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Operation and Maintenance Manual

Roof Support

Serial-N°. LWF11466 – LWF11669

LWB00675 – LWB00680

Doc-No.: 7420 209 000 BA 04

ID-Nr. BI628629 2 of 9 Febr. 2014 SAFETY.CAT.COM SAFETY.CAT.COM

EM019501-0 (EN-US)

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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.

EM019501-0 (EN-US)

Industriestraße1Phone:+49(0)2306/709-0Email:info@cat.com D-44534LünenFax:+49(0)2306/709-1421Web:www.mining.cat.com CaterpillarGlobalMiningEuropeGmbH OperatingManual Shieldsupport1676/3581-2X5341-2056 Doc.no.:7420209000BA04 EM019501-0 (EN-US)

Amendmentsandalterationstothispublicationarenotsubject tonotification.Caterpillarreservesallrightstothispublication.

Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.

Caterpillardeclinesanyliabilityfordirectorindirectconsequencesof printingerrors.

Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.

CaterpillarGlobalMiningEuropeGmbH,Lünen2014E ACaterpillarInc.Company

EM019501-0 (EN-US)

Tableofcontent Doc.no.:7420209000BA04VSSE/01 Tableofcontent 1.Aboutthismanual Beforestartingwork 1.3 .......................... Personsforwhomtheoperatingmanualisintended 1.3 Purposeofthisoperatingmanual 1.4 Charactersandsymbolsused 1.4 ........................ 2.Yoursafety Personnel 2.3 ................................... Operation 2.3 Installationandrepairs 2.4 Operatingconditions 2.5 ......................... Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.6 Basicprinciples 2.6 .................................... Storageandtransport 2.7 .............................. Installation 2.8 Operation 2.9 Maintenance 2.11 Hydraulicsystem 2.12 3.Storageandtransport Storage 3.3 ...................................... Storageoftheequipment 3.3 Storingusedequipment 3.4 Transport 3.5 .................................... Loadunits;dimensionsandweights 3.5 Beforetransport 3.5 Shieldtransport 3.7 Transportsafetydevice 3.8 4.Installation Pre-assemblyoftheshieldunits 4.3 ............... Installationoftheshieldunits 4.3 .................. Supplyconnections 4.5 Establishingalinkbetweenconnections 4.9 Requirementsforthefacehydraulicsystem 4.10 ..... Watersprayingsystemrequirements 4.11 ........... CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E EM019501-0 (EN-US)

5.Operation

Tableofcontent Shieldsupport1676/3581-2X5341-2056 Commissioning 4.12 .............................. Tobeobservedpriortostartup 4.12 Howtoputthesupportintooperation 4.14 Corrosionprotectionofhydraulic components4.14 ..................................

Requirements 5.3 ................................ Operatingconditions 5.3 ............................... Safetyrequirements 5.6 ................................ Operationoftheshieldsupport 5.9 ................ Worksafety 5.15 .................................. Shieldcomponents 5.16 Overviewofshieldhydraulics 5.18 .................. HPballvalveversions 5.18 FunctionsoftheHPballvalves 5.19 Operationoftheshieldhydraulics 5.20 .............. Arrangementofhydrauliccomponentsonthesupport5.20 Shieldhydraulics5.22 Controlunits5.30 ...................................... Supplyblock5.31 ...................................... Checkvalve,hydraul.piloted,forshiftingram5.32 .......... Prop5.33 ............................................. Electrohydrauliccontrolunit5.34 ......................... PMC®-R5.36 Solenoiddrivermodule5.37 Doublefilter5.37 Hydraulicforliftingcylinder5.38 Stabilizingcylinder5.38 Plugwithpressurerelief5.39 ............................. Operationofthedoublebackflushfilter5.41 Repairandemergencyoperation 5.42 ............... Operationandfunctionsofthe electrohydrauliccontrolunit 5.44 ................... Shieldvariantfunctions 5.45 Functionsofthewatervalveunit 5.47 Maintenance 5.48 Specialmeasures 5.48 .................................. Dailymaintenance 5.49 Weeklymaintenance 5.49 Everysixmonths 5.50 Regular,scheduleddamageassessment 5.50 CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E EM019501-0 (EN-US)

