Operation and Maintenance Manual
Roof Support
Serial-No. LFX00238, LFX00239
Doc-No.: 7420 244 000 BA 00
ID-Nr. BI628312_00_00_EN_CMPL Jun. 2013 SAFETY.CAT.COM SAFETY.CAT.COM
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© 2003 CATERPILLAR ALL RIGHTS RESERVED
CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.
Industriestraße1Phone:+49(0)2306/709-0Email:info@cat.com D-44534LünenFax:+49(0)2306/709-1421Web:www.mining.cat.com CaterpillarGlobalMiningEuropeGmbH Operatingmanual Shieldsupport2100/4500-2/2x7156/1789 Doc.No.:7420244000BA00 Translationoftheoriginaloperatingmanual
Amendmentsandalterationstothispublicationarenotsubjectto notification.Caterpillarreservesallrightstothispublication.
Itscontentisprotectedbycopyright.Nopartofthispublicationmaybe reproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.
Caterpillardoesnotassumeanyliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsduetotechnicaldevelopmentwithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2013E ACaterpillarInc.Company
Tableofcontent Doc.No.:7420244000BA00VESP/01 Tableofcontent 1.Aboutthismanual Beforestartingwork1.3 .......................... Personsforwhomtheoperatingmanualisintended1.3 Purposeofthisoperatingmanual1.4 .................... Signsandsymbolsused1.4 ............................ 2.Yoursafety Personnel2.3 ................................... Operation2.3 ......................................... Installationandrepairs2.4 ............................. Operatingconditions2.5 ......................... Intendeduse2.5 Unauthorizeduse2.5 Safetyinstructions2.6 ........................... 3.Storageandtransport Storage3.3 ...................................... Storingtheequipment3.3 .............................. Storingusedequipment3.4 ............................. Transport3.5 .................................... Loadunits,dimensionsandweights3.5 Beforetransport3.5 Transportsafetydevice3.8 ....................... Relaybarassembly3.8 ................................ Flipper3.9 Stapleclip3.10 Sideseal3.11 4.Installation Preassemblyoftheshieldunits4.3 ................ Installationoftheshieldunits4.3 ................. Pressureequalizationoftheelectroniccontrol system4.5 Supplyconnectionsforauxiliarysupply4.6 ............... Establishingaconnectionbetweentheshields4.9 ......... Requirementsforthefacehydraulicsystem4.10 .... Watersprayingsystemrequirements4.11 ........... Commissioning4.12 .............................. Tobeobservedpriortocommissioning4.12 ............... Howtoputthesupportintooperation4.14 ................. Anticorrosionprotectionofhydrauliccomponents4.14 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
5.Operation
Tableofcontent Shieldsupport2100/4500-2/2x7156/1789-2050
Requirements5.3 ................................ Operatingconditions5.3 Safetyrequirements5.6 Operationoftheshieldsupport5.9 ................ Worksafety5.15 .................................. Shieldcomponents5.16 ........................... Maincomponents5.16 Overviewofshieldhydraulics5.18 ................. HPballvalveversions5.18 FunctionsoftheHPballvalves5.20 Operationoftheshieldhydraulics5.21 ............. Arrangementofthehydrauliccomponents5.21 Shieldhydraulics5.23 Controlunits5.42 ...................................... Intershieldmanifold5.43 ................................ Emulsionfilters5.44 Manifold5.45 PMC®-Rcontrolunit5.45 Electrohydrauliccontrolunits5.46 Watervalves5.46 Flipper5.47 Flippercylinder5.48 Leg5.49 Plugwithpressurerelief5.52 ............................ Measuringcouplingforpressurerelief5.53 ................ Repairandemergencyoperation5.54 ..................... Operationandfunctionsoftheelectrohydraulic controlunit5.56 Shieldfunctions5.57 ................................... Operationofthedoublebackflushfilter5.61 ................ Maintenance5.62 ................................. Specialmeasures5.62 .................................. Dailymaintenance5.63 ................................. Weeklymaintenance5.64 Everysixmonths5.64 Regularlyscheduleddamageassessment5.64 Troubleshooting5.65 ............................. Instructionsfortroubleshooting5.65 Faultlocalization5.65 3/2-wayorpilotvalve5.68 Pilotedcheckvalves5.68 Internalbypassinsidetheleg5.69 Pressurereliefvalvedefective5.69 ....................... Defectiveorcloggedfilter5.69 ........................... CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
6.Technicaldata
7.Foryourinformation
Tableofcontent Doc.No.:7420244000BA00VESP/01
