧，泵电机，截割

电机主回路绝缘。

A. Cut off the isolating switch, shorted the leading power contacts, with the isolation

switch insulation under normal conditions, press the total start up button, if the front

level switch continuously tripping, it can make sure that it is not the shearer's switch

tripping caused by grounding fault inside of shearer and then mainly check power

supply cable.

B. If the front level switch does not trip, it can be determined it is the grounding

fault at internal shearer that causing the switch tripping, using 1000V megger to test

the main circuit that single relatively ground insulated, check the haulage transformers,

control transformers line side, pump motor, cutting motor circuit insulation.

（2）先导回路接地造成前级开关启动不起来，检查主电缆先导线是否有接地现象，

各温度接点连接线是否有接地现象 The pilot circuit grounding caused the

front-level switch cannot booting up, check whether the main lead cable is grounded,

and each temperature contact point cable is grounded

（3）牵引电机、牵引电机电缆漏电造成变频器报接地故障，检查牵引电机、牵引

电机电缆绝缘。 The haulage motor, motor cable power leakage that cause the

  48
  

frequency convert box ground fault and then check the haulage motors, haulage

electrical cable insulation.

2.5.6 开机后采煤机自动加速 Shearer speed up automatically after turning on
检查 PLC 的输入，左右牵引输入指示灯是否常亮，若有常亮则检查 PLC 输入侧

是否有线路粘连或端头站、遥控器、按钮误动作；如果 PLC 输入输出都正常请检

查 PLC 到主变频器 X22 端子的连线是否有粘连现象。Check the PLC input whether

the left and right haulage input LEDs is light up, if lit up constantly, check whether the

PLC input side line adhesions, or end stations, remote, button pressing are malfunction;

if the PLC inputs and outputs are normally check whether the line from PLC to main

X22 terminals of frequency converter is sticking.

2.5.7 截割电机不能启动 Cutting machine cannot start
检查 PLC 截割启动是否有输出信号，如果有信号输出请检查截割输出继电器

和接触器，如果 PLC 截割没有信号输出,请检查 PLC 截割绝缘反馈信号是否有输

入或者截割停按钮没拔上来，如绝缘反馈信号无输入请检查截割电机和截割电机

电缆绝缘是否正常，如果正常请检查绝缘监测模块是否损坏，如果绝缘检测模块

损坏，应急处理可以将绝缘检测接点短接。Check PLC cutting started whether has

output signal, if it has signal output please check cutting output following electrical

and contact device, if PLC cutting has no signal output, please check PLC cutting

insulated feedback signal whether it has entered or the cutting stopped button didn't

pulled up, if insulated feedback signal is not entered, please check cutting motor and

cutting motor cable insulated whether it is normal, if it is ok, please check the insulated

monitoring module whether it is damaged, if insulated detection module is damaged,

emergency processing can take measure to short cut the insulate detection point.
2.5.8 变频器故障 Inverter fault
（1）MOTOR STALL(7121)，电机堵转 MOTOR STALL (7121), the MOTOR is

blocked

该故障属于保护动作，引起的原因有多种 The fault belongs to protect action

problem, it is caused by various reasons:

  49
a.煤壁夹矸比较多，或者平滑靴损坏或卡阻、齿轨轮断齿等造成采煤机牵引超负

荷，排除故障复位后，采煤机能够正常运行；

b.制动闸未打开。

根据左右摇臂升降正常与否，判断电磁阀 24V 电源好坏。

观察给牵引时 PLC 的抱闸输出回路指示灯是否亮；亮，则检查电磁阀线路

和电磁阀是否损坏。

c.扭矩轴损坏。

在采煤机运行的过程中，操作人员会发现从变频器的转速显示比较大，甚至超过

速度设定上限，主变频器转速显示非常小，但电流较大，这种现象说明从变频器

拖动的牵引电机的扭矩轴损坏 ，造成主变频器拖动的牵引电机超负荷造成变频器

报堵转故障。

A because of there are too many parting on coal wall, or smooth boots damaged or

blocked, or rack wheel tooth broken that causing shearer overload, after doing the

troubleshooting reset, the shearer can operate functional;

B. braking is not open.

According to whether the left and right arm lift is normal or not to judge it is good or

bad of solenoid valve 24V power supply.

Observe whether it is lit up constantly for haulage PLC brake output circuit; if it is,

then check the wiring and solenoid valve whether the solenoid valve is damaged.

C. torque shaft is damaged.

During the shearer operate, operators will find the sub-frequency converter speed is

fast, even exceeding the maximum limit speed setting, the main frequency converter

speed is very small, but the current is relatively large, this phenomenon shows that the

haulage motor torque shaft that drag by sub-frequency converter is damaged, causing

the haulage motor drag by the main converter overloading causing the inverter

blocked.

（2）通讯故障 The communication failures

a.当两个控制盘均显示如下 when two control panel are shown as follows：

  50
  

ACS800-04-0140-5

***FAULT***

COMM MODULE(7510)

则可以判断是主变频器没有接到调用工厂宏命令，两台变频器均为转

矩宏，都在等待主变频器给它发送指令。检查 PLC 调宏输出，检查 PLC 到

主变频器 X22 端子的连线。特别是图纸中注明“调宏”的那根线。Can judge

that the main converter factory did not receive any call macros, two transducers

are torque and all waiting for the main inverter send instruction to it. Check the

PLC output macro; check the line connects PLC to the main inverter X22

terminal. Especially the drawings marked line of "macro".

b.只有从变频器控制盘显示如下 only the sub-inverter control panel

display as follows

ACS800-04-0140-5

***FAULT***

COMM MODULE(7510)

则需要检查主从通讯光纤和通讯模块 RDCO-03C。判断光纤是否损坏可以用矿灯

在光纤的一头用矿灯照射，观察另一头是否能透出光线，通讯模块 RDCO-03C 可

以用替换的方法来判断其是否损坏。You may need to check the master-slave

communication optical fiber and communication module RDCO - 03 - c. to judge

whether the fiber is damaged can use miner's lamp lighting at one end of the optical

fiber, to see if the other side can see the light, communication module RDCO - 03 - c

can use replace method to determine whether it is damaged.

（3）采煤机无法牵引 The shearer cannot haulage

a.请检查变频器面板是不是点亮，如果没有点亮检查变频器供电是否正常。A.

please checks the frequency inverter panel is light up, if there is no light, then check

the inverter power supply is normal.

b.请检查变频器是不是处于正常状态。下图分别表示主变频器、从变频器正常

状态以及变频器故障时的画面。B. Please check the inverter is in the normal state.

  51
 Graphs below are diagram show the main inverter, Subsidiary frequency converter

in normal state and failure state.

主变频器处于正常状态

The main frequency converter in the normal state

从变频器处于正常状态

The main frequency converter in the normal state

变频器处于故障状态

The inverter in the fault state

c.ACS 800 0140-3SR 表示变频器的版本和功率 shows the version and the

power of the frequency converter；

d.***FAULT***出现故障时不停的闪烁 when * * * * * * FAULT failure it keeps

flashing；

e.LINE CONV 表示当前变频器故障信息 shows current converter fault

information；

f.（FF51) 是故障信息代码(FF51) is the fault information code。

g.请检查 PLC 输入口牵停信号是否一直有输入，如果有输入检查 PLC 输入侧

是否有线路粘连或端头站、遥控器、按钮误动作 please check whether the PLC

  52
  

input port led stop signal has input, if yes, check whether the PLC input side line

adhesion or end station, remote controls, buttons, is mal-operation。

（4）变频器过温警告 Inverter over-heating warning

显示信息：TACS 800 TEMP

故障原因：变频器装置内部过温，过温温度整定在 100°C

解决方法：检查变频器箱内环境温度条件。

检查冷却水压力和流量是否正常。

检查变频器底板水套是否被堵。

检查变频器冷却底板与变频器箱底板是否紧密结合。

Display information: TACS 800 TEMP

The cause of the problem: frequency converter device internal temperature overheat,

temperature setting at 100 ° C

Solution: check the inverter at the ambient temperature conditions.

Check whether the cooling water pressure and flow is normal.

Check whether the frequency converter bottom water jacket is stuck.

Check whether converter box floor cooling plate and converter is stick with each

others.

（5）变频器输出过流 Inverter output flow

显示信息：OVERCURRENT

故障原因：变频器输出电流过流或电机、电缆发生短路，触发极限是 3.5Ie。

解决方法：检查电机负载，电机、电机电缆是否短路。

检查电机和机械部件的连接处。

The cause of the problem: the inverter output current overflow or motor, cable short

has been circuit, and trigger limitation is \3.5Ie.

Solution: check the motor load; whether the motor, electrical cable is short circuit.

Check the joint of motor and mechanical components.

（6）变频器输出短路 Inverter output short circuit

显示信息：SHORT CURRENT

  53
故障原因：电机电缆或电机短路

解决方法：检查电机和电机电缆。

Display information: SHORT CURRENT

The cause of the problem: the motor cable or motor is short circuit

Solution: check the motor and cable.

（7）变频器直流母线过压 Inverter dc bus is over-voltage

显示信息：DC OVERVOLT

故障原因：变频器内部直流母线电压太大。

解决方法：检查过压控制器设置是否正确。

检查牵引变压器输出有无波动或静态过压。

检查减速时间。

Display information: DC OVERVOLT

The cause of the problem: frequency converter internal dc bus voltage is too big.

Solution: check the over voltage controller is setting correctly.

Check whether there is any fluctuation or static overpressure on the haulage

transformer output.

Check the deceleration time.

（8）变频器输入电源缺相 Inverter input power

显示信息：SUPPLY PHASE

故障原因：变频器内部中间直流电压振动，可能是主电路缺相，快速熔断器烧

断，或是整流桥内部故障引起。

解决方法：检查供电电源是否缺相。

检查变频器输入回路上的快速熔断器是否烧坏。Display information: SUPPLY

PHASE

The cause of the problem: internal intermediate frequency inverter dc voltage vibration

may be the main circuit is phased, fuse burn out quickly, or internal fault of the

rectifier bridge.

Solution: check whether the power supply is lack of phase.

  54
  

Check whether the quick fuse of the inverter input circuit is burnt out.

（9）变频器中间直流回路欠压 Converter middle dc circuit is under voltage

显示信息：DC UNDER VOLT

故障原因：变频器供电电源缺相，快速熔断器烧坏，或整流桥内部故障损坏。。

解决方法：检查牵引变压器是否正常工作。

检查变频器输入端快速熔断器是否烧坏。

Display information: DC UNDER the VOLT

The cause of the problem: the inverter power supply is lacks, fuse burn out quickly, or

internal fault of the rectification bridge damage.

Solution: check the haulage transformer is working correctly.

Check whether inverter input quick fuse if burn out.

（10）变频器输出接地故障 Inverter output ground fault

显示信息：EARTH FAULT

故障原因：电网不平衡。

相应牵引电机、电机电缆或变频器内部故障造成。

解决方法：检查电机和电机电缆。

检查在变频器输出侧有无功率因数矫正电容或浪涌吸收装置。

Display information: EARTH FAULT

The cause of the problem: power grid is imbalance

It causing by internal fault of the corresponding haulage motor、cable or frequency

converter

Solution: check the motor and cable.

Check the inverter output side has the power factor correction or surge absorbing

device.

（11）控制板故障 Control board failure

显示信息：I/O COMM

故障原因：变频器内部中的 NAMC 板通道 CH1 发生通讯故障。

电磁干扰。

  55
 变频器中的 I/O 控制板（NIOC）内部故障。

解决方法：检查 NIOC 和 NAMC 板之间的光纤连接是否松动。

检查 NIOC 和 NAMC 板之间的光纤是否完好。

更换 NIOC 板。Display information: the I/O COMM

The cause of the problem: the NAMC plate channels CH1 that inside of frequency

converter.

There is electromagnetic interference.

The internal fault happens of the I/O control board (NIOC) in frequency converter.

Solution: check whether NIOC and optical fiber connection between NAMC plates is

loose.

Check the NIOC and NAMC plate between the optical fiber are in good condition.

Replace the NIOC plate.

（12）变频器环境温度 Inverter environment temperature

显示信息：CTRL B TEMP

故障原因：变频器内部的 I/O 控制板温度高于 88°C。

解决方法：检查冷却风机和冷却水流量。

检查变频器冷却通道是否畅通。

Display information: CTRL B TEMP

The cause of the problem: the temperature of I/O control board in frequency converter

is higher than 88 ° C.

Solution: check the cooling fan and cooling water flow rate.

Check the converter cooling channels whether it is unblocked.

2.5.9 显示屏故障 Display failure

（1）显示屏出现黑屏现象，检查显示屏 150V 电源是否正常，若正常则为硬件

损坏。

（2）显示屏数据不显示，检查 PLC 和显示屏通讯线是否松动。

(1) the screen occur black phenomenon, check whether the display 150 v power supply

is in normal condition, if yes, it means the hardware is damage.

  56
  

(2) Display screen data does not display, check whether PLC and display

communication line is loosed.

2.5.10 PLC 故障 PLC failure

（1）PLC 上 ERR/ALM 灯常亮，PLC 硬件异常，请更换 PLC; ERR/ALM 灯闪

烁 PLC 程序出错，需重新刷新程序。

（2）PLC 正常供电但 POWER 灯不亮，并且 PLC 不能正常工作，PLC 电源板

损坏请更换 PLC。

（3）PLC 输出指示灯亮,但接点不导通，PLC 输出继电器损坏。

（4）PLC 没有输出并且输出指示灯不亮，但输出继电器接点导通，PLC 输出继

电器接点粘连。

(1) the PLC ERR/ALM light is always on, PLC hardware is unusual, please change the

PLC; ERR/ALM light is flashing means PLC program is error, need to refresh the

program again.