Tableofcontent Doc.no.:7420209000BA04VSSE/01 Troubleshooting 5.51 ............................. Instructionsfortroubleshooting 5.51 Faultlocalization 5.51 3/2-wayorpilotvalve 5.54 Pilotedcheckvalves 5.54 Internalby-passinprops 5.55 Pressurereliefvalvedefective 5.55 ....................... Defectiveorblockedfilter 5.55 ........................... 6.TechnicalData Description 6.3 .................................. Mainsubassemblies 6.4 ................................ Maindimensions 6.6 ................................... Skidwithlemniscaticlinksandrelaybarassembly 6.7 ...... Canopy 6.11 Cavingshield 6.14 Cavingflap 6.16 Accessories 6.17 ................................. Steeringdevice“canopy-canopy” 6.17 Technicaldata,steelstructure 6.21 ................. Endshield,devicenumber74202090000004 6.21 Hydraulicsystem 6.22 ............................. Shieldcontrolsystem 6.22 ............................... Hydraulicprop,two-stage 6.24 ........................... Hydrauliccylinder 6.26 ............................ Shiftingram 6.27 Stabilizingcylinder 6.27 Liftingcylinder 6.28 Technicaldata,hydrauliccylinder 6.28 Pressurereliefvalves 6.30 ......................... Anglesofinclinationofthecanopy 6.32 ............. Permissiblemedia 6.33 ............................ Hydraulicfluids 6.33 Qualityoftheprocesswater 6.35 ......................... Lubricatinggreasesandpastes 6.37 ...................... Tighteningtorques 6.39 ........................... ScrewswithISOmetricthread 6.39 7.Foryourinformation Standardsandguidelines 7.3 ..................... Referencedstandardsandguidelines 7.3 ................. Identificationoftheshield 7.5 ..................... Nameplate 7.5 Shieldnumber 7.6 CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E EM019501-0 (EN-US)

Tableofcontent Shieldsupport1676/3581-2X5341-2056 CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E EM019501-0 (EN-US)

1 Aboutthismanual EM019501-0 (EN-US)

EM019501-0 (EN-US)

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL

Aboutthismanual

Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Itprovidesyouwithinformationaboutthe structureofthemanualandthesymbolsusedinit.

Beforestartingwork

Usinganoperatingmanualthatisnotwrittenfortheproducttypeat handcanresultinasafetyhazardforyourselfandothers. Ensurethatthedataontheshieldagreeswiththedatagiveninthe operatingmanual.

Thisoperatingmanualbelongstothe: Shieldsupport 1676/3581-2X5341-2056* IDnumber74202090000004

andisonlypermittedtobeusedforshieldsofthistype!

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththeshield.

Thereshould,ifpossible,alwaysbeanoperatingmanualforthe productavailableattheplaceofoperation.

Sendforanewoperatingmanualimmediatelyifthepresentoperatingmanualisnolongercompleteorhasbecomeillegible.

Personsforwhomtheoperatingmanualisintended

Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.

Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.

Thisincludespersonswho: areinchargeoftransport, preparetheriseheading, performassembly/disassemblywork, operatetheshields, correctmalfunctions, performdailyroutineworkontheface, monitor/lookafterforthehydraulicsystem, performmaintenancework, performrepairwork.

supervisorypersonnelwho:

Supervisorypersonnelwho: initiatetheactivitiesnamedaboveand/or supervisetheactivitiesnamedabove.

Beforestartingwork Doc.no.:7420209000BA04VSSE/01 1.3

CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E

*Theshieldsupportisreferredtoasthe"shield"inthefollowingtext. applicableoperatingmanual shieldtype

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newoperatingmanual

Purposeofthisoperatingmanual

Thisoperatingmanualcontainsgeneralinformationonthesafeand efficienthandlingofshieldsupportsandprovidesyouwithimportantinstructionsontheworkperformeddirectlyonorwiththeshield support.

Therefore,readthisoperatingmanualcompletelyandatleisure. Payspecialattentiontothesafetyinstructions.

Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.

Shouldyouhaveanyquestions,pleasecontactourServiceDepartment.

PayspecialattentiontoChapter2,“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.

Observethisinformationandfollowtheproceduralinstructions.

Charactersandsymbolsused

Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

Danger!

Pointsinthetextmarkedwiththissymbolalertyoutoanimminentdanger.Possibleconsequencesareveryseriousinjury orevendeath.

Warning!

