Operation and Maintenance Manual
Roof Support
Serial-No. LWB00681 – LWB00684
Doc-No.: 7420 262 000 BA 00
ID-No. BI628534-EN Dec. 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 ShieldSupport1321/3048-2x5655-1850 Doc.No.:7420262000BA00 Translationoftheoriginaloperatingmanual
Amendmentsandalterationstothispublicationarenotsubjectto notification.Caterpillarreservesallrightstothispublication.
Itscontentisprotectedbycopyright.Nopartofthispublicationmaybe reproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.
Caterpillardoesnotassumeanyliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsduetotechnicaldevelopmentwithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2013E ACaterpillarInc.Company
Tableofcontent Doc.no.:7420262000BA00SSSP/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 ........................... Basicprinciples2.6 .................................... Storageandtransport2.7 Installation2.8 Operation2.9 Maintenance2.11 Hydraulicsystem2.12 .................................. 3.Storageandtransport Storage3.3 ...................................... Storingtheequipment3.3 .............................. Storingusedequipment3.4 ............................. Transport3.5 .................................... Loadunits,dimensionsandweights3.5 Beforetransport3.5 Transportsafetydevice3.8 ....................... Base3.8 ............................................. Relaybarassembly3.9 Hoseconnections3.9 Transportposition3.10 4.Installation Pre-assemblyoftheshieldunits4.3 ............... Installationoftheshieldunits4.3 .................. Pressureequalizationoftheelectroniccontrol system4.5 Supplyconnectionsforauxiliarysupply4.6 ................ Establishingalinkbetweenconnections4.9 ............... Requirementsforthefacehydraulicsystem4.10 .....
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5.Operation
Tableofcontent Shieldsupport1321/3048-2x5655-1850 Watersprayingsystemrequirements4.11 ........... Commissioning4.12 .............................. Tobeobservedpriortostart-up4.12 Howtoputthesupportintooperation4.14 Anticorrosionprotectionofhydrauliccomponents4.14
Requirements5.3 ................................ Operatingconditions5.3 ............................... Safetyrequirements5.6 Operationoftheshieldsupport5.9 ................ Worksafety5.15 .................................. Shieldcomponents5.16 ........................... Maincomponents5.16 Overviewofshieldhydraulics5.18 .................. HPballvalveversions5.18 FunctionsoftheHPballvalves5.19 Operationoftheshieldhydraulics5.20 .............. Arrangementofhydrauliccomponentsonthesupport5.20 Shieldhydraulics5.22 ............................. Controlunits5.31 Supplyblock5.32 PMC®-Rcontrolunit5.33 Electrohydrauliccontrolunit5.34 ......................... Solenoiddrivermodule5.36 ............................. Doublefilter5.37 ....................................... Prop5.37 Checkvalve5.39 Sprayingvalve5.39 Watersprayingsystem5.40 StabilizingcylinderZ35.40 Plugwithbleedscrew(Bleedscrew)5.41 Repairandemergencyoperation5.42 Operationandfunctionsoftheelectrohydrauliccontrolunit5.44 Shieldfunctions5.45 ................................... Operationoftheautomaticdualbackflushfilter5.47 ......... Maintenance5.48 ................................. Specialmeasures5.48 Dailymaintenance5.49 Weeklymaintenance5.50 Everysixmonths5.50 Regular,scheduleddamageassessment5.50 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
