CAT Operating Manual Rock Feeder RF300 (EM009381) - PDF DOWNLOAD

EM009381-01-EN April 2013

Translation of the original operating manual

Operating manual Rock Feeder RF300 Doc. No.: 5445 001 800 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 as a result of technical development without prior 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 . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.3 2.3 2.4

2.5 2.5 2.5 2.5 2.5

2.7

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

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

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

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

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

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

Transporting the components . . . . . . . . . . . . . . . . . . . . . . . .

Transport units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.4

3.5 3.5 3.5 3.6 3.7

4. Installation Installing the rock feeder . . . . . . . . . . . . . . . . . . . . . .

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to install the rock feeder . . . . . . . . . . . . . . . . . . . . . . . .

Before connecting the dozer and the pusher cylinder . . . .

How to put the rock feeder into operation . . . . . . .

Before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to carry out a test run . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to move the rock feeder into the working position . . .

How to dismantle and lower the rock feeder . . . . .

Who is authorized to dismantle and lower the rock feeder?

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4.3 4.3 4.4 4.4 4.5

4.8 4.8 4.9 4.9

4.12 4.12

Table of content 5. Operation

Operating the hydraulic system . . . . . . . . . . . . . . . .

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

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

Operation and functions of the electrohydraulic control unit Important information concerning basic hydraulic functions

How to maintain the rock feeder . . . . . . . . . . . . . . . .

Temperature and acoustic emission monitoring . . . . . . . . .

Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

How to maintain the steel structure . . . . . . . . . . . . . . . . . . .

How to maintain the hydraulic system . . . . . . . . . . . . . . . . .

Maintenance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

M4-15 control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5.3 5.3 5.6

5.7 5.7 5.12 5.12 5.13

5.14 5.14 5.14 5.14 5.15 5.16

5.18 5.18 5.18 5.20 5.20 5.20 5.21

6. Technical data Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

6.4

Pusher cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dozer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 6.5 6.6 6.7

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

6.8

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

6.10

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

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.10

6.11 6.11 6.11 6.12

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

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

7.3 7.3

Rock Feeder RF300

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Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rock feeder components . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2013

How to operate the rock feeder . . . . . . . . . . . . . . . . .

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

type designation

Take care to ensure that the operating manual available to you is applicable for the Rock Feeder used. Failure to do so can result in a safety hazard for yourself and others.

Make sure the information on the Rock Feeder complies with that given in the operating manual.

This operating manual is for: Rock Feeder RF300 ID no.: 5445 001 800 00 00 It may only be used for Rock Feeders of this type.

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The operating manual must be available at all times to all persons working on or with the Rock Feeder.

If possible, there should always be an operating manual for the Rock Feeder 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 Rock Feeder.

This includes persons who: are in charge of transport perform installation/removal work on the Rock Feeder operate the Rock Feeder eliminate faults perform maintenance work carry out repair work.

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

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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 activities relating to the Rock Feeder.

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. To find our service address, refer to the “For your information” chapter.

safety

Carefully read through the chapter entitled “Your safety”. This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

Make sure you know what they mean.

Danger!

Passages in the text marked with this symbol indicate an imminent danger. Possible consequences are: very serious injury or even death.

Warning!

This symbol indicates information on hazardous situations.

The possible consequences are very serious injury or even death.

Caution!

This symbol draws your attention to hazardous situations. The 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 machine or damage to the equipment.

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.

J

Items in lists are indicated by bullet points.

–

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

.

1.4

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.

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Signs and symbols used

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 Rock Feeder has been manufactured in accordance using state of the art technology and generally accepted 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 Rock Feeder. 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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The European directives and standards referred to in this operating manual must be applied when using the Rock Feeder within the member states of the European Union (EU).

When used outside the EU, the directives and standards applicable in the countries in question must be complied with.

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: of the mining company, of the mines inspectorate and of the mining supervisory authorities additional operating manuals

Please also read the operating manuals of components required for operation, such as of the Rock Mover RM900, the power pack etc. carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation The Rock Feeder may only be operated by trained personnel. training

The Rock Feeder may only be operated by qualified personnel who can provide proof of having been trained on the control 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 and 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 electrics (controls, signaling devices, etc.), the hydraulic system

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

2.4

Rock Feeder RF300

Operating conditions Operating conditions Intended use The Rock Feeder has been exclusively designed and manufactured as a transport unit below draw points in block caving mines.

It may only be used in non-explosive areas. Use the Rock Feeder only as intended!

Intended use includes: conveying material to downstream conveyor equipment pushing the dozer into the debris below the draw point using the pushing device retracting the dozer from the draw point area using the pushing device operating the dozer below the draw point using the pushing device as a thrust bearing.

Unauthorized use

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Applications not expressly listed as intended use represent unauthorized use, which may not performed using the Rock Feeder.

Caterpillar assumes no liability for damage caused by unauthorized use.

Ambient conditions fire protection

Suitable measures must be taken by the operator to combat explosion hazards due to the ignition of dust and equipment, such as hydraulic oil and lubricants, which might occur in a mine.

These include: water spraying systems fire protection equipment, such as – fire alarm equipment – extinguishing equipment etc.

The atmosphere in the mine must be monitored continuously at the hazardous points, in order that all necessary fire protection and extinguishing measures can be taken immediately in the case of damage.

The Rock Feeder is to be stopped immediately and secured to prevent a restart if damage is detected on the monitoring and fire protection equipment.

It may only be switched on again by an authorized person.

Prerequisites for operation Putting the Rock Feeder into service is prohibited until the complete system in which the Rock Feeder is installed has been found to comply with all of the safety and accident prevention regulations in the country of use.

As the Rock Feeder is only part of an overall system, the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. These shall be marked according to legal provisions applicable at the time they are placed on the market.

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2.5

Operating conditions The Rock Feeder may only be operated if all safety requirements have been met. These include: systems that prevent unauthorized start-up pre-start warning systems safe lock-out command systems EMERGENCY STOP systems noise insulation equipment dust extraction systems fire protection equipment etc.

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Electrical equipment required to operate the Rock Feeder must also be marked according to the legal provisions of the country of use applicable at the time it is placed on the market.

2.6

Rock Feeder RF300

Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes wearing ear protection since the noise emitted by the Rock Feeder may at times exceed 85 dB(A) (e.g. when the dozer or its pusher is moved).

safety equipment

Only start the Rock Feeder if it is in perfect technical condition and all safety equipment, such as EMERGENCY STOP devices etc., is installed.

Keep the signaling and lighting systems in proper working order.