Thesepointscontaininformationonhazardoussituations. Possibleconsequencesareveryseriousinjuryorevendeath.

Caution!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesarelighttominorinjuriesanddamagetomachinery.

Notice!

Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesaredamagetothe shieldordamageinitsimmediatevicinity.

Important!

Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.

Itemsinlistsaremarkedwithbullets.

–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.

. Textpassagesindicatedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Thiswillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.

Beforestartingwork Shieldsupport1676/3581-2X5341-2056 1.4

CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E operatingmanual service safety EM019501-0 (EN-US)

EM019501-0 (EN-US)

2 Yoursafety

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Yoursafety

Thischapterprovidesimportantinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.

Theshieldsupporthasbeenmanufacturedusingstate-of-the-art technologyandinaccordancewiththegenerallyrecognizedsafety standardsandregulations.

Youandotherscanneverthelessbeexposedtodangeroussituations,e.g.,asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.

Donotmakeanymodificationsorcarryoutconversionswhich couldimpairthesafetyoftheshieldsupport.Allmodificationsand conversionsmustbeapprovedbyCaterpillar.

UseonlyoriginalsparepartsfromCaterpillar.Notethatuseofparts fromothermanufacturerswillvoidtheguarantee.

Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsforaccidentpreventionin yourcountry.

Observethesafetyandaccidentpreventionregulationsofthefollowingparties: ofthemine, oftheminesinspectorate,and ofminingsupervisoryauthorities.

Pleasealsoreadtheoperatingmanualsofthecomponentsrequiredforoperation,e.g.gearboxes,E-motors,etc.carefullyand thoroughly.Clarifyanyquestions before startingwork.

Personnel Operation

Theshieldsupportmaybeoperatedonlybytrainedpersonnel.

Theshieldsupportmayonlybeoperatedbyqualifiedpersonnel whocanprovideproofofhavingbeentrainedonthecontrol system installed.

Readingoftheoperatingmanual,especiallythechapteronsafety, mustconstituteapartofthistraining.

Theymustpossessandfurnishproofofadequatefamiliaritywith the mechanical system, hydraulicsystem,and controltechnology.

Personnel Doc.no.:7420209000BA04VSSE/01 2.3

CaterpillarGlobalMiningEuropeGmbH,Lünen2014 state-of-the-arttechnology

training EM019501-0 (EN-US)

additionaloperatingmanuals

Installationandrepairs

Asafundamentalrule,installationandrepairworkmayonlybecarriedoutbypersonnelwhohavebeentrainedadequatelyforthese particularrequirements.

Installationandrepairworkon: safetycomponents(pressurereliefvalves,extinguishers,etc.), theelectricalsystems(controlsystems,signalingdevices,etc.), thehydraulicsystem, mayonlybecarriedoutbyCaterpillarserviceengineersorbyspeciallytrainedpersonneloftheminingcompany.

Personnel Shieldsupport1676/3581-2X5341-2056 2.4

CaterpillarGlobalMiningEuropeGmbH,Lünen2014 E EM019501-0 (EN-US)

Operatingconditions Intendeduse

Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasashieldunitforlongwalls. Usetheshieldonlyasintended.

Intendedusesare: proppingtheroofagainsttheminefloor, ensuringanadequatetravelway, thefollowingshieldoperations: –lowering, –pullingup, –aligning,and –setting, thefollowingconveyoroperations: –advancing, –retracting, formingathrustbearingfor: –theconveyorandminingequipment, –conveyorsteeringdevices, –devicesforraisingtheconveyor, –conveyorsteeringcylinders.

Unauthorizeduse

Alluseswhicharenotexpresslyincludedinthelistof“intended uses”areconsideredtobeunauthorizedusesandarenotpermissiblewiththeshield.

Unauthorizeduseincludes: pushingtheshieldrearintothecavingarea, raisingtheconveyorbymeansofthehydraulicforceofthe shield, settingofthecanopyinrooffalls. Furtherinformationaboutthiscanbefoundinthe“Operation” sectionofthischapterandinchapter5inthe“Operationofthe shieldsupport”section.

Caterpillardoesnotacceptanyliabilityfordamageresultingfrom anysuchunauthorizeduse.

Operatingconditions Doc.no.:7420209000BA04VSSE/01 2.5

E EM019501-0 (EN-US)

CaterpillarGlobalMiningEuropeGmbH,Lünen2014

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL