Operation and Maintenance Manual
Roof Support
Serial-No.: LFZ00163, LFZ00164, LFZ00165
Doc-No.: 7420 233 000 BA 01
ID-No. BI628535-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 Shieldsupport2400/4300-3x5330-2050 Doc.no.:7420233000BA01 Translationoftheoriginaloperatingmanual
Amendmentsandalterationstothispublicationarenotsubject tonotification.Caterpillarreservesallrightstothispublication.
Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.
Caterpillardeclinesanyliabilityfordirectorindirectconsequencesof printingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2013E ACaterpillarInc.Company
Tableofcontents Doc.No.:7420233000BA01SSSP/01 Tableofcontents 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 Transportsafetydevice3.10 ....................... Baseandrelaybarassembly3.10 Sideseal3.10 Flipper3.11 ........................................... Controlunits3.11 Transportpositions3.12 Transportposition3.13 4.Installation Pre-assemblyoftheshieldunits4.3 ............... Installationoftheshieldunits4.3 ................. Pressureequalizationoftheelectroniccontrol system4.5 Supplyconnectionsforauxiliarysupply4.6 Requirementsforthefacehydraulicsystem4.10 .... Watersprayingsystemrequirements4.11 ........... Commissioning4.12 .............................. Tobeobservedpriortostart-up4.12 Howtoputthesupportintooperation4.14 ................. Corrosionprotectionofhydrauliccomponents4.14 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
Tableofcontents Shieldsupport2400/4300-3x5330-2050
Requirements5.3 ................................ Operatingconditions5.3 Safetyrequirements5.6 Operationoftheshieldsupport5.9 ................ Worksafety5.14 .................................. Shieldcomponents5.15 ........................... Maincomponents5.15 Overviewofshieldhydraulics5.18 ................. HPballvalveversions5.18 FunctionsoftheHPballvalves5.20 Operationoftheshieldhydraulics5.21 ............. Arrangementofthehydrauliccomponents ontheshieldwithcanopyI5.21 ShieldhydraulicsforshieldwithcanopyI5.23 Functionsoftheshieldcontrolunits forshields01,03,055.26 ................................ Arrangementofthehydrauliccomponents ontheshieldwithcanopyIIandIII5.34 ShieldhydraulicsforshieldwithcanopyIIandIII5.37 Functionsoftheshieldcontrolunits forvariants02,04,065.40 ............................... Controlunits5.47 Supplyblock5.48 PMC®-Rcontrolunit5.49 Electrohydrauliccontrolunits5.49 PRV5.51 Checkvalve5.51 Emulsionfilter5.52 ..................................... Manifold5.52 .......................................... Flipper5.53 ........................................... CanopyIIIwithslidingcap5.53 .......................... CanopyIIandIII5.54 Leg5.55 Plugwithpressurerelief5.56 Repairandemergencyoperation5.57 Operationandfunctionsoftheelectrohydraulic controlunit5.60 Shieldfunctions5.61 Maintenance5.69 ................................. Specialmeasures5.69 Dailymaintenance5.70 Weeklymaintenance5.71 Everysixmonths5.71 Regular,scheduleddamageassessment5.71 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
5.Operation
Tableofcontents Doc.No.:7420233000BA01SSSP/01 Troubleshooting5.72 ............................. Instructionsfortroubleshooting5.72 Faultlocalization5.72 3/2-wayorpilotvalve5.75 Pilotedcheckvalves5.75 Internalbypassinlegs5.76 Pressurereliefvalvedefective5.76 Defectiveorcloggedfilter5.76
Description6.3 .................................. Mainsubassemblies6.5 Maindimensions6.8 Basewithlemniscaticlinksandrelaybarassembly6.10 Canopy6.16 ........................................... Flipper6.19 ........................................... CanopyI6.21 CanopyII6.23 CanopyIII6.25 Legheadwithretainer6.28 Sideseal6.29 Cavingshield6.42 Accessories6.44 ................................. Antitoppledevice"canopy–canopy"6.44 Relaybarassembly,exterior6.48 Relaybarassembly,exterior,left6.49 ..................... Conveyordrawgear6.50 ................................ Sideplates6.51 ........................................ Spacerbox6.53 Winchholder6.54 Technicaldata,steelstructure6.55 Hydraulicsystem6.59 ............................. Shieldhydraulics6.59 Hydraulicleg,two-stage6.61 Hydrauliccylinders6.63 ........................... Layout6.63 Shiftingram(Z2a)6.66 Outriggerramontheouterrelaybarassembly(Z2b)6.66 .... Sidesealcylinder(Z4a)6.67 ............................. Sidesealcylinder(Z4b)6.67 ............................. Adjustingcylinder(Z5a)6.68 ............................. Adjustingcylinder(Z5b)6.68 ............................. Adjustingcylinder(Z5c)6.69 Dozercylinder(Z6)6.69 Flippercylinder(Z7)6.70 Flipperextensioncylinder(Z8)6.70 Baseliftingcylinder(Z9)6.71 Technicaldata,hydrauliccylinders6.72 ................... CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
6.Technicaldata
Tableofcontents Shieldsupport2400/4300-3x5330-2050 Pressurereliefvalves6.76 ......................... Anglesofinclinationofthecanopy6.78 ............ Hydraulicfluids6.79 .............................. Permissiblehydraulicfluids6.79 Maintenanceofthehydraulicfluid6.81 Qualityoftheprocesswater6.81 Greasesandlubricatingpastes6.83 Tighteningtorques6.85 ........................... ScrewsandboltswithISOmetricthread6.85
Standardsanddirectives7.3 ...................... Appliedstandardsanddirectives7.3 Identificationoftheshield7.5 ..................... Nameplate7.5 Shieldnumber7.6 CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
7.Foryourinformation
1 Aboutthismanual
• 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
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Aboutthismanual
Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Italsoprovidesyouwithinformationabout thestructureofthemanualandthesymbolsandsignsusedinit.