(2) PLC is powered normally but the POWER light is not on, and PLC cannot work

normally, it means the PLC power supply board is damaged, please replace the PLC.

(3) PLC output indicator light is on, but contact is not conducted, it means the PLC

output relay is damaged.

(4) PLC has no output and the output light is not bright, but the output relay contact is

conducted, it means the PLC output relay contacts adhesion.

3 大修 Overhaul

采煤机在采完一个工作面后应升井大修。 大修要求采煤机进行解体清洗检查，更

换损坏零件，测量齿轮啮合间隙，对液压元件应按要求进行检查和试验，电气元

件检修更换时，应做电气试验，机器大修后，主要部件应做性能试验，整机空运

转试验，检测有关参数，符合大修要求后，方可下井。

After excavating a working face, the shearer should be raised out well and need a

overhaul. Overhaul requires disassembling, cleaning and inspections the shearer,

  57
replace the damaged parts, measuring gear mesh clearance, the hydraulic components

should be inspected and tested according to the requirements.

When the electrical components need repair or replace, it should take the

electrical test, after the machine repairs, the main components should be tested its

performance, and also the machine empty running test should be done, all related

parameters must be tested, after it is conformed to the requirements of the overhaul, it

may good to go down hole.

建议：更换所有从过盈配合面拆除的轴承。不要自行选配轴承内、外圈，应

成套更换轴承。

 用新密封圈替换所有拆下来的密封圈和 O 型圈。

检查所有部件密封区域的磨损情况。

Suggestion: Replace all bearings from interference fit surface. Do not match the

bearing inner and outer ring on your own, sets of bearings should be replaced

completely.

Use new seals to replaces all removed seals and O-rings.

Check the wear condition of the sealing area of all components.

4 储存管理 storage management

1.目的 Purpose

为保证产品使用性能，用户在储存采煤机整机、大部件、零件等应按西安煤

矿机械有限公司采煤机储存管理执行。

In order to ensure the performance of product, users should obey and execute the

Xi’an Coal Machinery Company Co., Ltd, shearer storage management specification

during storage of shearer, large parts and components.

2.适用范围 Using scope

采煤机整机、大部件、变频器、电机（整机上电机）、隔离开关等。Shearer,

large parts, frequency converter, motors (all shearer motors), isolating switches, etc.

3.存储 Storage

  58
  

（1）储存于通风、干燥的仓库；

（2）外露的加工面应涂以防锈油脂；

（3）储存时冷却喷雾系统、中心水管中的积水应用风管吹干净；开放的管口

需封堵；接线喇叭口应防止灰尘杂质进入；各种电缆接线头、接线端子应做好防

护措施；

（4）所有整机、部件存放方式须正放，请勿倒置。

(1) Shearer needs to be stored in ventilated, dry warehouse;

(2) The anti-rust should be coated on oil leakage of the processing surface.

(3) The seeper inside cooling spraying system and center pipe should be cleaned when

storage; the opening pipe mouth should be plugged; dust should be prevented from

getting into horn mouth; protective measures should be taken on all kinds of cable

plugs, terminals.

(4) Both machine and parts must not be stored upside down.

4.内容 Content

（1）如果整机（含断机大部件）在验收合格后到用户使用产品时间超过一个

月，需对电机进行绝缘检测，重新开机运行 2 个小时，检验确认机组各项主要性

能，合格后才能使用 If the time interval of machine (including dissembling main

parts)that from acceptance to the application is more than a month ,it should take the

motor insulation test, restart the machine and run it for 2 hours to confirm the each

main unit’s performance, it can be used again only after it is qualified；

（2）如果整机（含断机大部件）在验收合格后到用户使用产品时间超过六个

月，需对电机进行绝缘检测，用户按照西安煤矿机械有限公司内部验收标准再次

检验，确认机组各项主要性能，合格后才能使用 If the time interval (including

dissembling main parts) that from acceptance to the application is more than six month,

it should take the motor insulation test, according to the internal acceptance standard

inspection of Xi 'an Machinery Company Co., ltd, user needs to check again to confirm

the each main unit’s performance and if it is qualified for use；

  59
 （3）如果整机（含断机大部件）在验收合格后到用户使用产品时间超过八个

月，必须对以下条款进行逐一落实 If the machine (including dissembling main parts)

have an eight months interval , which is from acceptance to application, the following

terms must be conducted:

a.所有油液进行更换（液压油和齿轮油）；

b.检查各个注油点必须通畅；

c.水道做通水试验，对水道盖板、电控箱盖板的密封进行更换；

d.对摇臂、牵引部、破碎装置旋转密封进行更换；

e.对电机进行绝缘检测；

f. 用户按照西安煤矿机械有限公司内部验收标准再次检验，确认机组各项性能，

合格后交付用户。

A. Replaces all oil (hydraulic oil and gear oil);

B. Check each injection point to ensure they must be unobstructed;

C. The water channel test should be done, the channel cover plate, electric cabinet

cover seal should be replaced;

D. The ranging arm, haulage unit, crushing device rotating seal should be replaced;

E. The insulation detection should be done for motor;

F. According to the internal acceptance standard of Xi 'an Machinery Company Co.,

ltd, user needs to inspect again to confirm the performance of each unit, after it is

qualified, delivered to the user.

（4）电控箱、变频器的存放 The storage of electric cabinet, frequency converter

a.电控箱存放时间超过 1 个月，更换干燥剂，重新检查确认性能；

b.电控箱存放时间超过 6 个月，对电控箱所有防爆面进行检查并做防锈处理，

并更换干燥剂；

  60
  

c.变频器存放，必须用塑料袋包装，内放置干燥剂，然后放在木箱中，在通风、

干燥的地方储存，严禁倾斜、倒置；备件变频器存放超过三个月，要进行上电运

行。

A. If electric cabinet storage time is more than 1 month, change the desiccant, identify

and review performance again;

B. If electric cabinet storage time is more than 6 months, the antirust processing and

inspection should be done for all electric explosion-proof surface and replace the

desiccant;

C. The inverter must be packed in plastic bags, put the desiccant inside first, then put it in wooden

cases that is stored in ventilated and dry place, it is forbidden to tilt and inverse; If spare frequency

converter is stored more than three months, electricity should be on for operation.

（5）针对长时间运输及储存的摇臂、牵引部需将油腔注满 For a long time

transport and storage , the ranging arm and haulage unit should be filled with oil in

cavity.

  61
PART II: Maintenance Guide
  

目录

1 机械维修指南 MECHANICAL MAINTENANCE GUIDE .............. 1 

1.1 牵引机构齿轮箱拆卸 THE HAULAGE GEARBOX DISASSEMBLE .............................1 

1.2 截割机构齿轮箱拆卸 CUTTING DEVICE GEARBOX DISASSEMBLE .......................13 
1.3 破碎机构拆卸 REMOVE THE BROKEN BODY ........................................................24 

2 电控维修指南 ELECTRIC MAINTENANCE GUIDE................... 29 

2.1 高压开关箱 HIGH VOLTAGE SWITCH BOX ............................................................29 

2.2 变频器箱 CONVERTER BOXES .............................................................................33 
2.3 变压器箱 THE TRANSFORMER BOX ......................................................................37 

附录一：导向滑靴和平滑靴的磨损 APPENDIX 1: ABRASION OF

GUIDE SKID SHOE AND FLAT SKID SHOE ................................. 38 

附录二：易损件说明 APPENDIX 2: DESCRIPTION OF QUICK

WEAR PARTS ................................................................................... 40 

附录三：铰轴拆卸工具 APPENDIX 3: ARTICULATED SHAFT

DISMOUNTING TOOL..................................................................... 42 

附录四：扭矩值 APPENDIX 4: TORQUE VALUES ........................ 43 

附录五：机组注油要求 THE APPENDIX 5:OILING

REQUIREMENTS FOR MACHINE SET......................................... 44 

附录六：滚筒使用说明书 APPENDIX 6: OPERATION

INSTRUCTION OF DRUM IN SHEARER ...................................... 45 

附录七：油缸使用说明书 THE APPENDIX 7: CYLINDER

OPERATION INSTRUCTION .......................................................... 54 

I 
 
  

1 机械维修指南 mechanical maintenance guide

1.1 牵引机构齿轮箱拆卸 The haulage gearbox disassemble

a．行走箱齿轮使用以下步骤拆卸 Use the following methods to

disassemble the haulage gearbox
（1）将每个截割滚筒降至地面或垫入垫块。Lower each cutting drum to the
ground or pad the block under it.
（2）切断采煤机和工作面运输机的电源。Cut off the power of the shearer and
the working face conveyor.
（3）拆下足够的销板给牵引杆留出空间。Remove the pin board to give haulage
rod enough space.
（4）垫入垫块防止设备下落。Pad the block under the machine to prevent the
equipment falling down.
（5）拆下 3 条用于固定铭牌螺钉，拆下铭牌。Remove the three pieces of stable
screws for fixing nameplate, then remove the nameplate.
（6）拆下 6 条用于固定盖板螺钉，拆下盖板。Remove the six pieces of screws
for fixing cover plate, then remove the cover plate.
（7）拆下挡圈，拆下距离套，可用 4 个 M8 的螺纹孔将其拆下。Remove the
retaining ring and remove the distance set, four M8 threaded holes can be used.
（8）拆下牵引扭矩轴，用 M24 的拉扒孔将其拆下。Remove the haulage torque
shaft, use M2-m24 threaded holes to remove it.
（9）拆下 12 条用于固定主动轮轴承座端面的 M16×45 的内六角头螺栓。拆
下轴承座、油杯、盖板等零件，轴承座拆卸可使用 4 个 M24 顶丝孔。Remove the
12 pieces of M16 x 45 inside hex head bolt used for fixing the end face of the bearing
set of driving wheel. Remove the bearing, oil cup, cover plate and other parts, remove
the bearing, and four M24 top thread holes could be used.
（10）拆下 8 条 M12×30 固定主动轮轴承的内六角头螺钉，拆下压板、轴承、
O 形圈。Remove the 8 pieces of M12 x 30 hex head screws that fix the driving wheel
bearing, and remove the pressure plate, bearing, o-rings.
注意：不要损坏主动齿轮两端的密封槽内的 O 型圈。

1 
 
 （11）拆下主动轮，可使用 2 个 M12 的螺纹孔。Remove the driving wheel , you
can use two M12 top thread holes.
（12）拆下 6 条 M16 ×35 固定惰轮轴的内六角头螺钉，拆下压盘，可使用 2
个 M16 的顶丝孔。然后拆下油杯。Remove the 6 pieces of M12 x 30 hex head screws
that fix the idler shaft, remove the dish, you can use two M16 top thread holes to
remove it. Then remove the oil cup.
（13）拆下惰轮轴，可使用 M36 的拉拔螺栓孔，然后拆下惰轮组。Remove the
idler shaft, the M36 drawing bolt hole, and then remove the idler wheel.
（14）从驱动齿轮的开口处取出惰轮。Remove idler from the opening place of
the drive gear.
（15）拆下 8 条 M12×35 用于固定惰轮组压盖的内六角头螺钉，左右对称，
拆下惰轮、轴承、挡圈等零件。Remove the eight pieces of M12 x 35 hex head screws
used for fixing idler wheel gland, the left and right sides are symmetrical, remove the
idler, bearings, retaining ring, etc.
注意：安装齿轮步骤按照以下步骤更换牵引部主动轮和惰轮。如果要进行更换，

先装入惰轮，然后装入主动轮。Note: The installation of gear steps complies with the

following steps to replace the haulage drive wheel and idler. If you want to replace it,

loaded idler first, and then load the driving wheel.

（16）拆除足够的销板，给导向靴和链轮留出空间。Remove enough pin board

to give the space for guiding shoes and sprockets.
（17）用千斤顶或液压工具从采空区侧升起采煤机，直到导向靴不承受采煤
机重量。在该位置给采煤机垫入垫块。Use the hydraulic tools or jack to rise the gob
side of the shearer, until the guide shoes don't bear the shearer weight. Put the block
inside when shearer at this position.
（18）拆下 8 条 M16×45 固定齿轨轮轴的内六角头螺钉，拆下压盘。Remove
the eight pieces of M16 x 45 hex head screws to fix the rack shaft, remove the pressure
plate.
（19）拆下齿轨轮轴的固定螺栓 M36×3×485，拆下防转套。Remove the bolt
M36 x 3 x 485 used for fixing the rack shaft, remove the anti-rotating sets.