Description6.3 .................................. Mainsubassemblies6.5 Maindimensions6.7 ................................... Basewithlemniscaticlinksandrelaybarassembly6.8 ..... Lemniscaticlink6.12 ................................... Canopy6.14 Flipper6.16 Legretainers6.18 Sideseal6.19 Cavingshield6.24 Cavingflap6.26 ....................................... Accessories6.27 ................................. Antitoppledevice“canopy/canopy”6.27 ................... Brackets6.35 Covers6.37 Informationsigns6.38 Technicaldata,steelstructure6.39 Hydraulicsystem6.40 Shieldhydraulics6.40 Hydraulicleg,two-stage6.43 Hydrauliccylinder6.46 ............................ Setup6.46 Shiftingram(Z2)6.48 Stabilizingcylinder(Z3)6.48 Sidesealcylinder(Z4)6.49 .............................. Flippercylinder(Z7)6.49 ................................ Baseliftingcylinder(Z9)6.50 Technicaldata,hydrauliccylinders6.51 Pressurereliefvalves6.53 ......................... Anglesofinclinationofthecanopy6.55 ............ Hydraulicfluids6.56 Permissiblehydraulicfluids6.56 .......................... Maintenanceofthehydraulicfluid6.58 .................... Qualityoftheprocesswater6.58 Greasesandlubricatingpastes6.60 Tighteningtorques6.62 ........................... ScrewsandboltswithISOmetricthread6.62
Standardsanddirectives7.3 ...................... Appliedstandardsanddirectives7.3 ..................... Identificationoftheshield7.5 ..................... Nameplate7.5 Shieldnumber7.6 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
Tableofcontent Shieldsupport2100/4500-2/2x7156/1789-2050 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
1 Aboutthismanual
Aboutthismanual
Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Italsoprovidesyouwithinformationabout thestructureofthemanualandthesymbolsandsignsusedinit.
Beforestartingwork
Usinganoperatingmanualthatisnotwrittenfortheshieldsupport athandcanresultinasafetyhazardforyourselfandothers.Make suretheinformationontheshieldcomplieswiththatgiveninthe operatingmanual.
Thisoperatingmanualbelongstothe
Shieldsupport 2100/4500-2/2x7156-1789*
IDno.:74202440000001
andisonlypermittedtobeusedforshieldsofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththeshield.
Thereshould,ifpossible,alwaysbeanoperatingmanualforthe shieldavailableattheplaceofoperation.
Requestanewoperatingmanualimmediatelyifthecurrentoperatingmanualisnolongercompleteorhasbecomeillegible.
Personsforwhomtheoperatingmanualisintended
Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.
Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.
Thisincludespersonswho: areinchargeoftransport; setupontheinstallationface; performinstallation/removalwork; operatetheshields; rectifymalfunctions; performdailyroutineworkontheface; monitor/lookafterthehydraulicsystem; carryoutmaintenancework; carryoutrepairwork.
Supervisorypersonnelwho: initiatetheactivitiesmentionedaboveand/or supervisethem.
* Theshieldsupportisreferredtoastheshieldinthefollowingtext.
Beforestartingwork Doc.No.:7420244000BA00VESP/01 1.3
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
applicable operatingmanual shieldtype
newoperatingmanual
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtotheshieldsupport.
Readthisoperatingmanualinitsentiretyandatyourleisure.Pay specialattentiontothecorrespondingsafetyinstructions. Familiarizeyourselfwellwiththeappearanceandmeaningofthe safetyandinformationsymbols.
Shouldyouhaveanyquestions,pleasecontactourservicedepartment.
Payspecialattentiontochapter2“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheproceduralinstructions.
Signsandsymbolsused
Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationinthisoperatingmanual. Memorizethesymbolsandtheirmeanings.
Danger!
Textpassagesindicatedwiththissymboldrawyourattention toimminenthazards.Possibleconsequencesare:veryserious injuryorevendeath.
Warning!
Thissymbolindicatesinformationonhazardoussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.
Caution!
Thissymboldrawsyourattentiontohazardoussituations. Possibleconsequencesare:lighttominorinjuriesanddamage tomachinery.
Notice!
Sectionsmarkedwiththissymboldrawyourattentiontoharmfulsituations.Possibleconsequencesare:damagetothe shieldordamageinitsimmediatevicinity.
Important!
Passagesinthetextmarkedwiththissymbolcontainuseful tipsandinformationintendedtomakeworkeasierforyou. Theydonotwarnaboutharmfulorhazardoussituations.
Itemsinlistsareindicatedbybulletpoints.
–Itemsinsub-listsareindicatedbyalongdashatthestartof theline.
. Textpassagesindicatedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Thiswillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.
Beforestartingwork Shieldsupport2100/4500-2/2x7156/1789-2050 1.4
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E efficiency service safety