Beforestartingwork
Usinganoperatingmanualthatisnotwrittenfortheshieldsupport athandcanresultinasafetyhazardforyourselfandothers.Make suretheinformationontheshieldcomplieswiththatgiveninthe operatingmanual.
Thisoperatingmanualisdesignedfor Shieldsupport 2400/4300-3x5330-2050*
IDNo.:74202330000005 74202330000007
andisonlypermittedtobeusedforshieldsofthistype!
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththeshield.
Thereshould,ifpossible,alwaysbeanoperatingmanualforthe shieldavailableattheplaceofoperation.
Requestanewoperatingmanualimmediatelyifthecurrentoperatingmanualisnolongercompleteorhasbecomeillegible.
Personsforwhomtheoperatingmanualisintended
Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.
Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.
Thisincludespersonswho: areinchargeoftransport, setupontheinstallationface, performinstallation/removalwork, operatetheshields, correctmalfunctions, performdailyroutineworkontheface, monitor/lookafterforthehydraulicsystem, carryoutmaintenancework, carryoutrepairwork.
Supervisorypersonnelwho: initiatetheactivitiesmentionedaboveand/or supervisethem.
* Theshieldsupportisreferredtoastheshieldinthefollowingtext.
Beforestartingwork Doc.No.:7420233000BA01SSSP/01 1.3
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
Applicable operatingmanual Shieldtype
New operatingmanual
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtotheshieldsupport.
Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontotherespectivesafetyinstructions.
Memorizetheappearanceandmeaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservice department.
Payspecialattentiontochapter2,"Yoursafety".Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheproceduralinstructions.
Signsandsymbolsused
Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationinthisoperatingmanual. Memorizethesymbolsandtheirmeanings.
Danger!
Textpassagesindicatedwiththissymboldrawyourattention toimminenthazards.Thepossibleconsequencesare: veryseriousinjuryorevendeath.
Warning!
Thissymbolindicateshazardoussituations. 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 Shieldsupport2400/4300-3x5330-2050 1.4
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E Efficiency Service Safety
Yoursafety
Thischapterprovidesimportantinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedureareintendedtohelpyouavoidhazardoussituationsandperformthenecessaryworkassafelyaspossible.
Theshieldsupporthasbeenmanufacturedusingstateoftheart technologyandinaccordancewiththegenerallyrecognizedsafety standardsandregulations.
Youandotherscanneverthelessstillbeexposedtodangerous situations,e.g.asaresultofenvironmentalinfluences,machine damageoroperatorerrors.
Donotmakeanymodificationsorcarryoutconversionswhich couldimpairthesafetyoftheshieldsupport.Allmodificationsand changesmustbeapprovedbyCaterpillar.
OnlyuseoriginalsparepartsfromCaterpillar.Notethatusingparts fromothermanufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanual,makesureyoualsoobserve thelegalprovisionsandregulationsforaccidentpreventioninyour country.
Observethesafetyandaccidentpreventionregulationsofthe followingparties: oftheminingcompany, oftheminesinspectorateand oftheminingsupervisoryauthorities. Pleasealsoreadtheoperatingmanualsofthecomponents requiredforoperation,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.:7420233000BA01SSSP/01 2.3
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
theart
Training
Stateof
Additionaloperatingmanuals
Installationandrepairs
Asafundamentalrule,installationandrepairworkmayonlybe carriedoutbypersonnelwhohavebeenadequatelytrainedfor theseparticularrequirements.
Installationandrepairworkon: thesafetycomponents(pressurereliefvalves,extinguishers, etc.), theelectricalsystem(controls,signallingdevices,etc.), thehydraulicsystem, mayonlybecarriedoutbydealershipserviceengineersorby speciallytrainedpersonneloftheminingcompany.
Personnel Shieldsupport2400/4300-3x5330-2050 2.4
CaterpillarGlobalMiningEuropeGmbH,Lünen2013 E
Operatingconditions Intendeduse
Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasashieldunitforlongwallfaces. Usetheshieldonlyasintended.
Intendeduseincludes: proppingtheroofupagainsttheminefloor, ensuringanadequatetravelway, thefollowingshieldoperations: –lowering, –pullingup, –aligningand –setting, thefollowingconveyoroperations: –advancing, –retracting, formingathrustbearingfor: –theconveyorandminingequipment, –conveyorantitoppledevices, –devicesforraisingtheconveyor, –conveyorsteeringcylinders.
Unauthorizeduse
Anyusewhichisnotexpresslyincludedinthelistof"intended uses"isconsideredtobeunauthorizeduseandisnotpermissible withtheshield.
Unauthorizeduseincludes: pushingtheshieldbackintothecavingarea, raisingtheconveyorbymeansofthehydraulicforceofthe shield, settingtheshieldcanopyinrooffalls. Furtherinformationaboutthiscanbefoundinthe"Operation" sectionofthischapterandinchapter5inthe"Operationofthe shieldsupport"section.
Caterpillarassumesnoliabilityfordamagecausedbyunauthorized use.
Operatingconditions Doc.No.:7420233000BA01SSSP/01 2.5
E
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
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