2 
 
  

（20）拆下齿轨轮轴，可以使用 M42 的拉拔孔。然后拆下螺塞、油杯、O 型

圈等零件。Remove the rack shaft; you can use the M42 drawing holes. Then remove
the plug, oil cup, o-rings, etc.
（21）用千斤顶或液压工具升起采煤机直至导向靴和齿轨轮组脱离采煤机。
在该位置用垫块垫起采煤机。Use the hydraulic tools or jack to raise the shearer until
the guide shoes and gear wheel apart from the shearer. In this position, put block inside
to underlay the shearer.
（22）用撬棍沿链轮齿座移动导向靴和齿轨轮组。当齿轨轮组脱开惰轮并能
从导向靴上拆下时停止移动。Use the crowbar to move the guide shoe rack wheel set
along the sprocket seat Stop moving when off the rack wheel idler apart of the idler
and remove from the guide shoes
（23）将齿轨轮组挂到吊索上，使用起重设备将齿轨轮组吊离导向靴。Hang
up the gear wheel set to slings, use lifting equipment to pull out rack wheel from guide
shoes.
（24）从齿轨轮组齿座上拆下齿轨轮轴。Remove the gear rack wheel from gear
wheel set.
（25）将导向靴挂到吊索上，使用起重设备将链轮和导向靴作为整体吊下。
Hang up the guide shoes to Slings, use lifting equipment under the crane the sprocket
and the boots as a whole.
（26）从链轮齿座上拆下导向靴。Remove the guide shoes from the sprocket
seat.
（27）拆下 16 条 M16×65 固定齿轮和齿轨轮的内六角头螺钉，拆下齿轮。然
后拆下轴承、挡圈、轴套、油杯等零件。Remove the 16 pieces of M16 x 65 hex head
screws for fixing the gear wheel and rack, remove the gear. Then remove the bearing,
collar, sleeves, oil cup, etc.
危险警告：不要用手指检查销孔的对中。元件滑动将导致挤压、损伤或切断
手指。
Risk warning: Do not use finger to check the pin hole. Element sliding will result in

the extrusion, damage or finger cutting.

3 
 
 图 7-1 行走减速箱拆卸图 Walking gearbox dis-assembly graph
1 行走箱壳体 2 螺钉 3 铭牌 4 轴承座 5 盖 6 油杯
7 垫圈 8 螺钉 9 压盖 10 O 型圈 11 轴承 12 挡圈
13 距离套 14 花键轴 15 驱动轮 16 螺钉 17 压盖 18 惰轮轴
19 螺钉 20 压盖 21 轴承 22 O 型圈 23 惰轮 24 套
25 挡圈 26 定位套 27 螺钉 28 压盘 29 堵 30 过渡接头
31 螺钉 32 齿轨轮轴 33 防转套 34 螺钉 35 O 型圈 36 齿轮
37 轴承 38 轴套 39 距离垫 40 齿轨轮 41 挡圈 42 导向滑靴
43 螺帽 44 螺母 45 垫 46 螺母 47 螺栓 48 螺栓
49 螺母 50 螺栓 51 液压螺母 52 垫 53 堵

  4
  

1 walking tank 2 screw 3 nameplate 4 bearing seat 5 cover 6 oil cup

7 gasket 8 screw 9 gland 10 O ring 11 bearing
12 Retaining ring 13 Distance set 14 Spline shaft 15 Driving wheel
16 screw 17 gland 18 Idler shaft 19 screw 20 gland
21 bearing 22 O ring 23 idler 24sleeve 25 Retaining ring
26 Locating sleeve 27 screw 28 Pressure plate 29 plug 30
Transition joints 31 screw 32 Rack shaft 33 anti-rotating sleeve
34 screw 35 O ring 36 gear 37 bearing 38 Shaft sleeve
39 Distance mat 40 Wheel rack 41 Retaining ring 42guide shoes
43 nut 44 nut 45 mat 46 nut 47 bolt 48 bolt
49 nut 50 bolt 51 the hydraulic nut 52 mat 53 plug
b．牵引减速箱齿轮拆卸 Haulage reducer gear removal
（1）将摇臂滚筒降至地面或垫上垫块。Lower the ranging arm to the ground or
pad the cushion block.
（2）切断采煤机和刮板机的电源。Cut off the power of the shearer and
conveyor.
（3）排干齿轮箱中的润滑油并重新装上排油堵。Drain the lubricant oil of the
gearbox and reload the oil discharge blocking.
（4）拆卸牵引电机螺栓，拆卸牵引电机。Remove the haulage motor bolt,
remove the haulage motor.
（5）拆下牵引齿轮箱护板。Remove the haulage gear plate.
（6）拆下牵引液压制动器护罩和制动装置。参考牵引制动闸拆卸步骤。
Remove the haulage hydraulic brake shield and brake device. See the reference of the
steps of brake disassembly drawing.
（7）拆下把液压制动器连接板固定到齿轮箱盖上的 8 条 M12 x 20 内六角螺
栓，然后拆下端盖和油封。Remove the eight pieces of M12 x 20 hex bolt connecting
hydraulic brake plate to the gear case cover, and then remove the end cover and oil
sealing.
（8）拆下固定电机齿轮轴上的轴齿轮。Remove the axle shaft gear fixing motor
gear.
（9）拆下固定电机的齿轮轴。Remove the fixed motor gear shaft.

  5
 （10）从电机齿轮轴上拆下轴承。Remove bearings from the motor gear shaft.
（11）拆下电机油封。Remove the motor oil seal.
（12）拆下牵引轴端盖，拆下牵引轴。Remove the haulage shaft end cover, and
then remove the haulage shaft.
（13）拆下牵引轴，拆下轴承。Remove the haulage axis, remove the bearings.
（14）拆下惰轮轴压盖，拆下惰轮轴，从电机齿轮轴孔拿出。Remove the idler
shaft gland, remove the idler shaft and take out from the motor gear shaft hole.
（15）拆下惰轮轴轴承。Remove the idler shaft bearing.
（16）拆下轴承座固定销和螺栓，拆下轴承座。Remove the fixed pin of bearing
and bolt, remove the bearing seat.
（17）拆下轴承座，拆下轴承。Remove the bearing seat, and then remove the
bearings.
（18）拆卸二级行星减速机构。Remove the secondary planet retarding
mechanism.
（19）拆下二级行星减速机构，拆卸轴承，行星轮轴，行星轮，轴承等零件。
Remove the secondary planet retarding mechanism; remove the bearing, planetary
wheel, a planet wheel, bearing and other parts.
（20）拆下二级齿圈。Remove the secondary gear ring.
（21）拆下二级太阳轮。Remove the secondary sun wheel.
（22）拆下二级齿圈和一级齿圈连接套。Remove the secondary gear ring and
primary gear ring connection.
（23）拆卸一级行星减速机构。Remove the primary planetary reduction
mechanism.
（24）拆下一级行星减速机构，拆卸轴承，行星轮轴，行星轮，轴承等零件。
Remove the primary planetary reduction mechanism; remove the bearing、 planetary
wheel shaft、planetary wheel、bearing and other parts.
（25）拆下一级齿圈。Remove the primary gear ring.
（26）拆下中心齿轮组。Remove the center gears.
（27）拆下中心齿轮组，拆下挡圈，一级太阳轮，中心齿轮，轴承等。Remove
the center gear set; remove the retaining ring, primary sun wheel, the center gears,
bearings, etc.

  6
  

（28）拆卸调高泵箱检修孔盖板。Remove raise pump tank manhole cover plate.

（29）拆卸滤芯器盖板，拆下滤芯器。Remove the filter cover plate and remove
the filter element.
（30）拆卸油位探尺。Remove the oil level gage.
（31）拆卸电机检修堵，检查电机油封是否损坏，进油。Remove motor repair
plug, check whether the motor oil seal is damaged, fill the oil in.

图7-2a 牵引减速箱拆卸图

  7
 图7-2b 牵引减速箱拆卸图haulage gearbox disassembly graph

1 护板 2 螺栓 3 螺钉 4 液压制动器 5 端盖
6 电机齿轮轴 7 油封 8 螺栓 9 牵引电机 10 惰轮轴
11 惰轮组 12 端盖 13 轴承 14 轴承 15 牵引轴
16 固定销 17 螺钉 18 轴承座 19 二级行星减速机构
20 二级齿圈 21 太阳轮 22 连接套 23 一级行星减速机构
24 一级齿圈 25 太阳轮 26 轴承座 27 中心齿轮 28 滤清器
29 端盖 30 油位探尺 31 盖板 32 螺钉 33 检修堵
34 检修堵
1 guard board 2 bolt 3 screw 4 hydraulic brake 5 end
cover
6 The motor shaft 7 oil sealing 8 bolt 9 haulage motor 10 idler
shaft 11 Idler wheel 12 end cover 13 bearing 14

  8
  

bearing 15 haulage axis 16 fixed pin 17 screw

18 bearing base 19 secondary planet retarding mechanism 20 secondary
gear ring 21 sun wheel 22 connecting sleeve 23
primary planetary reduce mechanism
24 primary gear ring 25 sun wheel 26 bearing block 27 sun gear
28 filter 29 end cover 30 Oil level gage 31 cover plate
32 screw 33 repair plug 34 repair plug

c．液压制动器的维护 The maintenance of the hydraulic brake

1.使用与维护 The operation and maintenance
安装前先将制动器以机械方式松开，即用两个 M10x25 螺栓从后盖旋入把活
塞拉向后盖内端面，制动器处于松开状态。若液压系统发生故障或检修拆卸时，
可采用同样方式松开制动器。Before installing, release the brake in mechanical way
which screw two M10x25 bolts into back cover and pull the piston to the inside end
face , and the brake will be in loose state. If the hydraulic system failures or needs
dismantled during maintenance, it can uses the same way to loose the brake.
使用时注意： 当采煤机工作面倾角≤15°时，建议用 M8x25 螺栓把制动器提
起，使其处于松开状态以消除由于经常制动发热和摩擦片磨损。更换新的摩擦片
3 或密封圈 11、12 时需先从后盖上提起活塞，慢慢松开螺栓取出弹簧，方可更换。
Note: When shearer working face angle is 15 ° or less, it is suggested to use M8x25
bolt to lift up the brake, make it in loosen condition to eliminate the heat and the
friction wear that caused by braking frequently. When you replace new friction disk 3
or sealing ring 11 and 12, it needs to pull out the piston from the rear cover, loosen
bolts slowly and get spring out of it, and then replace the friction disk or sealing ring.
液压制动器能够自动调整制动力。如果油压较高或操作频繁活塞密封圈 11、
12 可能产生少量漏油现象，制动器应每月检查一次。检查时卸下内圈上的螺堵，
观察内部如有漏油则更换密封圈。Hydraulic brake can automatically adjust the
braking force. If oil pressure is high or frequent operation piston sealing ring 11 and 12
may lead a small amount of oil leakage, the brake should be checked once a month.
Remove the screw on inner ring when check the hydraulic brake, observe if there is
any oil leakage inside, replace the sealing ring if necessary.
2.磨损检测 The wear test

  9
 制动器后盖上有 3 个 M10x1 螺塞孔，其中两个对称 用于提起活塞，松开制
动器。剩余螺孔可检测摩擦片磨损情况。每月检查一次磨擦片的磨损情况，新制
动器活塞释放行程为 2mm，对应图中 h 尺寸为 15mm，测量无油压状态下 h 尺寸
即可知磨擦片磨损程度。检查方法：拆去后盖 7 上与活塞 10 上 M8 螺孔不对应的
一个 M10×1 螺塞，用深浅尺测量 h 尺寸值，若磨损程度达到 4mm 以上(即
h≥19mm)，即应换磨擦片。There are three M10x1 plug holes on the brake rear cover,
two of them are symmetrical and used for lifting the pistons, loosen the brake. The
remaining screw hole can be used for detecting the abrasion of friction disk. Check the
abrasion of friction disk once a month, the stroke of new brake piston release is 2 mm,
corresponding to the picture h, the size is 15 mm, measure h size in no oil pressure
condition so that you can understand the friction wear degree. Inspection methods:
Remove one M10 x 1 plug, which is not corresponding to M8 screw hole on the back
cover 7 and piston 10, use depth ruler to measure h dimension value, if the wear degree
reaches more than 4 mm(h≥19mm), namely the friction disk should be replaced.
3.故障处理 Fault handling
故障形式 产生原因 消除方法

摩擦片磨损过大 更换摩擦片
制动力矩减小
干式工作有漏油 消除漏油，更换有污染的摩擦片

开启压力低 调整释放压力
制动器过热
形成过小 增大行程

Failure Mode The Reasons Elimination method

the excessive friction
replacing the friction disk
of friction disk

Braking Torque
eliminating oil leakage, changing the
Decreasing
polluted friction slices
oil leakage

Brake Overheat opening pressure is adjusting the release pressure

too low
  10
  

stroke is too small Increasing the stroke

4.制动器的拆卸 Remove the brake

使用下列步骤拆卸牵引制动闸（见图 7-7） Use the following steps to remove
the haulage brake (see figure 7-7) :
（1）把每个滚筒降到地面或用垫块支撑。Lower each drum to the ground or pad
with block.
（2）切断采煤机和刮板机的电源。Cut off the power of the shearer and conveyor.
（3）排空齿轮箱内的油液，然后装上排油堵。Need to empty the gear box oil, and
then set up the oil extraction plug.
(4) 拆下把护板固定在牵引机架上的 8 条 M16x 30 螺栓，然后拆下护板。
Remove the eight pieces of M16x 30 bolts that fix the guard plate on the haulage
frame, and then remove the guard board.
（5）拆开制动闸的胶管。所有胶管和出入口都要用帽或堵堵住，以免污染和
损坏。Open brake hose. All hose and inward、outward must be plugged by cap or plug,
so that can avoid pollution and damage.
（6）拆下把制动闸固定到连接板上的 4 条 M12 x 35 内六角螺栓。拆下制动
闸。拆下制动闸上的 O 型圈，废弃。Remove the 4 pieces of M12 x 35 socket head
bolts that fix brake to the connection plate, remove the brake. Remove the o-rings on
the brake, abandoned them.
（7）拆下固定轴齿轮的挡圈，从齿轮箱中拆下轴齿轮检查轴是否磨损或损坏，
如有必要更换。Remove the retaining ring that fix shaft gear wheel, remove the shaft
gear from the gearbox ,check the shaft whether it is wear or damaged, replace it if
necessary.
（8）如有必要拆下把连接板固定到齿轮箱盖上的 16 条 M12 x 20 螺栓，然后
拆下盖板。If necessary, remove 16 pieces of M12 x 20 bolts that fix the connection
plate to the gear case cover, and then remove the cover plate.