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Pay special attention to the Rock Feeder's acoustic and visual start-up warnings. information signs

Observe the information signs at the Rock Feeder's working area.

EMERGENCY STOP

Press the EMERGENCY STOP immediately in the event of faults or irregularities in operation. Notify your supervisor of every detail, so that necessary action can be taken immediately.

Also press the EMERGENCY STOP switch if safety equipment fails.

protection against being switched back on again

Secure the Rock Feeder against being switched back on again while carrying out: maintenance work inspection work repair work Never enter the dozer if it has not been locked out!

carrying out work on the Rock Feeder

Before you carry out work at the front area of the dozer, use the mobile mounting frame to pull it out of the draw point into a protected area.

cordoning off the working area

Secure your working area over a wide range for wheel loaders, etc.

moving parts

Never reach into or enter areas between machine components which can move, such as: dozer pushing device release locking mechanism

danger of explosion

Hot surfaces may ignite dust. Regularly remove any dust deposits from all drive components and assemblies whose surfaces can become hot during operation.

oil binding agent

Oil pollutes the environment as soon as it enters the ground. Bind any oil that escapes immediately with a suitable oil binding agent.

Keep a sufficient stock of oil binding agent at the hazardous areas.

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2.7

Safety instructions environmental acceptability

Dispose of auxiliary equipment which has been soiled with oil, grease or other chemical substances in an environmentally acceptable manner.

When working with oils, greases and other chemical substances, pay attention to the safety regulations and safety data sheets applicable to the product.

Observe the separate operating manuals for the components used.

Storage and transport Observe the prescribed storage periods and the storage instructions.

Do not store any materials or components in the travel way or in your working area.

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

Make sure that the transport safety devices have been correctly fitted.

E

Lock all moving components in place.

Never walk or stay under unsecured components or suspended loads. mobile handling systems

When using wheel loaders for transport make sure that the center of gravity is as low as possible.

means of attachment

Connect the lifting tackle only to the lifting points provided for that purpose. Observe the different load limits of the lifting points. Follow the instructions on the transport sheets.

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

For round components use transport straps only. Never use chains or steel cables for this purpose.

For lifting, only use: the intended lifting points, lifting tackle of adequate load-carrying capacity.

Installation and commissioning Secure the installed E-motors during installation against unauthorized or unintentional starting.

Do not damage the finished or polished surfaces of cylinders, sealing surfaces, etc.

Operation Operate the control only if you have comprehensive knowledge of the operating elements and their method of operation. You need to have been instructed on the control concerned.

Make sure that there are no persons in the hazardous area of the Rock Feeder before switching it on.

Check that all protective devices are installed on the Rock Feeder and are in working order.

2.8

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

transport safety device

Safety instructions Clean the operating plates at regular intervals. Make sure that the operating symbols are clearly recognizable in order to avoid any operating errors and accidents that could result.

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

Inform your colleagues of: your exact location, the work you are carrying out, the amount of time you will probably require.

Pull the Rock Feeder of the area below the draw point until there is no longer a risk of falling material. securing

Secure the Rock Feeder against being switched on unintentionally or by unauthorized persons prior to any work.

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

Make sure you observe the prescribed maintenance and inspection intervals. replacing components

Stop and lock out the Rock Feeder to prevent it from restarting before replacing any defective components.

Immediately remove defective components in order not to hinder other persons. This measure also prevents the unintentional reinstallation of these components elsewhere.

Immediately pass on the components for servicing.

original parts

Only use spare parts which meet the technical requirements. This is only ensured with original parts from Caterpillar. Please refer to the spare parts lists for the order numbers.

protective devices

Reattach removed protective devices immediately after completing the work, and check they are functioning correctly.

Hydraulic system

handling hydraulic fluids

protective devices - hydraulic system

Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

When dismantling protective devices that contain hydraulic components, bear in mind that these hydraulic 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.

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

maintenance, repairs

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

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2.9

Safety instructions pressure relief valves

Ensure that the pressure relief valves are always protected 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: the hoses are not pinched. the hoses have no swollen parts or blisters. the hoses or the outer sheaths of the hoses are not abnormally rigid or hard. the outer sheath of the hoses is not damaged. the connectors are firmly seated in the coupling connectors. connections are leak-tight.

All screw connections on the hydraulic system can be reused.

Tighten the screw connections to approx. 20-30 Nm (hand-tight), without twisting the hose. Then use a suitable spanner to turn on the screw connection another quarter to half turn.

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 connections.

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

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

2.10

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Before you release hydraulic hoses, turn the hose at the connector a few turns 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.

E

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. Flush out the hydraulic lines thoroughly before connecting.

Safety instructions Fig. 1:

Example: Hydraulic hose, identification 2

3

1

4

1 manufacturer 2 calendar week

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.

laying hydraulic hoses

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Replace hydraulic hoses at the first suspicion of damage.

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

Lay hydraulic hoses so that they: always have a little slack.

Fig. 2:

Laying a hydraulic hose, slack RIGHT

WRONG

are not twisted.

Fig. 3:

Laying a hydraulic hose, twisted RIGHT

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WRONG

2.11

Safety instructions are not bent directly behind their connections (distance minimum 1.5 x nominal diameter).

Fig. 4:

Laying a hydraulic hose, bending RIGHT

WRONG

cannot chafe.

Fig. 5:

Laying hydraulic hoses, crossovers WRONG

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

Only push hydraulic hoses into the connector sockets by hand.

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

When installing the hydraulic hoses, ensure that the movements of the Rock Feeder will not cause them to be: torn out kinked pinched driven over or twisted by the movement of the equipment (fig.: 6).

Fig. 6:

Laying hydraulic hoses, connections on moving parts RIGHT

2.12

WRONG

Rock Feeder RF300

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RIGHT

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and safe transport of the Rock Feeder.

The service life of the Rock Feeder will be increased if you observe the instructions and notes. 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 anticorrosion protection

protection from direct exposure to sunlight/artificial light with high UV content

Protect the equipment from direct exposure to sunlight and artificial light with high UV content. Only store the electrical equipment, electronic components, spare parts made out of rubber or plastic such as seals and hoses, as well as hydraulic fluids in closed rooms at 15C to 25C. The windows of the storage rooms should also be given a red or orange coating.

dirt and moisture

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

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

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic 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 items listed above in the section entitled “Storing the equipment” can be applied in the same way to the storage of hydraulic components that have already been in use. Please also observe the following instructions: If the hydraulic system is to be temporarily put out of service, the complete system and all components need to be drained completely. Exposed connections and hose lines must be sealed.

Do not store any hydraulic components containing hydraulic oil fire risk!

frost protection

Equipment parts for conveying water must be completely drained, and possibly also filled with an antifreeze agent, if required.

