CAT Bucyrus Shield support 2100/4500-2/2x7156/1789 Operating Manual - PDF DOWNLOAD

Translation of the original operating manual

Operating manual Shield support 2100/4500-2/2x7156/1789 Doc. No.: 7420 244 000 BA 00

Caterpillar Global Mining Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@cat.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.mining.cat.com

Amendments and alterations to this publication are not subject to notification. Caterpillar reserves all rights to this publication.

Its content is protected by copyright. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar.

Caterpillar does not assume any liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications due to technical development without previous notice.

Caterpillar Global Mining Europe GmbH, Lünen 2013E A Caterpillar Inc. Company

Table of content

Table of content 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4 1.4

2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . .

E

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.3 2.4

2.5 2.5 2.5

2.6

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load units, dimensions and weights . . . . . . . . . . . . . . . . . .

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport safety device . . . . . . . . . . . . . . . . . . . . . . .

Relay bar assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Staple clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.4

3.5 3.5 3.5

3.8 3.8 3.9 3.10 3.11

4. Installation Preassembly of the shield units . . . . . . . . . . . . . . . .

4.3

Installation of the shield units . . . . . . . . . . . . . . . . .

4.3

Pressure equalization of the electronic control system . . .

Supply connections for auxiliary supply . . . . . . . . . . . . . . .

Establishing a connection between the shields . . . . . . . . .

Requirements for the face hydraulic system . . . .

4.10

Water spraying system requirements . . . . . . . . . . .

4.11

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12

To be observed prior to commissioning . . . . . . . . . . . . . . .

How to put the support into operation . . . . . . . . . . . . . . . . .

Anticorrosion protection of hydraulic components . . . . . . .

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4.5 4.6 4.9

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4.12 4.14 4.14

Table of content 5. Operation 5.3 5.3 5.6

Operation of the shield support . . . . . . . . . . . . . . . .

5.9

Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15

Shield components . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of shield hydraulics . . . . . . . . . . . . . . . . .

HP ball valve versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functions of the HP ball valves . . . . . . . . . . . . . . . . . . . . . .

Operation of the shield hydraulics . . . . . . . . . . . . .

Arrangement of the hydraulic components . . . . . . . . . . . . .

Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intershield manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emulsion filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrohydraulic control units . . . . . . . . . . . . . . . . . . . . . . . .

Water valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug with pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring coupling for pressure relief . . . . . . . . . . . . . . . .

Repair and emergency operation . . . . . . . . . . . . . . . . . . . . .

Operation and functions of the electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of the double backflush filter . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regularly scheduled damage assessment . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

Fault localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/2-way or pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piloted check valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal bypass inside the leg . . . . . . . . . . . . . . . . . . . . . . . .

Pressure relief valve defective . . . . . . . . . . . . . . . . . . . . . . .

Defective or clogged filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16

5.18 5.18 5.20

5.21 5.21 5.23 5.42 5.43 5.44 5.45 5.45 5.46 5.46 5.47 5.48 5.49 5.52 5.53 5.54 5.56 5.57 5.61

5.62 5.62 5.63 5.64 5.64 5.64

5.65 5.65 5.65 5.68 5.68 5.69 5.69 5.69

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Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of content 6. Technical data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base with lemniscatic links and relay bar assembly . . . . .

Lemniscatic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leg retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Antitopple device “canopy/canopy” . . . . . . . . . . . . . . . . . . .

Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, steel structure . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic leg, two-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting ram (Z2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizing cylinder (Z3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side seal cylinder (Z4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper cylinder (Z7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base lifting cylinder (Z9) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinders . . . . . . . . . . . . . . . . . . .

6.3 6.5 6.7 6.8 6.12 6.14 6.16 6.18 6.19 6.24 6.26

6.27 6.27 6.35 6.37 6.38 6.39

6.40 6.40 6.43

6.46 6.46 6.48 6.48 6.49 6.49 6.50 6.51

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . .

6.53

Angles of inclination of the canopy . . . . . . . . . . . .

6.55

Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.56

Permissible hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of the hydraulic fluid . . . . . . . . . . . . . . . . . . . .

Quality of the process water . . . . . . . . . . . . . . . . . . . . . . . . .

Greases and lubricating pastes . . . . . . . . . . . . . . . . . . . . . .

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screws and bolts with ISO metric thread . . . . . . . . . . . . . .

6.56 6.58 6.58 6.60

6.62 6.62

7. For your information Standards and directives . . . . . . . . . . . . . . . . . . . . . .

Applied standards and directives . . . . . . . . . . . . . . . . . . . . .

Identification of the shield . . . . . . . . . . . . . . . . . . . . .

Name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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7.3 7.3

7.5 7.5 7.6

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Table of content

Shield support 2100/4500-2/2x7156/1789-2050

1

About this manual

Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It also provides you with information about the structure of the manual and the symbols and signs used in it.

Before starting work applicable operating manual

shield type

Using an operating manual that is not written for the shield support at hand can result in a safety hazard for yourself and others. Make sure the information on the shield complies with that given in the operating manual.

This operating manual belongs to the Shield support 2100/4500-2/2x7156-1789 * ID no.:

7420 244 000 00 01

and is only permitted to be used for shields of this type.

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The operating manual must be accessible at all times to all persons working on or with the shield.

There should, if possible, always be an operating manual for the shield available at the place of operation. new operating manual

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields.

All persons working on the face, at the edge of the face or at the entry must read this operating manual.

This includes persons who: are in charge of transport; set up on the installation face; perform installation/removal work; operate the shields; rectify malfunctions; perform daily routine work on the face; monitor/look after the hydraulic system; carry out maintenance work; carry out repair work.

Supervisory personnel who: initiate the activities mentioned above and/or supervise them.

*

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The shield support is referred to as the shield in the following text.

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1.3

Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the shield support.

Read this operating manual in its entirety and at your leisure. Pay special attention to the corresponding safety instructions.

Familiarize yourself well with the appearance and meaning of the safety and information symbols.

service

Should you have any questions, please contact our service department.

safety

Pay special attention to chapter 2 “Your safety”. This chapter contains important information indicating possible hazards.

Observe this information and follow the procedural instructions.

Signs and symbols used

Danger!

Text passages indicated with this symbol draw your attention to imminent hazards. Possible consequences are: very serious injury or even death.

Warning!

This symbol indicates information on hazardous situations.

Possible consequences are: very serious injury or even death.

Caution!

This symbol draws your attention to hazardous situations.

Possible consequences are: light to minor injuries and damage to machinery.

Notice!

Sections marked with this symbol draw your attention to harmful situations. Possible consequences are: damage to the shield or damage in its immediate vicinity.

Important!

Passages in the text marked with this symbol contain useful tips and information intended to make work easier for you.

They do not warn about harmful or hazardous situations.

Items in lists are indicated by bullet points.

– Items in sub-lists are indicated by a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Memorize the symbols and their meanings.

E

The following signs and symbols are used for safety instructions and important information in this operating manual.

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of conduct are intended to help you avoid hazardous situations and perform the necessary work as safely as possible. state of the art

The shield support has been manufactured using state-of-the-art technology and in accordance with the generally recognized safety standards and regulations.

You and others can nevertheless still be exposed to dangerous situations, e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any modifications or changes which could impair the safety of the shield support. All modifications and changes must be approved by Caterpillar.

Only use original spare parts from Caterpillar. Note that using parts from other manufacturers will void the guarantee.

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In addition to this operating manual, make sure you also observe the legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations of the following parties: the mining company the mines inspectorate the employers' liability insurance association for mining. additional operating manuals

Please also read the operating manuals of the components required for operation, e.g. gearboxes, E-motors, etc., carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation The shield support may be operated by trained personnel only. training

The shield support may only be operated by qualified personnel who can provide proof of having been trained on the control system installed.

Reading the operating manual, especially the chapter on safety, must constitute part of this training.

Personnel must possess sufficient knowledge of: the mechanical system the hydraulic system the control system and be able to demonstrate this.

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2.3

Personnel Installation and repairs As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: the safety components (pressure relief valves, extinguishers, etc.) the electrical system (controls, signaling devices, etc.) the hydraulic system

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shall only be carried out by Caterpillar service engineers or by specially trained personnel of the mining companies.

2.4

Shield support 2100/4500-2/2x7156/1789-2050

Operating conditions Operating conditions Intended use The shield has been designed and manufactured exclusively for use as a shield unit for faces.

Use the shield only as intended!

Intended use includes: propping the roof up against the mine floor ensuring an adequate travel way the following shield operations: – lowering – pulling up – aligning – setting E

the following conveyor operations: Caterpillar Global Mining Europe GmbH, Lünen 2013

– advancing – retracting forming an anchor for: – the conveyor and mining equipment – conveyor antitopple devices – devices for raising the conveyor – conveyor steering cylinders.

Unauthorized use Any use which is not expressly included in the list of “intended uses” is considered to be unauthorized use and is not permissible with the shield.

Unauthorized use includes: pushing the shield back into the caving area raising the conveyor by means of the hydraulic force of the shield setting the shield canopy in roof falls.

Further information about this can be found in the “Operation” section of this chapter and in chapter 5 of this manual in the “Operation of the shield support” section.

Caterpillar assumes no liability for damage caused by unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective equipment.

Inform your colleagues of: your exact location the work you are performing the time which you will probably require.

prerequisite

Only use shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

Observe the acoustic and visual start-up warnings. Pay special attention to the start-up warnings for the conveyor and for the mining equipment.

EMERGENCY STOP

Press the emergency stop switch immediately in the event of malfunctions or irregularities in operation. Notify your supervisor of every detail, so that necessary action can be taken immediately.

support lock-out switch

- Only applies to the version with the electrohydraulic shield control system: Actuate the support lock-out switch (repair switch) before: maintenance work inspection work repair work prolonged presence in the shield.

moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: bases and relay bar assemblies canopies lemniscatic links side seals front cantilevers hydraulic legs and cylinders antitopple devices.

automatic mode

2.6

In automatic mode, the shield units of a face are controlled by an automatic program without any human intervention. When traveling along the face you should therefore always bear in mind that the shield units may move automatically. Therefore, it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals emitted by the control unit in the shield unit currently operated.

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signaling systems and safety equipment

Maintain the lighting systems in working condition.

Caterpillar Global Mining Europe GmbH, Lünen 2013

lighting system

Safety instructions Storage and transport For this purpose, read chapter 3 “Storage and transport”.

Never stand under unsecured or suspended loads.

Observe the prescribed storage periods and the storage instructions.

Never store materials of any kind in the travel way or in your working area.

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

Inform the persons concerned about the intended transport route and the probable duration of transport. transport safety device

Make sure that the transport safety devices have been correctly fitted. Pay special attention to the transport safety devices on:

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side seals flippers relay bars (face side and gob side). transport

Connect the means of attachment only to the lifting points provided for the purpose. Observe the different load limits of the lifting points. Also observe the instructions for transport given on the spare part drawings which are included in the spare parts catalog.

Non-standard transport units are shown on special drawings which are added to the appendix of the operating manual, if required.

Do not damage the polished surfaces of the cylinders and the legs.

Damage of this kind necessitates elaborate and expensive repair work.

For round components, such as cylinders and legs, which are not provided with lifting points, only use transport straps. Never use chains or steel cables for this purpose.

Only use means of attachment which are in good condition and have been designed for the loads involved.

Firmly secure all components which might start moving on their own.

Observe the position of the center of gravity, especially during transport with mobile handling systems. The center of gravity must be as low as possible in order to prevent the transport unit from tipping over.

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2.7

Safety instructions Installation Only use appropriate loading equipment for the safe transfer of the transport units.

Prior to commencing any work on the shield, make sure that the shield is secured to prevent it from retracting automatically.

Mechanically secure the caving shield against involuntary lowering during: installation of the legs and cylinders installation of the canopies work on the open hydraulic system.

The shield can be secured, for instance, by placing hardwood wedges between the pairs of lemniscatic links.

Self-locking hardwood wedges between the lemniscatic links stabilize the position of the caving shield

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Fig. 1:

transport safety device

If the shield is equipped with movable side seals these are pre-tensioned by spring force. Therefore, do not use force to remove the transport safety device of the side seals. Use the hydraulic control system to adjust the side seal cylinders in such a way that the locking pins either drop down or can be pulled out without the use of brute force.

When removing the transport safety device of the flipper ensure that nobody is present in the flipper's swiveling area as it may swing down.

travel way

Make sure that the minimum dimensions specified for the travel way with the shield are maintained at all times.

Any equipment subsequently added to the shield, such as antitopple devices, must not reduce the minimum travel way. It may be necessary to install additional devices in order to ensure that the minimum travel way is maintained.

2.8

Shield support 2100/4500-2/2x7156/1789-2050

Safety instructions Operation shield control

In automatic mode, the shield units of a face are controlled by an automatic program without any human intervention. When traveling along the face you should therefore always bear in mind that the shield units may move automatically. Therefore, it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the shield unit currently operated.

Check whether all protective devices are present on the shield and in working order. See also chapter 6 “Technical data”.

You may only operate the shield control if you have comprehensive knowledge of the control elements and their functions. You must have been trained on the respective control and know the contents of the respective operating manual for that control.

You should not be in the same shield as the one you wish to operate. Always operate the shield only from a neighboring shield.

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Make sure that no persons are present in the area of the shield being actuated.

Caterpillar Global Mining Europe GmbH, Lünen 2013

During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the support is being moved, and prevent any hazards by acting with caution.

Always set the shield until the full setting pressure has been reached, since good roof support can only be ensured in this manner.

Extend the flipper towards the coal face as far as possible to prevent coal or surrounding rock from falling into the travel way.

Clean the operating controls of the control units regularly. Make sure that the operating symbols are clearly recognizable. This measure avoids operating errors and accidents which would result from them.

Keep the floor as clean as possible. Keep the mine floor free of debris. You will thus be able to extend the relay bar assembly without obstacles and advance the conveyor without problems.

Ensure that the water spraying system responds during advancement. inclined face

On inclined faces it may be necessary to anchor the conveyor with respect to the support. You can thus prevent the conveyor from shifting to the side compared to the support. That reduces the risk of the relay bar assembly jamming between the bases.

Hydraulic anchorages must always be charged with the specified working pressure since only thus is a sufficient anchorage between support and conveyor ensured.

When advancing the shields, always observe the specified sequence of steps to prevent the shields from colliding with the anchorage cylinders.

On inclined faces, always advance the shields from the bottom to the top. Operate the shield to be advanced always from within the neighboring shield above. This reduces your risk of injury by falling rocks and also gives you a better view of the advancing operation.

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2.9

Safety instructions shield alignment

The shields must be aligned at right angles to the conveyor and parallel to each other. Use the aligning devices or the side seal for aligning the shields.

Align the shields as early as possible. Use the aligning device or the side seal for aligning the shields.

Early alignment prevents: the canopy from getting under the neighboring shield the shields from tilting the shields from slipping delays in supporting the newly mined roof.

roof falls

Prevent roof falls by supporting the newly mined roof as early as possible.

Never set the tip of the canopy into a roof fall so that

the canopy is loaded excessively in the longitudinal direction; as this may cause damage due to excessive stress and strain on the components.

During the temporary support of a roof fall, ensure that the sloping canopy does not get in the way of passing mining equipment. residual stroke

Ensure that sufficient residual stroke is still present in the legs as the seam thickness decreases. This prevents the shields from jamming between the roof and floor.

retracting the conveyor

To retract the conveyor, preferably use the functions of the electronic shield control. If this is not possible, do as specified in the applicable work instructions of the mine.

Secure all mining equipment against unauthorized starting.

Cordon off your working area so that no unauthorized persons may enter this area.

Check to determine whether the shields are set sufficiently tight between the roof and floor.

raising the conveyor

Secure your working area against falling rock. This is particularly important if you have to raise the conveyor on the face side.

Only use the lifting points intended for that purpose.

Never attach loads to hydraulic cylinders or their points of attachment.

Reset all shields in the area where the conveyor is to be raised.

Check the setting pressure again. Do not under any circumstances loosen the canopy from the roof; it must be in place along the entire length.

If you raise the conveyor in the area of several shields, the shields to which lifting gear is attached must not be located next to one another.

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the stabilizing cylinder is fully out or fully in;

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the maximum admissible angle of inclination of the canopy is exceeded;

Safety instructions For raising the conveyor, use only the following: High-strength, undamaged chain slings.

The lifting points provided for the purpose.

Check that the lifting points are undamaged before attaching the load.

Lifting gear of adequate load-carrying capacity.

Maintenance Make sure that all safety and protective equipment of the shield units is complete and in working order. If the safety and protective equipment is included in the Caterpillar scope of delivery, refer to chapter 6 “Technical data”, for its location.

Be sure to observe the intervals specified for maintenance and inspection. See chapter 5, section “Maintenance”.

Check the shield at least once every shift for externally visible damage.

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Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its probable duration.

Cordon off your working area over a wide range to avoid endangering other persons.

Immediately replace damaged components relevant for safety. Shut down the affected shield immediately if component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible superiors without delay.

Use only spare parts which comply with the specified technical requirements. This is best ensured by using original Caterpillar spare parts.

Please refer to the spare parts catalog provided for the equipment for the order numbers for the required spare parts.

Do not make any modifications or changes which might impair the safety of the shield. Caterpillar must be informed of all changes and modifications to check whether they have any effect on the approval or whether it is necessary to apply for a revised approval.

Any modifications carried out without authorization invalidate the Caterpillar declaration of conformity and a new conformity test will be required.

During work on the relay bar assembly, cordon off the working area for the mining equipment.

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2.11

Safety instructions You may only carry out work in the mining area if: the roof has been secured against falling rock; the coal face has been secured against collapsing; the mining equipment and conveyor have been shut down and secured against restarting or if you have otherwise ensured that continuation of mining does not affect the safe performance of the repair work.

Before disconnecting the shield from the conveyor, you must: arrange for the mining operation to be either stopped completely or done outside the required safety area; completely relieve the load on the components which are under hydraulic pressure or mechanical stress.

Immediately discontinue any work on the shield if conveying and crushing operations are in progress in your working area.

Immediately after completion of work, reinstall any protective plates or similar items which have been removed, and check them for correct function. handling hydraulic fluids

Hydraulic system Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids are very harmful to your health.

protective devices - hydraulic system

Note that when dismantling protective devices that include hydraulic components, those components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. It is therefore imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repairs

Only persons who have and can demonstrate special knowledge of hydraulics are allowed to work on the hydraulic system.

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace any defective protective caps immediately.

Carry out a visual inspection of all hydraulic components at regular intervals. In particular, check that: hoses are not pinched; hoses have no bubbles or blisters; hoses or outer sheaths of hoses are not abnormally rigid or hard; the outer sheath of hoses is not damaged; plug connectors are securely inserted in the sockets; connections are leak-tight.

Make sure that no dirt penetrates the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage to the entire system. Backflush the hydraulic lines thoroughly before installing them.

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Caterpillar Global Mining Europe GmbH, Lünen 2013

On inclined faces secure the components to be replaced against slipping using chains or lifting gear, for example.

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The support must be mechanically secured for all work where there is a danger of the support retracting automatically.

Safety instructions Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the connector to check whether the line is still pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the hydraulic line.

Always secure the coupling connectors of the hydraulic elements with the corresponding staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials.

Check all connectors and connections of the depressurized system for leaks after finishing repair work. permissible hoses

Only use hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn O-rings.

Only replace hydraulic hoses with hydraulic hoses of the same or higher quality.

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Observe the date of manufacture stamped on the hose fittings of the hose lines. Never use hydraulic hoses which are more than 2 years old, even if they show no visible signs of damage.

Fig. 2:

Example of a hose line, marking

1 1 manufacturer 2 calendar week

2

3

4 3 year 4 max. working pressure

Never try to hold a hydraulic hose that is thrashing about. Depressurize the section in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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2.13

Safety instructions installing hydraulic lines

Lay the hydraulic lines correctly behind the brackets and clips provided for them.

Lay hydraulic lines so that they: are always slightly slack; Fig. 3:

Laying hydraulic line, slack

are not twisted; Laying hydraulic line, twist

are not bent directly behind the connections (minimum distance 1.5 x nominal diameter); Fig. 5:

Laying hydraulic line, bend

1.5 x d

d

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Fig. 4:

Safety instructions cannot chafe; Fig. 6:

Laying hydraulic line, crossing

are not kinked; do not have to withstand tensile loads; are protected against thermal radiation; are accessible at all times.