  11
 图 7-4 牵引液压制动器 haulage hydraulic brake
1 护板 2 螺栓 M16 x30 3 螺钉 M12 x35 4 液压制动器
5 O 型圈 6 端盖 7 轴齿轮
1 guard board 2 bolt M16 x30 3 screw M12 x35 4 hydraulic brake
5 O ring 6 end cover 7 Shaft gear
（9）拆卸时应均匀松开联结后盖 16 个 M12 x 20 的螺栓，缓慢均匀地释放弹簧
的预压力，注意防止弹力伤人事故。更换磨擦片或密封圈 13、16 时才需拆卸后盖，
磨擦片组件 3 一般应成组成对进行更换，换下来的组件如内齿无损伤只更换磨擦
片即可。Loosen 16 pieces of M12 x 20 bolts gradually that connect the back cover,
slow release the pressure of spring, be aware of preventing the stretch from damaging.
Only remove the back cover when replace the friction disk or retaining ring 13, 16,
sealing friction component 3 should be replaced in pairs generally, replace components
such as inner gear that without damage, changing the friction piece is enough.

5.重要提示 Important Note:

  12
  

本制动器用于采煤机牵引箱，可防止采煤机在坡度较大的工作面上停止时因
机重自动下滑的倾向，它只起到机器停止后的止动作用保持机器静止不动。不能
用于制动运动着的机器吸收机器运行中所发生的动能，但偶尔的“紧急停车”除外
（每次紧急停车后应及时检修制动器），经常的紧急停车把它当作制动闸用将促
使闸片急剧磨损、发热、冒烟甚至起火，这样不但损坏了制动器而且对工作面也
是非常危险的，为了机器和工作面的安全，用户必须根据工作面的实际条件采取
得力的措施保证机器的安全运行。任何违规使用和操作及有损性能安全方面的改
造和使用假冒配件等行为都是不该发生的，制造厂将不承担任何责任。The brake
is used for shearer haulage box, it can prevent the machine’s automatically decline
tendency when shearer stops on the surface of the large slope, it only works on after
the machine stop that keep machine at a standstill. It cannot be used for braking the
moving machines to absorb the kinetic energy during the operation, but except for the
occasional "emergency stop" (should be timely maintenance the brake after each
emergency stop), the frequent emergency stop used as braking will lead to brake
sharp wear, heat, smoke or fire, those will not only damage the brake but also be very
dangerous to working face, in order to keep the working face and machine safe, the
user must take the advanced measure to protect the machine safe operating base on the
actual working conditions. Any illegal usage and reconstruction that are detrimental to
the safe performance and fake parts must not be used; otherwise factory would not
undertake any responsibility.

1.2 截割机构齿轮箱拆卸 Cutting device gearbox disassemble

a 工作面侧齿轮使用如下步骤拆卸 The following steps are used to remove working
face gear:
（1）将要维修的揺臂放到水平位置。排空齿轮箱里的油，然后拧上油堵。
（2）把每个截割滚筒降到地面或用垫块支撑。
（3）切断采煤机和刮板机的电源。
（4）排空齿轮箱里的油，然后拧上油堵。
（5）拆下 12 条固定齿轮箱盖板的 M12 螺栓，然后拆下一轴齿轮盖板。
（6）拆下一轴齿轮、轴承、挡圈、油封等零件。
（7）拆下 12 条固定齿轮箱盖板的 M12 螺栓，然后拆下二轴齿轮盖板。

  13
（8）拆下二轴齿轮、轴齿轮、轴承等零件。
（9）拆下 2 条固定惰轮轴压盖 M12 螺栓，拆下惰轮轴压盖。
（10）拆下惰轮轴，惰轮轴上有 C24/38 的拉拔孔。
（11）拆除惰轮组，从工作面侧二轴齿轮摇臂安装孔拿出。
(1) Put ranging arm into the horizontal position. Empty the oil in the gear box, and then
twist the oil plug.
(2) Lower each cutting drum to the ground or use block to support.
(3) Cut off the power of the shearer and conveyor.
(4) Empty the oil in the gear box, and then screw the oil plug.
(5) Remove the 12 pieces of M12 bolts which fix the gear box cover plate, and then
remove primary shaft cover plate.
(6) Remove the shaft gear, bearing, retaining ring, oil seal, etc.
(7) Remove the 12 pieces of M12 bolts that fix the gear box cover plate, and then
remove the secondary shaft gear cover plate.
(8) Remove the secondary shaft gear, gear shaft, bearings and other parts.
(9) Remove 2 pieces of M12 bolts fixing the idler shaft gland, remove the idler shaft
gland.
(10) Remove the idler shaft, there is C24/38 drawing hole on the idler shaft.
(11) Take the idler wheel out of the face side of secondary shaft gear ranging arm
installation holes.
b 摇臂采空侧齿轮使用以下步骤拆卸 The ranging arm on goaf side gear can use the
following steps to remove：
（1）将要维修的揺臂放到水平位置。排空齿轮箱里的油，然后拧上油堵。
（2）把每个截割滚筒降到地面或用垫块支撑。
（3）切断采煤机和刮板机的电源。
（4） 排空齿轮箱里的油，然后拧上油堵。
（5）拧下固定采空区侧揺臂离合器 6 条 M10 外六角螺栓，拆除离合器，拆下扭
矩轴。
（6）拧下固定揺臂电机 15 条螺栓 M24，拆除电机。
（7）拆除二轴挡圈和盖板。
（8）拆除惰轮轴铰接螺栓和高压软管。

  14
  

（9）拧下固定通水座组件螺栓，通水座上有 3 个 M12 顶丝孔是用来拆除通水座。

拆除通水座组件和中心水管。
（10）拧下固定轴承座螺栓和定位销，轴承座上有 4 个 M12 顶丝孔是用来拆除轴
承座，拆除轴承座、油标、轴承等零件。
（11）拆除中心齿轮和轴承。
（12）拧下固定轴承座螺栓和定位销，轴承座上有 4 个 M12 顶丝孔是用来拆除轴
承座，拆除轴承座、油标、轴承、油封等零件。
（13）拧下固定惰轮轴的 4 条螺栓 M12，惰轮轴上有 4 个 M20 顶丝孔是用来拆
除惰轮轴。
（14）拆除惰轮组，从采空侧中心齿轮摇臂安装孔拿出。(1) Lower ranging arm that
needs repair to the horizontal position. Empty the oil of the gear box, and then twist on
oil plug.
(2) Each of cutting drum need to drop to the ground or use block to support.
(3) Cut off the power of the shearer and blowing machine.
(4) Empty of the oil of the gear box, and then screw oil plug.
(5) Twist the six pieces of M10 hexagon bolts that fix ranging arm clutch of the gob
side, dismantle the clutch and the torque shaft.
(6) Unscrew 15 pieces of M2xM24 bolts which are used to fix ranging arm motor,
remove the motor.
(7) Remove the biaxial retaining ring and the cover plate.
(8) Dismantle the idler shaft hinged bolts and high pressure hose.
(9) Unscrew bolt that fix water tower components; there are three M12 silk holes on
water seat used for dismantle water base. Dismantle the water components and center
pipe.
(10) Unscrew bolts and positioning pin that fix bearing, there are 4 M12 top threads are
used to dismantle the bearing seat, remove the bearing, oil standard parts, bearings, etc.
(11) Remove the center gear and bearing.
(12) Unscrew bolts and positioning pin that fix bearing, 4 M12 top thread holes are
used to dismantle the bearing seat, dismantle oil bearing, bearing, oil seal, etc.
(13) Twist off 4 pieces of M12 bolts that fix idler shaft; there are 4 M20 thread holes
idler shaft on the top used to remove the idler shaft.

  15
(14) Dismantle the idler wheel; and take it out from the mounting holes under the goaf
side of center gear ranging arm.
c 摇臂齿轮箱行星齿轮使用一下步骤拆卸 Use the ranging arm planetary gear the
following steps to remove:
（1）将不维修一侧的截割滚筒落地或用垫块支撑好。
（2）将要维修的揺臂放到水平位置，并用垫块支撑好。
（3）切断采煤机和刮板机电源。
（4）排空齿轮箱里的油，然后装上油堵。
（5）关闭采煤机主供水阀。
（6）拧下固定两个采空区侧盖板的 7 条 M16 × 35 螺钉，拆除盖板。
（7）拆开进水管的供水胶管。
（8）拧下固定轴承座螺栓和定位销，轴承座上有 4 个 M12 顶丝孔是用来拆除轴
承座，拆除轴承座、油标、轴承等零件。
（9）拆除中心齿轮和轴承。
（10）拧下固定轴承座螺栓和定位销，轴承座上有 4 个 M12 顶丝孔是用来拆除轴
承座，拆除轴承座、油标、轴承、油封等零件。
（11）参看本书截割滚筒章节，拆卸截割滚筒。
（12）用吊装装置或垫块支撑好方形驱动轮毂和外轴承座。(1) Drop the
non-repaired side of the cutting drum on the ground or use block to support it.
(2) Put the ranging arm that needs to repair to horizontal position, and use block to
support.
(3) Cut off the power supply of shearer and conveyor.
(4) Empty the oil in the gear box, then install the oil plug.
(5) Close the shearer main water supply valve.
(6) Unscrew the 7 pieces of M16 x 35 screws that fix two gob side cover, remove the
cover plate.
(7) Open the inlet pipe water supply hose.
(8) Unscrew bolts and positioning pin that fix bearing, there are 4 M12 orifices on the
bearing is used to dismantle the bearing seat, remove the bearing, oil standard parts,
bearings, etc.
(9) Remove the center gear and bearing.

  16
  

(10) Unscrew bolts and positioning pin that fix bearing, there are 4 M12 orifices on the
top of the bearing used for dismantling the bearing seat, then remove the bearing seat,
oil bearing, bearing, oil seal, etc.
(11) See the details of cutting drum chapter, remove the cutting drum.
(12) Use lifting device or block to well support the square drive wheel hub and the
outer bearing seat.
警告：拆除通水座/ 密封座装置前，用起吊装置，千斤顶或垫块将方形驱动
轮毂支撑好。如果方法兰脱落，会造成严重的伤亡事故。仅由水套固定螺栓把驱
动轮毂与输出行星组件连接。Warning: Before disassembling the water seal
device, use lifting device, jack or block to well support the square drive wheel. If
the flange falls off, it will cause serious injuries. Only use the water jacket fixing
bolt to connect drive wheel and output planetary components together.
（14）拆下固定通水座/ 密封座组件和输出行星组件的 10 条 M30×2×80 螺栓。
（15）利用两个 M30 拉拔孔拆下通水座/ 密封座组件，密封座和通水座一起被拆
下。
（16）从输出行星组件上拆除方法兰和外轴承座。拆卸时可利用 2 个 M24 顶丝孔，
拆下方法兰和外轴承座。利用 2 个 M24 顶丝孔，拆下方法兰和外轴承座。
（17）从方法兰和输出行星组件的密封盖上拆除浮动油封。
（18）拆下固定密封座和外轴承座的 24 条 M24×70 螺栓，如有必要，从轴承座上
撬出密封座。
（19）用起吊装置、千斤顶或垫块将外轴承座和输出内齿圈支撑好。
(14) Remove the 10 pieces of M30×2×80 bolt connecting water bridge/sealing
components with output planetary components.
(15) Use two M30 drawing holes to remove water bridge/sealing components, sealing
bridge and drainage systems should be removed together.
(16) Remove the flange and outer bearing seat from the output component planets. It
can use two M24 orifices to remove the square flange and the outer bearing seat.
(17) Dismantle the floating oil seal from the square flange and the sealing cover of
output planet components.
(18) Remove 24 pieces of M24 x 70 bolts that fix the seal seat and outer bearing seat,
to extract seal seat from the bearing seat if necessary.

  17
(19) Use lifting device, jack or block to support the bearing seat and the output gear
ring well.
警告：拆除外轴承座/齿圈固定螺栓前用起吊装置或垫块将外轴承座和输出行
星齿圈支撑好。轴承座和齿圈脱落会造成严重的伤亡事故。外轴承座和输出行星
齿圈是用普通螺栓固定在齿轮箱架上的。Warning: Before removing the fixed bolt
of outer bearing seat/gear ring, use lifting device or block to support well of the
outer bearing seat and output planetary gear ring. Outer bearing seat and output
planetary gear ring falling apart may cause serious injuries. Outer bearing seat
and output planetary gear ring are fixed on the shelf of the gear box by ordinary
bolts.
（20）拆下将外轴承座和输出行星齿圈固定到齿轮箱架上的 24 条 M30×643 内六
角头螺钉。
（21）从齿圈上拆除外轴承座。轴承和轴承座一起脱出。
（22）先用 4 条均匀间隔的 M30×643 螺栓将输出行星齿圈固定到齿轮箱上。当
拆除输出行星时，齿圈将固定在齿轮箱上。
（23）将 M30 的吊环螺栓装到输出行星齿轮的端部。用一条链子连接吊环螺栓和
生根在支架上的导链，并用该装置支撑好输出行星组件的外端。
（24）从齿圈和齿轮箱上拆除输出行星组件。用支撑齿圈的吊钩吊住行星组件的
内侧，用吊环螺栓从外侧向外拉，内外圆锥滚子轴承和输出行星组件一起被拆下。
（25）拆除输出行星组件中心衬套。
（26）用起吊装置、千斤顶或垫块支撑好输出行星齿圈。
（27）拆除固定输出行星齿圈和齿轮箱的 4 条螺栓，将行星齿圈用垫块支撑好。
（28）从行星齿圈或齿轮箱上拆下 4 个定位销，放好以备安装使用。
（29）拆除固定轴承座组件的 12 条 M20×160 内六角头螺钉，从二级行星齿圈上
拆除轴承座组件。
（30）拆除固定压盖的两组 12 条 M16×35 内六角头螺钉，拆除压盖、轴承座、轴
承。
（31）用起吊装置、千斤顶或垫块支撑好输入行星齿轮组件。
（32）从输入行星行星齿圈上拆除输入行星行星齿圈衬套，衬套上有 4 个 M12 顶
丝孔用来帮助拆卸。
（33）从输入行星齿圈上拆除输入行星齿轮组件。

  18
  

（34）拆除输入行星齿轮组件中心衬套。
（35）拆下固定输入行星齿圈和齿轮箱的 12 条 M20×120 内六角头螺钉。
（36）从齿轮箱上拆除输入行星行星齿圈。从行星齿圈或齿轮箱上拆下两个定位
销，将定位销放好以备安装使用。
(20) Remove the 24 pieces of M30 x 643 hex head screws that connect the outer
bearing seat and the output planetary gear ring to the gear box shelf.
(21) Remove the ring gear from the bearing seat. Pull the bearing and bearing seat out
together.
(22) Use four evenly spaced M30 x 643 bolt to fix the output planetary gear ring on the
gear box first. When dismantle the output planetary bearing, the bearing ring will be
fixed on the gear box.
(23) Install M30 eyebolt at the end of the output planetary gear. Use a chain to connect
the eyebolt and leading chain which take root on the bracket, and use this device to
well support the outer end of the output planetary component.
(24) Remove output planetary components from the ring gear and gear box. Use hook
on the support ring gear to capture on the inside wall of the planetary components, use
suspension loop bolt to pull it out from outside, and then the inside and outside tapered
roller bearings and output planetary components will be removed together.
(25) Remove the center bushing of output planetary.
(26) Use lifting device, jack or block to well support the output planetary gear
component.
(27) Dismantle the four bolts that fix the output planetary gear ring and gear box, and
then use block to support the planetary gear ring well.
(28) Remove the four positioning pins from planetary gear ring or gear box, place them
and ready for installing or using.
(29) Dismantle 12 pieces of M20 x 160 hex head screws which fix the bearing
component, remove the bearing seat components from the secondary planetary gear
ring.
(30) Dismantle 2 groups of 12 pieces M16 x 35 hex head screws that fix gland, remove
the gland, bearing seat, bearing.
(31) Use lifting device, jack or block to well support the input planetary gear
components.

  19
(32) Remove sleeve from the input planetary gear ring, sleeve has 4 M12 top thread to
help removing.
(33) Remove planetary gear components from the input planetary gear ring.
(34) Dismantle the input planetary gear component center sleeve.
(35) Remove 12 pieces of M20 x 120 hex head screws that fix input planetary gear ring
and gear box.
(36) Remove the planetary gear ring from the gear box. Detach two positioning pin
from the planet gear ring or gear box, place the positioning pin ready for installation.

  20
  

图 7-5a 摇臂减速箱 ranging arm reducer

  21
 图 7-5b 摇臂减速箱 ranging arm reducer

  22
  

图 7-5c 摇臂减速箱 ranging arm reducer

1 摇臂壳体 2 螺栓 3 截割电机 4 扭矩轴 5 离合器手把
6 挡圈 7 端盖 8 惰轮轴 9 惰轮组 10 惰轮轴
11 惰轮组 12 通水座组 13 螺钉 14 中心水管 15 压盖
16 中心齿轮 17 轴承座 18 定位销 19 太阳轮 20 定位销
21 堵 22 端盖 23 齿轮组件 24 压盖 25 惰轮轴
26 惰轮 27 端盖 28 轴齿轮组 29 螺栓 30 水封座
31 螺栓 32 方法兰 33 浮动油封 34 螺栓 35 密封盖
36 轴承座 37 轴承 38 二级行星减速器 39 轴承
40 二级齿圈 41 中环 42 螺栓 43 压盖 44 轴承座
45 太阳轮 46 一级行星减速器 47 一级齿圈 48 加油阀
49 透气塞 49 行星头油标 50 液位计 51 检修堵 52 油位探尺
1 ranging arm shell 2 bolt 3 cutting motor 4 the torque shaft
5 the clutch handle 6 retaining ring 7 End cover 8 idler shaft
9 idler wheel 10 idler shaft 11 idler wheel 12 water bridge set
13 screw 14 center hose 15 gland 16 sun gear 17 bearing block
18 positioning pin 19 sun wheel 20 positioning pin
21 block 22 end cover 23 the gear components 24 gland
25 idler shaft 26 idler 27 end cover 28 shaft gear set
29 bolt 30 water seal base 31 bolt 32 the flange
33 floating oil seal 34 bolt 35 Sealing cover 36 bearing block
37 bearing 38 the secondary planet reducer 39 bearing
40 The secondary gear ring 41 center ring 42 bolt 43 gland
  23
 44 bearing block 45 sun wheel 46 primary planetary gear
reducer 47 primary ring gear 48 gas valve 49 vent plug
49 planet head oil leveler 50 level gauge 51 overhaul wall 52
oil level gage rod
提示：检修齿轮箱前应先拆除水套、水管和截割滚筒。有关内容参看本手
册的"中心水路和水管、水套和密封座" 和" 截割滚筒水分配器" 章节。
建议：部件每次大修时要安装新的轴承、密封和 O 型密封圈。这将减少由
于轴承或密封失效而引起的停机。切勿混淆或自行匹配轴承滚道，要成套安装轴
承的内外圈。
Tips: Remove the water jacket, water pipes and cutting drum before repair gear box
should be. See the relevant content of this manual "center waterway and water pipes,
water jacket and seal seat" and "cutting drum water dispenser" chapter.

Suggestions: Each time when overhaul, it needs to install new bearing, seal and O type sealing
ring. This measure can reduce the downtime caused by the bearing or seal failure. Do not confuse
or match the bearing roller track yourself, complete install the bearing inner and outer ring.
1.3 破碎机构拆卸 Remove the broken body
破碎机构使用一下步骤拆卸（见图 5-3）Broken body use the following steps to
remove (see figure 5-3) :
（1）将不维修两个截割滚筒落地或用垫块支撑好。Lower two cutting drum on the
ground or use block well support which does not be maintenance.
（2）将要维修的破碎机构放到水平位置，并用垫块支撑好。Put the broken
mechanism that is going to repair in horizontal position, and use block to well support.
（3）切断采煤机和刮板机电源。Cutting off the shearer and blowing machine power
supply.
（4）排空齿轮箱里的油，然后装上油堵。Empty the oil in the gear box, and then
install the oil plug.
（5）关闭采煤机主供水阀。Close the shearer main water supply valve.
（6）拧下固定护罩的 12 条 M20×65 螺栓和 4 条 M16×60 螺栓，拆下护罩。
Unscrewing the 12 M20 x 65 bolts and 4 M16 x 60 bolts that fixed cover, remove the
cover.
（7）拧下固定盖板的 17 条 M12×35 螺钉，拆除盖板。Unscrewing 17 M12 x 35
screws fixed to cover plate, remove the cover plate.
（8）拆开进水管的供水胶管和电缆。Open inlet pipe water supply hose and cable.

  24
  

（9）拧下固定破碎电机的 9 条 M16×60 螺钉，拆除电机。Twist 9 M16 x 60 screws

that fixed broken motor, remove the motor.
（10）拧下固定端盖的 6 条 M16×30 螺栓，拆除端盖。Unscrew 6 pieces of M16 x 30
bolts that fixed end cover, remove the end cover.
（11）拧下固定限位座组件的 3 条 M16×30 螺栓，限位座上有 2 个 M16 顶丝孔是
用来拆除限位座，然后拆除空气滤清器、轴承、铜套、挡圈等零件。Unscrew the
3 pieces of M16 x 30 bolts that fixed limit component , limitation seat has two M16
silk holes are used for dismantling the limitation base, then removed air filter, bearing,
copper ring, ring, etc.
（12）拆下防转垫圈，拧下固定破碎滚筒的 6 条 M24×65 螺栓和 12 条 M12×35
螺栓，破碎滚筒上有 4 个 M24 顶丝孔是用来拆除破碎滚筒。拆下挡圈、堵、油杯
密、封圈等零件。Remove the anti-rotating washer, unscrewing 6 m24 x 65 and 12
M12 x 35 bolts that fixed broken drum, the crushing drum has four m24 crest orifices
are used to remove the broken drum. Remove the retaining ring, plug, oil cup, sealing
ring, etc.
（13）用吊装装置或垫块破碎机滚筒。Use lifting equipment or block to support the
crusher drum.
（14）拧下固定法兰的 16 条 M20×40 螺栓，拆下法兰。Unscrewing the 16 M20 x 40
bolts that fixed flange, remove the flange.
（15）拆下轴承、油封、密封环、密封座等零件。Remove the bearing, oil seal, seal
ring and sealing parts.
（16）拆下防转垫圈，拧下螺母 M16，拧下固定轴承座、齿圈和行星机构的 16
条 M16×272 螺栓，拆下轴承杯、轴承座、密封环、油封等零件。Remove the
anti-rotating washer, Unscrewing the nut M16, twist off the M16 x 272 bolts that fixed
bearing, gear ring and planetary mechanism, remove the bearing cup, bearing seat, seal
ring, oil seal, etc.
（17）拆除行星减速机构。然后拆下行星轮、轴承、垫、挡圈等零件。Remove the
planetary reduction mechanism. Then remove the planetary wheel, bearing, pad, ring,
etc.
（18）拆除齿圈和 O 形圈。Dismantle the gear ring and O ring.
（19）拆下太阳轮，太阳轮可使用 M24 的拉拔孔拆卸。Remove the sun wheel, sun
wheel can use m24 drawing hole to dismantle.

  25
（20）拆下密封盘和油封，可使用 M12 的拉拔孔拆卸。然后拆下油封。Remove the
seal plate and oil seal, it also can use M12 drawing hole to dismantle. And then remove
the oil seal.
（21）拧下固定压盖的 4 条 M16×40 螺钉，拆除压盖。Unscrewing the 4 M16 x 40
screws that fixed gland, remove the gland.
（22）拆下销轴，销轴可使用 M24 的拉拔孔拆卸。Remove the pin shaft, pin shaft can
use m24 drawing hole dismantle.
（23）拆下油缸，拆下耐磨套。Remove the oil cylinder, remove the wear-resisting.
建议：部件每次大修时要安装新的轴承、密封和 O 型密封圈。这将减少由
于轴承或密封失效而引起的停机。切勿混淆或自行匹配轴承滚道，要成套安装轴
承的内外圈。
Suggestion: Each time for overhaul, new bearings, seal and O sealing ring should be
installed. This will reduce the downtime caused by the bearing or seal failure. Do not
confuse or match the bearing ball track yourself, complete installing of bearing inner
and outer rings.

  26
  

图7-6a 破碎机构
Figure 7-6a Breaking Unit

  27
 图7-6b 破碎机构
Graph 7-6b Breaking Unit
1 破碎机构 2 螺栓M20 3 螺栓M16 4 护罩 5 螺栓M16
6 端盖 7 螺钉M4 8 滤清器 9 螺栓M16 10 限位座组件
11 铜套 12 挡圈 13 轴承 14 O形圈 15 螺栓M24
16 防松垫 17 螺栓M20 18 法兰 19 O形圈 20 滚筒体
21 螺钉M12 22 密封座 23 密封杯 24 O形圈 25 油封
26 轴承 27 O形圈 28 销 29 截齿 30 齿座
31 螺母 32 防松垫 33 螺栓 34 堵 35 销
36 轴承杯 37 轴承座 38 O形圈 39 轴承 40 密封杯
41 油封 42 O形圈 43 行星减速机构 44 齿圈
45 销 46 太阳轮 47 密封盘 48 油封 49 O形圈
50 螺钉M12 51 护板 52 螺钉M16 53 电机 54 螺钉M16
55 压盖 56 销轴 57 油缸 58 轴套 59 螺钉
60 压盖 61 销轴 62 轴套 63 挡圈 64 销轴
65 套 66 距离垫 67 垫 68 轴承 69 垫

  28
 70 行星轮 71 行星架 72 垫
1 Broken body 2 bolt M20 3 bolt M16 4 shield 5 bolt M16
6 end cover 7 screw M4 8 filter 9 bolt M16 10 Spacing limit set
11 Copper sleeve 12 Retaining ring 13 bearing 14 O ring
15 bolt M24 16 Locking mat 17 bolt M20 18 flange 19
O ring 20 drum body 21 screw M12 22 Seal seat 23 seal cup 24
O ring 25 oil sealing 26 bearing 27 O ring 28 pin
29 cutting pick 30 tooth-holder 31 nut 32 Locking mat 33 bolt
34 pin 35 pin 36 bearing cup 37 bearing block 38 O ring
39 bearing 40 Sealing cup 41 oil sealing 42 O ring 43
Planetary reduction mechanism 44 Ring gear 45 pin 46 sun wheel 47
Seal plate 48 oil sealing 49 O ring 50 screw M12 51 guard board
52 screw M16 53 motor 54 screw M16 55 gland 56 pin
57 Oil cylinder 58 Shaft sleeve 59 screw 60 gland 61 pin
62 Shaft sleeve 63 Retaining ring 64 pin 65 sleeve
66 Distance mat 67 mat 68 bearing 69 mat 70 planet wheel
71 Planet carrier 72 mat

2 电控维修指南 Electric Maintenance Guide

2.1 高压开关箱 High voltage switch box
高压开关箱主要部件位置如下图 About the main parts position of high voltage
switch box, see the graph below：

1 电缆连接器 2 主电源进线盖板 3 盖板 4 盖板
1 cable connector 2 Main power inline cover plate 3 cover plate 4 cover plate

29
 5 支撑板 6 隔离开关组件 9 高压保险 10 耦合仪
5 supporting plate 6 isolating switch components 9 high pressure insurance
10 coupling device

7 控制变压器 11 接触器组件 12 电流互感器

7 control transformer 11 connector component 12 Current transformer
1） 更换高压保险 Replace the high-voltage fuse
a. 拆除电缆引入装置①；
b. 打开盖板③；
c. 拆除高压保险⑨一端紧固螺丝，更换保险管。

A. Dismantle the cable entry device① ;

B. Open the cover plate③ ;

C. Dismantle high voltage fuse`s side fastening screws⑨, replace the fuse tube.

2） 更换隔离开关 Change the isolating switch

30
 a. 拆除高压保险；
b. 拆除支撑板⑤；
c. 松开隔离开关连接电缆；
d. 拆除隔离开关组件⑥底部与电控箱紧固螺栓，抽出隔离开关。

A. Dismantle high voltage fuse;

B Dismantle the supporting board ⑤;

C. Loose the isolating switch connecting cable;

D. Dismantle isolating switch components⑥ and fastening bolts with the isolating
switch at the bottom of the electric cabinet.

3） 更换控制变压器 Change the control transformer

a. 拆除高压保险和隔离开关；
b. 断开控制变压器外部连线；
c. 松开控制变压器⑦底部与电控箱固定螺栓，更换控制变压器。

A. Dismantle high fuse and isolating switch;

B. Disconnect external connection wire of control transformer;

C. Loose the bottom of control transformer and fastening bolts with the isolating
switch ⑦at the bottom of the electric cabinet.

4） 更换接触器 Change the contactor

a. 打开盖板④；
b. 拆除控制分线盘；
c. 断开与三台接触器相连的电缆；
d. 松开接触器组件⑾与电控箱的固定螺丝，将接触器组件整体抽出；
e. 更换损坏接触器。

A. Open the cover plate④ ;

B. Dismantle control distributing panel;

C. Disconnect cables between three contactors;

D. Loosen fix screws on contactor assembly⑾ and electric cabinet, take out the entire
contactor components;

31
E. Replace damaged contactor.

5） 更换耦合仪 Replace the coupling device

a. ⑩为检测漏电用耦合仪，上面两个为左右截割检测用，后面一个为破碎检
测用；
b. 如果损坏耦合仪为左右截割检测用，打开盖板③；
c. 断开耦合仪组件外部连线；
d. 拆除耦合仪组件与电控箱顶板连接螺丝，取出耦合仪组件；
e. 更换损坏耦合仪。
f. 如果损坏耦合仪为破碎检测用，打开盖板 3；
g. 拆除高压保险；
h. 拆除隔离开关组件；
i. 更换损坏耦合仪。

A. Item ⑩ is a coupler used for detecting leakage of electricity, the above two are for
testing cutting system, the one behind is for breaking system;

B. If damage about coupling device for testing left and right cutting system, open the
cover plate ③;

C. Disconnect external connection wire of coupler assembly;

D. Dismantle fix screws that connects coupler assembly connected with roof plate of
electric cabinet, remove the coupling device components;

E. Replace damaged coupling device.

F. if the damaged coupler is used for testing breaking system, open the cover plate 3;

G. Dismantle the high-voltage fuse;

H. Dismantle the isolating switch assembly;

I. Replace the damaged coupler.

2.2 变频器箱 Converter boxes

变频器箱主要部件位置如下图 Frequently converter box main part positions are
shown as follows：

32
 1 盖板 2 盖板 3 盖板 4 操作按钮
1 cover plate 2 cover plate 3 cover plate 4 operating buttons

6 中文显示屏组件 7 控制组件 8 分线盘组件 9 电源组件

11 快速熔断器组件 12 牵引接触器组件
6 Chinese display screen components 7 The controlling components
8 distribution panel components 9 The power supply components
11 Quick fuse components 12 Haulage contactor components

33
 5 变频器主体 10 控制盘组件 13 变频器上层板组件
5 Frequency converter body 10 Control panel components 13 Upper plate
components of frequency converter

1） 更换按钮 Change the button

a. 打开盖板①；
b. 断开损坏按钮外部连线；
c. 拆除按钮组件与盖板紧固螺丝；
d. 更换损坏按钮。
A. Open the cover plate①;
B. Disconnect the external connection wire of damaged button assembly;
C. Dismantle the button components and fastening screws of cover plate;
D. replace damaged button.
2） 更换变频器主体 Change converter body
a. 打开损坏变频器对应的前、后盖板；
b. 断开变频器外部连接电缆；
c. 拆除变频器紧固螺丝，在电控箱前端抽出变频器。
A. Open the corresponding front and back cover plate of the damaged frequency
converter;
B. Disconnect external connection wire of converter;
C. Dismantle fastening screws of converter, pull out the converter from the front of
electric cabinet.
注：更换变频器时必须在变频器后端 IGBT 处的底板上涂抹导热硅脂。
Note: when replace the frequency converter, paint thermal conductive silicone on the
IGBT at back of the inverter.
3） 更换更换显示屏 Change the display screen
a. 打开盖板②；

34
 b. 断开显示屏外部连线；
c. 拆除显示屏组件和电控箱连接螺丝；
d. 拆除显示屏与固定弯板连接螺丝，更换显示屏。
A. Open the cover plate② ;
B. Disconnect external connection wire of display screen ;
C. Dismantle fix screw that connects the display screen components and electric
cabinet;
D. Dismantle fix screw that connects the display screen with the fixed bending plate ,
replace the screen.

4） 更换电源组件 Replace the power supply components

a. 打开盖板②；
b. 拆除显示屏；
c. 断开电源组件⑨与外界的连线；
d. 松开电源组件与电控箱的固定螺丝，取出电源组件。
A. Open the cover plate② ;
B. Dismantle display screen;
C. Disconnect the connection wire ⑨between the power supply and external
environment;
D. Loosen screw of power components and electric cabinet, took out the power
components.
5） 更换分线盘组件 Change distribution panel components
a. 打开盖板②；
b. 拆除显示屏；
c. 断开分线盘组件⑧与外界连接插头；
d. 松开分线盘组件与电控箱的固定螺丝，取出分线盘组件。
A. Open the cover plate② ;
B. Dismantle display screen;
C. Disconnect distribution panel components⑧ connected with the external plug;
D. Loosen fix screws connects distribution panel components and electric cabinet, take
out the distribution panel components.
6） 更换控制组件 Replace the controlling components
a. 打开盖板②；
b. 拆除显示屏；
c. 断开控制组件⑦与外界的连线；
d. 松开控制组件与电控箱的固定螺丝，取出控制组件。

35
A. Open the cover plate② ;
B. Dismantle display screen;
C. Disconnect connection wire between control components ⑦ connection with the
outside world;
D. Loosen screw control components and the electric cabinet, took out the control
component.
7） 更换快速熔断器 Replace the rapid fuse
a. 打开盖板②；
b. 拆除显示屏；
c. 拆除电源组件；
d. 拆除分线盘组件；
e. 拆除损坏熔断器连接线，更换新快速熔断器。
A. Open the cover plate ②;
B. Dismantle display screen;
C. Dismantle the power supply components;
D. Dismantle distribution panel components;
E. Remove damaged fuse connection wire, change new rapid fuse.
8） 更换牵引接触器 Replace the haulage contactor
a. 打开盖板②；
b. 拆除显示屏；
c. 拆除控制组件；
d. 拆除分线盘组件；
e. 拆除电源组件；
f. 拆除快速熔断器组件；
g. 断开牵引接触器外部连线；
h. 松开牵引接触器与电控箱紧固螺丝，取出牵引接触器。
A. Open the cover plate② ;
B. Dismantle display screen;
C. Dismantle control components;
D. Dismantle distribution panel components;
E. Dismantle power supply components;
F. Dismantle rapid fuse components;
G. Disconnect external connection of haulage contactor;
H. Loosen fastening screws connects haulage contactor and electric cabinet, take out
the haulage contactor.

36
9） 更换变频器上层板损坏元件 Replace the frequency converter of the upper plate
damaged components
a. 拆除对应损坏变频器前、后盖板；
b. 断开变频器上层板组件与外界连线；
c. 抽出变频器上层板；
d. 更换损坏元件。
A. Remove the corresponding front and back cover plate of converter;
B. Disconnect the connection between upper plate components with external
environment;
C. Take out the upper plate of converter;
D. Replace the damaged components.
2.3 变压器箱 The transformer box
变压器箱主要部件如下图 Transformer box main parts as follows:

1 盖板 2 牵引变压器 1 cover plate 2 haulage transformer

更换牵引变压器 Replace the haulage transformer：
a. 断开变压器箱与外部电缆连接；
b. 松开变压器箱与连接框架紧固螺丝，取出变压器箱；

37
 c. 打开盖板 1,；
d. 松开牵引变压器与电控箱紧固螺丝，取出牵引变压器。

A. Disconnect the connection between the transformer box and external cable;

B. Loosen the fastening screw of the transformer tank and connection framework ,
remove the transformer tank;

C. Open the cover plate 1 ;

D. Loosen the fastening screw connecting the haulage transformer with electric
cabinet , remove the haulage transformer

附录一：导向滑靴和平滑靴的磨损 Appendix 1: Abrasion of

guide skid shoe and flat skid shoe
导向滑靴的磨损是不可避免的正常现象，应注意根据采煤机使用情况及时检

测导向滑靴的磨损量。导向滑靴上下承重面之间的距离为 120mm，上下承重面允

许的最大磨损量为单面 4.5mm（双面 9mm）。左右导向面之间的间距为 200mm

左右导向面允许的最大磨损量单面为 3.5mm（双面 7mm）。

Abrasion of the guide skid shoe is an unavoidable normal phenomenon, and the

abrasion degree of the guide skid shoe should be detected in time according to the

service condition of the shearer loader. The distance between the upper and lower

bearing surfaces of the guide skid shoe is 108mm (it is 120mm according to the guide

skid shoe of the super-huge type shearer loader of our company), and the allowable

maximum abrasion of the upper and lower bearing surfaces is 4.5mm in single surface

(9mm in double surfaces). The distance between the left and right guide surfaces is

200mm, and the allowable maximum abrasion of the left and right guide surfaces is

3.5mm in single surface (7mm in double surfaces).

  38
  

每周应测量导向靴的磨损量，每次检测每个导向靴左侧和右侧的尺寸时应测量两
次. Need to check the guide shoes abrasion loss every week，every time when
testing each the size of the guide shoes on both side should be measured twice.

如果导向滑靴磨损量达到或超过允许值，应予以更换。或将导向滑靴拆下，

通过堆焊和再加工达到规定尺寸，保证齿轨轮和销排之间的正常啮合。The guide

skid shoe should be replaced if its abrasion reaches or exceeds the allowed value, or

dismounted and then surface-welded and reprocessed to the specified dimension so as

to ensure normal engagement between the toothed rail wheel and the pin row.
采煤机煤壁侧平滑靴底面允许的最大磨损量为 10mm，如果平滑靴磨损量达
到或超过允许值，应予以更换。The allowable maximum abrasion of the bottom
surface of the flat skid shoe at the coal wall side of the shearer is 11mm, and the flat
skid shoe should be replaced if its abrasion loss reaches or exceeds the allowed value.

  39
 附录二：易损件说明 Appendix 2: Description of quick wear parts
由于井下工作面地质条件复杂，采煤机行走方向有坡度，推进方向煤层有起

伏，煤层中有夹矸和断层，以及采煤机在工作过程中，由于人为操作因素的影响，

经常出现采煤机滚筒割顶梁和铲板现象。这些因素均会引起采煤机摇臂和牵引部

减速机构及电机（截割电机和牵引电机）过载。为了避免外在阻力对摇臂和牵引

部零部件及电机（截割电机和牵引电机）因过载而造成的损坏，我公司在设计时

除电气保护外，对摇臂和牵引部分别安装了机械保护装置。摇臂一轴和截割电机

中心通孔内安装扭矩轴，牵引部末级减速出轴安装花键轴，此两种件均加工有危

险断面，当外在阻力超过要求值时，则从危险断面处剪断（相当于电路中的保险

丝），对摇臂、截割电机、牵引部、牵引电机起保护作用，因此扭矩轴和花键轴

为易损件，不在三包范围。As the working face in the mine is complex in geological

conditions, the travel direction of the shearer loader has gradient, the coal seam in the

propelling direction is rugged, dirt band and faults are formed in the coal seam, and

due to influences of manual operation factors during working of the shearer loader, the

top beam and ramp plate are frequently cut by the drum of the shearer loader. All these

factors will cause overload of the ranging arms, the haulage part reduction mechanisms

and the motors (cutting motors and haulage motors) of the shearer loader. For

preventing the damages caused by overload due to the external resistance to the

ranging arms, the components of the haulage parts and the motors (cutting motors and

haulage motors), except the electrical protective parts, our company respectively adds

  40
  

mechanical protective devices on the ranging arms and the haulage parts when design.

The shaft I of the ranging arm and the central through hole of the cutting motor are

internally equipped with torque shafts; the last-stage reduction output shaft of the

haulage part is equipped with the spline shaft; these two elements are both provided

with dangerous sections by machining; and the dangerous sections will be sheared

(equivalent to the fuse wire in the circuit) if the external resistance is higher than the

required value so as to protect the ranging arms, the cutting motors, the haulage parts

and the haulage motors, so the torque shafts and the spline shafts are quick wear parts,

which are not included in the ‘‘three guarantees” range.

平滑靴、导向滑靴支撑整个采煤机的重量，由于受结构和尺寸的限制不可能

做得很大，因此单位面积上的比压很大。采煤机行走时，平滑靴、导向滑靴与工

作面刮板机接触面为滑动摩擦，虽然接触面含有特殊耐磨材料，但采煤机在工作

时也会不断的磨损，因此要经常观察平滑靴和导向滑靴的磨损情况，当磨损量如

上图所示时，要及时更换修复，以免造成采煤机齿轨轮等相关零件的损坏。因此

导向滑靴和平滑靴也为易损件，不在三包范围内。The flat skid shoes and the guide

skid shoes support the weight of the whole shearer loader. Limited by structure and

size, the flat skid shoes and guide skid shoes cannot be made in a too large size, so the

specific pressure in unit area is quite high. In travel of the shearer, the contact surfaces

between the flat skid shoes, the guide skid shoes and the conveyor have sliding friction,

so the shearer loader will be gradually abraded during working even the contact

surfaces contain special wear-resisting materials, therefore, the abrasion conditions of

the flat skid shoes and guide skid shoes should be observed frequently, and the flat skid

shoes and guide skid shoes should be replaced and repaired in time if the abrasion

degree is as shown in the figure above so as to prevent damages of the relevant

components such as the toothed rail wheels and the like of the shearer. Therefore, the

guide skid shoes and the flat skid shoes are quick wear parts as well, which are not

included in the ‘‘three guarantees” range.

  41
 附录三：铰轴拆卸工具 Appendix 3: Articulated shaft dismounting
tool
原理如图所示 The principle is shown in the figure below：

1 超高压手动泵 2 齿轨轮轴拆卸杆（C0N0035-06）

3 M27×2 液压拉紧装置 4 支撑套（C0N0035-07）

5 铰轴拆卸过渡板（C0N0035-08） 6 铰轴拆卸杆（C0N0035-09）

7 螺栓 M24×80
1-Ultrahigh-pressure manual pump
2-Toothed rail wheel shaft dismounting rod（C0N0035-06）
3-Hydraulic tension device M27X2
4-Support sleeve（C0N0035-07）
5-Articulated shaft dismounting transition plate （C0N0035-08）
6-Articulated shaft dismounting rod （C0N0035-09）
7-Bolt M24X80
工作方式：按图示结构将各件装好后，用超高压手动泵给 M36×3 液压拉紧装

置打压，因液压拉紧装置有 12mm 的行程，在打压中会将铰轴拔出，即一个工作

周期会将铰轴拔出 12mm，重复以上工作即可拔出铰轴。Operating Mode: After all

  42
  

the components are well installed according to the indicating diagram, an

ultrahigh-pressure manual pump is used to pressurize the M36X3 hydraulic tension

device, the articulated shaft will be pulled out during pressure increase, because the

hydraulic tension device has a stroke of 12mm, it means that the articulated shaft will

be pulled out by 12mm in each working cycle, and it can be pulled out completely by

repeating the operation above.

附录四：扭矩值 Appendix 4: Torque Values

下表列出的是采煤机上所使用的公制紧固件的扭矩值，该值适用于镀层和非

镀层的紧固件，这些紧固件涂有少量的机械油或普通（非极压）油，防卡死剂或

螺纹紧固剂，如果使用降低摩擦的润滑剂（如二硫化钼）,使用所列的扭矩值会导

致过度扭紧和断裂。The contents listed in the table below are the torque values of the

metric fasteners used on the shearer, the values are suitable for plated or non-plated

fasteners, and these fasteners are coated with a little mechanical oil or common

(non-extreme pressure) oil, anti-locking agent or thread fastening agent. Using the

listed torque values may cause over-screwing and breakage if the lubricating agent

(such as molybdenum disulfide) for reduction friction is used.

公制紧固件力矩范围

公称尺
寸
N Nm N Nm N Nm
M4 3825 3.040 5374 4.315 6453 5.148
M6 8836 10.300 12405 14.710 14906 17.652
M8 16230 25.497 22751 35.304 27360 42.168
M10 25791 50.014 36284 70.608 43541 85.317
M12 37657 87.279 52956 122.60 63547 147.10
M16 71196 210.80 100027 299.10 120131 357.90
M20 111305 411.90 156415 578.60 187796 696.30
M24 160338 711.00 225552 1000 270662 1196
M30 255952 1422 359902 2010 432471 2403
M36 374612 2481 527595 3491 632526 4197
M42 515827 3991 725688 5609 870726 6727

Torque Range of Metric Fastener

Grade 8.8 Grade 10.9 Grade 12.9

  43
 Nominal N Nm N Nm N Nm
Dimension
M4 3825 3.040 5374 4.315 6453 5.148
M6 8836 10.300 12405 14.710 14906 17.652
M8 1623 25.497 22751 35.304 27360 42.168
0
M10 2579 50.014 36284 70.608 43541 85.317
1
M12 3765 87.279 52956 122.60 63547 147.10
7
M16 71196 210.80 100027 299.10 120131 357.90
M20 11130 411.90 156415 578.60 187796 696.30
5
M24 1603 711.00 225552 1000 270662 1196
38
M30 2559 1422 359902 2010 432471 2403
52
M36 3746 2481 527595 3491 632526 4197
12

附录五：机组注油要求 The Appendix 5:Oiling Requirements

for Machine Set
ᇞ 重要：行走箱及机身连接各铰轴的润滑

The Appendix 5:Oiling Requirements for Machine Set

行走箱内的轴承及机身连接各铰轴需要定期加注润滑脂润滑，首先在维护上

要求每个检修班注油，因为长时间不加油，其油脂会出现沉淀结痂现象，给以后

的注油造成困难。The bearings in walking box and articulated shafts in machine body

connection part need to be filled grease regularly, firstly, in terms of maintenance, it

requires oiling should be done in each maintenance shift, if there is no oiling for a long

time, the oil and grease will appear sedimentation and incrustation phenomenon, and

that will cause a difficulty for oiling afterwards.

维护：要求每班加注润滑脂 Maintenance: Injecting grease must to be done in

every shift.

  44
  

润滑点：查看出厂图册〈润滑系统图〉Lubrication points: Please see the

“lubrication system chart” in factory catalogue

工具：随机工具中的脚踏式黄油枪 Tools: Pedal grease gun in attached tools

润滑脂的牌号：3 号极压锂基润滑脂 The Grease Type: No. 3, extreme pressure

lithium grease

附录六：滚筒使用说明书 Appendix 6: Operation Instruction of

Drum in Shearer
一、滚筒的型号、结构及性能特点 Drum model, structure and
performance characteristics
公司生产的采煤机螺旋滚筒、截齿、齿座分别符合中华人民共和国煤炭行业

标准 MT/T 321-2004、MT/T 246-2006、MT/T 247-2006 的要求。The screw drums

of shearer, cutting tooth, tooth holders the company produced respectively conform to

the law of the People's Republic of China Coal Industry Standard MT/T 321-2004,

MT/T 246-2006, MT/T 247-2006.

1.滚筒的型号 The Drum Model

滚筒的型号图示如下 Drum model is shown below:

□ □□□□
滚筒连接方式：方轴连接为 F，锥轴连接为 Z

锥盘连接为 P，其它连接为 Q

滚筒直径 D/截深/叶片头数

安装截齿形状：扁平截齿为 B，锥形截齿为 Z

叶片旋向：左旋为 Z，右旋为 Y

滚筒：T

Indications:

Drum connection mode: square shaft connection mode is F, cone shaft

connection mode is Z

Cone plate connection mode is P, other connection mode is Q

  45
 Drum diameter D/cutting depth/blades numbers

Installation section of tooth shape: flat cutting tooth is B, conical tooth is Z

Blades rotation direction: left-handed is Z, right-handed is Y

Drum: T

滚筒型号示例：TZZ2700/865/4F 型滚筒表示为:直径为 2700mm,截深为 865mm,

左旋、锥形截齿、四头螺旋、方轴连接滚筒。Drum type example: TZZ2700/865/4 f

type drum is expressed as: diameter is 2700 mm, cutting depth is 865 mm, left-handed,

conical cutting tooth, four blades screw, square shaft connection mode.

2.滚筒的结构 The structure of the drum

滚筒由结构连结系统、截割系统、内喷雾系统等部分构成。如下图。The drum

structure consists of linking system, cutting system, spraying system, etc. The diagram

is shown below.

结构连结系统由轮毂、筒体、端盘、叶片、端盖等部分组成。其中轮毂是按

照滚筒所配采煤机轮毂图纸（用户提供）加工制造的，端盘、叶片采用加厚优质

钢板制成。结构连结系统具有连结采煤机摇臂、传递采煤机动力、支持滚筒截割

系统和内喷雾系统、输送所截割下的煤炭于刮板运输机上等重要作用。作为滚筒

特加的防磨损措施，在端盘及叶片的输煤侧焊有加强板及肯纳金属特制的耐磨材

  46
  

料。这种耐磨材料是肯纳金属集团特制低合金碳化钨铸钢，具有特殊的抗磨损性

能，保证了滚筒的结构连结系统具有更高的强度和耐磨性。The linking system

consists of wheel hub, cylinder body, blades,end plate, end cover and other parts. The

wheel hub is strictly made in accordance with the hub drawings (provided by user),

end plate and blades are made of thickening, high-quality steel plate. The linking

system has the important functions, including linking the shearer arm, transferring the

movement power to shearer, supporting drum cutting system and spraying system,

conveying the falling coal onto conveyor .As a drum unique wearproof measure , there

is a reinforcing plate and Kenna metal specially-made wearproof materials welded in

end plate and the coal side of blade. The wearproof material is a special low-alloy

carbonized tungsten steel, with its special wearproof performance, it makes sure that

the linking system has higher strength and better wearproof performance.

截割系统由齿座、齿靴、截齿等部分组成。强力锻造制成的齿座，采用的

是经过完全热处理的中碳合金钢，因而提供了良好的焊接性能和更长的使用寿命。

利用高强度的焊丝，确保了齿座、叶片、端盘、筒体之间的坚固连接。其独特的

齿座—齿靴—截齿组合，对于重型和中型滚筒，齿座—齿靴—截齿均能相对旋转，

在截割过程中使的截齿能够得以充分均匀磨损；对于超重型滚筒，既有齿座—齿

靴相对固定、齿靴—截齿相对旋转的齿座—齿靴—截齿组合型式，又有齿座—齿

靴—截齿均能相对旋转的齿座—齿靴—截齿组合型式。这样即保护了重型齿座的

内孔不被磨损又使得截齿能够得以适当均匀磨损。根据用户要求、配套设备情况

及实际开采条件，可选用以上不同组合型式的截割系统。在截煤过程中，通过及

时更换齿靴和适当型号的截齿就能保证滚筒迅速地适应各种截割条件。The

cutting system combines with cutting tooth, tooth holders, tooth boosts and other parts.

Tooth holder is medium carbon alloy steel after complete heat treatment, thus provides

a good welding performance and longer service life. The use of high strength wire

ensures a strong connection among the tooth, blade, end plate and the cylinder body.

Its unique combinations of tooth holder, tooth boost, and cutting tooth for heavy-duty

  47
type and medium drum, they all can relatively rotate, making cutting teeth can be fully

evenly worn in the cutting process; for the super-heavy duty drum, there are both

forms of tooth holder and tooth boost relatively fixed, and all the tooth holder, tooth

boost and cutting teeth can relatively rotate type, which not only protects the inner hole

of the heavy-duty tooth holder against wearing and also makes the cutting teeth can be

appropriately uniform worn. According to user’s requirements, the matched equipment

situation and practical mining conditions, the different forms of cutting system

combination above can be selected. In the process of coal cutting, the timely

replacement teeth boots and the proper type of cutting teeth can ensure machine

quickly adapt to various cutting conditions.

内喷雾系统由喷嘴座、喷嘴、U 形卡及“O”形密封圈等部分组成。该喷雾系

统能产生大空间的雾化，其降尘效果极佳。另外，该喷雾系统还能起到降降低截

齿摩擦温度、延长截齿使用寿命的作用。The spraying system includes the nozzle set,

the nozzle, u-shaped clip, "O" rings and other components. The atomized spraying

system can produce a large space of atomization, its has a excellent effect on the dust

suppression. In addition, the spray system also can lower cutting tooth friction

temperature and prolong the service life of the cutting tooth.

3．滚筒的性能特点 The performance characteristics of drum

为了取得最佳使用效果，公司执行一套滚筒一个设计方案。即在滚筒设计、

制造之前，详细了解滚筒使用条件及用户要求，切实掌握有关数据及信息，然后

利用美国肯纳金属集团滚筒设计的计算机专家系统进行滚筒优化设计。In order to

achieve the best effect of use, the company performs one design for each drum solution.

Namely, before the drum design and manufacturing, the designer should

comprehensively learn about drum use conditions and user requirements, and master

relevant data and information, and then use the Kenna Metals group drum design of the

computer expert system to optimize design.

  48
  

本公司生产的滚筒能与国内外各种型号的采煤机配套使用，广泛适用于煤矿

各种煤炭开采条件。与传统滚筒相比有以下特点 The company produces the drum

that can be used in various types of shearer at home and abroad, which are widely used

in varieties of coal mining conditions. Compared with the traditional drum, it has the

following features：

1）滚筒设计均衡考虑截割性能和装煤性能，使得其截割特性非常稳定，减

少了采煤机的震动，降低了采煤机的维护量，延长了采煤机的使用寿命；Drum

design balance considers the cutting performance and coal properties, makes its cutting

properties very stable, reduces the shock on shearer, and shearer maintenance amount,

prolongs the service life of shearer;

2）滚筒强度大，对开采条件适应性强；Drum has high strength and a strong

adaption to different mining conditions;

3）强力锻造的齿座及耐磨板使得滚筒具有更高的强度和耐磨性；Strong

forging tooth boost and wear proof plate make the drum has a higher strength and wear

resistance property;

4）滚筒截齿数目大大减少，采煤块煤率有所提高；Greatly reduces cutting

tooth number, and coal lump rate is increased;

5）独特的齿座、齿靴、截齿组合，确保了滚筒能迅速地适应各种切割条件，

且使得截齿磨损均匀；Unique tooth holder, tooth boots and cutting tooth combination,

that ensures the drum can quickly adapt to various cutting conditions, and makes the

cutting tooth wear evenly.

6）喷雾系统能产生大空间的雾化，其降尘效果极佳，同时还能降低截齿磨

擦温度、延长了截齿使用寿命 Spraying system can produce a large space of

atomization, has excellent results on dust extinguishing, can also reduce the cutting

tooth friction temperature and prolong the service life of cutting tooth at the same

time；

  49
 7）滚筒寿命长、采煤效率高。The drum has a long service life and high

efficiency of coal mining.

二、滚筒的安装、使用及维护保养
The installation, use and maintenance of
drum
为了保障滚筒达到产煤设计要求，必须进行合

理地安装、使用、维护，并且要做好其维护及保工作。

In order to ensure the drum achieve coal mining design

requirement, it must be properly installed, used and

maintained, and need to do well on the maintenance and management.

1、在运往井下途中， 不要安装截齿，并且检查各进水孔和出水孔是否用堵

头堵塞好，以防脏物进入水道；Do not install the cutting tooth on the way to mine,

and check whether the inlet holes and drainage holes are inserted by plug, and prevent

dirt from dropping into waterways;

2、吊装运输时，注意不要损伤齿靴内孔，以免影响截齿的安装及转动；During

lifting and transport, do not damage inner hole of tooth holder, otherwise it would

affect the cutting tooth installation and rotation.

3、滚筒安装完毕后需拆除其进水孔及出水孔的封闭物，安装好喷嘴；After

the installation, it need to dismantle the enclosure of the water-inlet holes and

water-outlet holes , then install the nozzle; the installation, it need to dismantle the

enclosure of the water-inlet holes and water-outlet holes , then install the nozzle;

4、安装截齿时，应用截齿安装套（或钢管）套在截齿头部（不要触及硬质

合金头），如图一所示，用锤敲击截齿安装套使截齿进入齿靴。严禁直接锤击截

齿头部，以免损坏硬质合金刀头；When installing cutting tooth, need to use cutting

tooth install set (or steel) to set in the head of the cutting tooth (do not touch the

carbide head), as shown in figure 1, use hammer to knock tooth installation set to let

  50
  

the cutting tooth get into tooth boots. Using hammer knocking the cutting tooth head

directly is forbidden, so that to avoid the damage on carbide head.

5、采煤时，截深应保持在设计范围内，不宜太深。严禁截割支架顶梁和运

输机铲煤板。请勿截割顶板和底板。要求在整个采区范围内，岩石含量比例不超

过 4%，所切割岩石的硬度应控制在用户原所提设计要求之内；During coal mining,

cutting depth should be keep within the scope of the design, and should not be too deep.

Cutting support roof beam and coal conveyor ramp plate is strictly forbidden. Do not

cut the roof and floor of coal seam. It is required that within the scope of the whole

mining area, rock content proportion should be less than 4%, the cutting hardness of

the rock should be controlled within the originally proposed design by user;

6、由于该滚筒强度高，且切割阻力小，建议适当提高滚筒转速 Because of the

drum has high strenghth, and the cutting resistance is small, it is suggested to

appropriately increase the drum rotation speed；

7、采煤过程中要密切注意截齿的损耗情况，对失效截齿及齿靴应及时更换，

以免影响采煤效果。如果不及时更换，一方面会造成齿座的非正常磨损，减少滚

筒的使用寿命；另一方面会造成邻近的截齿极度过载，从而使更多的截齿进一步

加剧损坏并且加大采煤机的震动 Please pay close attention to coal cutting tooth loss

situation in the process of cutting, the faulted cut teeth, tooth boots should be replaced

in a timely manner, so that not affect to coal mining effect. If you do not change in

time, on the one hand, it can cause tooth abnormal wear and tear, reduce the drum

service life; On the other hand, it will cause the extreme overload on adjacent cutting

tooth, so that can lead more further damage of the teeth and increase the vibration of

the shearer；

8、良好的内喷雾效果可以有效在地保护截齿。因此在采煤时应尽可能地使

用内喷雾，以便降低截齿耗量 Good spraying effect can protect cutting teeth

effectively. So in coal mining , the inner spraying should be used as many as possible,

thus it can reduce the cutting tooth consumption；

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 9、随着采煤地质条件的变化，用户可根据前述截齿适用范围或征求本公司

意见来选择不同型号的配套截齿，以便取得良好的切割效果和经济效益 Comply

with the change of mining geological conditions, the user can choose different types of

a complete set of cut tooth according to the cutting tooth scope or opinions from our

company in order to obtain good cutting effect and economic benefits；

10、滚筒上严禁混装不同型号的截齿，以免降低截齿及滚筒的使用寿命 It is

forbidden to mix install different types of drum cutting tooth, in order to avoid the

decrease the service life of cutting teeth；

11、肯纳金属滚筒上务必要配套肯纳金属的配件(如截齿、齿靴及内喷雾系

统等)，这样才能充分发挥出肯纳金属产品的优势，并且还能提高滚筒的使用寿命，

提高用户的经济效益 Kenna Metal drum must form a complete set of Kennametal

accessories, such as cutting tooth, tooth boots and inner spraying system, etc., which

can give the full play of the Kennametal products advantages, and also can improve

the service life of drum, improve the economic benefits of the user；

12、采煤机滚筒的内喷雾供水压力（每个喷嘴）应不低于 0.3MPa，每个喷

嘴每分钟的水流量应不低于 0.56 升；滚筒使用运转时应先供水，防止喷嘴堵塞。

Shearer drum spraying water supply pressure (each nozzle) shall be not less than 0.3

MPa, each nozzle water flow should be not less than 0.56 liter per minute; water

supply is needed during drum operation and need prevent the nozzle from blocking.

13、滚筒使用时，操作人员等禁止站在滚筒前后侧，并严禁将手、足、金属

器具等置入叶片内，以免发生危险。When drum operation, operators is prohibited

standing on both front and back of the drum, and it is strictly prohibited putting hands

and feet, metal appliances into blades, which can reduce production risk.

14、滚筒闲置不用时，应置于室内。并且应将齿靴从齿座中取出，在滚筒轮

毂各机加工部位、齿座内孔及其两端面处应涂刷防锈油，以防由于这些部位的锈

蚀影响了以后滚筒的正常使用。When drum is not used, it must be placed inside the

house, and removing the tooth boots from tooth holders, the drum wheel hub and

  52
  

machining parts, tooth inner holes and its two end surface should be brushed anti-rust

oil, prevent against corrosion of these areas, in order to avoid this affect the drum

normal use afterwards.

三、滚筒的适用范围及技术参数 Scope of application and

technological parameters of the drum
1、本滚筒用户名称： 中煤海外印度江基拉 Drum user name: China coal

overseas Jhanjra India

2、本滚筒适用范围：适用于 MG650/1630GWD 型采煤机。尤其适合在用

户所提供的设计工况条件下工作。The drum of scope of application: applicable to the

MG650/1630 GWD type shearer. Especially suitable under the working conditions of

the design provided by the user.

3、本滚筒主要技术参数 the drum of main technical parameters：

采煤机型号 滚筒直径(mm) 有效截深(mm) 总截深(mm) 叶片头数

MG650/1630GWD 2800 800 950 4

Drum Effective Total

Shearer type Leaf blade No.
diameter(m cutting cutting

MG650/1630GWD 2800 800 950 4

4、本滚筒零部件参数表 Shearer parts parameter list ：

单位：只 unit：single
零件名称 齿座 齿靴 挡圈 截齿 开邦齿

型 号 K225SP IH U170K225R KR225 U170LRD 4.0 U47-22NB

数目/只滚 56 56 56 56 12

零件名称 开邦齿座 喷嘴座 喷嘴 密封圈 喷嘴卡

型 号 U43H SC SC SC SC

数目/只滚 12 46 46 46 46

  53
 Part Tooth Tooth Retainin Cutting Rakhine
tooth
Name Holder Boot g Ring Tooth
Type K225SP U170K22 KR225 U170LRD U47-22N
No./singl 56 56 56 56 12
e drum
Part Rakhine Nozzle Nozzle Sealing Ring Nozzle
tooth
name base Clip
Type U43H SC SC SC SC
No./singl 12 46 46 46 46
e drum

附录七：油缸使用说明书 The Appendix 7: Cylinder Operation

Instruction
（1）油缸主要技术参数为 Main technical parameters for the oil cylinder:
油缸行程 815mm 油缸外径 Φ340mm
油缸缸径 Φ280mm 油缸安装距 1530mm
活塞杆直径 Φ160mm 工作压力 25MPa
油缸最大推力 1130KN 油缸最大拉力 66.7kN
Oil cylinder stroke 815mm Oil cylinder outer diameter
Φ340mm
Cylinder diameter Φ280mm Oil cylinder mounting distance
1530mm
The piston rod diameter Φ160mm Working Pressure 25MPa
Oil cylinder maximum thrust 1130KN Oil cylinder maximum tension
66.7kN

  54
  

图 5-3 调高油缸简图
Figure 5-3 higher oil cylinder diagram
（2）使用时主要必须对油缸活塞杆表面镀铬层进行有效的保护，使用和运输
过程不能对活塞杆进行敲击和磕碰。when using it must put chrome plated layer on
the surface of a cylinder piston rod to provide a effective protection, During use and
transportation process, during the process, be aware of not to knock or bump the piston
rod.
油缸运输过程中确保活塞杆处于回缩到到底状态，可以采取适当固定措施使
油缸下井运输过程油缸活塞杆处于回缩到到底状态，活塞杆镀铬层在运输过程不
外漏。Transport oil cylinder need to ensure that the piston rod is retracted back to the
end, take appropriate measures to make the oil cylinder piston rod retracted back to the
end ,during oil cylinder transportation process, make sure that chrome plate must not
be leaked.
（3）油缸在采煤机上安装到位后必须使油缸在最小行程及油缸最大行程情况
下，油缸所有部位不能与采煤机机架产生干涉，油缸在伸出或缩回时油缸缸筒及
活塞杆均不能与机架任何部位磕碰干涉，油缸缸筒在采煤机投入使用后也不能由
于现场煤尘堆积在缸筒上而使缸筒与采煤机机架挤死这种情况发生。Oil cylinder
must be installed on the shearer under the condition of minimum stroke and maximum
stroke, all parts of oil cylinder cannot interference with the shearer frame, when oil
cylinder at extended or retracted state, cylinder and piston rod were not knocked
against interference of any part of the frame, after shearer being put into use, it cannot

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allow the oil cylinder and shearer frame stuck due to dust accumulation on the
cylinder.
（4）油缸安装销轴时应在油缸二销轴孔处涂适量的润滑油脂。When installing
pin shaft on cylinder, it should put the right amount of lubricating grease at second pin
hole of the cylinder.
（5）油缸在使用过程中：调高液压系统中应设有对油缸二腔起保护作用的平
衡阀（安全阀），对油缸锁定后由于外负载对油缸的作用力引起的油缸二腔交变
冲击压力进行控制。During the oil cylinder use, hydraulic height-adjusting system
need set balancing valve (safety valve) to protect second pipe cavity of oil cylinder,
after the oil cylinder is locked, take control of alternating shock pressure caused by
external load on second cavity of oil cylinder.
（6）确保采煤机调高系统管路安装的清洁度及采煤机使用过程液压油的清洁
度控制，推荐系统液压油清洁度等级为 NAS7 级。Ensure the purity of installation of
pipeline on height-adjusting system and the control of cleanliness of hydraulic oil
during shearer operation. It is recommended that system hydraulic oil cleanliness level
should be NAS7 .
（7）油缸使用过程中如发现活塞杆外露表面镀铬层有破坏痕迹应对活塞杆表
面进行修复处理，否则导致活塞杆导向套处密封件损坏，从而导致活塞杆导向套
处油液外漏，并进一步导致导向套内表面拉伤破坏。If there is damage trace of
chromium plating layer of exposed surface of the piston rod, it has to repair it, or it
would lead to damage on seal components of guiding sleeve of the piston rod, then
lead to oil leakage, and further lead to strain on internal surface of guiding sleeve.
（8）油缸吊装允许用吊带通过油缸缸筒吊装或通过油缸前后二个销轴孔吊
装，但必须使用吊带，不推荐使用钢丝绳进行吊装。吊装时确保活塞杆处于缩到
底状态。Cylinder assembly allows use sling to lift through the oil cylinder`s cylinder
or by second pin shaft front and back hole, but must use sling to do it, it is not
recommended to use hoisting wire rope. Ensure the piston rod is exactly retracted to
the end when lifting.

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