Tableofcontent Doc.no.:7420262000BA00SSSP/01 Troubleshooting5.51 ............................. Instructionsfortroubleshooting5.51 Faultlocalization5.51 3/2-wayorpilotvalve5.54 Pilotedcheckvalves5.54 Internalbypassinlegs5.55 Pressurereliefvalvedefective5.55 Defectiveorcloggedfilter5.55 6.Technicaldata Description6.3 .................................. Mainsubassemblies6.4 Maindimensions6.6 Basewithlinksandrelaybarassembly6.7 Lemniscaticlinks6.12 .................................. Canopy6.14 ........................................... Canopyextension6.16 Propheadwithpawl6.18 Cavingshield6.19 Cavingflap6.21 Technicaldata,steelstructure6.22 Hydraulicsystem6.23 ............................. Shieldhydraulics6.23 Hydraulicleg,double(pawl)6.24 Hydrauliccylinders6.26 ........................... Layout6.26 Shiftingram(Z2)6.27 ................................... Stabilizingcylinder(Z3)6.27 ............................. Liftingcylinder(Z4)6.28 ................................. Technicaldata,hydrauliccylinders6.29 ................... Pressurereliefvalves6.31 ......................... Anglesofinclinationofthecanopy6.33 ............. Permissiblemedia6.34 ............................ Hydraulicfluids6.34 Qualityoftheprocesswater6.36 Greasesandlubricatingpastes6.38 Tighteningtorques6.40 ........................... ScrewsandboltswithISOmetricthread6.40 7.Foryourinformation Standardsanddirectives7.3 ...................... Appliedstandardsanddirectives7.3
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Tableofcontent Shieldsupport1321/3048-2x5655-1850 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
1 Aboutthismanual
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Aboutthismanual
Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Italsoprovidesyouwithinformationabout thestructureofthemanualandthesymbolsandsignsusedinit.
Beforestartingwork
Usinganoperatingmanualthatisnotwrittenfortheshieldsupport athandcanresultinasafetyhazardforyourselfandothers.Make suretheinformationontheshieldcomplieswiththatgiveninthe operatingmanual.
Thisoperatingmanualbelongstothe Shieldsupport 1321/3048-2x5655-1850*
ID.No.:74202620000001
andisonlypermittedtobeusedforshieldsofthistype!
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththeshield.
Thereshould,ifpossible,alwaysbeanoperatingmanualforthe shieldavailableattheplaceofoperation.
Requestanewoperatingmanualimmediatelyifthecurrentoperatingmanualisnolongercompleteorhasbecomeillegible.
Personsforwhomtheoperatingmanualisintended
Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.
Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.
Thisincludespersonswho: areinchargeoftransport, setupontheinstallationface, performinstallation/removalwork, operatetheshields, correctmalfunctions, performdailyroutineworkontheface, monitor/lookafterthehydraulicsystem, carryoutmaintenancework, carryoutrepairwork.
Supervisorypersonnelwho: initiatetheactivitiesmentionedaboveand/or supervisethem.
* Theshieldsupportisreferredtoastheshieldinthefollowingtext.
Beforestartingwork Doc.no.:7420262000BA00SSSP/01 1.3
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
applicableoperatingmanual shieldtype
newoperatingmanual
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtotheshieldsupport.
Readthisoperatingmanualcompletelyandatyourleisure. Payspecialattentiontothecorrespondingsafetyinstructions. Memorizetheappearanceandmeaningofthesafetyandinstructionsymbols.
Shouldyouhaveanyquestions,pleasecontactourservicedepartment.
Payspecialattentiontochapter2,“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheproceduralinstructions.
Signsandsymbolsused
Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationinthisoperatingmanual. Memorizethesymbolsandtheirmeanings.
Danger!
Textpassagesindicatedwiththissymboldrawyourattention toimminenthazards.Thepossibleconsequencesareveryseriousinjuryorevendeath.
Warning!
Thissymbolindicatesinformationonhazardoussituations. Thepossibleconsequencesareveryseriousinjuryoreven death.
Caution!
Thissymboldrawsyourattentiontohazardoussituations.The possibleconsequencesarelighttominorinjuriesanddamage tomachinery.
Notice!
Sectionsmarkedwiththissymboldrawyourattentiontoharmfulsituations.Possibleconsequencesaredamagetotheshield ordamageinitsimmediatevicinity.
Important!
Passagesinthetextmarkedwiththissymbolcontainuseful tipsandinformationintendedtomakeworkeasierforyou. Theydonotwarnaboutharmfulorhazardoussituations.
Itemsinlistsareindicatedbybullets.
–Itemsinsub-listsareindicatedbyalongdashatthestartof theline.
. Textpassagesindicatedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Thiswillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.
Beforestartingwork Shieldsupport1321/3048-2x5655-1850 1.4
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Yoursafety
Thischapterprovidesvitalinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedureareintendedtohelpyouavoidhazardoussituationsandperformthenecessaryworkassafelyaspossible.
Theshieldsupporthasbeenmanufacturedusingstateoftheart technologyandinaccordancewiththegenerallyrecognizedsafety standardsandregulations.
Youandotherscanneverthelessstillbeexposedtodangerous situations,e.g.asaresultofenvironmentalinfluences,machine damageoroperatorerrors.
Donotmakeanymodificationsorchangeswhichcouldimpairthe safetyoftheshieldsupport.Allmodificationsandchangesmustbe approvedbyCaterpillar.
UseonlyoriginalsparepartsfromCaterpillar.Notethatusingparts fromothermanufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanual,makesureyoualsoobserve thelegalprovisionsandregulationsforaccidentpreventioninyour country.
Observethesafetyandaccidentpreventionregulationsofthefollowingparties: oftheminingcompany, oftheminesinspectorateand oftheminingsupervisoryauthorities. Pleasealsoreadtheoperatingmanualsofthecomponentsrequiredforoperation,e.g.gearboxes,E-motors,etc.carefullyand thoroughly.Clarifyanyquestions before startingwork.
Personnel Operation
Theshieldsupportmaybeoperatedbytrainedpersonnelonly. Theshieldsupportmayonlybeoperatedbyqualifiedpersonnel whocanprovideproofofhavingbeentrainedonthecontrol system installed.
Readingtheoperatingmanual,especiallythechapteronsafety, mustconstitutepartofthistraining.
Personnelmustpossesssufficientknowledgeof themechanical system, thehydraulicsystemand thecontrolsystem andbeabletodemonstratethis.
Personnel Doc.no.:7420262000BA00SSSP/01 2.3
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E stateof theart additionaloperatingmanuals training
Installationandrepairs
Asafundamentalrule,installationandrepairworkmayonlybecarriedoutbypersonnelwhohavebeenadequatelytrainedforthese particularrequirements.
Installationandrepairworkon:
thesafetycomponents(pressurereliefvalves,extinguishers, etc.),
theelectricalsystem(controls,signalingdevices,etc.), thehydraulicsystem
mayonlybecarriedoutbyDealershipengineersorbyspecially trainedpersonneloftheminingcompany.
Personnel Shieldsupport1321/3048-2x5655-1850 2.4
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Operatingconditions Intendeduse
Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasashieldunitforlongwalls. Usetheshieldonlyasintended!
Intendeduseincludes: legpingtheroofupagainsttheminefloor, ensuringanadequatetravelway, thefollowingshieldoperations: –lowering, –pullingup, –aligningand –setting, thefollowingconveyoroperations: –advancing, –retracting, formingananchorfor: –theconveyorandminingequipment, –conveyorsteeringdevices, –devicesforraisingtheconveyor, –conveyorsteeringcylinders.
Unauthorizeduse
Anyusewhichisnotexpresslyincludedinthelistof“intended uses”isconsideredtobeunauthorizeduse.andisnotpermissible withtheshield.
Unauthorizeduseincludes: pushingtheshieldbackintothecavingarea, raisingtheconveyorbymeansofthehydraulicforceofthe shield, settingtheshieldcanopyinrooffalls. Furtherinformationaboutthiscanbefoundinthe“Operation” sectionofthischapterandinchapter5inthe“Operationofthe shieldsupport”section.
Caterpillarassumesnoliabilityfordamagecausedbyunauthorized use.
Operatingconditions Doc.no.:7420262000BA00SSSP/01 2.5
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CaterpillarGlobalMiningEuropeGmbH,Lünen2013
• 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
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