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Only push hydraulic lines into the connector sockets by hand.

Never try to drive the hydraulic lines in with a tool, as this will damage the connectors.

When laying hydraulic lines, ensure that they cannot be: torn out kinked pinched driven over twisted as a result of moving equipment (Fig.: 7).

Fig. 7:

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Laying hydraulic line, connections to moving parts

2.15

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Safety instructions

2.16

Shield support 2100/4500-2/2x7156/1789-2050

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and secure transport of the shields.

Following the instructions and the manuals will increase the service life of the shield. You will be able to carry out transport work more safely and quickly.

Paying careful attention to this chapter will also help you to simplify your day-to-day work.

Storage Storing the equipment

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anticorrosion protection

Components coated with temporary anticorrosion protection are protected for about six months.

no direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, spare parts made of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15°C to 25°C.

dirt and moisture

Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. by using tarpaulins.

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic plug-type connections and the connections of the electrical cables with the caps and plugs supplied.

short-term storage

For short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must especially be protected against excessive temperatures, dirt and moisture.

long-term storage

For long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

After a storage period of approximately two years, an inspection must be performed to determine whether the measures taken and the method of storage have prevented damage.

This inspection can be carried out by Caterpillar upon request.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. Do not use these components if they have been stored for more than two years.

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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3.3

Storage Storing used equipment The points listed above, with the exception of the one concerning anticorrosion protection, can be applied in the same way to the storage of hydraulic components that have already been in use. anticorrosion protection

If the hydraulic system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly backflushed in advance and then filled with a suitable corrosion inhibitor (e.g. HYDROCOR® CV 50*). If this is not done, then the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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Equipment parts for conveying water, such as the parts for the water spraying system of a shield, must be completely drained, and possibly also filled with an antifreeze fluid, if required.

*

3.4

HYDROCOR® CV 50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

Shield support 2100/4500-2/2x7156/1789-2050

Transport Transport Load units, dimensions and weights Make sure to pay attention to the transport sheet. It includes information on: dimensions weight lifting points centers of gravity.

The load units are provided with suitable lifting points for transport and installation as far as technically possible.

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Warning!

Only use load handling devices which comply with the technical and legal regulations for transporting loads.

Falling components can cause serious injury and death.

Only use suitable load handling devices.

Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components that are operated with emulsion (HFAE or HFAS) must be completely drained and filled with a corrosion inhibitor (e.g. CV 50).

It is only permitted to transport equipment at temperatures of -21°C to -40°C if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with mobile handling systems at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

At very low temperatures and on roads in bad condition, the transport vehicle's speed must therefore be limited to a maximum of 25 km/h for truck transport.

electrical and electronic components

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Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the entire equipment are protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully from transport damage and the connectors must be protected from dirt.

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3.5

Transport transport units

A shield unit can be transported as a completely assembled unit or broken down into subassemblies. If it is necessary to disassemble it into transport units, this is planned and agreed on in close cooperation with the customer.

Tab. 1: Transport units

transport safety devices

Designation

Alignment

Complete shield unit

As for normal use

Note

For the purpose of safe transport, the movable parts of every transport unit are to be fastened in addition to the standard available transport safety devices, e.g. on side seals and flipper, so that their positions cannot shift inadvertently. Specifically, the following transport safety devices listed are provided on the transport units.

Tab. 2: Transport safety devices Component

Transport safety device

Quantity

Face side

Transport safety device

1

Side seal, movable

Pin and securing device

4

Hydraulic system

Unused hydraulic connections are protected by protective caps or plugs

-

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Caution!

Transport safety devices may get damaged during transport to the mine, for example when loading and unloading the transport units. Therefore, check all transport safety devices for damage and replace damaged ones before allowing the units to be transported into the mine shaft.

Damaged transport safety devices may be the cause of serious damage to the transport unit or to the transport shaft if load units are transported suspended under the cage with damaged or inadequate transport safety devices.

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Relay bar

Transport Fig. 8:

Transporting the segment shield as a complete unit

X4 S1

Sy

HR

1613

So

3480

X1

157

Sx

S2

3770 4340

X5 X2

L

9359

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5843

W X3 S1 transport hole in base, load capacity of 30000 kg S2 transport hole in base, load capacity of 30 000 kg X1 transport safety device for relay bar, face side X2 transport safety device for relay bar, gob side X3 transport safety device for movable side seal X4 transport safety device for flipper X5 transport safety device for flap So center of gravity W1 Tab. 3: Transport shield support 7420 244 000 00 01, dimensions and weights Device number 7420 244 000 00 01

L in mm

W in mm

W1 in mm

HR in mm

9 200

1 950

1 820

2 100

Sx/Sy in mm 1 800/1 481

Weight in kg 61 500

Important!

For transporting, use the two lifting points S1 and S2.

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3.7

Transport safety device Transport safety device Relay bar assembly A transport safety device is to be attached to the relay bar assembly during face-side transportation.

Transport safety device, relay bar assembly, face side

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Fig. 9:

3

1 2

1 pin 2 locking clip

3.8

3 spring clip

Shield support 2100/4500-2/2x7156/1789-2050

Transport safety device Flipper Fig. 10:

Transport safety device, flipper

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1

3

2

1 flipper 2 pin

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3 spring clip

3.9

Transport safety device Staple clip Fig. 11:

Securing the staples, examples

3

4 2

1

1 staple clip DN 10 2 staple clip DN 12

3 staple clip DN 20 4 staple clip DN 25

Important!

All staples on the travel way and under the canopy are secured with staple clips.

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1

Transport safety device Side seal For transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured using staples or spring clips (see also chapter 6, “Side seal” section).

Transport safety device, side seal, principle

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Fig. 12:

10 10 10 pin 30/22x120

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16

16 16 spring clip 3.2

3.11

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Transport safety device

3.12

Shield support 2100/4500-2/2x7156/1789-2050

4

Installation

Preassembly of the shield units

Installation In this chapter, you will be given information about installing the shield units. Please pay special attention to the warnings and tips.

Warning!

In addition to the safety instructions given in this manual, also make sure you observe the special safety instructions and operation instructions which apply to the operation of the mine.

Failure to do so can lead to extremely serious accidents which may be fatal.

Caution!

Before the hydraulic lines are connected with one another, the sockets and nipples of the plug-in connections must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, section “Grease and lubricating pastes”.

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Caution!

All slide surfaces must be treated with the molybdenum disulfide-free B6 lubricating paste in accordance with EWN 7068 before the transport units of the steel structure are connected with one another. See chapter 6, section “Grease and lubricating pastes”.

Preassembly of the shield units The shield units are delivered completely preassembled. Accordingly, no further pre-assembly is required on the mechanical and hydraulic systems of the shield units.

Installation of the shield units Caution!

For underground transportation, only those lifting points may be used which are described in detail in chapter 3 “Transport”.

Failure to comply can lead to personal injury and damage to property.

Further information about this can be found in chapter 3 “Transport”. installation plan

The shield units are installed in the face according to the installation plan of the mine.

Important!

When installing the shields in the face, be sure to pay attention to the shield numbers. Since some shield units may be equipped with different functions, their setup on the face is not arbitrary!

identification for installation in the face

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In order to identify the shield units or their transport units more easily for the purpose of assembling and installing them in the face, they should be labeled with a consecutive number. The numbers should correspond to the order in which the shield units are to be arranged in the face, for example. The numbers should be written in color so that they are clearly visible on the surface of the parts.

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4.3

Installation of the shield units shield number

The shield number serves as an identification feature. All shields are numbered consecutively. The corresponding shield number is on the face side, on the left side of the base.

Shield number, centered, face side

a

b a shield number

b shield weight

Tab. 4: Shield support 0010 700 000 00 00, numbering Device no.

Quantity Use

Shield

Shield number

Special design Conveyor pulling device

7420 242 000 00 01

138

Face shield

8 to 143

SH001 to SH138

7420 243 000 00 01

1

Transition shield HG

5

TS001

Extension, right

7420 243 000 00 02

1

Transition shield TG

144

TS001

Extension, left

3

GS001

4

GS002

Side plate extension, right, side plate, right

Gate end shield HG 7420 245 000 00 01

Antitopple device 1 “canopy/canopy”

5

Antitopple device 2 “canopy/canopy” Gate end shield TG

7420 245 000 00 02

7420 244 000 00 01

4.4

2

2

GS005 to GS007

145

GS003

Side plate extension, left Side plate, left

146

GS004

Anchoring device “canopy/canopy”

1 to 2

BS001 to BS002

Antitopple device 3 “canopy/canopy"

Gate end shield TG

Segment shield HG

Anchoring device “canopy/canopy”

147 to 149

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Fig. 13:

Installation of the shield units Pressure equalization of the electronic control system The shield units can be used in a number of different height positions at various prevailing air pressure levels.

These are equipped with a vent screw in order to enable pressure equalization between the internal and external pressure of the electronic control system housing.

. Release the vent screw (hex socket 4 mm) on the control system by several turns.

Pressure equalization is indicated by an audible hissing.

Caution!

Make sure that the vent screw for pressure equalization on the control system is released. The foil displays may become damaged if no pressure equalization is established.

Fig. 14:

Example of a vent screw on an electronic control system b

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a

a vent screw

b electronic control system PMC®-R

. Afterwards, re-tighten the vent screw by hand.

Caution!

Take care to ensure that the vent screw is tightened by hand again after the control system pressure has been equalized.

If this is not done, then dirt and moisture could penetrate the control unit and firedamp protection is no longer ensured.

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4.5

Installation of the shield units Supply connections for auxiliary supply During installation, pressure can be applied to the individual shield and it can be operated using what is referred to as the auxiliary supply.

The shield functions must then be operated by means of an additional external PMC®-R control unit. An appropriate cable is used to connect it to the internal PMC®-R control unit.

Important!

More information on the PMC®-R control unit is available in the separate operating manual.

Important!

More information on the shield hydraulics is available in chapter 5, in the section “Operation of the shield hydraulics”.

How to move the individual shield over the auxiliary supply is explained to you on the following pages.

Important!

More information on the 5/3-way ball valve is available in chapter 5, in the section “HP ball valve versions”.

. Move the lever (1) to the PTO position.

Fig. 15:

Supply block with 5/3-way ball valve 1

HP DN 32

P

DN 50

W

DN 50

T

T

DN 63

DN 63

Lever position ON working position (pressure and return open) OFF depressurized (return open) PTO depressurized (pressure and return shut off) HP high-pressure line connection P pressure line connection T return line connection

4.6

W water line connection 1 5/3-way ball valve

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Caterpillar Global Mining Europe GmbH, Lünen 2013

The lever on the supply block (5/3-way ball valve) must be set to the PTO (power take off) position during installation by means of the auxiliary supply. Only in this position is the shield is depressurized and the return line is blocked. There is an information sign on the supply block, where the respective lever positions are explained.

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Lever position on the supply block

Installation of the shield units Connecting the auxiliary supply The auxiliary supply connections can be found on the left under the outer canopy, near the left side seal of the shield. An HP ball valve is in the pressure line of the auxiliary supply, which must remain open during the procedure.

Fig. 16:

Auxiliary supply, closed

29

23

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T

29 P 50 46b 23 PRV, 80 bar 29 plug with pressure relief 46b HP ball valve DN 12 for auxiliary supply - open

connecting the auxiliary supply

50 through sleeve DN 20 P connection for pressure line, auxiliary supply T connection for return line, auxiliary supply

. Check whether the lever on the supply block is in the PTO position.

. Open the HP ball valve, item 46b. . Remove the plugs from the connections P and T of the auxiliary supply.

. Connect the auxiliary supply to the pressure and return lines of the pump.

. Secure the connections with staples.

The shield can now be moved by means of the external control units PMC®-R.

. Move the shield to the desired position.

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4.7

Installation of the shield units Fig. 17:

Auxiliary supply, open

50

23

T P 29

50 through sleeve DN 20 P connection for pressure line, auxiliary supply T connection for return line, auxiliary supply

29 plug with pressure relief 46b HP ball valve DN 12 for auxiliary supply - open disconnecting the auxiliary supply

If the shield is in the desired position, the auxiliary supply can be disconnected. To do this, proceed as follows:

. To relieve the pressure line, shut off the pressure supply line of the pump. Make sure the pump's return line remains open.

. Move the lever on the supply block to the OFF position. The pressure is released via the return line.

. Then move the lever on the supply block back to the PTO position.

. Close the HP ball valve, item 46b.

Notice!

The connections of the auxiliary supply must be sealed with plugs during normal operation.

. Disconnect the connection lines of the auxiliary supply and seal the connections with the plugs.

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23 PRV, 80 bar

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46b

Installation of the shield units Establishing a connection between the shields hydraulic system

The supply block for the supply of the shield hydraulics is positioned in the center under the canopy.

The connection to the supply block of the neighboring shield is established by means of five hose lines: one high-pressure line HP (DN 32 SSKV-HD) two return lines T (DN 63 SSKV-ND) one pressure line P (DN 50 SSKV-HD) one water line W (DN 50 SSKV-ND).

Proceed as follows to join the shields to one another:

. Remove the plugs from the connections HP, T, W, P of the shields to be connected.

. Install the connection lines on the connections HP, T, W, P on Caterpillar Global Mining Europe GmbH, Lünen 2013

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the supply block and connect them to the supply block of the neighboring shield.

Fig. 18:

Connection lines to the neighboring shield (schematic diagram)

control unit

Each shield unit is equipped with a model PMC®-R electronic control unit. The control unit and the electrohydraulic control unit are connected via a solenoid driver module. The connecting cables required for this are included in the delivery of the PMC®-R control.

For more details on how to connect the control device, please refer to the separate operating manual for the PMC®-R control system.

An overview of the design of the control is also given in chapter 6 of this operating manual in the section “Shield control system”.

additional equipment

The shield units are designed to accommodate the installation of additional equipment which is not included in the Caterpillar scope of delivery, for example: lighting system two-way intercom system.

The information required for the installation of additional equipment can be found in the corresponding operating manual from the respective manufacturer.

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4.9

Requirements for the face hydraulic system Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulic components included in the Caterpillar scope of delivery: Contamination class 18/14 as per ISO 4406 Hydraulic fluids in accordance with the section “Permissible media” in chapter 6 of this operating manual.

permissible pressure

Nominal pressure: . . . . . . . . . . . 320 bar Tolerance range: . . . . . . . . . . . . . ± 10% of nominal pressure

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Caution!

If there is a pressure drop, dangerous situations may arise, leading to accidents involving damage to property and/or injuries to personnel.

Make sure that the system pressure can never fall below 180 bar anywhere in the face hydraulic system.

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If the face hydraulic system is designed in such a way that it is unstable or too weak, there could be a temporary pressure drop during operation.

In the event that the pressure falls to 180 bar or less, there is a risk of malfunctions occurring in the electrohydraulic control system.

Valve functions might not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Water spraying system requirements Water spraying system requirements If the design of the water spraying system is unstable or too weak, explosive dust mixtures may develop. minimum pressure

When the water spraying system is switched on, a minimum pressure must be ensured during active water spraying. This value must not be undershot.

minimum pressure

For the Shield support 2100/4500-2/2x7156-17879 ID no.: 7420 244 000 00 01 a minimum pressure of 30 bar applies to the water spraying system.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Warning!

Insufficient water spraying could cause the ignition of explosive atmospheres (air) and dust.

Make sure that the minimum pressure of 30 bar is maintained during active water spraying.

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4.11

Commissioning Commissioning Warning!

The initial commissioning and the test run may only be carried out by a well-trained and experienced crew familiar with the special conditions in underground mining, especially with the safety requirements. The crew must also be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

Notice!

Make sure that all transport safety devices required for transport have been removed.

See chapter 3, section “Transport”.

To be observed prior to commissioning Commissioning may only be carried out by trained and qualified personnel. If the support is being used for the first time, it is absolutely imperative that commissioning is carried out under the instructions of the dealership installation service.

Mechanical system:

. Make sure that all transport safety devices have been removed.

. Remove all plugs from the hydraulic connections of the legs and/or hydraulic cylinders. Install the legs and/or hydraulic cylinders in accordance with the hydraulic circuit diagram in chapter 5.

. Check whether the plugs in the annular space connection of the legs have been removed.

. Position the symbol bar on the bracket of the electrohydraulic control unit so that the symbols are clearly legible.

. Check all mechanical connections on the shield units. . Check the plugs of the relay bar assembly.

If the relay bar assembly is designed with a plug-in crawl pan, it must be made sure that it is plugged in correctly. Under no circumstances may the crawl pan be plugged in for normal operation in the “lowering position” 1) .

. Make sure that the additional device is mounted and secured on the bases.

1) Maximum possible plugging

4.12

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Please observe the following:

Commissioning Hydraulic system:

. Check the entire hydraulic system for leaks. Seal any leaky connections immediately.

. In particular, check whether the hinges and hoses can be damaged due to movements of the shields.

Danger!

Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others could be seriously injured or even killed.

Make sure that hydraulic hoses cannot be damaged by movements of the shield.

Lay the hydraulic hoses correctly behind the brackets provided for them.

. Check the hydraulic supply pressure. . Check the load-carrying function of the legs. The current presCaterpillar Global Mining Europe GmbH, Lünen 2013

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sure under the piston of a leg can be queried on the PMC®-R control unit. Here, you can query the pressure for a neighboring support or the support in which you are currently located. The pressure gauge on the leg control valve of the leg indicates the pressure directly.

. Check all operating elements to make sure they are working properly. Test whether the function is correctly executed when the corresponding operating element is activated.

Signaling and lighting systems, information signs: Important!

For further information, please see the corresponding separate operating manual of the respective manufacturer.

. Check all signaling devices. . Make sure that the face lighting is sufficient. . Check whether the face area, especially the travel way, is sufficiently marked with signs. It is imperative that you observe the regulations of the responsible mines inspectorate.

EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems are working properly.

Mining and conveying:

. Before commissioning, check all functions of the face system. . Test to make sure the entire face system (mining equipment, conveying system, supports) is working perfectly.

Warning!

Bent support canopies must not project into the mining area.

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4.13

Commissioning How to put the support into operation Move the shield units to their original positions, i.e.: shields and conveyors are aligned in a straight line; the shields are aligned at right angles to the conveyor; the shield canopies are aligned parallel to the floor.

Check the support for any installation errors or other sources of error:

. Check all line connections established during the installation of the shields, especially all supply lines of the shield hydraulics, for completeness and correctness.

face.

. Check all functions of the shield control unit.

Do not allow the support to be operated until all deficiencies have been eliminated and the support has been found to be in perfect working order.

Anticorrosion protection of hydraulic components The Caterpillar hydraulic components are tested before delivery with an anticorrosion medium.

When these components are commissioned, no special measures have to be taken with regard to anticorrosion protection since the testing and anticorrosion medium used is completely compatible with the approved operation fluids of the group HFA. See “Permissible media” section in chapter 6 of this operating manual.

4.14

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Check the function of the hydraulic and water supply for the

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Warning!

Shut-off valves must not be installed in the return lines for the shield hydraulics, since otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in serious injuries to persons or even death.

5

Operation

Requirements

Operation This chapter provides general information on the operation and maintenance of the shields. This information is to be regarded as preparation for or an addition to hands-on training. It is recommended that you read this chapter as a supplement to the training, but this in no way releases the operator from participating in the training.

Danger!

You are only allowed to operate the shield control system if you have extensive knowledge of the control elements and of the way the control system works. You must have been given instructions on the actual control system and have consolidated your knowledge during a corresponding hands-on training session. Should this not be the case, you are not allowed to operate the control system! Inform your superior immediately and request the required training.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Warning!

Ignoring the safety regulations may cause accidents and result in serious injuries or even death.

The regulations about safe operation of your mine must be followed strictly. Apply the following instructions in addition to and in accordance with the individual safety regulations of the mine.

Requirements Operating conditions face crew

face equipment

The face crew must be informed about possible hazards. The safety measures to be taken must be laid down in writing and must be made known to the face crew.

The face must be sufficiently illuminated.

For warning and communicating with the face crew, intercom systems must be provided.

travel way

The minimum dimensions for the travel way specified must be complied with at all times.

Notice!

Make sure you observe the corresponding national regulations.

Debris or objects lying in the travel way must be removed immediately. This applies particularly to low seam thicknesses.

If variable-length crawl pans are used, care has to be taken that a safe travel way of adequate width is maintained.

If the height of the travel way is restricted by the use of additional equipment, e.g. for conveyor antitopple devices, care has to be taken that a safe travel way of adequate height is maintained.

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5.3

Requirements Fig. 19:

Minimum dimension for the travel way, schematic diagram

W

If the area behind the front legs is to be used as a travel way, e.g. in cases of thick seams, in the presence of steeply inclined faces or if the shield support can be advanced up to the conveyor, then the travel way must be marked at the ends of a face by a sign. roof support work

Roof support work must be carried out so that the filling cross-section of the face conveyor remains unobstructed. This means that the shield canopies of the shield units must be set against the roof immediately after the shield unit has been lowered and advanced.

work in the mining area

Work in the mining area must not be carried out unless the mining equipment and the face conveyor have first been locked out and secured to prevent restarting. All work in the mining area may only be carried out from a safe position.

The conveyor and the space above the conveyor may only be entered if the roof has been secured against falling rock.

In thick seams, the coal face must also be protected against collapsing in these places. On faces equipped with shield supports, this is best done by using flippers.

Care must be taken that the flippers are always extended towards the coal face far enough to achieve the desired protection. This does not apply during shield unit advancing.

If flippers are not used for the shield units, some other kind of protection must be applied to shield the mining area from the rest of the face. e.g. extra-high spill plates, wire mesh, nets or the like.

Work which has to be performed in the immediate vicinity of the face conveyor at or above the spill plates may also only be carried out after the place of work has been secured against falling rock and coal layers.

With inclined faces, additional barriers, such as air cushions, must be set up above the work area in the conveyor to protect against the following material. The design and amount of required safety equipment depends on the local conditions.

5.4

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

A travel way (minimum dimension, country-specific)

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H

Requirements repair work

Before you start work on the hydraulic system, you must always first make sure that the respective section of the system has been depressurized. Also, take appropriate measures to prevent the pressure from being reactivated by unauthorized personnel.

If the shield units are to be detached from the conveyor, mining must either be completely stopped or it must be otherwise ensured that mining can be continued only outside the safety zone required for safely carrying out repair work.

Parts which are under mechanical or hydraulic pre-tension must be relieved before they can be released or dismantled. The pre-tension can be relieved, for example, by aligning, lifting, or lowering.

If, in exceptional cases, the pre-tension cannot be relieved completely, it must be reduced as far as possible, and the respective part must be secured by suitable means, such as chains or locking elements, so that the tension can be safely absorbed as it is released. All work in this area may only be carried out from a safe position.

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Safety equipment increases safety and may only be removed if it is required for carrying out work. The protective devices should be reinstalled immediately following completion of the work. water spraying system

The water spraying system serves to actively counteract dust. To prevent explosive dust mixtures, the water spraying system must be operated properly at a minimum water pressure (see also chapter 4 “Water spraying system requirements”).

Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily, depending on the operating state of the system, for example, when advancing the shield and when the mining equipment passes the support. The spraying valves are controlled by the program of the electronic shield control system or directly by means of the hydraulic shield control system.

conveyor antitopple device

On inclined faces it may be necessary to anchor the conveyor with respect to the support. You can thus prevent the conveyor from shifting to the side compared to the support. That reduces the risk that the relay bar assembly will get stuck in the base frame.

The intended working pressure must always be applied to the hydraulic conveyor antitopple device. This is the only way to guarantee that there will be sufficient tension between the support and conveyor.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor antitopple device can be damaged and become unfit for use.

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5.5

Requirements Safety requirements automatic mode

Take special care and caution when traveling along a face that is working in automatic mode. Make sure you observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be aware that the shield which you are in is controlled by the automatic system. For this reason, make sure you observe the acoustic and visual warnings from the electronic control unit of the currently controlled shield.

Press the “Support lock-out” switch if you have to be in the shield for a longer period of time.

operating the shield unit

The shield unit must always be operated from a safe position and from a neighboring shield unit.

Never stand in a shield unit which has not been set.

No one may be in a shield unit while it is being advanced.

You may not lower or advance a shield unit if there is any person in the vicinity of the shield unit or in the shield unit.

You may not lower or advance a shield unit manually if the mining equipment is directly in front of or in the range of action of the support.

Advancing should be started from bottom to top in the case of inclined faces. The neighboring control offers the operator in the shield unit above protection and allows the shield unit being pulled up to be monitored.

The legs of the shield units must always be set until the setting pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as an anchor for conveyor antitopple devices.

The supports must be advanced as soon as possible to prevent the potential danger of roof falls.

5.6

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the support is being moved, and prevent any hazards by acting with caution.

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Never allow parts of the body to get between the canopy and the roof, base and the floor, the base and relay bar assembly or between the side seals of neighboring shield units.

Requirements Fig. 20:

W r o n g , support advanced too late, basic illustration

Shield unit with plow

R i g h t , support advanced in time, basic illustration

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 21:

Shield unit with shearer

Shield unit with plow

Shield unit with shearer

When taking down a step in the roof, a shield canopy which is angled downwards must not get in the way of mining equipment passing by.

Before a shield unit can be pulled up, the flipper must be completely folded in. Under no circumstances may the support be advanced against the coal face with the flipper extended. Failure to observe this can lead to serious damage, especially to the flipper cylinders and the flipper suspension.

When advancing the support, make sure that the shield canopy does not get under the side seal of a neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged.

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5.7

Requirements control, hydraulic system

Take care to avoid incorrect operation of the shield control system.

The symbol plates on the control units indicate the functions of the shield control system. They should be legible at all times and may not be removed or damaged.

Hoses must always be able to move freely. They may not be pinched or overstretched. Make sure the hose lines are bundled properly.

Damaged hydraulic hoses and hose connections must be replaced immediately. This work may only be carried out by skilled personnel.

The shield canopy and caving shield must be mechanically secured against falling when replacing hose lines between piloted check valves and legs or other hydraulic cylinders lying in the flow of force, such as stabilizing cylinders or adjusting cylinders. This also applies in the same way to work on the hinges of the shield unit.

damage, spare parts

Special incidents, especially any deficiencies and damage detected, must be reported immediately.

Machine and hydraulic parts may only be replaced with original parts.

5.8

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

To make sure the return lines cannot be clamped shut, safety valves must be installed in the return line (see hydraulic layout, if provided by Caterpillar). If the layout was provided by the operator, we recommend that safety valves are installed at 50 m intervals in the return line. The valves should be set to 25 bar and spray into the atmosphere.

E

Shut-off valves may not be installed in the return lines!

Operation of the shield support Operation of the shield support definition of viewing direction

In the following figure, the sides are defined on a support shield.

If the right or left side is named in the following document, the view toward the coal face is considered to be standard.

Definition of viewing direction, schematic diagram

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Fig. 22:

A looking toward coal face B looking toward gob general

1 right side, face side 2 right side, gob side

Well-trained operating personnel, knowledge of and compliance with the safety regulations, as well as the operating instructions listed below largely prevent dangerous situations from arising, and are good preconditions for the fail-safe interaction of the support and mining within the face system.

If the support is equipped with an electrohydraulic shield control, it is imperative that the operator is familiar with the separate operating manual for this control system.

The shield units must always be set until the setting pressure has been reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as an anchor for anchoring devices.

In general, the supports should be advanced to support the exposed roof surface as quickly as possible.

The shield units must be aligned at right angles to the conveyor.

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5.9

Operation of the shield support shield canopy position

The shield units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible. In the context of the maximum inclination and swivel angles specified on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

Caution!

Never exceed the permissible angle of inclination of the canopy!

Exceeding the permissible angle of inclination of the canopy specified in the “Technical data” section of chapter 6 can lead to the support becoming damaged. This applies in particular to stabilizing cylinders for which the fastening elements and fulcrum points are on the shield canopy and the caving shield.

Fig. 23:

Shield support in normal position

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α=0 M

M = height of the set shield support α = angle of inclination of the canopy

Caution!

Never extend or retract the stabilizing cylinders of the shield support completely!

Stabilizing cylinders must always have sufficient residual stroke!

Indicative value: at least 20 mm!

The same applies to the adjusting cylinder of the front cantilever.

This is the only way that any potential, suddenly occurring load surges can be “cushioned” by the hydraulic safeguard of the stabilizing cylinders.

If there is not sufficient residual stroke available, this could result in serious damage to the support under unfavorable conditions - high force and unfavorable lever ratio.

5.10

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield support Fig. 24:

Shield support with extremely inclined shield canopy

α1

s1

M

s2 α2 Caterpillar Global Mining Europe GmbH, Lünen 2013

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M

M = height of the set shield support α = angle of inclination of the canopy s = residual stroke of the stabilizing cylinder

Caution!

Ensure that the stabilizing cylinder has sufficient residual stroke when there is a tendency of roof falls and/or an extremely soft mine floor.

This is especially true if the shield control system is equipped with an automatic positive setting function. Then there is a danger that under unfavorable conditions, for example a soft floor and possibly an additional tendency of roof falls, the automatic positive setting function could lead to the stabilizing cylinders not having enough residual stroke or that they even are completely extended. For this reason, in such or similar cases, move the support without the automatic positive setting.

Caution!

Keep the canopy from being excessively inclined by filling out the roof falls, for example, or by moving a horizontally positioned shield under smaller roof falls!

At this point, we would again like to explicitly emphasize that any damage caused by not complying with these instructions is not covered by the warranty.

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5.11

Operation of the shield support Caution!

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield), which is specified in chapter 6, section “Technical data”, is exceeded, this could lead to damage to legs, hydraulic cylinders and their fastening elements, as well as to the part hinges.

Since angle changes in the ends of the shield canopies or base ends involve major height changes, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the mine floor and roof, or fill roof falls.

Shield canopies of two-legged shields with stabilizing cylinders may never be set with the tip of the canopy in breakouts (see Fig. 25), when the stabilizing cylinder is completely extended. There must always be enough residual stroke available so that dynamic loads from the roof can be absorbed by the hydraulically secured stabilizing cylinder.

W r o n g : do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended!

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Fig. 25:

WRONG

Roof falls can be overcome by filling them (see Fig. 26) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

Fig. 26:

R i g h t : fill out roof falls

RIGHT

5.12

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield support When underpinning a step in the roof, ensure that a shield canopy angled downwards doesn't get in the way of the mining equipment passing by.

Accumulation on the shield canopy can be avoided by using contact advance while advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy. adjustment range of support/ changing face thickness

The retracted height of the shield units must be suitable for the lowest seam thickness.

The support must be operated so that there is always sufficient residual stroke remaining for lowering the shield unit. Otherwise, the shield unit can get stuck between the roof and floor and be seriously damaged by sudden load peaks, caused by a rock burst, for example. Load peaks cannot be hydraulically cushioned if there is not sufficient hydraulic fluid under the piston of the leg or if it is already in the lower end position.

The minimum residual stroke required for lowering the shield unit can be maintained by:

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keeping the longwall opening at a sufficient height using the mining equipment avoiding the accumulation of debris and fine coal on the floor removing accumulations of rock on the shield canopies.

Before advancing a shield unit, the floor should be free of rough debris so that the entire forward movement can be performed without obstacles and the subsequent advancing operation is not hindered for the conveyor. In addition, aligning operations can be carried out more easily.

If the seam thickness increases considerably and the hydraulic stroke is not sufficient, the legs must be extended in time or replaced by legs with a longer stroke. Only approved parts may be used for this purpose.

When the legs are extended or shortened, the shield canopy must be securely supported. Before a leg can be lowered for the purpose of dismantling, it must be secured against tipping over. operating on inclines

Especially when operating on inclines, the shield units must be prevented from slipping and jamming by correcting their alignment in time using side seals and aligning devices. This prevents a shield canopy from moving under its neighboring unit, often causing considerable damage.

Since, in operations where there are inclines, the shield unit advance usually begins in the lower-lying part of the face, it is important that the gate end shields are well-aligned. Usually, hydraulic end supports, as well as aligning devices are used on the shield canopies and base frames or between the base frames and shield canopies for this.

Automatic controls can be used for the side seals which prevent a lowered shield unit from tipping over during the advancing operation. Other aligning operations which might be necessary are only possible using manual control, however.

The side seal of the caving shield must only be used for aligning with respect to the neighboring shield when that shield has been aligned to the same extent.

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5.13

Operation of the shield support On an inclined face, the conveyor must be anchored with respect to the support. You can thus prevent the conveyor from shifting to the side compared to the support. That reduces the danger of jamming the relay bar assembly in the base frame, which would hinder pulling up and advancing the shield.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor antitopple device can be damaged and become unfit for use. Further information can be found in chapter 6, in the “Accessories” section, or in the operating manual for the conveyor antitopple device. unfavorable mine floor conditions

In the case of unfavorable floor conditions, the base frame of the shield unit can sink into the floor. Then, the base frame must be lifted when the shield is pulled up so that the system follows the course of the seam and does not sink into the floor.

For shield units which are equipped with a special hydraulic lifting device, it is lifted out by actuating a valve, or automatically during advancing.

Shield units with undivided base frames must be lifted and supported using standard mining methods.

Important!

Familiarity with the circuit diagram and skilled personnel are required for both procedures. Make sure that you observe the safety regulations under all circumstances.

5.14

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Individual bases on two-legged shields can usually be lifted hydraulically by actively lowering a leg.

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For shield units without a lifting device, the procedure is different, depending on the design:

Work safety Work safety For the purpose of safe operation, the supports are equipped with a neighboring control. This means the support functions are operated using the control unit on the right or left neighboring support or with the automatic sequential phase control system.

Warning!

Never be on a support which is currently being moved. Circumstances which are not always apparent may lead to unexpected movements in the shield units. This could result in serious injury or even death.

For example, the shield canopy may jerk free during lowering if it was stuck between the canopies of the neighboring shields.

Caution!

Take care not to damage the pilot valve buttons. Sticking buttons might lead to malfunctions and cause an accident.

Observe the following safety regulations:

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Make sure that your body is completely under a set shield. Keep away from shields which are in the process of being moved or which are to be moved soon.

If groups of shields are automatically advanced, no one may be in the area between the operator and the moved shield.

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: malfunction of the electronic control system, external jamming: – shield is wedged in between the neighboring shields; – tip of the canopy is stuck in the roof; – floor step or debris is blocking the base.

2. If the automatic function of the electronic control system is not working properly, the support can be manually controlled using the individual control of the control unit of a neighboring shield. See the separate operating manual for the electronic control system.

3. If the cause is an external obstruction, try to get the shield free by manually moving the neighboring shields.

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5.15

Shield components Shield components Main components Fig. 27:

Segment shield 11

41

21

53 26 31

43 B

A 51

32

52*

View A

1

5, 6

7, 8

View B 85

86

84

61

d

e

f

b

c

a 1 base 2/2x7156/1789 3 relay bar assembly 5 lemniscatic link, front right 6 lemniscatic link, front left 7 lemniscatic link, rear right 8 lemniscatic link, rear left 11 canopy 3x5330-1080-2050 21 side seal, canopy 26 side seal, caving shield

5.16

31 caving shield 32 caving flap 41 leg 43 leg 51 base lifting cylinder 52 shifting ram 53 stabilizing cylinder 84 pin holder 85 rubber covering

86 rubber covering, center a transport rod b electrohydr. control unit, 12-function c electrohydr. control unit, 8-function d water valve unit, 2-function e water valve unit, 4-function f PMC®R control unit * concealed

Shield support 2100/4500-2/2x7156/1789-2050

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3

Shield components Tab. 5: Segment shield 7420 244 000 00 01, mainassemblies Description

01

Base 2/2x7156/1789

7420 244 300 00 01

13 286 Length: 4340 mm

03

Relay bar assembly

7420 244 330 00 01

1610 Length: 4611 mm

05

Lemniscatic link, front right

7420 244 303 00 00

926 Length: 2295 mm

06

Lemniscatic link, front left

7420 244 304 00 00

927 Length: 2295 mm

07

Lemniscatic link, rear right

7420 244 305 00 00

908 Length: 1924 mm

08

Lemniscatic link, rear left

7420 244 306 00 00

908 Length: 1924 mm

11

Canopy 2/2x7156/1789-1080-2050

7420 244 400 00 01

2/11

Flipper

7420 242 470 00 01

1200 Flipper cylinder

8241 521 000 00 00

7420 244 710 00 01

Length: 5292 mm 1657 Side seal cyl. Ø 78

8241 352 000 00 00 8241 352 000 00 00

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21

Side seal, canopy

ID no.

Approx. weight in kg

Item

19 758

Note

Length: approx. 6390 mm + flipper 1292 mm

26

Side seal, caving shield

7420 242 760 00 00

Length: 2668 mm 82 Side seal cyl. Ø 78

31

Caving shield

7420 244 800 00 01

9033 Length: 3020 mm

12

Caving flap

7420 244 851 00 00

656

Length: 1250 mm Width: 1700 mm

41

Hydraulic leg

8250 203 000 00 00

2868

SD-7150-450-1625/3875-BN PRV 520 bar

43

Hydraulic leg

8250 204 000 00 00

576

SD-7190-225-1505/3760-BN PRV 520 bar

51

Base lifting cylinder

8241 516 000 00 00

124 ZE-165/90-300-CR

52

Shifting ram

8241 517 000 00 00

375 ZE-200/125-1080-CR

53

Stabilizing cylinder

8241 522 000 00 00

230 ZE-200/125-540-BN Electrohydraulic control unit, 12-function Electrohydraulic control unit, 8-function Water valve unit Water valve unit Intershield manifold Lines Water spraying system Brackets

61

Hydraulic 4-legged shield

8112 376 000 00 00

81

Information sign

7420 244 000 01 00

0.5

82

Information sign

7420 244 000 02 00

0.6 CSLH 5x120x160

83

Information sign

7420 244 000 03 00

0.9 CSLH 5x120x180

84

Pin holder

7420 242 030 00 00

1.1

85

Rubber covering

7420 242 050 00 00

13.7

86

Rubber covering, center

7420 242 060 00 00

24.3

8154 182 000 00 00 8154 176 000 00 00 8401 008 150 00 00 8401 008 500 00 00 8401 009 150 00 00 8112 376 010 00 00 8112 376 020 00 00 8112 376 030 00 00

1 set no. 1 to 2 CSLH 5x120x160

Important!

More information on the shield components is available in chapter 6 “Technical data”.

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5.17

Overview of shield hydraulics Overview of shield hydraulics HP ball valve versions Caution!

Ensure that the ball valve is engaged at all times.

A ball valve that is not engaged prevents an optimum through-flow. This can damage the ball valve.

2-way ball valve The 2-way ball valve is for shutting off the pressure supply line during maintenance work or repairs.

Installed, blue 2-way ball valves are for shutting off lines conveying water, such as the water supply.

Fig. 28:

2-way ball valve, open and closed

open

Flow for medium enabled

5.18

Flow for medium stopped

Shield support 2100/4500-2/2x7156/1789-2050

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closed

Overview of shield hydraulics 5/3-way ball valve The 5/3-way ball valve has three switching or lever positions.

The 5/3-way ball valve is installed on the intershield manifold and is for shutting off the pressure supply line during maintenance work or repairs.

In the PTO (Power Take Off) lever position, the pressure supply line and the pressure relief are shut off.

Fig. 29:

5/3-way ball valve, with three lever positions

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

ON

2

PTO

1

(Power Take Off)

OFF PTO depressurized (pressure and pressure relief shut off) medium flow stopped

OFF depressurized (pressure relief for output side to the tank) medium flow stopped 1 lever

ON working position (pressure open) medium flow open 2 engagement pin

. Change the lever position by 1. pulling the engagement pin (2), 2. turning the hand lever (1) in the respective position until the lever engages.

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.19

Overview of shield hydraulics Functions of the HP ball valves The following table gives you an overview of the function and use of the HP ball valves installed on the face shield.

The following ball valves are open during normal operation: 45a, 45b, 45c, 45d, 46a, 47, 48, 49 The following ball valves are closed during normal operation: 46b Tab. 6: HP ball valves Designation

45a

red

HP ball valve DN 10

45b

red

HP ball valve DN 10

45c

red

HP ball valve DN 10

45d

red

HP ball valve DN 10

46a

red

HP ball valve DN 12

46b

red

HP ball valve DN 12

47

red

HP ball valve DN 20 with safety locking handle

48

blue

HP ball valve DN 10

49

blue

HP ball valve DN 20

5.20

Function For shutting off the rear leg. Leg is not retracted when lowering. no function For shutting off the piston space of the base lifting cylinder. Base lifting cylinder is not retracted when setting the leg.

For shutting off the annular spaces of the side seal cylinders.

For shutting off the front leg.

Pressure supply during commissioning and for auxiliary devices Closed in normal operation!

For shutting off the two rear legs.

For shutting off the water spraying system.

For shutting off the water spraying system.

Use During maintenance work and repairs on the leg and any removal.

During maintenance and repair work.

Closed during transport, to prevent the side seal from extending in order that the mechanical lock can be fitted, for maintenance and repair work.

During maintenance work and repairs on the leg and any removal.

For moving the shield during commissioning and for connecting hydraulically operated auxiliary devices.

During maintenance and repair work.

Function of the side seal spraying system is deactivated.

Function of the water spraying system is deactivated.

Shield support 2100/4500-2/2x7156/1789-2050

E

Color

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

Operation of the shield hydraulics Operation of the shield hydraulics Warning!

During normal operation, the support may only be moved by means of the control unit of the electrohydraulic neighboring control system. Always observe the instructions in the control unit's separate operating manual.

Arrangement of the hydraulic components The hydraulic components of the segment shield are specified in the following table.

Tab. 7: Hydraulic components Item 01

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

02

Quantity Designation Electrohydraulic control unit, 1 12-function Electrohydraulic control unit, 1 8-function

Arrangement

Remarks

In the center beneath the canopy

On a bracket

On the left beneath the canopy

On a bracket

03

1

Leg CV, NG 20

1x on the front left leg (Z1*)

04

1

Leg CV, NG 20

1x on the front right leg (Z1*)

05 06

1 1

1x behind right leg (Z1) 1x behind right leg (Z1)

07

1

1x in the center, under the canopy

On a bracket

08

2

09

2

Water valve unit, 2-function Water valve unit, 4-function Intershield manifold SSKV 65; 65; 50; 50, 32 Accumulator cartridge DN 20-SS Leg CV, compact, DN 12

With shuttle valve, without compensating valve With shuttle valve and compensating valve On a bracket On a bracket

10

1

Double filter

11

1

Emulsion filter DN 12, 420 bar

12

1

Emulsion filter DN 20-40

15

2

Dual CV DN 10

18

1

CV, hydr. piloted DN 12

19

1

Dual CV

20

1

Shuttle CV DN 20-SSO

21

2

CV DN 10

22

4

CV, NW 25

23

1

PRV DN 10, 80 bar

24

8

PRV DN 10, 380 bar

25 26

4 2

28

2

PRV, 450 bar PRV, 450 bar Rock burst valve DN 40-480 bar

29

2

Plug DN 10 with pressure relief

30

4

Pressure gauge port

1x each on electrohydraulic control unit (1+2) 2x1 each on the front leg (Z1*) In the center under canopy in front of electrohydraulic control unit (1) 1x behind the right leg on the caving shield next to the CV (18) 1x behind the left leg on the caving For water valve unit (6) shield next to the HP ball valve (49) 2x1 each on flipper cylinder (Z7) For flipper cylinders (Z7) 1x on the manifold (11) behind the right leg on the caving shield 1x on the stabilizing cylinder (Z3) For stabilizing cylinder (Z3) 1x on the shifting ram (Z2) behind the base lifting cylinder (Z9) 2x1 each on the rear leg (Z1) In the return line of the legs 4x on the intershield manifold (7) (Z1) Left, under the canopy, next to the In the return line HP ball valve (46b) a) 2x on the shifting ram (Z2) a) For shifting ram (Z2) b) 1x on the manifold (35b) under b) For base lifting cylinder (Z9) the canopy c) 1x on the manifold (35a) c) For side seal cylinder (Z4) d) 2x2 on the flipper cyl. (Z7) d) For flipper cylinder (Z7) 4x1 each on the leg (Z1, Z1*)) In the piston space of the legs 2x on stabilizing cylinder (Z3) 2x1 each on the rear leg (Z1) 2x1 left, under the canopy, on PRV, 80 bar (23) a) 2x1 each on the leg (Z1) b) 2x1 each on the leg (Z1*)

With pressure relief valve

CV = check valve, PRV = pressure relief valve, HP = high pressure

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.21

Operation of the shield hydraulics

15

32

2

33

1

35

4

Glycerine pressure gauge NG 50

Fan plug Screw-in socket DN 10 with throttle 4.0

Manifold

36

1

Manifold

38

2

Through sleeve DN 10

40

1

41

1

42

1

Hose lines Water spraying system accessories Brackets and accessories

45

5

HP ball valve, DN 10, red handle

Arrangement a) 2x1 on the rear right and left legs (Z1) b) 1x1 on the leg, CV (3) on the rear right leg (Z1) c) 2x1 each on the front leg (Z1*) d) 2x1 on the double filter (10) e) 1x on electrohydraulic control unit (1) f) 1x on electrohydraulic control unit (2) g) 1x1 on the manifold (35b) h) 2x1 on the emulsion filter (12) k) 2x1 on the emulsion filter (11) l) 1x1 on the manifold (35c) 2x1 each on water valve unit

3

HP ball valve, DN 12, red handle

47

2

48

1

HP ball valve DN 20-SS, with safety locking handle HP ball valve DN 10, blue handle

49

1

HP ball valve DN 20, blue handle

50

1

Through sleeve DN 20/DN 12

51

12

Measuring coupling SMK20

52 Z1 Z1* Z2 Z4a Z4b Z7 Z9 S1

1 2 2 1 2 2 2 1 2

Diffuser Leg Leg Shifting ram Side seal cylinder Side seal cylinder Flipper cylinder Base lifting cylinder Pressure sensor

5.22

b) For HP-Set c) For front leg (Z1*) d) e) f) g) h) For water valve unit (6) k) For HP-Set l)

On shuttle CV DN 20-SSO (20) a) 2x1 right, under caving shield, behind rear right leg b) 1x1 right, under the canopy, in front of the front right leg (Z1*) c) 1x1 right, under the canopy, in front of the front right leg (Z1*) 1x on the rear left leg (Z1) a) Right, under the canopy, in front of the manifold (35c) b) Left, under the flap, behind the visual lamp

a) For side seal cylinder (Z4) b) For base lifting cylinder (Z9) c) For side seal cylinder (Z4)

For shutting off the water spraying Subassembly Subassembly

a) 2x1 on the rear right and left legs (Z1) b) 1x on the rear right leg (Z1) c) 1x1 each on the manifold (35b) d) 1x1 each on the manifold (35c) a) 2x1 each on the front leg (Z1*)

46

Remarks a)

b) Left, under the canopy, on the through sleeve (50) and PRV (23) 2x1 each on the rear leg (Z1) 1x on water valve unit (6) via electrohydr. control unit (1) 1x on the emulsion filter (12) behind the left leg on the caving shield 1x left, under the canopy, next to the HP ball valve (46b) a) 1x1 on manifold (35b) b) 1x on shifting ram (Z2) c) 1x on the rear left leg d) 2x2 each on the flipper cylinder (Z7) f) 1x on the double filter (10) g) 2x1 on the stabilizing cylinder (Z3) h) 1x on the CV (18) k) 1x1 on manifold (35c) On the right beneath the canopy 2x rear 2x front Centered in the base 2x for canopy 2x for caving shield Canopy-flipper Base (relay bar assembly) On each leg (Z1)

Subassembly a) Pressure relief of piston space of the rear leg b) ) c) For base lifting cylinder (Z9) d) For side seal cylinder (Z4) a) Pressure relief of piston space of the front leg b) For auxiliary supply Interrupts the main pressure line to the shield For shutting off the water spraying For shutting off the water spraying

For the connection of measurement devices

Shield support 2100/4500-2/2x7156/1789-2050

E

31

Quantity Designation

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

Operation of the shield hydraulics Shield hydraulics Fig. 30:

Shield hydraulics, arrangement Image caption: see table 7 View A

12

31h

View B A

32

19

49

51g(2x)

B

24c

26

35a (2x)

2 Caterpillar Global Mining Europe GmbH, Lünen 2013

E

48 B 7

1 31d

51f

6

5

40 View C

10 31d

45c

24b 51a

31g

45d

38a 31l

C D

35c

35b 15

41

51k

View D 23

24d(2x)

24d(2x)

51d(2x)

51d(2x)

46b

50

29 (2x)

Doc. No.: 7420 244 000 BA 00

VESP / 01

38b

5.23

Operation of the shield hydraulics Fig. 31:

Shield hydraulics, arrangement Image caption: see table 7

52

A

View A 11

31k (2x)

22

8

31f Caterpillar Global Mining Europe GmbH, Lünen 2013

E

8

31e

22

18

51h

5.24

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield hydraulics Fig. 32:

Shield hydraulics, arrangement Image caption: see table 7

View A

31c A 25 B C

E

9

Caterpillar Global Mining Europe GmbH, Lünen 2013

46a E D

View C View B 31a

9 30a 25 4

31c 30b

45b

28

46a

45a

47 25 21

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.25

Operation of the shield hydraulics Fig. 33:

Shield hydraulics, arrangement Image caption: see table 7 View D 36

31a

31b

30a

51c 3 28

47 51b

25

21

View E

33

20

5.26

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

24a

E

45a

Operation of the shield hydraulics Functions of the electrohydraulic control unit, 12-function, symbol plate

SP

Fig. 34:

8

1

T P

2 2 3 X2 1 X1

4

2 X2 3

5 X3

4 6

X4 5 X5 6

7 X6

7 8

X7

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

8 X8

9

9 X9 10

10

X10 11 X11

11

12 X12

12

12 functions

1

3

2

4

5

7

9

11

6

8

10

12

Tab. 8: Electrohydraulic control unit with 12 functions, assignment of functions Function, designation

Doc. No.: 7420 244 000 BA 00

Function no.

Advance shield

1

Set leg

2

Push conveyor

3

---------

4

Positioning the canopy tip

5

Extend adjusting cylinder

6

Extend side seal cylinder

7

Retract side seal cylinder

8

---------

9

---------

10

Extend base lifting cylinder

11

Retract leg

12

VESP / 01

5.27

Operation of the shield hydraulics Fig. 35:

Functions of the electrohydraulic control unit, 8-function, symbol plate

SP

8

T

1

P 2

3 1 X1

4

2 X2 3

5 X3

X4 5 X5 6

7 X6

7 8

X7 8 X8

8 functions 1

3

5

7

2

4

6

8

Tab. 9: Electrohydraulic control unit with 8 functions, assignment of functions Function, designation

5.28

Function no.

---------

1

---------

2

---------

3

---------

4

Set high pressure

5

---------

6

---------

7

---------

8

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

6

E

4

Operation of the shield hydraulics Fig. 36:

Functions of the water valve units, 2-function and 4-function, symbol plate 2-function

4-function

W2

W6

W1 W5

5 breather W4

32

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

W3

6 breather

32 2 + 4 functions W3

W5

W1 W2 W4

W6

Tab. 10: Water valve unit with 2+4 functions, assignment of the functions Function, designation

Doc. No.: 7420 244 000 BA 00

Function no.

Lemniscatic link spraying system

W1

Base spraying system

W2

Rear conveyor spraying system

W3

Shearer pathway water spraying system

W4

Canopy tip spraying system

W5

Left side seal spraying system

W6

VESP / 01

5.29

Operation of the shield hydraulics

canopy tip spray

380 bar

380 bar

15

Z7

Z7 Z1* si

si

leg

water curtain

Z1*

15

leg

Shield hydraulics Image caption: see table 7

flipper cyl.

Fig. 37:

380 bar

380 bar

25

25 38 Pi 46a

30b

31c

450 bar

46a

450 bar

31c 30b

29

50

PTO

x x

46b

80 bar

41

pontoon wash spray

23 HP = DN 32 SSKV-HD W = DN 50 SSKV-ND R = DN 63 SSKV-ND R = DN 63 SSKV-ND P = DN 50 SSKV-HD

48

10 52

12 8 1

X1

2

4

X3

3

5

6

7

8

9

10

11

12

3

4

5

6

7

8

SP

SP

8 X5

X7

X9

X11

X1

X3

X5

X7

X2

X2

X4

X6

X8

X10

X12

X2

X4

X6

X8

1 2

T P

2

1 2

35b

21

31a 30a 47 21

Z9

450 bar

A 480 bar

18

leg

31a

P/R

PXPA 4mm

20 Z2

520 bar

26

450 bar 450 bar

rear conveyor spray

4 28

480 bar

33 520 bar

Z3 Z1

100 bar

A

380 bar

leg

36

PA PB AA

A

lemniscate linkage wash spray

A A AR

380 bar

i s

28

A

stab. cyl.

A A AR PA PB

D.A.ram cyl.

i p

3

i p

450 bar

Z4b

45b

45a

Z1

19

lemniscate linkage wash spray

45a

25

45c

Z200 bar

380 bar

lift cyl.

47

25 30a

31b

5.30

3 4

31g

45 380 bar

Z4b

5 6

side seal cyl.

Z4a

7 8

35

9 10

11 12

Z9

T P

1 2

3 4

5 6

7 8

Z4a

rear conveyor spray

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

5/3 way

7

backflush-filter

breather

10

1

W6

2

W5

W4

breather

49

11 22 W3

W2

W1

side shield spray

P

HP

32

Z4a

E

32 6

5

Operation of the shield hydraulics Hydraulic line diagram Image caption: see table 7 24d 51d 24d

24d 51d 24d

Z7

1*

DN10

DN10

DN10

DN10 NIRO

DN25

2

DN10

32

5 32

DN10

6 48

DN10 NIRO DN10 NIRO

Z4a

DN10 NIRO

DN20

22

P W W1W2

7

W2 P W W1 W3 W4

22

DN10 DN10 NIRO

20

31f

DN10 DN20 DN10 DN25

22

DN12

DN63 SSKV-ND DN32 SSKV DN50 SSKV-ND NIRO DN50 SSKV-HD DN63 SSKV-ND

K

22

33

DN10 DN25SS

DN12

DN10 DN25

DN10 DN20SS

31k 11 DN25

DN10 31k

DN10 NIRO

DN25

18

DN10

47 21 S1

DN10 DN10

DN12

DN12 DN25SS DN12

DN25

DN10

DN10 NIRO DN10 NIRO DN10 NIRO DN10 NIRO

45b

8 31e

26 51g

19 DN10

DN10 NIRO

35a

35a

R

Z3

52

K

DN10 NIRO DN10 NIRO DN20 NIRO DN20 NIRO DN20 NIRO

51g

DN10 NIRO

SP

30a

DN20SS

DN20SS

1

8

4 45a 28 25

DN10 DN12 DN20SS

a

51h

DN10

DN25SS

Z2

46b

DN20SS

DN20SS

DN10 DN25SS

DN10 NIRO DN10 NIRO DN12 DN12

DN20SS

DN10 DN10 DN10 DN10 DN20 DN12

DN10

21

DN10 NIRO

Z4b

Z4b

R K

VESP / 01

DN10 DN10

K

1* hose lines 2* plug-in parts a whip chek x rear side, leg

Doc. No.: 7420 244 000 BA 00

R

49

DN10

12 31h

DN10

24c

DN10 NIRO

E

DN10 DN10

23

31a

R

Caterpillar Global Mining Europe GmbH, Lünen 2013

S1

Z1

DN10

47 25

28

Z4a

24a

29

50

31a 30a

R

DN10

DN10

K

3

51b 24a

38a

46a

K

K

38b

31c

24b 45d 51k 31l 51a

a

51f R

31b

45a

DN10 NIRO DN10 NIRO

Z9

9

R

DN10 NIRO DN10 NIRO

a

30b

35b 31g 35c

45c

31d

Z1

36

DN10

DN10

DN10

10

31d

9

25

DN10 DN12

DN12 DN10

46a

51

DN10 NIRO

DN10 DN10

K

R

31c

Z1*

2*

30b 25

DN10 DN10

15

R K

K

Z1*

15

R

DN10 NIRO

Z7

DN10

Fig. 38:

5.31

Operation of the shield hydraulics Water spraying accessories 6, 10

DN10 DN10

DN10 DN10

Z1*

DN10 NIRO DN10 NIRO

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

DN10

DN10

DN10

DN10 NIRO DN10 NIRO DN10 NIRO DN10 NIRO

DN25SS

DN10 NIRO

DN25

DN10 NIRO K

Z4b

DN10

DN10 DN20 DN10 DN25

DN10 DN10

DN10 DN10 DN10 NIRO

DN10 NIRO

2, 12 R

Z3 DN10 NIRO

DN10 NIRO DN10 NIRO DN20 NIRO DN20 NIRO DN20 NIRO

DN10

2, 12

Z4a

DN10

DN10 DN20SS DN10 DN25SS

DN25 DN20

P W W1W2

DN10 DN10 NIRO DN10 NIRO

K

DN63 SSKV-ND DN32 SSKV DN50 SSKV-ND NIRO DN50 SSKV-HD DN63 SSKV-ND

W2 P W W1 W3 W4

DN10 DN25

7, 11

R

DN12

7, 11

DN10 NIRO

DN12

DN20SS

DN12 DN25SS DN12

DN20SS

DN20SS

DN25 DN10

SP

7, 11

DN10 DN12 DN20SS

1

DN10 NIRO

DN10

DN10 DN25SS DN10 NIRO DN10 NIRO DN12 DN12

DN20SS

DN10 DN10 DN10 DN10 DN20 DN12

DN10 DN10

Z2

DN25

DN10 NIRO

Z1

R

DN10

K

DN20SS

R

DN10 DN10 R

7, 11

K

3, 11 (2x) 3, 11 (2x) 1, 4 spray manifold 8 spray manifold 90° 2, 3 nozzle head 10 nozzle, cpl.

5, 6 spray manifold 11 ball valve Z4b 7 water spraying fitting DN 10-G1/4A 12 ball valve

K

7, 11

5.32

K

K

R

DN10

Z4a DN10

Z9

4, 10

R

DN10 NIRO DN10 NIRO

DN10

DN10

5, 10

Z1

DN10

DN10

DN10 DN12

DN12 DN10

DN10

DN10 NIRO

K

R

DN10

R K

K

R

Z1*

4, 10

DN10 NIRO

4, 10

8, 10

6, 10

Z7

Z7

DN10

Fig. 39:

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield hydraulics Fig. 40:

Shield hydraulics, brackets and accessories

6

46

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

28

39

22

38

52 33

31

4 bracket, electrohydraulic control unit, 6-function 24 12 25 24 1 3 24

29

2

4

30 9

34

34 19

37 54

53 49

20

21

41

5

44

44

Doc. No.: 7420 244 000 BA 00

1 bracket, electrohydraulic control unit, 12-function 2 bracket, intershield manifold 3 bracket for PMC®-R, long

VESP / 01

5 clip for hose holder 6 support for water spraying block 9 bracket, electrohydraulic control unit, 10-function 12 bracket, backflush filter 19 hose guide and visual lamp holder 20 hose holder 21 hose holder 22 bracket, visual lamp, front 24 hose cover, PTO 25 cover, filter 28 staple clip, flipper cylinder 29 strain relief 30 strain relief 31 bracket 33 bracket, PTO 34 support for nozzle head 37 bracket 38 bracket 39 bracket 41 hose guide, caving shield 44 support for nozzle head 46 spray manifold fastening 49 information sign 52 anti-twist device for socket with retaining bolt 53 hose holder 54 hose holder

5.33

Operation of the shield hydraulics Fig. 41:

Shield hydraulics, brackets and accessories A

B

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

View A

View B 47

27 56

10

11

46

10 hose guide, right 11 hose guide, left 27 hand grip for leg

5.34

46 spray manifold fastening 47 support for nozzle head 56 symbol plate

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield hydraulics Fig. 42:

Shield hydraulics, brackets and accessories

48

48 8

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

26

7

43 35 40

42

45

15 26

7 cover, left 8 cover, right 15 bracket 26 hose guide 35 bracket, manifold, 4-function

Doc. No.: 7420 244 000 BA 00

VESP / 01

40 bracket 42 hose guide, base, left 43 hose guide, base, right 45 fastener, leg valve NG 20 48 fastener, leg, CV NG1

5.35

Operation of the shield hydraulics Bracket for control units and water valves The two electrohydraulic control units and the water valve units are fastened in brackets below the canopy.

Fig. 43:

Bracket for control unit, 12-function, dimensions (439) (434)

Fig. 44:

70

Bracket for control units, items

12 11 10

4

15

B

2 7 5

3

a 10

13, 14 6 1 bracket 2 staple securing device 3 holding plate, symbol plate, 12-function 4 staple securing device 5 staple locking plate

5.36

6 symbol plate, 12-function 7 fastener, solenoid driver module 10 hex. head screw M 10x20-A 2-7 11 flat head screw M 12x50-A 2-70 12 hex. nut M 12-A 4-80

13 hex. head screw M 6x20-A 2-70 14 hex. nut M 6-A 4-80 15 hex. head screw M 10x30-A 2-70 a electrohydr. control unit, 12-function b information sign

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

Operation of the shield hydraulics Fig. 45:

Bracket for control unit, 10-function, dimensions A

View A

Fig. 46:

(190)

(82)

(361)

Bracket for control unit, items 1

E

5

Caterpillar Global Mining Europe GmbH, Lünen 2013

10 2, 3 9 4 11 b

8

7 a

4 14, 15

13 1 bracket 2 hex. head screw M 12x50-A 4-80 3 hex. nut M 12-1.4571 4 hex. head screw M 10x20-A 2-7 5 fastener, solenoid driver module

7 locking plate for staple 8 locking plate for staple 9 coupling staple clip 10 hex. head screw M 10x35-A 2-70 11 bracket, symbol plate, 8-function

Doc. No.: 7420 244 000 BA 00

VESP / 01

13 symbol plate, 8-function 14 hex. head screw M 6x16-A 2-70 15 hex. nut M 6-A 4-80 a electrohydr. control unit, 8-function b information sign

5.37

Operation of the shield hydraulics Fig. 47:

Bracket for water valve units, dimensions A

View A

(70)

(70)

(300)

Fig. 48:

Bracket for water valve units, items

5, 6

4

a 4

b 2

7, 8 3 c 1 bracket 2 bracket, symbol plate 3 symbol plate 4 hex. head screw M 10x20-A 2-7 5 hex. head screw M 12x50-A 4-80 6 hex. nut M 12-1.4571

5.38

7 hex. head screw M 6x16-A 2-70 8 hex. nut M 6-A 4-80 a water valve unit, 2-function b water valve unit, 4-function c information sign

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

Operation of the shield hydraulics Bracket for PMC®R The PMC®R is fastened on a bracket.

Bracket for PMC®R, dimensions

(669)

Fig. 49:

(519)

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

(511)

Fig. 50:

Bracket for PMC®R, items 9, 11

1 2 3

View A

8, 11 10, 11 5

4

A 6

a

Doc. No.: 7420 244 000 BA 00

1 support I 2 support II 3 support III 4 support IV 5 plate 6 tube 25x5 32 lg.

VESP / 01

8 hex. head screw M 12x30-A 2-70 9 flat head screw M 12x50-A 2-70 10 cyl. head screw M 12x110-A 2-70 11 hex. nut M 12-A 4-80 a PMC®R

5.39

Operation of the shield hydraulics Bracket for intershield manifold The intershield manifold is fastened in a bracket below the canopy.

Bracket for intershield manifold, dimensions

496 Fig. 52:

Bracket for intershield manifold, items 4

2

a

3

1 bracket 2 pin 30/25x60 3 spring clip 3.2

5.40

1

4 hex. head screw M 16x45-A 4-80 a load ring load capacity 3000 kg

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

460 (400)

150

Fig. 51:

Operation of the shield hydraulics Connecting the brackets The brackets for the two electrohydraulic control units and the water valve units are arranged below the canopy.

The bracket of the PMC®R is located between the brackets for the control units and the bracket of the intershield manifold.

Fig. 53:

Overview at side of the brackets for control units, PMC®R and intershield manifold 1

2

9

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

3

1 bracket, electrohydraulic control unit, 12-function 2 bracket for intershield manifold Fig. 54:

3 bracket for PMC®R, long 9 bracket for electrohydraulic control unit, 10-function

Overview of the brackets for control units, PMC®R and intershield manifold 6 b

5

2 7 1

a

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1 electrohydraulic control unit, 12-function 2 electrohydraulic control unit, 8-function 5 water valve unit, 2-function

VESP / 01

6 water valve unit, 4-function 7 intershield manifold a PMC®R, long b bracket for electrohydraulic control unit, 6-function

5.41

Operation of the shield hydraulics Control units The segment shield is equipped with the following control units: intershield manifold electrohydraulic control unit, 12-function electrohydraulic control unit, 8-function water valve unit, 2-function water valve unit, 4-function PMC®-R control unit.

Control units on the shield

E

Fig. 55:

Caterpillar Global Mining Europe GmbH, Lünen 2013

10

1

6

5 2 a 7

1 electrohydr. control unit, 12-function 2 electrohydr. control unit, 8-function 5 water valve unit, 2-function 6 water valve unit, 4-function

5.42

7 intershield manifold SSKV 10 double filter a PMC®-R control unit

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield hydraulics Intershield manifold Fig. 56:

View of the intershield manifold, left

31k

a 7

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

5 6

5 water valve unit, 2-function 6 water valve unit, 4-function 7 intershield manifold SSKV Fig. 57:

31k pressure gauge a 5/3-way ball valve DN25-PN350/DN10-PN500

View of the intershield manifold, right

22 11

6

48

31k

26 Z3

7

6 water valve unit, 4-function 7 intershield manifold SSKV 11 emulsion filter DN 12 22 CV NW 25 26 PRV 450 bar

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a

31k pressure gauge 48 HP ball valve DN 10 a 5/3-way ball valve DN25-PN350/DN10-PN500 Z3 stabilizing cylinder

5.43

Operation of the shield hydraulics Fig. 58:

View above the intershield manifold

5

6

48 12 49

E

26

7

5 water valve unit, 2-function 6 water valve unit, 4-function 7 intershield manifold SSKV 12 emulsion filter DN 20 26 PRV 450 bar

31h pressure gauge NG 50 48 HP ball valve DN 10 49 HP ball valve DN 20 Z3 stabilizing cylinder

Emulsion filters Fig. 59:

View under the canopy behind the rear right leg 24c

49

35a

12

12 emulsion filter DN 20 24c PRV DN 10 380 bar 31h pressure gauge NG 50

5.44

31h

35a manifold 49 HP ball valve DN 20

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Z3

31h

Operation of the shield hydraulics Manifold Fig. 60:

View under the canopy behind the rear right leg

24b

38a 51a

51k

31g

31l

45c

45d

35c

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

35b

24b PRV DN 10 380 bar 31g pressure gauge NG 50

38a through sleeve DN 10 45c HP ball valve DN 10

31l pressure gauge NG 50 35b manifold 35c manifold

45d HP ball valve DN 10 51a measuring coupling SMK20 51k measuring coupling SMK20

PMC®-R control unit PMC®-R control unit

Fig. 61:

d

b

c

a

a PMC®-R control unit b EMERGENCY STOP switch

Doc. No.: 7420 244 000 BA 00

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c support lock-out switch d bracket

5.45

Operation of the shield hydraulics Electrohydraulic control units Fig. 62:

Electrohydr. control units, 12-function, side b 31d

31e

1

E

a

1 electrohydr. control unit, 12-function 31d pressure gauge

Caterpillar Global Mining Europe GmbH, Lünen 2013

c

a symbol bar b solenoid driver module c bracket, PMC®-R control unit

31e pressure gauge

Water valves Fig. 63:

Water valves, front

6 5

a

48 5 water valve unit, 2-function 6 water valve unit, 4-function

5.46

48 HP ball valve DN 10 a symbol bar

Shield support 2100/4500-2/2x7156/1789-2050

Operation of the shield hydraulics Flipper Fig. 64:

Flipper, extended a b

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z7

Z7

Z7 flipper cylinder

Fig. 65:

a canopy b flipper

Flipper, retracted a

b a canopy

Doc. No.: 7420 244 000 BA 00

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b flipper

5.47

Operation of the shield hydraulics Flipper cylinder Fig. 66:

Flipper cylinder

b

Z7

a

24d

51d

51d

24d

15

15 dual CV DN 10 24d PRV 380 bar 51d measuring coupling SMK20

5.48

Z7 flipper cylinder a canopy b flipper

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z7

Operation of the shield hydraulics Leg The hydraulic components mounted on the gob side: of the two rear legs are not identical; of the two front legs are identical.

Fig. 67:

Leg, towards coal face

Z1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z1

Z1*

Z1 leg, rear

Doc. No.: 7420 244 000 BA 00

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Z1* leg, front

5.49

Operation of the shield hydraulics Fig. 68:

Rear leg Rear left leg

Rear right leg a

a 31b 51c

30a 31a 31a

45a

30a c 4 3 45b 28 45a

28 47 b

25 25

21 b

3 leg CV DG 20 4 leg CV DN 20 21 CV DN 10 25 PRV, 450 bar 28 rock burst valve 30a pressure gauge port 31a pressure gauge 31b pressure gauge

5.50

21

45a HP ball valve DN 10 45b HP ball valve DN 10 47 HP ball valve DN 20-SS 51c measuring coupling SMK20 a PRV, 520 bar b sensor c compensating valve

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

47

Operation of the shield hydraulics Fig. 69:

Front leg, left

31c 31c

30b

25 9

9

E

46a Caterpillar Global Mining Europe GmbH, Lünen 2013

b

9 leg CV DN 12 25 PRV, 450 bar 30b pressure gauge port

Doc. No.: 7420 244 000 BA 00

VESP / 01

31c pressure gauge 46a HP ball valve DN 12 b sensor

5.51

Operation of the shield hydraulics Plug with pressure relief Via a pressure relief valve, the enclosed pressure can be relieved by screwing in the vented cap screw.

After releasing the pressure, this screw must be screwed all the way out again.

Fig. 70:

Plug DN 10 with pressure relief

To open pressure relief: Screw in screw.

To close pressure relief: Screw out screw.

b

a hex. head screw M 6x16-A 2-70

b sealing ring

Important!

Regularly check the sealing ring (b) to see if it has become porous. For safety, cover the ring with a rag to prevent hydraulic fluid from spraying out.

The shield is equipped with two plugs DN 10 with vented cap screw.

The plugs (29) positioned on a through sleeve with pressure relief are used to relieve any potential pressure in the return line. This can be necessary, e.g. when the supply line connections have been closed off for transport and increased pressure has built up in the return line during installation.

5.52

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

Operation of the shield hydraulics Fig. 71:

View of the through sleeve 23 29

29

50 46b

E

23 PRV, 80 bar 46 HP ball valve DN 12

29 plug DN 10 with pressure relief 50 through sleeve

Caterpillar Global Mining Europe GmbH, Lünen 2013

Measuring coupling for pressure relief The measuring coupling (SMK20) is used to monitor and check the pressure in the system. The measuring couplings are, for example, installed on cylinders and legs.

The pressure can be read and the system relieved of pressure by connecting measurement and test devices.

Fig. 72:

Measuring coupling for pressure relief 3

2

1 1 leg or cylinder connection 2 measurement device connection for pressure relief

Doc. No.: 7420 244 000 BA 00

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3 protective cap

5.53

Operation of the shield hydraulics Repair and emergency operation This section contains information on the functions and operation of the hydraulic control system, which may only be used in exceptional cases such as for repair and emergencies.

In the following, it is assumed that the shield has already been correctly installed. It is also assumed that all shut-off valves are open as during normal operation.

Operation of the control unit of the electronic control system is not described here, but in a separate operating manual for the control unit.

The fundamental design of the shield unit and the shield control system is shown in chapter 6 “Technical data”, “Description” section of this manual.

Fig. 73 shows the arrangement of the PMC®-R control unit and the electrohydraulic control unit on the support.

The operation of the PMC®-R control unit is not described in this operating manual. For information on this, please refer to the separate operating manual for the PMC®-R control unit.

5.54

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special operating manuals of the mining company. During normal operation they should not be used.

Otherwise, dangerous situations could arise which could result in very serious injury or death.

The shield support is operated in normal operation by means of the electronic control system only. It is imperative that you observe the instructions in the control unit's separate operating manual.

E

Furthermore, it is assumed that the reader is familiar with the fundamental principles of the hydraulic shield support and the operation of the control unit.

Operation of the shield hydraulics The symbol plate is located above the pilot valves on the electrohydraulic control unit. The symbols correspond to the various functions which are initiated by actuating the respective button. The meaning of the symbols and functions are described below.

Fig. 73:

Control units on the shield

1

6

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

5

a

2

7

1 electrohydr. control unit, 12-function 2 electrohydr. control unit, 8-function

6 water valve unit, 4-function 7 intershield manifold SSKV

5 water valve unit, 2-function

a PMC®-R control unit

Important!

Note that - depending on the marking on the connecting cable the end with the shorter distance is to be connected to the pilot valve. See also the separate operating instructions for the control unit.

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5.55

Operation of the shield hydraulics Operation and functions of the electrohydraulic control unit This section provides information on the functions of the electrohydraulic control unit. Always observe the instructions contained in the operating manuals of the electrohydraulic control unit and the electronic control system.

Warning!

You are only allowed to operate the controls of the electrohydraulic control unit when you know exactly what effects the functions have with respect to the shield support. You must therefore have attended a special training course to this purpose. Otherwise, there is a risk of operating errors. This could result in serious injury and even fatal accidents.

There are two pushbuttons on the cover of each individual pilot valve. When you press a button, the corresponding working valve is activated immediately.

The function stops as soon as you release the button.

Danger!

Jammed or locked buttons can cause uncontrolled movements of the shield. This could seriously injure or kill you.

For this reason, never lock the buttons and ensure that damaged pilot valves are replaced immediately.

Warning!

Manual actuation of a button on one of the pilot valves initiates the direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order.

5.56

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

While actuating the shield using repair mode, no other persons may stand in the shield's area of movement.

E

Controlling the shields during repair operation is especially dangerous since you are then operating the shield directly and immediately under which you are standing. It is therefore extremely important that you know and understand the relationships between the functions and movements of the shield.

Operation of the shield hydraulics Shield functions Functions of the control unit, 12-function Fig. 74:

Symbol plate for electrohydraulic control unit, 12-function, symbol plate

1

3

2

4

1

5

7

9

11

6

8

10

12

Advance shield Function 12 “Retract leg” needs to have been performed before this function can be performed.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

2

Set leg Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

The baselift cylinder is actively retracted during the performance of this function.

3

Move conveyor Before executing this function, ensure that the shield unit is completely set.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

4

----------

5

Positioning the canopy tip - extend front leg The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

After the canopy has been correctly aligned, the legs must be reset.

Caution!

Do not exceed the permissible inclination!

Do not go below the value for the minimum residual stroke!

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.57

Operation of the shield hydraulics 6

Lowering the canopy tip - retract front leg Before executing this function, it must be made sure that the neighboring shields are completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached.

After the canopy has been correctly aligned, the legs must be reset.

Caution!

Do not exceed the permissible inclination!

Do not go below the value for the minimum residual stroke!

The function is for aligning the shield unit opposite the neighboring support.

The side seal cylinders are only extended as long as the button is pressed or until the end position is reached.

In the idle state, the side seal is always pressed outward by the force of the compression springs.

8

Retract side seal cylinder Before executing this function, the function “retract legs” must have been carried out for both legs with the side seal in place.

The side seal cylinders are only retracted as long as the button is pressed or until the end position is reached.

In the idle state, the side seal is always pressed outward by the force of the compression springs.

9

----------

10

----------

11

Extend base lifting cylinder The legs of the shield unit must be actively released before this function is executed.

The function is executed as long as the button is pressed or until the end position is reached.

The base lifting cylinder cannot retract automatically, e.g. in the event of a pressure drop, because the supply line to the piston space is blocked by a piloted check valve.

12

Lower leg Before executing this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

5.58

Shield support 2100/4500-2/2x7156/1789-2050

E

Extend side seal cylinder

Caterpillar Global Mining Europe GmbH, Lünen 2013

7

Operation of the shield hydraulics Functions of the control unit, 8-function Fig. 75:

Symbol plate for electrohydraulic control unit, 8-function, symbol plate

1

3

2

4

----------

2

----------

3

----------

4

----------

7

6

8

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

5

5

Set high pressure Before this function is actuated, the shield canopy must be correctly aligned.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

6

----------

7

----------

8

----------

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.59

Operation of the shield hydraulics Functions of the water valve units Fig. 76:

Symbol plate for water valve unit, symbol plate W3

W5

W1 W2 W4

W1

W6

Lemniscatic link spraying system The spraying valve on the lemniscatic link is opened by pressing the button. It is locked in idle status.

The function is executed as long as the button remains pressed.

Pressing the button causes the spraying valve on the base to open.

It is locked in idle status.

The function is executed as long as the button remains pressed.

W3

Rear conveyor spraying system The spraying valve on the rear conveyor is opened by pressing the button. It is locked in idle status.

The function is executed as long as the button remains pressed.

W4

Shearer pathway water spraying system The spraying valve on the caving shield is opened by pressing the button. It is locked in idle status.

The function is executed as long as the button remains pressed.

W5

Canopy tip spraying system The spraying valve on the canopy tip is opened by pressing the button. It is locked in idle status.

The function is executed as long as the button remains pressed.

W6

Side seal spraying system, left The spraying valve on the left side seal is opened by pressing the button. It is locked in idle status.

The function is executed as long as the button remains pressed.

5.60

Shield support 2100/4500-2/2x7156/1789-2050

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Base spraying system

Caterpillar Global Mining Europe GmbH, Lünen 2013

W2

Operation of the shield hydraulics Operation of the double backflush filter Warning!

Do not put the filter into operation before making sure that all connections have been properly established. normal operation

The filter is in normal operation when both levers are parallel. It must be backflushed when the contamination of the filter elements leads to reduced flow or pressure loss.

backflushing

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid), the frequency of backflushing must be specified individually. We recommend backflushing both filters regularly once a shift.

Warning!

Never put both levers into the backflush position simultaneously. Always backflush one filter element at a time. Otherwise, the flow of the emulsion can be completely interrupted and the filter elements will not be backflushed.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Only one filter element may be backflushed at a time. For this, simply turn one of the levers by 90° and after about 2 seconds, put it in its original position. Then repeat the procedure with the other lever.

Note that a volume flow of at least 70 l/min is required.

Fig. 77: Operating the double filter

A normal operation: both levers in position “A” B backflushing: one of the levers in position “B”

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VESP / 01

5.61

Maintenance Maintenance Warning!

If operational safety is endangered, damaged components must be replaced immediately. If this is not possible, you must immediately shut down the shield and secure it. Immediately notify the entire face crew and your superiors. electronic control system

Refer to the separate operating manual for the PMC®-R control unit.

hydraulic control system

Special measures

filter cartridges

The filter cartridges on the intershield manifold and on the electrohydraulic control unit of the shield control system protect the downstream hydraulic components from damage caused by contaminants in the hydraulic medium. They only have to be regularly replaced if the filtering system of the face supply unit is inadequate.

Therefore, it is very important to ensure the required hydraulic medium quality!

If problems occur during preparation of the medium, there will be an increased risk of malfunctions due to clogged filters.

replacing filters

The intervals between mandatory filter replacements depend on the degree of contamination in the water and/or of the emulsion (HFA fluid) used and must therefore be determined on a case-by-case basis. Clogged filters may be the reason that functions start to slow down or even reach a point where they can no longer be carried out.

Our recommendation:

emulsion filters piston rods

5.62

Replace the emulsion filters directly.

On all shields which are equipped with a water spraying system, the piston rods of cylinders that are usually only rarely extended and retracted completely, for example legs and stabilizing cylinders, must be thoroughly cleaned every 6 months and then treated with a suitable preservative.

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

After working on a hydraulic system, you can assume that dirt has penetrated the hydraulic system. Depending on the degree of contamination, this can clog the filters in the system. As a result, functions are slowed down, performed incorrectly, or not performed at all.

E

Caution!

Filter cartridges on electrohydraulic shield control systems must be replaced immediately after commissioning or restart (e.g. after changing to another face or working on the hydraulic system).

Maintenance pressure relief valves

All pressure relief valves must be subjected to a functional test at the latest after one year of operation, or when the equipment is moved to another face. If it is not possible to keep this deadline because the end of the section planned to be mined will only be reached shortly after the deadline, the pressure relief valves can, as an exception, be checked after the respective section has been completed.

Pressure relief valves which are pre-tensioned with gas pressure must be additionally random checked at regular intervals to ensure their correct function. We recommend random inspections at quarterly intervals.

high-pressure hydraulic hoses

All high-pressure hydraulic hose lines must be replaced irrespective of any visible damage at the latest after 2 years of operation for safety reasons and to ensure the correct function of the system.

double filter, can be backflushed

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid), the frequency of backflushing must be specified individually. We recommend backflushing both filters regularly once a shift.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid at: – hose lines – electrohydraulic control unit – valves – legs – shifting ram and baselift cylinders (lifting) – hinge, alignment and flipper cylinders.

. Check the pressure gauges on the legs for visible damage and correct function. steel structure

. Check all shields by visually inspecting them for damage to the steel structure, for example: – on the relay bar assembly, – on pin connections and retaining devices, – on brackets, etc.

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5.63

Maintenance Weekly maintenance control system

. Check each control system for correct functioning. . Replace defective control systems or individual components immediately.

. Clean the control systems, especially the control panel.

Notice!

It is important that the control system symbols are easily legible. This prevents the risk of operating errors and any resulting accidents.

Every six months

. Apply a preservative to the piston rods of the hydraulic cylinders. Further details are contained in this chapter in the “Special measures” section. lubricating nipples. Use the grease A2 in accordance with EWN 7068. See chapter 6, section “Greases and lubricating pastes”.

Fig. 78:

Lubricating nipples on the hydraulic leg

b

a

a lubricating nipples on the guide bushing

b grease escaping at wiper seal

Regularly scheduled damage assessment We recommend keeping a record of any damage found. The records should be evaluated regularly, for example every month, and summarized in a damage report. This will enable you to detect frequently occurring damage and take preventative action. This will improve system availability and reduce operating costs accordingly.

5.64

Shield support 2100/4500-2/2x7156/1789-2050

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. Lubricate the wiper seals of both telescope stages via the Caterpillar Global Mining Europe GmbH, Lünen 2013

hydraulic leg

Troubleshooting Troubleshooting Instructions for troubleshooting The shield hydraulics of a shield unit consists of a number of individual components. The linking of the components with each other is shown in the diagrams and hose diagrams for the shield hydraulics. Refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

Malfunctions can basically occur on all components. Most faults on hydraulic valves, however, are caused by hydraulic bypass flows.

These are normally audible to the operator.

The following information is provided to assist you in the detection and elimination of faults.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Warning!

There is an increased risk of accidents when performing troubleshooting on hydraulic systems. In particular, malfunctions in the hydraulic system and hydraulic medium escaping at high pressure can cause serious injury.

Therefore, take special care and always wear the specified protective clothing and equipment.

Failure to comply with these instructions can result in serious injury.

Fault localization support cannot be lowered

Doc. No.: 7420 244 000 BA 00

Possible cause

Measure required

The shut-off valve for the shield supply on the intershield manifold is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Determine the cause. If required, lower neighboring supports and align them in order to free the canopy.

Control piston on the leg control valve is not working.

Check whether the pressure is sufficient to control the valve; approx. 80 bar is the minimum.

The leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

Replace the hose line if necessary. Make sure hose lines are laid properly.

Leg is defective.

Check the leg for damage and leaks. Replace the leg, if necessary.

VESP / 01

5.65

Troubleshooting support cannot be set

Possible cause

Measure required

The shut-off valve for the shield supply on the intershield manifold is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck Determine the cause. If required, lower between the neighboring supports. neighboring supports and align them in order to free the canopy.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Control piston on the leg control valve is not working.

Check whether the pressure is sufficient to control the valve; approx. 80 bar is the minimum.

The leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

Replace the hose line if necessary. Make sure hose lines are laid properly.

Leg is defective.

Check the leg for damage and leaks. Replace the leg, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the intershield manifold is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The support is stuck between the neighboring supports.

Determine the cause. If required, lower neighboring supports and align them in order to free the support.

Step on roof or floor blocking the support.

Lower the canopy sufficiently to clear the step or lift the base one step.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Control piston on the piloted check valve is not working.

Check whether the pressure is sufficient to control the valve; approx. 80 bar is the minimum.

The leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked shifting ram hose lines. Replace the hose line if necessary. Make sure hose lines are laid properly.

Shifting ram is defective.

Check whether the - shifting ram is damaged, - the piloted check valve is working properly.

Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressurized fluid escapes, replace the shifting ram.

support cannot be advanced

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Caterpillar Global Mining Europe GmbH, Lünen 2013

E

The pressure of the hydraulic supply is too low.

Troubleshooting setting pressure is not reached/leg pressure drops again after setting

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

canopy cannot be positioned

canopy cannot be lowered

Doc. No.: 7420 244 000 BA 00

Possible cause

Measure required

Leg control valve is defective.

Replace leg control valve. Continue troubleshooting if the pressure continues to drop.

Legs are damaged.

Check legs for damage and replace, if necessary.

Remove hose from leg lowering connection and check whether pressurized fluid is escaping even though the leg is no longer being extended. If applicable: piston packing defective, replace leg.

Pressure relief valve is defective.

Monitor pressure drop on the pressure gauge.

Is pressurized fluid leaking from the pressure relief valve? If applicable: Replace the pressure relief valve and retest the function.

Possible cause

Measure required

The shut-off valve for the shield supply on the intershield manifold is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Determine the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the intershield manifold is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Determine the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose line.

Check hose lines for controlling the leg/ stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

VESP / 01

5.67

Troubleshooting 3/2-way or pilot valve The valve is jammed or a bypass has formed due to internal leakage. The latter can normally be detected on the working valves of the electrohydraulic control unit by a clearly audible hissing noise.

Pilot or control valves with a significantly lower volume flow will become noticeably warmer due to the constantly flowing medium.

Defective pilot valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, such as discharged pressurized fluid.

The 3/2-way valve or the pilot valve may therefore be faulty. valve jamming

. Try to solve the problem by actuating the function several times at the electrohydraulic control unit or control unit. sequence.

If the noise stops while a function is actuated, that valve is faulty.

You may have to press the button for the faulty function for several seconds before the noise ceases.

valve replacement

. Close the main shut-off valve in the pressure feed line for the shield at the pipe manifold.

. Then actuate the functions manually to depressurize the system.

. Replace the 3/2-way valve or pilot valve.

Piloted check valves The formation of a bypass is indicated by a drop in pressure.

. Try to solve the problem by actuating the function several times at the electrohydraulic control unit or control unit.

If the problem occurs again, the valve may be defective.

. Check the valve and replace it, if defective.

Checking the leg check valves To check the leg check valves please proceed as follows:

. Set the leg until the setting pressure has been reached. . Remove the “set leg” hose line on the piloted check valve.

If fluid escapes from the connection of the piloted check valve, it is defective.

5.68

Shield support 2100/4500-2/2x7156/1789-2050

E

. Locate the faulty valve by actuating the functions individually in

Caterpillar Global Mining Europe GmbH, Lünen 2013

internal leakage

Troubleshooting Internal bypass inside the leg If an internal bypass in the leg is suspected proceed as follows:

. Set the leg until the setting pressure has been reached. . Make sure that the annular space of the leg is depressurized. . Release the hose of the leg annular space connection at the leg.

. Actuate the “set leg” function from the neighboring support.

If there is an internal bypass in the leg, for example due to damaged piston packing, fluid will flow out of the leg's lowering connection. If this happens, the leg must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

Pressure relief valve defective

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Leaking pressure relief valves can normally be detected by the discharge of fluid, or a pressure drop is displayed on the pressure gauge. If pressurized fluid is already discharged at working pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

In the hydraulic circuit of a shield unit, various types of pressure relief valves are used. For example, pressure relief valves with a high flow rate are used on the legs, whereas the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow rate.

Pressure relief valves for different cylinders or for the piston and ring sides of a cylinder can be set to different maximum pressure values. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

Defective or clogged filter Operation of the shield is slow although the system pressure lies in the normal range.

It is also possible that the hydraulic system has been contaminated, for example during repair work on the hydraulic system.

. Check the filters in the hydraulic system.

Backflush filters can be cleaned by backflushing. The filter elements must be replaced on fine-mesh filters, such as on the electrohydraulic control unit.

Doc. No.: 7420 244 000 BA 00

VESP / 01

5.69

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Troubleshooting

5.70

Shield support 2100/4500-2/2x7156/1789-2050

6

Technical data

Description

Technical data This chapter contains the technical description of the support and its main subassemblies as well as the technical data for the described subassemblies.

Description Type 2100/4500-2/2x7156/1789-2050 The four-legged shield mainly consists of the following main subassemblies: base frame with lemniscatic links and relay bar assembly, canopy with flipper, side seal for canopy and caving shield, caving shield and caving flap, hydraulic legs - 2 rear legs, 2 front legs, Caterpillar Global Mining Europe GmbH, Lünen 2013

E

hydraulic equipment with hose lines and control.

Tab. 11: Shield support variants, dimensions and weight Use

Device number

Dimensions, L x H x W max. / min. in mm

Approx. weight in kg

Segment shield

7420 244 000 00 01

9200 x 2100 x 1950 4500 x 1950

59 000

Tab. 12: Shield support, numbering Device number

Shield number

Special design

003 and 002 GS001 and BS002

Antitopple device 2 canopy/canopy Dr. no. 7427 116 000 00 00

001 to 002 BS001 to BS002

Antitopple device 3 canopy/canopy Dr. no. 7427 117 000 00 00

7420 244 000 00 01

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.3

Description base frame

The shield is equipped with a one-piece base frame.

This consists of two bases which are tightly connected to each other, in the middle of which is the channel for the relay bar assembly.

caving shield

The caving shield is a one-piece steel construction, it is flexibly connected with the canopy and also to the base frame by means of the so-called lemniscatic link.

canopy

The shield canopy transmits the supporting force of the legs to the roof. The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

hydraulic system

Programmed methods of calculation ensure the best possible support. This ensures that the support resistance and range of vertical adjustment is coordinated in optimum fashion. The multi-stage hydraulic legs have the same load capacity at any stage and act on both sides.

6.4

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

The shield units are equipped with all components required for implementing an electrohydraulic neighboring control with the electronic PMC®-R control system.

E

The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

Description Main subassemblies Fig. 79:

Segment shield 21

11

53 26 31

43

C B

A 51

View A

32

3

82 Caterpillar Global Mining Europe GmbH, Lünen 2013

E

52*

1

41 View C 5

7

View B 85

86

84

81

83

61

8 6

1 base 2/2x7156/1789 3 relay bar assembly 5 lemniscatic link, front right 6 lemniscatic link, front left 7 lemniscatic link, rear right 8 lemniscatic link, rear left 11 canopy 3x5330-1080-2050 21 side seal, canopy

Doc. No.: 7420 244 000 BA 00

26 side seal, caving shield 31 caving shield 32 caving flap 41 leg 43 leg 51 base lifting cylinder 52 shifting ram 53 stabilizing cylinder

VESP / 01

81 information sign 82 information sign 83 information sign 84 pin holder 85 rubber covering 86 rubber covering, center * concealed

6.5

Description Tab. 13: Segment shield 7420 244 000 00 01, subassemblies Description

01

Base 2/2x7156/1789

7420 244 300 00 01

13 286 Length: 4340 mm

03

Relay bar assembly

7420 244 330 00 01

1610 Length: 4611 mm

05

Lemniscatic link, front right

7420 244 303 00 00

926 Length: 2295 mm

06

Lemniscatic link, front left

7420 244 304 00 00

927 Length: 2295 mm

07

Lemniscatic link, rear right

7420 244 305 00 00

908 Length: 1924 mm

08

Lemniscatic link, rear left

7420 244 306 00 00

908 Length: 1924 mm

11

Canopy 2/2x7156/1789-1080-2050

7420 244 400 00 01

2/11

Flipper

7420 242 470 00 01

1200 Flipper cylinder

8241 521 000 00 00

7420 244 710 00 01

Length: 5292 mm 1657 Side seal cyl. Ø 78

8241 352 000 00 00 8241 352 000 00 00

6.6

Length: approx. 6390 mm + flipper 1292 mm

26

Side seal, caving shield

7420 242 760 00 01

Length: 2668 mm 982 Side seal cyl. Ø 78

31

Caving shield

7420 244 800 00 01

9033 Length: 3020 mm

32

Caving flap

7420 244 851 00 00

656

Length: 1250 mm Width: 1700 mm

41

Hydraulic leg

8250 203 000 00 00

2868

SD-7150-450-1625/3875-BN PRV 520 bar

43

Hydraulic leg

8250 204 000 00 00

576

SD-7190-225-1505/3760-BN PRV 520 bar

51

Base lifting cylinder

8241 516 000 00 00

124 ZE-165/90-300-CR

52

Shifting ram

8241 517 000 00 00

375 ZE-200/125-1080-CR

53

Stabilizing cylinder

8241 522 000 00 00

230 ZE-200/125-540-BN Electrohydraulic control unit, 12-function Electrohydraulic control unit, 8-function Water valve unit Water valve unit Intershield manifold Lines Water spraying system Brackets

61

Hydraulic 4-legged shield

8112 376 000 00 00

81

Information sign

7420 244 000 01 00

0.5

82

Information sign

7420 244 000 02 00

0.6 CSLH 5x120x160

83

Information sign

7420 244 000 03 00

0.9 CSLH 5x120x180

84

Pin holder

7420 242 030 00 00

1.1

85

Rubber covering

7420 242 050 00 00

13.7

86

Rubber covering, center

7420 242 060 00 00

24.3

E

Side seal, canopy

19 758

Note

8154 182 000 00 00 8154 176 000 00 00 8401 008 150 00 00 8401 008 500 00 00 8401 009 150 00 00 8112 376 010 00 00 8112 376 020 00 00 8112 376 030 00 00

1 set no. 1 to 2 CSLH 5x120x160

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

21

ID no.

Approx. weight in kg

Item

Description Main dimensions Fig. 80:

Gate end shield, dimensions L1 L2

L3

150

L4

1292

157

2025

4340

115

LT

1500

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

HR

H

HE

32°

60

M W

HE height, extended HR height, retracted LT transport length

W3 W2 W1

W width M support center distance

Tab. 14: Segment shield, dimensions LT

L1

L2

L3

L4

H

HE

HR

W

W1

W2

W3

M

9200

6540

3600

1250

1540

3500

4500

2100

1950

1820

1080

400

2050

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.7

Description Base with lemniscatic links and relay bar assembly The one-piece base frame transmits the shield load of the hydraulic props to the floor. The legs are mounted on hinges in the ball sockets in the bases and are held on both sides by leg retainers.

The four lemniscatic links are hinged to the base frame with a pin connection.

Characteristic for the base frame is the arrangement of the relay bar assembly in the middle between the two bases. The relay bar assembly is reverse-mounted. This means, the force applied to the piston surface of the shifting ram is used to advance the shield.

Correspondingly, the conveyor is advanced with the smaller force generated via the annular surface.

The fork joint of the relay bar assembly establishes the connection to the conveyor. With the help of the base lifting cylinder, the shield can be lifted during shield advance.

150 2025

725

800

4340

1165 1405

780

Base, dimensions

395

Fig. 81:

400 1080 1820

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.8

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Base

Description Fig. 82:

Base, items View A

2

20 16

31

15

21

24, 40 7 22

B

A 18 50, 55 9

C View D

10

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

30 13

17

D

43

25, 42 12

57, 53 14

View C 52, 60

11 6

13

View B

26 44

23, 41

3

8 5

a

b 1 base 2 cylinder bearing 3 leg retainer, right 4 leg retainer, left (not visible) 5 mounting link 6 plug 7 safety segment 8 safety segment 9 leg retainer 10 running board, right 11 running board, left 12 running board 13 cover plate 14 cover plate

23

Doc. No.: 7420 244 000 BA 00

15 running board 16 running board, center 17 running board 18 cover 20 lemniscatic link pin 219.3x677 21 lemniscatic link pin 179.3x677 22 pin 60/50x135 23 pin 35/29x66 24 pin 25/16x154 25 pin 25/16x138 26 transport rod 30 filler piece, front 31 filler piece, rear 40 spring clip 2.5 41 spring clip 4

VESP / 01

51, 56

42 spring clip 3.2 43 spring cotter 5 44 spring clip Ø6 50 hex. head screw M 12x70-A 4-80 51 hex. head screw M 16x80-A 4-80 52 hex. head screw M 30x50-A 4-50 53 special-purpose screw 55 hex. nut M 12-A 4-80 56 hex. nut M 16-1.4571 57 hex. nut M 20-1.4571 60 washer 60x12 a load ring load capacity 1000 kg b load ring load capacity of 3000 kg

6.9

Description Relay bar assembly The relay bar assembly is used to push the conveyor and advance the shield. To do this, it is telescopically extended or retracted using the shifting ram. The shifting ram functions directly. This means that the greater force generated by the piston surface is used to advance the conveyor.

Fig. 83:

Relay bar assembly, dimensions 4611

150

440

305

295

165

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

Fig. 84:

Relay bar assembly, items 6

2

15

b 20 1

a

9, 16 8

7

5

a

11, 15 10

1 relay bar 2 clevis assembly for conveyor 5 shear pin 60/53x240 6 pin 65/58x193 7 pin 15/12x95 8 pin 80/60x320 9 pin 25/16x138

10 retaining ring RD 85x30 11 pin 12/20x95 15 spring clip 2.5 16 spring clip 3.2 20 hex. head screw M 16x20-A 2-70 a load ring load capacity 3000 kg b name plate

*) EWN = works standard

6.10

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

330

270

390 115

4330

Description Functions of the relay bar assembly 1. Original position of the shield The shifting ram is retracted.

2. Advancing the shield While the shield is being advanced, the base lifting cylinder presses on the relay bar, causing the bases to be lifted up off the floor.

Warning!

Parts of the body which get between moving parts of the relay bar assembly and support can be crushed.

For this reason, make sure that you keep a distance from shields which are being advanced or are to be advanced soon.

3. Setting the support When setting the shield, the base lifting cylinder retracts again automatically.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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4. Advancing the conveyor The shifting ram is retracted.

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.11

Description Lemniscatic link The lemniscatic links of the segment shield deviate in: the length the design.

Front lemniscatic links The front lemniscatic links have the same dimensions, however, they are equipped with different components.

Fig. 85:

Lemniscatic links, dimensions

H

L

B

B1

E

(650)

Tab. 15: Front lemniscatic link, dimensions, 7420 244 303/304 00 00 Item

5

6

Fig. 86:

Lemniscatic links

Quantity

Drawing number

Front right

7420 244 303 00 00

Front left

7420 244 304 00 00

1

L

L1

2 295

1

2 295

D

1 855

1 855

200

200

H

B

440

B1

510

440

510

Note

360

1x bent plate 1x limit stop 2x screw holders 1x load ring 1x clip

360

1x bent plate 1x limit stop 4x screw holders 1x load ring 1x clip

Front lemniscatic link

lemniscatic link, front right

A

lemniscatic link, front left

View B

3 5 6 4

10 View A

4

5

1 6

2 10

3 2 1 lemniscatic link, front 2 bent plate 3 limit stop 4 screw holder M 12

6.12

1 B

5 load ring load capacity of 3000 kg 6 clip 10 name plate 1x60x110

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

1120

200

620 520

D

D

(290)

50

L1

Description Rear lemniscatic links The rear lemniscatic links have the same dimensions and the same components, but are mirror-inverted, however.

Fig. 87:

Lemniscatic links, dimensions

D

H

D

L1 L2

L 965

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

B

B1

200

450

Tab. 16: Lemniscatic link, dimensions, 7420 244 303/304 00 00, Item

Lemniscatic links

Drawing number

Quantity

L

L1

L2

D

H

B

B1

Note

7

Rear right

7420 244 305 00 00

1

1 924

1 950

1 550

180

680

510

360

2x load rings 1x name plate

8

Rear left

7420 244 306 00 00

1

1 924

1 950

1 550

180

680

510

360

2x load rings 1x name plate

Fig. 88:

Rear lemniscatic link

View A

5

5 A

1 10

1 lemniscatic link, rear 5 load ring load capacity of 3000 kg

Doc. No.: 7420 244 000 BA 00

VESP / 01

10 name plate 1x60x110

6.13

Description Canopy The canopy transfers the supporting force of the legs to the roof. It is hinged to the caving shield by means of pin connections.

Canopy, dimensions

5003

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

6390

1292

Fig. 89:

650

375 275

150

250

1080

390

1470

390

1910

6.14

Shield support 2100/4500-2/2x7156/1789-2050

Description Fig. 90:

Canopy, items 1

25

d, f, 23 A

b 18, 19 24

B a c, e, 23 2

6 View B 21, 22

E Caterpillar Global Mining Europe GmbH, Lünen 2013

11, 20 10

16, 17

8, 20

7 18, 19 View A 13, 14, 15

12

4 *

3

5

10

18, 19

27 26 9 1 canopy 2 flipper 3 cover plate 4 cover plate 5 plug 6 retainer 69x158 7 retainer 65x132 8 pin 15x150 9 joint pin Ø164.3x660 10 securing device 11 pin 15/12x120 12 pin 63x240

Doc. No.: 7420 244 000 BA 00

13 retaining ring 14 hex. head screw M 10x110-A 2-70 15 hex. nut M 10-A 2-70 16 hex. head screw M 12x35-A 4-80 17 hex. nut M 12-A 4-80 18 hex. head screw M 12x50-A 2-70 19 hex. nut M 12-1.4571 20 spring clip 2.5 21 pin 50/44x92 22 staple DN 32-130 lg.

23 spring cotter 5

VESP / 01

24 limit stop 25 holding plate, limit stop 26 rubber seal 27 strip a clamping plate b clip 8000 kg c load ring 3000 kg d load ring 5000 kg e safety retainer 3000 kg e safety retainer 5000 kg * transparent

6.15

Description Flipper The flipper is identical for all shield variants.

122 178 90 203

(1217) (327)

(1250)

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.16

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

770

1140

Flipper, dimensions

(1500)

Fig. 91:

Description Fig. 92:

Flipper, items b 5 8, 13, 14

3 20

21

6, 12, 14

22

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

9, 14, 19 24 23

4, 10, 11

a 2

15, 16

17

1

7, 13, 14 6 18, 25

8, 13, 14

1 flap 2 flange plate 3 fork control arm 4 securing device 5 fork control arm 6 pin 55/43.5x153 7 pin Ø 58.5x400 8 pin Ø 58.5x240 9 pin Ø 58.5x170 10 hex. head screw M 16x170-A 2-70 11 hex. nut M 16-A 2-70 12 hex. head screw M 10x60-A 2-70 13 hex. head screw M 10x75-A 2-70 14 hex. nut M 10-A 2-70

Doc. No.: 7420 244 000 BA 00

VESP / 01

15 hex. head screw M 30x80-10.9 16 hex. nut M 30-10 17 flipper cylinder ZE-125/90-615 18 pin 45/38.5x165 19 hex. head screw M 10x70-A 2-70 20 damper 21 plate 22 washer 17 23 hex. nut VM 16-1.4571 24 cyl. head screw M 16x45-1.4301 25 spring cotter 7 a support (transparent) b load ring load capacity 3000 kg

6.17

Description Leg retainers Important!

Before installing the leg head, put the retainers of the leg head fixture into the bore holes of the mounting device. Secure the retainers with the securing device (pins, locking clips) in the second groove.

After installing the leg head, push the retainers in the bore holes of the leg head. Secure the retainers in the first groove by using the securing devices.

Fig. 93:

Fastening the leg head - rear leg 8

20

6 retainer 69x158 8 pin 15x150

6.18

20 spring clip 2.5

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

6

Description Side seal The side seals seal neighboring shield units off from one another.

In addition, they can be used for aligning one shield unit relative to the neighboring shield units.

The side seal is arranged on the canopy and the caving shield and can be moved on the left side. They are guided by guiding pins and are constantly pressed against the neighboring shield with compression springs. The side seals can be extended and retracted using hydraulic legs.

Warning!

Risk of injury due to the unexpected movement of the side seal! The moving side seal is under spring pressure!

Never remove the connection elements of the side seal before the side seal is pulled together and secured with clamp clips.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Caution!

The transport safety devices of the side seal must be removed before commissioning the shield unit.

For transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured with staples.

Notice!

Remove the transport safety devices during commissioning!

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.19

Description Side seal, canopy

Fig. 94:

Side seal, canopy, dimensions 4992

(830)

250

205

150

E

665

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.20

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

(133)

330

(133)

455

1325

(310)

(5292)

Description Fig. 95:

Side seal, canopy, items

8 13

7

2

11, 15

5, 14

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

10, 16

12, 17

6

9, 18 3 1 side seal cylinder ZE-63/50-215 2 side seal, CLH 3 cover 5 cylinder liner 133x105 6 securing device 7 guiding pin Ø133x1355 8 guiding pin Ø133x715 9 pin 35/28x232 10 pin 30/22x120

Doc. No.: 7420 244 000 BA 00

VESP / 01

11 pin Ø28x93 12 pin 15/12x120 13 compression spring 12x79x560 14 screw pin M 10x12 15 split pin 6.3x40 16 spring clip 3.2 17 locking clip 2.5 18 staple DN 20-100 lg.

6.21

Description Side seal, caving shield Fig. 96:

Side seal, caving shield, dimensions

455

103

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.22

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

445

E

205

1320

645 330

350

15

330

20

1430

950

400

2768 2668

Description Fig. 97:

Side seal, caving shield, dimensions 3

23, 24

23, 24

21

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

22

1 19, 20

6

8

12, 17 14

11, 16

9, 18

1 side seal cylinder ZE-63/50-215 3 side seal CSLH 6 guiding pin Ø103x1350 8 guiding pin Ø103x695 9 pin 30/25x175 11 pin 30/22x120 12 pin Ø28x93 14 compression spring 12x79x560 16 spring clip 3.2

Doc. No.: 7420 244 000 BA 00

VESP / 01

17 split pin 6.3x40 18 staple DN 12-97 lg.

19 cylinder liner 103x105 20 screw pin M 10x12 21 cover plate D245 22 cover plate D205 23 hex. head screw M 12x35-A 4-80 24 hex. nut M 12-A 4-80

6.23

Description Caving shield The caving shield protects the face area toward the caving area.

It is connected to the shield canopy and to the base frame via the front and rear lemniscatic links.

370

Caving shield, dimensions

3020

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.24

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

1455

E

370

380

860 1930

1460

380

Fig. 98:

Description Fig. 99:

Caving shield, items 9, 16, 18

6, 7, 17, 18 3

8

4

1

19, 20 30 19, 20 31 S2, a, 27 A

E

24

Caterpillar Global Mining Europe GmbH, Lünen 2013

22

S2, a, 27 25

21, 20 View A

23

28

10

19, 20

2

11, 12, 26

14, 15

S1 S2, a, 29 1 caving shield 2 cover plate 3 lemniscatic link pin 219.3x525 4 lemniscatic link pin 179.3x525 5 pin 78.5x565 6 pin 63x240 7 retaining ring 8 pin 65/55x188 9 retaining ring 10 pin 40/34x74 11 securing device 12 pin 15/12x120

Doc. No.: 7420 244 000 BA 00

S1

5

14 hex. head screw M 20x130-A 4-80 15 hex. nut M 20-1.4571 16 hex. head screw M 10x90-A 2-70 17 hex. head screw M 10x110-A 2-70 18 hex. nut M 10-A 2-70 19 hex. head screw M 12x35-A 4-80 20 hex. nut M 12-A 4-80 21 hex. head screw M 12x40-A 4-70 22 rubber seal 23 rubber seal 24 strip

VESP / 01

25 strip 26 locking clip 2.5 27 spring cotter 5 28 staple DN25-105 lg.

29 spring clip 6 30 cover plate D245 31 cover plate D205 S1 load ring, load capacity: 3000 kg S2 load ring, load capacity: 8000 kg a safety retainer 8000 kg

6.25

Description Caving flap The caving flap shields the further face area toward the caving area. It is connected to the caving shield by a hinge.

Fig. 100: Caving flap, dimensions 1330

(30)

1250

Base plate dimensions

360

870

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1700

360

Notice!

Apply lubricant B6 per EWN 7068*) to all connecting points and slide surfaces.

Fig. 101: Caving flap, items

1

2 4 3 1 base plate 2 limit stop

3 bent plate 4 limit stop

*) EWN = works standard

6.26

Shield support 2100/4500-2/2x7156/1789-2050

Accessories Accessories Antitopple device “canopy/canopy” Before aligning, the shield to be aligned should be lowered. The neighboring shield to which the alignment cylinder is attached must be set.

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

It may be necessary to also use the corresponding side seal or pusher cylinder to align more precisely.

Antitopple device 2 “canopy/canopy” according to drawing number 7427 116 000 00 00 and hydraulic system drawing 8112 374 083 00 00 can be used for the gate end shield with the shield number E

003 (GS001) and Caterpillar Global Mining Europe GmbH, Lünen 2013

the segment shield with the shield number 002 (BS002).

The shields for the antitopple devices are located on the head gate.

Antitopple device 3 “canopy/canopy” according to drawing number 7427 117 000 00 00 and hydraulic system drawing 8112 374 084 00 00 can be used for the segment shield with the shield number 001 (BS001) and the segment shield with the shield number 002 (BS002).

The shields for the antitopple devices are located on the head gate.

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.27

Accessories Antitopple device 2 “canopy/canopy” The antitopple device connects a 3-legged gate end shield to a 4-legged segment shield.

Fig. 102: Antitopple device 2 “canopy/canopy”, dimensions

2200

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield no. 002

Shield no. 003

6.28

Shield support 2100/4500-2/2x7156/1789-2050

Accessories Fig. 103: Antitopple device 2 “canopy/canopy”

a

Shield no. 002

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield no. 003

a antitopple device canopy/canopy Fig. 104: Antitopple device 2 “canopy/canopy”, items 15

16, 21

14

12 13

14 10

X

1 11, 20

a

23, 24 2

1 hydraulic cylinder ZE 135/80-800 retracted: 1120 mm extended: 1920 mm 2 terminal bracket 10 pin Ø 69.8x220 11 pin Ø 16x150 12 universal joint 13 universal joint 14 hinge piece

Doc. No.: 7420 244 000 BA 00

VESP / 01

15 hinge piece 16 pin 55/40x125 20 locking clip 3.2 21 spring clip 4 23 hammer head bolt M24x80-12.9 24 hex. nut M 24-8 a load ring load capacity 1000 kg X components of antitopple device 1

6.29

Accessories Warning!

Make sure that the offset between shield 1 and shield 2 does not exceed the maximum permissible dimension.

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 200 mm!

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Fig. 105: Hydraulic control for antitopple device 2 “canopy/canopy”

1

5 a

DN10x3200

DN10x3000

6 1

1 plug-in elbow socket DN 10 5 SHL-LTG 4SP-DN10x3200-ST 6 SHL-LTG 4SP-DN10x3000-ST

6.30

a electrohydraulic control unit, 6-function

Shield support 2100/4500-2/2x7156/1789-2050

Accessories Antitopple device 3 “canopy/canopy” The antitopple device connects the two 4-legged segments shields.

Fig. 106: Antitopple device 3 “canopy/canopy”, dimensions Shield no. 002

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield no. 001

2050

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.31

Accessories Fig. 107: Antitopple device 3 “canopy/canopy”

E

Shield no. 002

Caterpillar Global Mining Europe GmbH, Lünen 2013

Shield no. 001

a

a antitopple device canopy/canopy

6.32

Shield support 2100/4500-2/2x7156/1789-2050

Accessories Fig. 108: Antitopple device 3 “canopy/canopy”, items 23, 24 b 2

a

11, 20

12

14, 21

10

1 13

1 hydraulic cylinder ZE 135/80-800 retracted: 1120 mm extended: 1920 mm Caterpillar Global Mining Europe GmbH, Lünen 2013

E

2 terminal bracket 10 pin Ø 69.8x220 11 pin Ø 16x150 12 universal joint 13 hinge piece

14 pin 55/40x125 20 locking clip 3.2 21 spring clip 4 23 hammer head bolt M24x80-12.9 24 hex. nut M 24-8 a load ring load capacity 1000 kg b screw holder M 12

Warning!

Make sure that the offset between shield 1 and shield 2 does not exceed the maximum permissible dimension.

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 200 mm!

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.33

Accessories By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

Fig. 109: Hydraulic control for antitopple device 1 “canopy/canopy”

DN10x4000

5

a

1 A DN10x6200

6 1 plug-in elbow socket DN 10 5 SHL-LTG 4SP-DN10x4000-ST

6.34

6 SHL-LTG 4SP-DN10x6200-ST a electrohydraulic control unit, 12-function

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

Accessories Brackets Pin holder

100

48

Fig. 110: Pin holder

5

150 174

6

1 pin holder 5 hex. head screw M 12x30-A 2-70

6 hex. nut M 12-1.4571

Hose guide and visual lamp holder Fig. 111: Hose guide and visual lamp holder, dimensions

(297)

(70)

(476)

(164)

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.35

Accessories Fig. 112: Hose guide and visual lamp holder, items 9

1

a 2 6, 7 E

3, 10

1 bracket 2 mounting device for visual lamp 3 pin 16/12x30 6 hex. head screw M 12x30-A 2-70 7 hex. nut M 12-A 4-80

6.36

8 hex. head screw M 12x20-A 2-70 9 hex. head screw M 16x20-A 2-70 10 spring clip 2.5 a visual lamp

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

8, 7

Accessories Covers Rubber covering Fig. 113: Rubber covering 3, 4 2

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

1 rubber covering 2 limit stop

3 hex. head screw M 12x40-A 2-70 4 hex. nut M 12-1.4571

Fig. 114: Rubber covering, center A

View A

2

3 5, 6 1

4, 6

1 cover bracket 2 rubber covering 3 limit stop

Doc. No.: 7420 244 000 BA 00

VESP / 01

4 hex. head screw M 12x40-A 2-70 5 hex. head screw M 12x30-A 2-70 6 hex. nut M 12-1.4571

6.37

Accessories Information signs Fig. 115: Information sign 1

100

170

1 sheet 5 Fig. 116: Information sign 2

100

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

170

1 sheet 5 Fig. 117: Information sign 3

130

200

1 sheet 5

6.38

Shield support 2100/4500-2/2x7156/1789-2050

Accessories Technical data, steel structure Shield support, device number 7420 244 000 00 01 Height, retracted . . . . . . . . . . . . . . . . . . . . mm

2100

Height, extended . . . . . . . . . . . . . . . . . . . mm

4500

Height adjustment . . . . . . . . . . . . . . . . . . . mm

2400

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Height adjustment by means of hydr. leg stroke . . . . . . . . . . . . . . . . . . . . . mm

2400

mech. extension . . . . . . . . . . . . . . . . . . . . mm

-

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

1000

Cylinder stroke . . . . . . . . . . . . . . . . . . . . . mm

1080

Change in length of the support connection / PF . . . . . . . . . . . . . . mm

---

Leg clearance in inclines . . . . . . . . . . . . mm

1080

Leg clearance between front leg and third, rear leg (base) . . . . . . . . . . mm

1250

Forepole of canopy . . . . . . . . . . . . . . . . . . mm

4850

Rear projection of canopy . . . . . . . . . . . . mm

4540

Canopy width including side seal . . . . . . mm

1950

Canopy length . . . . . . . . . . . . . . . . . . . . . mm

6540

Caving shield inclination:

Doc. No.: 7420 244 000 BA 00

Support, retracted . . . . . . . . . . . . . . . . . . . degrees

12.7

Support, extended . . . . . . . . . . . . . . . . . . degrees

50.2

Width of caving shield . . . . . . . . . . . . . . . mm

1950

Base frame width . . . . . . . . . . . . . . . . . . . mm

1820

Total area of the base frame . . . . . . . . . . cm2

45 656

Support center distance . . . . . . . . . . . . . . mm

2050

Supporting force of support with average thickness of . . . . . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN

---

b) at 450 bar nominal pressure . . . . . . . . kN

---

Support resistance per m2 roof surface with average thickness of . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN/m2

---

b) at 450 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

---

VESP / 01

6.39

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. Supplemental information can be found in the replacement parts catalog for the shield support or the hydraulic components listed in chapter 5.

normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

Shield hydraulics Electrohydraulic control unit The pilot valves of the electrohydraulic control unit are equipped with buttons which allow the shield functions to be actuated manually. A symbol plate allows for the function/button allocation.

The shield 7420 244 000 01 is equipped with two electrohydraulic control units: Caterpillar Global Mining Europe GmbH, Lünen 2013

E

8154 182 000 00 00 has 12 functions, 8154 176 000 00 00 has 8 functions.

Fig. 118: Electrohydraulic control unit, 12-function 2

1

View A

9 5 10

15

3, 7 4, 8

1 manifold block 12-function 2 double 3/2-way pilot solenoid valve 3 control valve cartridge NG 20 4 control valve cartridge NG 13 5 check valve NG 2

6.40

6

A

6 filter cartridge 7 screw fitting 8 screw fitting 9 plug M 16x1 10 plug M 18x1 15 name plate

Shield support 2100/4500-2/2x7156/1789-2050

Hydraulic system Fig. 119: Electrohydraulic control unit, 8-function

View A

9

10

6 5

1 3, 7

2

4, 8

1 manifold block, 8-function 2 double 3/2-way magnetic pilot solenoid valve 3 control valve cartridge NG 20 4 control valve cartridge NG 13 5 check valve NG 2

A

6 filter cartridge 7 screw fitting 8 screw fitting 9 plug M 16x1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

10 plug M 18x1

In addition, the shield 7420 244 000 01 is equipped with two water valve units: 8401 008 150 00 00 with 2 functions, 8401 008 500 00 00 with 4 functions.

Fig. 120: Water valve unit, 2-function 1

4

2 3 1 connection plate 2 double 3/2-way magnetic pilot solenoid valve 3 valve cartridge

Doc. No.: 7420 244 000 BA 00

VESP / 01

4 filter cartridge Components not listed can be found in the spare parts catalog supplied.

6.41

Hydraulic system Fig. 121: Water valve unit, 4-function 4

2

1

Components not listed can be found in the spare parts catalog supplied.

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Non-compliance can cause unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

The buttons on the pilot valves should only be used in special exceptional cases, for example for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations.

6.42

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

4 filter cartridge

E

3 1 connection plate 2 double 3/2-way magnetic pilot solenoid valve 3 valve cartridge

Hydraulic system Hydraulic leg, two-stage The double-telescopic leg is double acting and designed for the same load-bearing capacity in all stages. Identical load capacity is ensured by a piloted check valve (floor valve) which is installed in the major stage.

The bottom and top of the leg are designed as a spherical joint.

This allows the leg to be joined to the support via a rotatable fastening.

The head is fastened using two retainers each that are inserted into the holes in the retainer before the leg head is installed. The retainers are secured in the second groove by a pin and locking clip.

After the leg head is installed, the retainers are pushed into the holes of the leg head and secured in the first groove with a pin and locking clip.

Rear leg Fig. 122: Double-telescopic leg, type SD-7150-450-1625/3875-BN 5 b

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

10 2

e

6

a

d 1

c 1 leg base 2 major stage 5 burst disc 6 PRV 520 bar 10 piston rod

a piston space connection b annular space connection c safety cam d load ring 3000 kg e lubricating nipple

Tab. 17: Telescopic leg Length in mm ID no.

Telescopic leg 8250 203 000 00 00

Doc. No.: 7420 244 000 BA 00

VESP / 01

Stroke in mm

retracted

extended

upper stage

lower stage

1625

3875

1126

1124

6.43

Hydraulic system Front leg Fig. 123: Double-telescopic leg, type SD-1790-225-1505/3760-BN b 7 28 2

5

d

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

a

c 1 leg base 2 major stage 5 PRV 520 bar 7 piston rod 28 burst disc

a piston space connection b annular space connection c safety cam d load ring 3000 kg

Tab. 18: Telescopic leg Length in mm ID no.

Telescopic leg 8250 204 000 00 00

Stroke in mm

retracted

extended

upper stage

lower stage

1505

3760

1115

1140

The technical data can be found in the section “Technical data, hydraulic cylinders”.

Warning!

Risk of injury due to pressurized fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never close the lowering connections on double acting legs so that they are pressure-tight! Otherwise, pressure might build up in the annular space when extending the leg which is several times higher than the setting pressure.

6.44

Shield support 2100/4500-2/2x7156/1789-2050

Hydraulic system Function set leg

Pressurized fluid is admitted under the major stage via the piston space connection. The major stage first extends, while the pressurized fluid in the annular space is discharged into the return line.

If the piston of the major stage moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressurized fluid is supplied at the same time via the check valve in the bottom of the major stage.

load leg

a) Major stage extended only: The force is transferred mechanically from the shield canopy via the leg head to the piston rod and again via the bottom of the piston rod to the bottom of the major stage. Further transmission of the force takes place hydraulically via the pressurized fluid under the major stage in the leg base and from there, mechanically into the base frame (base).

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

The hydraulic pressure under the major stage is regulated by a pressure relief valve which is installed in the corresponding check valve. If the pressure set on the pressure relief valve is exceeded, the pressurized fluid flows out of the leg and the leg is pushed in by the nominal leg force. b) Major stage and piston rod extended: The force is mechanically transferred from the shield canopy via the leg head to the piston rod.

The piston rod supports itself on the pressurized fluid, which is blocked by the check valve in the bottom of the major stage.

Further transmission of force up to the setting of the major stage is as described under a). lower leg

The pressurized fluid is connected to the return line under the middle leg via the control valve for the leg.

Both stages of the leg can be actively lowered. Only when the major stage is completely retracted is the check valve in the bottom of the major stage opened by the tappet and the piston rod can then retract.

A few millimeters before the major stage is “fully retracted”, the check valve is opened by a tappet, whereby the pressurized fluid underneath the major stage acts like a spring lifting the major stage to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.45

Hydraulic cylinder Hydraulic cylinder Setup The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod.

Fig. 124: Hydraulic cylinder, typical example Type a)

2 1

3

5

4

1

4

6

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

4 guide bushing 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical data, hydraulic cylinders” section for the shield unit used.

Warning!

Risk of injury due to pressurized fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, pressure that is several times higher than the setting pressure can build up in the annular space when extending the cylinder!

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against loosening using clamping screws or a spring pin connection.

The operating fluid is fed through the connections either on the outer cylinder (type a) or on the piston rod (type b).

6.46

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Type b)

Hydraulic cylinder Fig. 125: Items of the hydraulic leg Flipper

Canopy

Z3 Caving shield

Z7

*Z1

Z9 Caving flap Z2

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z1

Z4a

Z4b

Tab. 19: Leg and hydraulic cylinder, position QuanID tity Z1 2 Z1* 2 Z2 1 Z3 1 Z4a 3 Z4b 2 Z7 2 Z9 1

Name

Location

Drawing no.

Type

Leg Leg Shifting ram Stabilizing cylinder Side seal cylinder Side seal cylinder Flipper cylinder Base lifting cylinder

Base - 2x rear Base - 2x front On the relay bar assembly Caving shield canopy On the canopy On caving canopy Canopy-flipper Between the bases

8250 203 000 00 00 8250 204 000 00 00 8241 517 000 00 00 8241 522 000 00 00 8241 352 000 00 00 8241 352 000 00 00 8241 521 000 00 00 8241 516 000 00 00

SD-7150-450-1625/3875-BN SD-1790-225-1505/3760-BN ZE-200/125-1080 ZE-200/125-540-BN ZE-63/50-215 ZE-63/50-215 ZE-125/90-600 ZE-65/90-300

Doc. No.: 7420 244 000 BA 00

VESP / 01

6.47

Hydraulic cylinder Shifting ram (Z2) Fig. 126: Hydraulic cylinder, type ZE-200/125-1080

62 L

a

b

2

3

6 c

a piston space connection b annular space connection c load ring 1000 kg L retracted 1427 extended 2507 Stroke: 1080

Stabilizing cylinder (Z3) Fig. 127: Hydraulic cylinder ZE-200/125-540

65

65

L b

d

c

11

1 a 1 cylinder tube 11 piston rod a piston space connection b annular space connection

6.48

c valve connection plate d load ring 1000 kg L retracted 985 extended 1525 Stroke: 540

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

26, 27 1 cylinder tube 2 reed rod 3 piston rod 6 screw fitting 26 plug-in elbow, Lumberg-SKK24 27 staple DN 20-D

E

1

Hydraulic cylinder Side seal cylinder (Z4) Fig. 128: Hydraulic cylinder, type ZE-63/50-215

30 L

a 2

b 1 1 cylinder tube

b annular space connection L retracted 440 extended 655 Stroke: 215

2 piston rod

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a piston space connection

Flipper cylinder (Z7) Fig. 129: Flipper cylinder ZE-125/90-600

60 L a 7

2

1 1 cylinder tube 2 reed rod 4 piston rod 7 screw-in socket DN 20 a piston space connection

Doc. No.: 7420 244 000 BA 00

VESP / 01

c

b

4

b annular space connection c load ring 1000 kg L retracted 930 extended 1530 Stroke: 600

6.49

Hydraulic cylinder Base lifting cylinder (Z9) Fig. 130: Hydraulic leg, type ZE-165/90-300

c 2

L 20

1 17, 21 1 cylinder tube 2 piston rod 17 hex. nut M 16-1.4571 20 hex. head screw M 16x90-A 2-70 21 washer 16

a piston space connection b annular space connection c load ring 1000 kg L retracted 588 extended 888 Stroke: 300

6.50

Shield support 2100/4500-2/2x7156/1789-2050

E

b Caterpillar Global Mining Europe GmbH, Lünen 2013

a

Hydraulic cylinder Technical data, hydraulic cylinders

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

telescopic leg, double acting, 2-stage

telescopic leg Z1* double acting, 2-stage

shifting ram double acting, reverse mounted

Doc. No.: 7420 244 000 BA 00

Type SD-7150-450-1625/3875

Device no. 8250 203 000 00 00

Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1625

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

3875

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

2250

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

450 / 320

Piston rod diameter . . . . . . . . . . . . . . . . . mm

415 / 295

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

1590.4 / 804.2

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

237.8 / 120.8

Leg force at setting pressure, 350 bar . . kN

5566

Setting pressure, 450 bar . . . . . . . . . . . . kN

7157

Retracting force at 350 bar . . . . . . . . . . . kN

832

Type SD-1790-225-1505/3760

Device no. 8250 204 000 00 00

Leg length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1505

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

3760

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

2 255

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

225 / 165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

210 / 155

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

397.6 / 213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

51.2 / 25.1

Leg force at setting pressure, 350 bar . . . . . . . . . . . . . kN

1272

Setting pressure, 450 bar . . . . . . . . . . . . kN

1789

Retracting force at 350 bar . . . . . . . . . . . kN

164

Type ZE-200/125-1080 version with reed rod

Device no. 8241 517 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1080

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

200

Piston rod diameter . . . . . . . . . . . . . . . . . mm

125

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

314

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

191

Thrust force at 320 / --- bar . . . . . . . . . . . kN

1005/---

Pulling force at 320 / 380 bar . . . . . . . . . kN

612 / 726

VESP / 01

6.51

Hydraulic cylinder

flipper cylinder Z7, double acting

base lifting cylinder, double acting

6.52

Device no. 8241 522 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

540

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

200

Piston rod diameter . . . . . . . . . . . . . . . . . mm

125

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

314.2

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

191.4

Thrust force at 320 / 450 bar . . . . . . . . . kN

1005 / 1414

Pulling force at 320 / 450 bar . . . . . . . . . kN

613 / 861

Type ZE-63/50-215

Device no. 8241 352 000 00 00

Cylinder stroke . . . . . . . . . . . . . . . . . . . . . mm

215

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

63

Piston rod diameter . . . . . . . . . . . . . . . . . mm

50

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

31.2

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

11.5

Thrust force at 320 / --- bar . . . . . . . . . . . kN

100 / ---

Pulling force at 320 / 380 bar . . . . . . . . . kN

37 / 43.7

Type ZE-125/90-600

Device no. 8241 521 000 00 00

Cylinder stroke . . . . . . . . . . . . . . . . . . . . . mm

600

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

125

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

122.7

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

59.1

Thrust force at 320 / 380 bar . . . . . . . . . kN

393/ 466

Pulling force at 320 / 380 bar . . . . . . . . . kN

189 / 225

Type ZE-165/90-300

Device no. 8241 516 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

150.2

Thrust force at 320 / 380 bar . . . . . . . . . kN

684/ 812

Pulling force at 320 / --- bar . . . . . . . . . . kN

481 / ---

Shield support 2100/4500-2/2x7156/1789-2050

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side seal cylinder Z4, double acting

Type ZE-200/125-540

Caterpillar Global Mining Europe GmbH, Lünen 2013

stabilizing cylinder, double acting

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as legs and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalogue.

Tab. 20: Pressure relief valves, use of the various types Setting pressure in bar

Device no.

Application

Design

For return line

Spring-loaded

80

8220 042 080 00 00

For cylinders

Spring-loaded

380

7337 486 380 00 00

For legs

Spring-loaded

450

7337 486 450 00 00

For stabilizing cylinders

Spring-loaded

450

8220 027 450 00 00

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Caution!

The setting pressure of pressure relief valves must not be changed. Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance will endanger the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves with the same properties. Always compare with the hydraulic system circuit diagram. Non-compliance will endanger the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Non-compliance can lead to leaks on the connector and endanger the operational safety of the hydraulic system. identification

Pressure relief valves are color-coded and letter-coded according to DIN 21557.

The text code includes the following information: setting pressure, setpoint the week the setting was made the year the setting was made person who made the last changes.

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Pressure relief valves Tab. 21: Text code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

Color coding is with either one or two colors. It indicates the range within which its setting pressure lies. The following figure 131 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

a

The following table shows the relationship between the color code and the pressure range.

Tab. 22: Color codes for pressure relief valves, overview

1)

6.54

Color

Pressure range (bar)

black

0 - 49

black/white

50 - 99

brown

100 - 149

brown/white

150 - 199

green

200 - 249

green/white

250 - 299

blue

300 - 349

blue/white

350 - 399

red

400 - 449

red/white

450 - 499

yellow

500 - 549

yellow/white

550 - 599

orange

600 - 649

orange/white

650 - 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” corresponds to 420 bar, “08” corresponds to 80 bar

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

b

a color code b protective cap

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Fig. 131: Pressure relief valve, example

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the mine floor level are at least 15 degrees unless limited by the retracted/extended state of legs or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

Fig. 132: Angles α 1 / α 2

α1 α2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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M

Tab. 23: Change angle α 1 / α 2 at height M Inclination α at height M

Shield ID no.

7420 244 000 00 01

α1 in °

α2 in °

M in mm

8.8

10.0

24 700 to 2800

8.0

13.7

> 4100 to 4300

It can only be bent when the front or rear leg is extended pivot point “canopy/caving shield.”

Caution!

Exceeding the permissible angles specified can lead to damage to the legs and cylinders and their fastening elements as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the “canopy/caving shield” crosspoint moves correspondingly when the canopy is lowered or aligned/positioned.

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6.55

Hydraulic fluids Hydraulic fluids Permissible hydraulic fluids Notice!

Only use hydraulic fluids for which you have a valid certificate issued by Caterpillar. Otherwise, there is a risk that the hydraulic system could be seriously damaged and result in the loss of warranty claims.

Only those hydraulic fluids for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption certificate from Caterpillar may be used for the operation of hydraulic components from Caterpillar. Caterpillar will not accept any warranty claims for any components which have been or are operated with a different hydraulic fluid.

Suitability test Before Caterpillar issues a certificate for a hydraulic fluid, the respective fluid must be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health, safety and environmental protection.

To perform the suitability test, original samples are required of the concentrate and the water that will be subsequently used when preparing the hydraulic fluid at the mine.

The suitability test is carried out by an independent testing institute authorized by Caterpillar. The criteria as specified in EWN 8350 are applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: stability sealing materials corrosion.

Furthermore, a chemical “fingerprint” of the concentrate is created in order to rule out or verify any possible changes in the composition of the concentrate if necessary.

If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive a corresponding certificate from Caterpillar.

6.56

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

If a mine only uses individual hydraulic components without using Caterpillar shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Caterpillar. The same applies for example to hydraulic chain tensioners, hydraulically tensionable drives etc. A corresponding certificate of exemption will be issued

by Caterpillar upon request.

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In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

Hydraulic fluids Certificate The customer will be issued a certificate attesting the suitability of the hydraulic fluid for the operation of Caterpillar hydraulic systems for each product tested. Certificates are valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate is no longer valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

The following figure shows a typical certificate.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 133: Certificate, example

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6.57

Hydraulic fluids Maintenance of the hydraulic fluid Consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. Ideally, the most important properties of the hydraulic fluid are monitored automatically and documented continuously in order to directly counteract any harmful development. These properties include: temperature, foaming, pH value, concentrate content and microbial load.

The operator of the equipment must compile a hydraulic fluid maintenance plan for the specific application. The maintenance plan should be prepared in close cooperation with the manufacturer of the concentrate, and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed below should be checked at least once every week: pH value – setpoint: 7.5 to 9.5 – setpoint: see certificate microbial load – setpoint: ≤ 105 col/ml In addition, the electrical conductivity, foaming and the working temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55°C. During normal operation, however, an operating temperature of 45°C should not be exceeded. A higher working temperature will reduce the stability of the emulsion and shorten the service life of the sealing material.

Quality of the process water for use for hydraulic fluids

The quality of the water used to create the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limit values shown in the table 24 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not complied with this should be taken into consideration when selecting a concentrate. Furthermore, water treatment may also be necessary.

However, the customer shall in any case provide a sample of the original water to permit the conduction of the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

for use as spraying water

6.58

Water used for this purpose may not contain aggressive components or dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter of at least 100 μm.

In order to protect the components, the limit values listed in the table must not be exceeded.

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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concentrate content

Hydraulic fluids limit values

The following table lists limit values for the main properties and components of the process water.

Caution!

Using water that is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Only use water that complies with the specified limit values!

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Tab. 24: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, odor

No peculiarities permissible e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 μS/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+ content

Not specified

Water hardness

< 750 mg/l CaCO3 equivalent (≤ 42° dH)

Cl- content

≤

201 mg/l

SO42- content

≤

145 mg/l

NO3- content

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml 1)

Ratio of solid foreign matter at 1.2 μm filtering in accordance with DIN EN 12662

≤

10 mg/l 1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1) The values listed must be observed during the production of hydraulic fluids.

They do not apply if the water is used exclusively as spraying water.

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6.59

Hydraulic fluids Greases and lubricating pastes Only the recommended lubricants or products certified as equivalent may be used.

Important!

The lubricants to be used are specified in the respective chapters.

Greases grease A1

Greases for general application, e.g. for roller bearings subject to normal load, for labyrinths, and for installation.

Tab. 25: Grease A1 Supplier

Make

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

Worked penetration: . . . . . . . . . . . . . . . . 265 to 295 (0.1 mm)

Application temperature range: . . . . . . . -40 to +120°C grease A2

Greases containing additives for high pressure applications, e.g. for roller bearings and other bearings subject to extreme load.

Tab. 26: Grease A2 Supplier

Make

Base

Shell

Alvania E.P. grease 2

Lithium soap

NLGI class

Flashpoint in °C

2

205

Worked penetration: . . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . . practically insoluble in water Application temperature range: . . . . . . . -15 to +120°C grease A8

High-load grease for high loads and low speeds, e.g. for roller bearings in drive frame and crusher, for installation and corrosion protection purposes, suitable for central lubrication.

Tab. 27: grease A8 Supplier

Make

Base

Castrol

Molub-Alloy 3036/680-1

Lithium soap

NLGI class

Flashpoint in °C

1

210

Worked penetration: . . . . . . . . . . . . . . . . 310 to 340 (0.1 mm) Behavior in the presence of water: . . . . insoluble in water at 90°C Temperature of application: . . . . . . . . . . -20 to +120°C

6.60

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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Behavior in the presence of water: . . . . practically insoluble in water

Hydraulic fluids Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 28: Lubricating paste B3 Supplier

Make

Lubricant carrier

NLGI class

Flashpoint in °C

Gleitmolybdän

gleitmo 805

Lithium soap

2

220

Worked penetration: . . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . . insoluble in water Temperature of application: . . . . . . . . . . -20 to +120°C Lubricants Parting agents and lubricants with organic lubricating media on synthetic base material for greasing threaded areas and fitting points on legs and hydraulic cylinders, on pin connections and similar connecting elements on the support.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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lubricant B6

Tab. 29: Lubricant B6 Supplier

Make

Lubricant carrier

Flashpoint in °C

Chesterton

Parting agent/lubricant 785

Paraffin base

132

Behavior in the presence of water: . . . . insoluble in water Application temperature range: . . . . . . . -34 to +120°C

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6.61

Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 30: Tightening torques at μtot. = 0.14 Torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques listed in the spare parts lists must also be observed during installation and maintenance work.

1) The dimensions listed in brackets are applied in exceptional cases only.

2) According to works standard (EWN 6110, February 1985 edition).

3) Only for expansion bolts with a reduced shaft diameter of 24.2 mm.

4) The tightening torques comply with the Caterpillar works standard (EWN 6003).

6.62

Shield support 2100/4500-2/2x7156/1789-2050

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(mm)

Caterpillar Global Mining Europe GmbH, Lünen 2013

Thread 1)

7

For your information

Standards and directives

For your information If you require spare parts or technical problems occur, please contact our after-sales service personnel or contact us directly (web site: www.mining.cat.com).

Standards and directives Applied standards and directives Tab. 31: Standards and directives, excerpt

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Designation

Date of issue

Title

EC Directive of the European Parliament and Council on Directive 2006/42/EC the approximation of the laws of the Member States relat2006-05-17 ing to machinery Directive of the European Parliament and the Council on the approximation of the laws of the Member States conDirective 94/9/EC 1994-03-23 cerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100 Safety of machinery 2011-03 Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water content - Distillation method Non-electrical devices for use in potentially explosive DIN EN 13463-1 2009-07 atmospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079-0 2010-03 - Part 0: General requirements Basic and safety principles for man-machine DIN EN 60445 2007-11 interfaces Underground mining machinery DIN EN 12321 2009-07 Safety requirements for chain scraper conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shearer loaders and plough systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic self-advancing support 2010-05 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation DIN 2000 Quality of drinking water 2000-10 DIN 6789 Documentation system 1990-09 DIN 20043 Plug connectors for hydraulics 2003-09 DIN 24320 Fire-resistant hydraulic fluids 2006-12 DIN 24343 Maintenance and inspection list for hydraulic systems 1982-02 DIN 51558-1 Determination of the acid number 1979-07 DIN 51575 Determination of the sulfate ash 2011-01

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7.3

Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA-fluids in mining

1985-02 1992-06 1985-02 2008-01

Caterpillar Global Mining Europe GmbH, Lünen 2013

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EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = works standard

7.4

Shield support 2100/4500-2/2x7156/1789-2050

Identification of the shield Identification of the shield Name plate The main subassemblies of the shields are identified by a name plate.

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Fig. 134: Name plate, example

Caterpillar Global Mining Europe GmbH, Lünen 2013

1 manufacturer 2 SAP/order no.

3 date of manufacture 4 serial component no.

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5 device number 6 number of legs 7 leg force

7.5

Identification of the shield Shield number The shield number serves as an identification feature. All shields are numbered consecutively. The corresponding shield number is on the face side, on the left side of the base.

a

b a shield number

b shield weight

Tab. 32: Shield support 0010 700 000 00 00, numbering Device no.

Quantity Use

Shield

Shield number

Special design Conveyor pulling device

7420 242 000 00 01

138

Face shield

8 to 143

SH001 to SH138

7420 243 000 00 01

1

Transition shield HG

5

TS001

Extension, right

7420 243 000 00 02

1

Transition shield TG

144

TS001

Extension, left

3

GS001

4

GS002

Side plate extension, right, side plate, right

Gate end shield HG 7420 245 000 00 01

Antitopple device 1 “canopy/canopy”

5

Antitopple device 2 “canopy/canopy” Gate end shield TG

7420 245 000 00 02

7420 244 000 00 01

7.6

2

2

GS005 to GS007

145

GS003

Side plate extension, left Side plate, left

146

GS004

Anchoring device, “canopy/canopy”

1 to 2

BS001 to BS002

Antitopple device 3 “canopy/canopy”

Gate end shield TG

Segment shield HG

Anchoring device “canopy/canopy”

147 to 149

Shield support 2100/4500-2/2x7156/1789-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 135: Shield number, centered, face side