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fire protection

3.4

Rock Feeder RF300

Transport Transport Load units, dimensions and weights Observe the separate transport sheets for the respective transport units. It includes information on: dimensions weights lifting points centers of gravity, etc.

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

Warning!

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

Observe the permissible load capacities of the lifting points and keep a safe distance from suspended loads.

Lifting eye and load ring example

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Fig. 7:

Lifting eye

eye

load capacity (5000 kg)

Load ring

welded onto component

load capacity (5000 kg)

screwed onto component

Before transport temperatures below freezing

Prior to transport at temperatures below freezing, hydraulic components must be drained completely.

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.

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VESP / 02

3.5

Transport electrical and electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the complete equipment is 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.

Transporting the components Dozers, pushing devices and other components are equipped with lifting eyes or lifting points for transport.

In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport. The lifting points and the corresponding load capacities are specified further on in the document for the respective machine parts.

Fig. 8: RIGHT

Caterpillar Global Mining Europe GmbH, Lünen 2013

Danger!

Always use all the lifting points provided to transport loads.

Components may come loose due to incorrectly or insufficiently attached loads. Falling components can cause serious injury or even death.

Correct transport of machine parts WRONG

Danger!

Falling components can cause serious injury or even death.

Observe the safe working load of the lifting eyes and keep a safe distance away from suspended loads.

3.6

E

machine parts

Rock Feeder RF300

Transport transport protection

Components may be transported only if all transport safety devices, protection covers and covers etc. intended have been fitted completely and correctly.

Important!

Also observe the separate operating manuals for machine parts not listed here such as the power pack, hydraulic control etc.

Important!

Remove the lifting eyes after transport. Fill the tapped holes with grease and seal them using protective plugs.

Transport units Important!

Also observe the separate transport sheets for the machine parts and accessories not listed here.

Dozer

Caterpillar Global Mining Europe GmbH, Lünen 2013

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The dozer can be installed completely and does not need to be broken down into transport units for transport.

Fig. 9:

Dozer S1 S1

S1 S1

Tab. 1: Dozer, dimensions and weights Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 1) (load capacity in kg)

4322

1990

1050

15921

8000

Pushing device The pushing device can be installed completely and does not need to be broken down into transport units for transport. transport protection

Doc. no.: 5445 001 800 BA 00

Only remove the transport protection immediately before installation.

VESP / 02

3.7

Transport Fig. 10:

Pushing device

S1

S1

S1 S1 S1

1 S1 1 transport protection 1)

Width (mm)

Height (mm)

Weight (~kg)

S1 1) (load capacity in kg)

2080

2300

803

5724

15000

1) Remove after transport

3.8

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Length (mm)

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Tab. 2: Pushing device - head part, dimensions and weights

4

Installation

Installing the rock feeder

Installation Installing the rock feeder Before installation Foundations must be constructed according to the following sketch at the place of operation. The foundations serve as a thrust bearing and guideway for the rock feeder.

Caution!

Ensure that the foundations are designed such that they can absorb the forces generated by the rock feeder.

Fig. 11:

Arrangement of rock feeder in the draw point

Caterpillar Global Mining Europe GmbH, Lünen 2013

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1

Detail Z

b

a

2 5 3

4 4000

1700 Detail Z 560

580

570

360 7

515

6

Doc. no.: 5445 001 800 BA 00

1 mined out area 2 dozer 3 pusher cylinder 4 pusher cylinder thrust force 2573 kN pulling force 1670 kN 5 thrust bearing for locking the pusher cylinder

VESP / 02

6 embedded thrust bearings 7 mobile thrust bearings a pushing direction b dozer cylinder thrust force 4 x 1000 kN

4.3

Installing the rock feeder Notes on installation Caution!

Serious damage can be caused to the rock feeder as a result of incorrect installation.

Install the rock feeder only according to the instructions of Caterpillar technicians.

Caution!

Please take care to observe the respective separate operating manuals (e.g. for the power pack, the hydraulic control, etc.). tightening torques

Tightening torques not stated in the installation instructions for the components please refer to the list in Chapter 6.

handling instructions - connection points

Pins, holes, screws and securing devices must be lubricated with A1 grease (see Chapter 6, section entitled “Greases and lubricating pastes”) prior to installation.

How to install the rock feeder

For lifting or transportation, the dozer and the pusher cylinder are equipped with lifting eyes or transport eyes (see Fig. 9 and Fig. 10).

Warning!

Always use the lifting points when transporting components.

installation

The dozer (1) and the pusher cylinder (2) are arranged behind one an other in a straight line in the mined out draw point. The pusher cylinder is positioned in such a way that it is max. 2100 mm behind the dozer (see Fig. 13).

Remove the transport safety device from the pusher cylinder (a).

For this, undo the screw connections on both sides (b). Also remove the transport straps from the spacer plates (c).

Fig. 12:

Removal of the transport safety device and spacer plates c d

b a

b

a b c

a transport safety device b hex. head screw M 20x30-8.8

4.4

c spacer plate d pusher cylinder

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

lifting points

E

The rock feeder is preassembled at the factory. When the dozer and the pusher cylinder are installed they must be connected via the pusher cylinder.

Installing the rock feeder Warning!

Make sure nobody is inside the hazardous area as soon as you start operating the rock feeder.

Particularly during initial startup, a safe distance should be observed with respect to the conveyor as hazards may occur which would not occur during normal operation, e.g. due to installation errors.

Keep a safe distance from the rock feeder.

Notice!

In addition, observe the information in the separate operating manuals for the power pack, the hydraulic control unit, etc.

Before connecting the dozer and the pusher cylinder Before you connect the pusher cylinder with the dozer you must perform the following work:

. Ensure that the ball valve on the power pack is closed. . Establish the hydraulic connection between the dozer and the Caterpillar Global Mining Europe GmbH, Lünen 2013

E

pusher cylinder by connecting the two hoses between the electrohydraulic control unit and the connections for the dozer cylinder (see hydraulic circuit diagrams, Fig. 19 and Fig. 20 and hose diagram (Fig. 21).

. Establish the connection for the reed rod. The cylinder with reed rod is located on the dozer between the central dozer cylinders (Fig. 15).

. The two pusher cylinders each have a pressure sensor. Connect them.

Danger!

You can be seriously injured or even killed by uncontrolled movements of the dozer or of the pusher cylinder when connecting the pusher cylinders. Only stand in the connecting area if your are certain that there cannot be any uncontrolled movements.

. Connect the main supply lines with the supply block of the rock feeder.

. Check that all hydraulic lines are installed properly. . Check all hydraulic connections for correct fit. . Open the ball valve of the power pack. . Check the hydraulic connections and lines for leaks and damage.

. Ensure that the right and left-hand locks of the pusher cylinder are completely extended (locked).

Move the right-hand pusher cylinder into the right-hand point of attachment on the dozer. The connection is established using a pin (3), which is fastened in place by axially attached washers (4).

Doc. no.: 5445 001 800 BA 00

VESP / 02

4.5

Installing the rock feeder Fig. 13:

Installation - dozer and pusher cylinder (1)

1

8 7 3, 4 5, 6

max.2100

1 dozer 2 pusher cylinder

5 hex. head screw M16x350-8.8 6 hex nut M 16

3 pin 133x310 4 washer D155

7 right pusher cylinder 8 left pusher cylinder

Installation - dozer and pusher cylinder (2) 3 6

1

5 4

2

1 rock feeder 2 pusher cylinder 3 pin 133x310

4.6

4 washer D155 5 hex. head screw M16x350-8.8 6 hex. nut. M 16

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 14:

E

2

Installing the rock feeder Repeat the procedure with the left-hand pusher cylinder.

The middle cylinder with reed rod can be used to determine the current position of the dozer. The cylinder is mechanically extended and retracted with the dozer.

Fig. 15:

Cylinder with reed rod

Caterpillar Global Mining Europe GmbH, Lünen 2013

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X

Y

Y X X connection for reed rod

Doc. no.: 5445 001 800 BA 00

VESP / 02

Y cylinder with reed rod

4.7

How to put the rock feeder into operation How to put the rock feeder into operation The rock feeder must be put into operation according to the instructions of Caterpillar technicians.

Putting a single rock feeder into operation is described below.

If several rock feeders are in operation, this is possible with an automatic sequential control. Always observe the instructions in the control unit's separate operating manual.

Warning!

Make sure nobody is inside the hazardous area as soon as you start operating the rock feeder.

Particularly during initial startup, a safe distance should be observed with respect to the conveyor as hazards may occur which would not occur during normal operation, e.g. due to installation errors.

Keep a safe distance from the rock feeder.

Before startup The following work has to be performed before starting up the system:

. Remove all tools, auxiliary equipment, etc. from the rock feeder and your working area.

. Check all screw connections. . Check all hydraulic connections for correct fit. . Check the hydraulic connections and lines for leaks and damage.

. Check that all supply lines are installed properly. . Check the connection and layout of all electrical connections (refer to the circuit diagram).

. Test the functions of the signaling devices and the intercom system.

. Check all safety equipment to make sure they are working properly.

Important!

The following test run may only be performed if all checks and tests do not reveal any faults (e.g. installation faults etc.).

4.8

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Notice!

In addition observe the information in the separate operating manuals for the power pack, the hydraulic control unit, etc.

How to put the rock feeder into operation How to carry out a test run Danger!

When extending the pusher cylinder and a pusher cylinder that is not locked the pusher cylinder moves directly in your direction. Ensure that your feet do not get trapped beneath the pusher cylinder. Also ensure that the rear area is free of objects which could crush you or which you could trip over.

Perform a test run with the rock feeder before you move the system into the working position/draw point.

Proceed as follows:

. Check all hydraulic cylinders to make sure they are working properly. To this purpose extend and retract the cylinders: – of the dozer, – of the pusher cylinder and – both side locks several times.

(Ensure that the locks can dip freely into the foundations.)

Caterpillar Global Mining Europe GmbH, Lünen 2013

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. Check all hydraulic connections and lines for leaks and damage once more.

Observe the following points before releasing for operation:

. Inspect the rock feeder once again thoroughly for installation errors, damage or other deficiencies.

Important!

When inspection reveals no further deficiencies and all the functions can be performed without problems, the rock feeder can be released for operation.

How to move the rock feeder into the working position Requirements Important!

You must ensure the following before you move the rock feeder into the working position: The draw point incl. the embedded thrust bearing has been completed.

The power pack is installed on the left side of the draw point and the corresponding switch cabinet is installed on the right side of the draw point.

The electrical and hydraulic lines are installed.

The rock feeder must be positioned in the thrust direction in the draw point at a distance of 2100 mm from the wall opposite the draw point.

The mobile thrust bearings are connected to the embedded thrust bearings by connection straps and aligned horizontally.

Doc. no.: 5445 001 800 BA 00

VESP / 02

4.9

How to put the rock feeder into operation Connecting the pusher cylinder to the dozer

. Connect the pusher cylinder mechanically via pin connection to the dozer.

. Connect the pusher cylinder hydraulically to the dozer using hose connections.

. Connect the control block of the pusher cylinder to the power pack.

. Install the control system.

Putting the rock feeder into operation

. Make sure that the dozer of the pusher cylinder and the locks of the pusher cylinder are retracted completely.

. Position the pusher cylinder in relation to the first thrust bearing

the mounting devices of the thrust bearings.

. Extend the pusher cylinders up to their limit of 600 mm so that the dozer can be advanced.

. Retract the side locking elements. . Retract the pusher cylinder completely.

The pusher cylinder is now in front of the next opening of the mobile thrust bearings.

Repeat the steps until the rock feeder has reached the first embedded thrust bearing (7 cycles).

. Position the pusher cylinder in relation to the embedded thrust bearings in such a way that the locks can be retracted without problems into the mounting devices of the foundations.

. Lock the pusher cylinder by moving both locks completely into the mounting devices of the foundations.

. Move the dozer into the debris with the pusher cylinder. . Check whether the foundations are easily able to absorb the forces exerted by the rock feeder.

The dozer is now in its working position. The dozer's pusher can be moved.

4.10

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Lock the pusher cylinder by moving both locks completely into

E

in such a way that the locks can be inserted without problems into the mounting devices.

How to put the rock feeder into operation If the rock feeder does not reach its working position with one stroke of the pusher cylinder, proceed as follows:

. Unlock the pusher cylinder by retracting the right and left-hand locks completely.

. Retract the pusher cylinder. . Position the pusher cylinder in relation to the foundations that the locks can be freely extended. Ensure that the pusher cylinders are retracted if possible in order that the dozer can be pushed forwards.

. Lock the pusher cylinder by moving the right and left-hand locks completely into the foundations.

. Move the dozer with the pusher cylinders into the debris until it has reached its working position.

. Check whether the foundations are easily able to absorb the forces exerted by the rock feeder.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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. Remove the mobile thrust bearings. They are not necessary for operation.

The dozer can then be put into operation.

The pusher cylinder can be locked in 2 positions in the embedded thrust bearings: Position 1 is required for: – putting the rock feeder in the working position (position 2), – removing the rock feeder from the draw point.

Position 2 is the working position of the rock feeder.

Fig. 16:

Embedded thrust bearings 4

2

1 3

1 embedded thrust bearing, position 1 2 embedded thrust bearing, position 2

Doc. no.: 5445 001 800 BA 00

VESP / 02

3 mobile thrust bearings 4 draw point

4.11

How to dismantle and lower the rock feeder Caution!

Pusher cylinders may no longer be able to be extended in position 2.

If the pusher cylinders are extended in position 2, the dozer is pushed to far into the draw point.

The used control must ensure that the pusher cylinders no longer may be extended when the rock feeder is locked in the working position (position 2).

How to dismantle and lower the rock feeder drawing up a dismantling plan

Before the rock feeder can be dismantled, a dismantling plan should be drawn up. The dismantling plan helps you to coordinate dismantling and transport work.

Dismantling should be carried out in the most practical sequence, generally in reverse assembly order. Dismantling depends on the conditions prevailing in the mine.

Important instructions for dismantling handling sensitive components

. Protect all exposed shafts, hubs, labyrinth channels and flanges from corrosion, dirt and damage.

. Completely drain the hydraulic system. . Seal all exposed lines and separating points with protective caps or plugs.

. Pack loose parts, screws, etc. in suitable containers in order to protect the components from dirt and damage.

Dismantling and lowering operations may only be performed by persons with sufficient knowledge of the work to be performed and who have been adequately trained for these particular requirements.

4.12

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Dismantling and lowering operations may only be performed by persons with sufficient knowledge of the work to be performed and who have been adequately trained for these particular requirements.

E

Who is authorized to dismantle and lower the rock feeder?

5

Operation

How to operate the rock feeder

Operation How to operate the rock feeder automatic mode

The complete system consists of several rock feeders, which are controlled by an automatic sequential control. The owner must ensure that the necessary safety equipment, for example start-up warnings and barriers etc. are fitted and functional.

Notice!

Before releasing the system for automatic operation, you must ensure that no persons are in the active range of the rock feeder and that protective devices are installed and are in proper working order.

E

Danger!

Before operating the rock feeder, all persons must leave the hazardous area.

Pay special attention that no one is standing between the dozer and the pusher cylinder.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Functions The following functions can be run by hand using the electrohydraulic control unit:

Fig. 17:

1

Retract dozer

2

Extend dozer

3

Extend pusher cylinder on left

4

Retract pusher cylinder on left

5

Extend pusher cylinder on right

6

Retract pusher cylinder on right

7

Extend lock on both sides

8

Retract lock on both sides

Functions

7 8 4

3

1

2

8 6

5

7

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.3

How to operate the rock feeder Danger!

When the pusher cylinder is not locked it can move in your actual direction. Ensure that your feet do not get trapped beneath the pusher cylinder. Also ensure that the rear area is free of objects which could crush you or which you could trip over.

The dozer is pressed under the draw point by the pusher cylinder. If necessary, the pusher cylinder must be pulled on in order to reach the required position.

If necessary, the dozer can be retracted with the pusher cylinder for repair work.

The stroke of the pusher cylinder is 600 mm.

Observe the following before moving the cylinder of the pusher cylinder:

Fig. 18:

Pusher cylinder - lock

7

7 13, 22 7 lock 13 sleeve

moving the pusher cylinder

22 hex. head screw M20x220-8.8

To advance or retract the pusher cylinder, the locks must be retracted on both sides.

Caution!

Ensure that both pusher cylinders are extended/retracted to the same extent to prevent any jamming between the rock feeder components and the foundations.

5.4

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

The position of the lock can be viewed from the rear. In addition, the opening window of the locking elements on both locks (7) has a hex. head screw (22) with sleeve (13) attached, which enables the visual and sensor inspection of the position of the locking elements:

E

In order to push the rock feeder forwards or retract it, the locks on both sides must be extended.

Ensure that the locks engage in the corresponding holes of the foundations.

moving the rock feeder

How to operate the rock feeder Caution!

Ensure the locks at the side are completely pushed into the mounting devices of the thrust bearings. moving the dozer

Before starting to mine, the rock feeder must be released via the locks.

The pusher cylinder can be locked in 2 positions in the embedded thrust bearings: Position 1 is required for: – putting the rock feeder into the working position (position 2), – removing the rock feeder from the draw point.

Position 2 is the working position of the rock feeder.

Fig. 19:

Embedded thrust bearings

E

4

Caterpillar Global Mining Europe GmbH, Lünen 2013

2

1 3

1 embedded thrust bearing, position 1

3 mobile thrust bearings 4 draw point

2 embedded thrust bearing, position 2

Caution!

Pusher cylinders may no longer be able to be extended in position 2.

If the pusher cylinders are extended in position 2, the dozer is pushed to far into the draw point.

The used control must ensure that the pusher cylinders no longer may be extended when the rock feeder is locked in the working position (position 2).

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.5

How to operate the rock feeder Rock feeder components Fig. 20:

Rock feeder RF300 n c

a

m g

e

f d

i

k

b

5.6

a dozer b pusher cylinder c dozer

g pusher cylinder, right h dozer cylinder i lock indicator, left

d lock, left e lock, right f pusher cylinder, left

k lock indicator, right m electrohydraulic control unit n strip (guide strip)

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

h

Operating the hydraulic system Operating the hydraulic system Warning!

During normal operation, the rock feeder may only be moved using the automatic sequential control. Always observe the instructions in the control unit's separate operating manual.

Arrangement of the hydraulic components The following table specifies the hydraulic components of the rock feeder.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Tab. 3: Hydraulic components Item 01

Quantity Designation 1 Pressure filter

02

1

Copy valve

03

2

Steering cylinder

04

2

Pusher cylinder

05 06

8 1

Control block M4-15 Twin check valve

07

1

Pressure sensor

08

4

Working cylinders

09

1

Reed rod

Arrangement On every power pack in the pressure line On every power pack in the LS line

Note For protecting the system from contamination For pressure amplification of the LS signal At the rear, cross wise in the For locking the rock feeder in pusher cylinder the draw point At the side, on the pusher cylinder For moving the rock feeder, equipped with reed rods Centered on the pusher cylinder On carrier plate Centered on the pusher cylinder, in On carrier plate front of the control blocks In the control block For absorbing the pressure of the drawer cylinders In the drawer of the dozer Perform the working movement In the drawer of the dozer Record the drawer's path

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

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.7

3-A1

R

K

5.8

P

-Y1

”a” ”b”

A1

R

P

K

T

P X Y LS

B1

R

3-A4

”b”

MA MB

A2

T

P X Y LS

3-A5

B2

2

2

1

G

1

G

”a”

1

1

”b”

A P

P

P

B

A

E

MA MB

A3

T

P X Y LS

B3

”a”

P

T

B

T

A

T B

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

”a”

K

3-A6

”b”

A

T

LS

R K

3-A3

MA MB

A4

3-V3

3-A7

B4

C

A

T1

T

P X Y LS

B A

LSZ

Y

B A

D

B

3-A8

X

Fig. 21:

3-V2 M

3-A2

Operating the hydraulic system Hydraulic circuit diagram for the dozer

B

T

Doc. no.: 5445 001 800 BA 00

VESP / 02 ”a” ”b”

MB P MA

A1

T

P X Y LS

B1

”a” ”b”

A2

T

P X Y LS

B2

2

3-A6

1

G

”a”

1

”b”

A3

T

P X Y LS

B3

”a” ”b” A B

P T

A B

P T

A B

P T

B

A

B4

T1

T

P X Y LS

A

LSZ Y

D

B

A

B

C

3-A8

3-A7

MB MA

T

MB MA

P

MB MA

A4

3-V3

B

T

LS

P

K1

1

A

T2/6

P2/6 LS2/6

3-V2 M

R1

G 1

E

X

Fig. 22:

2

3-A5

Caterpillar Global Mining Europe GmbH, Lünen 2013

Operating the hydraulic system

Hydraulic circuit diagram for the pusher cylinder

5.9

Operating the hydraulic system Fig. 23:

Circuit diagram for dozer 3-A1

3-A2

R

R

K

3-A9

K

-Y1

3-A3

3-A4

R

R

K

K

3VTL1 5

3VTL2 5

3VTL3 5

3VTL4 5

3VTL5 5

3VTL6 5

3VTL7 5

3VTL8 5

3Z30 1 DN16X810

3Z31 1 DN16X810

3Z32 1 DN16X810

3Z33 1 DN16X810

3Z34 1 DN16X810

3Z35 1 DN16X810

3Z36 1 DN16X810

3Z37 1 DN16X810

3VTL13 4 3VTL9 7

3Z38 3VTL15 6 2 DN16x400

3VTL16 6

3Z39 2 DN16x400

3VTL14 3VTL17 6 4 3Z43 3 DN16x350

3Z40 2 DN16x400

3VTL18 6

3VTL12 7

3Z41 2 DN16x400

R

3-A1 working cylinder 3-A2 working cylinder 3-A3 working cylinder 3-A4 working cylinder

K

3-A6 pusher cylinder, right 3-A7 locking cylinder, left 3-A8 locking cylinder, right 3-A9 measuring cylinder 3-V3 piloted twin check valve

3-A5 pusher cylinder, left

Control block 4M4-15 The control block is installed on the pusher cylinder.

Warning!

The actuators on the electrohydraulic control unit on the pusher cylinder should only be used in an emergency and for repair work and only in accordance with the special work instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury.

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

5.10

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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3VTL11 7

3Z42 3 DN16x350

3VTL10 7

Operating the hydraulic system Fig. 24:

Control block 4M4-15 3

2

5

3

3

3 4

7 1

Caterpillar Global Mining Europe GmbH, Lünen 2013

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6

2

9

8 6 1 housing 2 electrohydraulic actuation 3 secondary valves 4 actuation of cover B 5 port X 6 end element, port LS, G 1/4

7 port P, G 1 8 port T, G1 9 port MA, pressure sensor connected, G 1/4

Piloted twin check valve DRH The piloted twin check valve is installed on the pusher cylinder.

With regard to this, observe the separate operating manual.

Fig. 25:

Piloted twin check valve DRH

1 2 1 threaded port A G 1/2 2 threaded port B G 1/2

Doc. no.: 5445 001 800 BA 00

VESP / 02

3

4

3 threaded port C G 1/2 4 threaded port D G 1/2

5.11

Operating the hydraulic system 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 rock feeder has already been correctly installed. It is also assumed that all shut-off valves are open as during normal operation.

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

The basic design of the rock feeder and of the control is shown in chapter 6, “Technical data”.

Operation and functions of the electrohydraulic control unit Important!

Always observe the instructions contained in the separate 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 if you know exactly what effects the functions have with respect to the rock feeder. You must have therefore 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.

The control of the rock feeder is particularly hazardous during repair work, as the rock feeder is then controlled directly. It is therefore extremely important that you know and understand the relationships between the functions and movements of the rock feeder.

While operating the rock feeder in repair mode, no other persons are permitted in the rock feeder's motion range.

All pushbuttons are on the control box of the pusher cylinder. When you press a button, the corresponding working valve is operated immediately.

The function stops as soon as you release the button.

5.12

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Warning!

The actuators on the electrohydraulic control unit on the pusher cylinder should only be used in an emergency and for repair work and only in accordance with the special work instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury.

The rock feeder is operated 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

It has also been assumed that the reader is familiar with the fundamental principles of the hydraulic control systems and the operation of the control unit.

Operating the hydraulic system Danger!

Jammed or locked buttons can cause uncontrolled movements of the rock feeder. 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, causing extremely serious injuries.

Important information concerning basic hydraulic functions This section will give you a brief overview of the basic hydraulic functions of the rock feeder.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Important!

Always observe the instructions contained in the separate operating manuals of the electrohydraulic control unit and the electronic control system.

Tab. 4: Overview of basic hydraulic functions Basic function Retract dozer Extend dozer Extend the pusher cylinders, right/left

Retract pusher cylinders, right/left Retract/extend lock

To be observed Before executing this function, the locks must be retracted completely into the foundation.

Before executing this function, the locks must be extended completely into the foundation.

If the rock feeder is to be moved, the locks must be retracted completely into the foundation.

If the pusher cylinder is to be moved, the locks must be completely extended out of the foundation.

If the rock feeder is to be moved, the locks must be retracted completely into the foundation.

If the pusher cylinder is to be moved, the locks must be completely extended out of the foundation.

If the lock is to be extended, it must first be made sure that this can properly extend into the foundation.

The functions of the locks are only possible using 2 buttons (Retraction and Extension). The steering cylinders are supplied via a common supply line. That and the shape of the embedded thrust bearings in the foundation are for ensuring that the pusher cylinder is centered.

Caution!

The position of the pusher cylinder in relation to the embedded thrust bearings in the foundation must allow the locks to move correctly into the foundation!

Caution!

If the inclination of the dozer is greater than that of the pusher cylinder, it can damage the pusher cylinder or the foundation.

Ensure that the dozer, the pusher cylinder and the foundation are always arranged in a straight line.

Important!

More information on how to operate the control unit can be found in the separate operating manual.

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.13

How to maintain the rock feeder How to maintain the rock feeder Maintenance at regular intervals increases the operational safety and prolongs the service life of the system.

Make sure you also observe the safety instructions in chapter 2, “Your safety”. danger of explosion

Make sure to observe the intervals specified for maintenance and checks of the rock feeder as hot surfaces may ignite dust.

Temperature and acoustic emission monitoring Hydraulic cylinders, valves and similar components of the rock feeder can be equipped with temperature and/or acoustic emission monitoring.

The operator can use a continuous monitoring system to switch off the drives if: an impermissible temperature is reached, unacceptable structure-borne noise characteristics are indicated.

Please observe the following instructions: In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the conveyor system as a whole, we recommend a general maintenance plan to be drawn up. You can, for example, create a checklist using this operating manual and the manuals of the other components.

Machine damage can be caused, resulting in considerable costs, if the maintenance work performed is inadequate.

Be sure to observe the specified maintenance intervals.

Only use suitable and approved tools for maintenance work.

Only use original spare parts from Caterpillar when replacing components.

How to maintain the steel structure Inspection and maintenance of the steel structure includes: Check all components of the system at least once a shift for visible signs of damage or faults.

Defective or missing parts must be replaced immediately.

Make sure all connecting elements are fitted firmly.

Check the system for faults and proper operation.

Checking wear parts In order to be able to determine in good time when a repair shift has to be scheduled and to avoid damage to other components, it is necessary to check all wearing parts regularly for their degree of wear.

For this, refer to the “Maintenance table“ (Tab. 5) on page 5.16 in this chapter.

The strips (guide strips, refer to Fig. 20, Item n) which are screwed on at the side can be replaced when worn. The wear limits must be determined during operation and coordinated with Caterpillar.

5.14

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Instructions for maintenance

How to maintain the rock feeder How to maintain the hydraulic system Exact knowledge of the hydraulic system is essential for its maintenance. You must, therefore, familiarize yourself with the wiring diagrams for the control elements and with the hydraulic diagrams (the hydraulic diagrams are to be found in the spare parts documentation).

Make sure you also observe the safety instructions in chapter 2, “Your safety”.

Maintenance of the hydraulic system Important!

Check and maintain all components for the hydraulic system, such as power packs, pumping stations, filter systems etc. in accordance with the corresponding supplier documentation of the respective manufacturer.

The hydraulic system must be maintained regularly. Perform the following work: Check that all components are in perfect condition.

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Make sure the connecting elements and securing devices are in perfect condition.

Check the correct installation of all lines.

Check that all connections are fitted firmly.

Check that all operating levers, rods, cylinders, locking pieces, springs, etc. are working perfectly.

Caution!

Report any damage, defective components or other faults to your supervisor immediately.

Replacing and cleaning filters as required

Contaminated hydraulic fluid will result in severe damage to the hydraulic system.

Check all filters according to the manufacturer's information.

Special measures The function of all pressure relief valves is to be checked at least once a year.

For reasons of safety and to maintain correct system function, all high-pressure hydraulic hose lines must be replaced every two years, regardless of whether there is any visible damage.

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.15

How to maintain the rock feeder Maintenance tables Tab. 5: Dozer maintenance checklist Item

Maintenance points

Maintenance intervals Before shift

Dozer D10

Daily

Weekly

Monthly

Duration (in hrs)

As required

xxxxx

xxxx 1)

Bearings pins, locking clips Lubricate.

Check for correct seat and position, and replace if required.

D20

Hydraulic cylinders and piston rods Visual inspection, check for damage and leaks, and replace if required.

D30

Mechanical kinematics Check for freedom of movement. Replace as required.

Hydraulic hose lines Check for damage, leaks and firm fit. Replace as required.

D50

Electrical connections Check for damage and firm fit.

D60

Screw connections Check for damage and firm fit.

D70

D80

Dozer, guide rails and sliding plate Check for wear and replace if required.

1/2a

Lubricate guide rails 2).

1/2a

Path measuring cylinder incl. bracket Check function.

Check for damage, leaks and firm fit. Replace as required.

D90

Steel structure Check for damage. Replace as required.

Check for contamination and remove as required.

Important!

Check and maintain all components according to the supplier documentation of the corresponding manufacturers.

Observe the manufacturer's information.

1) a = annually, 1/2a = every six months, 1/4a = every three months etc.

2) First time after 3 months, afterwards at the specified intervalls.

5.16

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

D40

E

Check for collisions. Replace as required.

How to maintain the rock feeder Tab. 6: Pusher cylinder maintenance checklist Item

Maintenance points

Maintenance intervals Before shift

Daily

Weekly

Monthly

Duration (in hrs)

As required

xxxxx

xxxx 1)

Pusher cylinder PD10 Bearings, guideways, pins, locking clips Lubricate.

PD20

Hydraulic cylinders and piston rods Visual inspection, check for damage and leaks, and replace if required.

PD30

Mechanical kinematics Check for freedom of movement. Replace as required.

Check for collisions. Replace as required.

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PD40

Guide faces of lock Check for freedom of movement. Replace as required.

Check for contamination and damage.

PD50

Lock Check function.

Check for wear and replace as required.

PD60

Hydraulic hose lines and components Check for damage, leaks and firm fit. Replace as required.

PD70

Screw connections and clamping pieces Check for damage.

Important!

Check and maintain all components according to the supplier documentation of the corresponding manufacturers.

Observe the manufacturer's information.

1) a = annually, 1/2a = every six months, 1/4a = every three months etc.

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.17

Troubleshooting Troubleshooting Instructions for troubleshooting The hydraulic system of the rock feeder consists of a large number of individual components. How the components are linked to each other is shown in the circuit and hose diagrams for the rock feeder: see section entitled “Operating the hydraulic system” in this chapter or in 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.

Fault localization the dozer cannot be extended/retracted

5.18

Possible cause

Measure required

The shut-off valve for the hydraulic system on the power pack is closed.

Open the shut-off valve.

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

Observe the separate power pack operating manual.

The pressure of the hydraulic supply is too low.

Check if the pressure gauge at the power pack indicates sufficient pressure. Observe any fault indication and check power pack.

Observe the separate power pack operating manual.

The dozer is mechanically jammed.

Determine the cause. If necessary, pull the dozer out of the mining field and free it from obstruction. If necessary replace the wearing strips.

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 check valve may be defective.

Damaged or trapped hose line.

Check the hydraulic pressure on the pressure gauge in the piston space/annular side of the hose lines for control of the dozer cylinder.

Check the hose lines and replace them if necessary. Make sure hose lines are laid properly.

Dozer cylinder defective

Check the dozer cylinder for damage and leakage. Replace the dozer cylinder if necessary.

Electr. fault reed rod

See separate control unit operating manual

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

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

Troubleshooting pusher cylinder cannot be extended/retracted

Possible cause

Measure required

The shut-off valve for the hydraulic Open the shut-off valve.

Valves can only be switched when the supply system on the power pack is line is open. closed.

Observe the separate power pack operating manual.

The pressure of the hydraulic supply is too low.

Check if the pressure gauge at the power pack indicates sufficient pressure. Observe any fault indication and check power pack.

Observe the separate power pack operating manual.

The dozers or pusher cylinders are Determine the cause. Remove compressed jamming mechanically. debris between the rock feeder and the access opening to the draw point. If necessary, align the dozer, pusher cylinder and foundations in one line.

Check the hydraulic pressure on the pressure gauge in the piston space/annular side of the hose lines for control of the pusher cylinders.

Check. the hose lines and replace them if necessary. Make sure hose lines are laid properly.

Pusher cylinder defective

Check the pusher cylinder for damage and leakage. Replace the pusher cylinder if necessary.

Electr. fault reed rod

See separate control unit operating manual

Possible cause

Measure required

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Damaged or trapped hose line.

the lock cylinder cannot be extended/retracted

The shut-off valve for the hydraulic Open the shut-off valve.

Valves can only be switched when the supply system on the power pack is line is open. closed.

Observe the separate power pack operating manual.

The pressure of the hydraulic supply is too low.

Check if the pressure gauge at the power pack indicates sufficient pressure. Observe any fault indication and check power pack.

Observe the separate power pack operating manual.

The lock is not correctly aligned with the foundations. The embedded thrust bearings of the foundations contain foreign matter

Determine the cause. Align the pusher cylinder correctly with the embedded thrust bearings. Remove the foreign matter.

Control piston on the piloted check Check whether the pressure is sufficient valve is not working. to control the valve; approx. 80 bar is the minimum.

The check valve may be defective.

Doc. no.: 5445 001 800 BA 00

Damaged or trapped hose line.

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

Lock cylinder defective

Check the lock cylinder for damage and leakage. Replace the lock cylinder if necessary.

VESP / 02

5.19

Troubleshooting M4-15 control block 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.

Control valves with a significantly lower volume flow will become noticeably warmer due to the constantly flowing medium.

Defective control blocks are difficult to detect as no medium is discharged at the valve terminal. There is therefore no obvious indication of faults, such as discharged pressurized fluid.

The control block 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.

replacing the control block

. Switch the power pack off. The pressure gauge of the unit then indicates a pressure of 0 bar.

. Then actuate the functions manually to depressurize the system.

. Replace the control block.

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 it is defective.

Pressure relief valve defective Leaky pressure relief valves can normally be identified by discharged pressurized fluid, a pressure drop indicated at a pressure gauge and/or by audible flow into the tank. 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.

The pressure relief valves are set to a maximum pressure of 350 bar. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

5.20

Rock Feeder RF300

E

. Locate the faulty valve by actuating the functions individually in

Caterpillar Global Mining Europe GmbH, Lünen 2013

internal leakage

Troubleshooting Defective or clogged filter Operation 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Backflush filters can be cleaned by backflushing. The filter elements must be replaced on fine-mesh filters, such as on the power pack.

Doc. no.: 5445 001 800 BA 00

VESP / 02

5.21

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Troubleshooting

5.22

Rock Feeder RF300

6

Technical data

Main components

Technical data This chapter contains the most important technical data for the Rock Feeder. Further data can be found in the spare parts lists and in the separate operating manuals of the individual components, such as the power pack, the control unit, etc. Information about tightening torques, greases etc. is given at the end of this chapter.

Main components general

Caterpillar Global Mining Europe GmbH, Lünen 2013

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dozer

pushing device

Noise level: . . . . . . . . . . . . . . . . . .

> 85 dB(A) 1)

System pressure . . . . . . . . . . . . .

Hydraulic medium . . . . . . . . . . . .

320 bar HLP 46

Max. dozer force: . . . . . . . . . . . . .

Dozer stroke . . . . . . . . . . . . . . . . .

4020 kN extension 2048 kN retraction 1350 mm

Length: . . . . . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . . . .

4322 mm 1990 mm 1050 mm 15921 kg

Max. pushing force: . . . . . . . . . . .

Pushing stroke . . . . . . . . . . . . . . .

5146 kN extension 3520 kN retraction 600 mm

Length: . . . . . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . . . .

2080 mm 2340 mm 2) 803 mm 5652 kg

1)) In certain operating phases (e.g. empty Rock Feeder) the noise emissions may 2)

Doc. no.: 5445 001 800 BA 00

temporarily exceed 85 dB (A).

Locks extended

VESP / 02

6.3

Hydraulic cylinder Hydraulic cylinder Pusher cylinder Fig. 26:

Hydraulic cylinder ZE-320/180-600-SO-W-CR

135 L b d c

3

a 10

2

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11 1

1 cylinder tube 2 cylinder head 3 reed rod (in the piston rod) 10 head of rod 11 piston rod pusher cylinder double-acting, electrical connection

6.4

a piston space connection b annular space connection c reed rod adapter d load ring 3000 kg

Type ZE-320/180-600-SO-W-CR, device number 8241 552 000 00 00 version with reed rod Length L retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm extended . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1419 2019

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

600

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

320

Piston rod diameter . . . . . . . . . . . . . . . . . mm

180

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

804

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

550

Thrust force at 320 bar . . . . . . . . . . . . . . kN

2573

Pulling force at 320 bar . . . . . . . . . . . . . . kN

1760

Rock Feeder RF300

Hydraulic cylinder Dozer cylinder Fig. 27:

Hydraulic cylinder ZE-200/140-1350-SO-CR

L

82

2 3

a

1

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1 external guard tube 2 piston rod 3 guard tube screw fitting a piston space connection (marked with K) annular space connection (marked with R) dozer cylinder double-acting

Doc. no.: 5445 001 800 BA 00

Type ZE-200/140-1350-SO-CR, device number 8241 538 000 00 00 Length L retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm extended . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1820 3170

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1350

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

200

Piston rod diameter . . . . . . . . . . . . . . . . . mm

140

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

314

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

160

Thrust force at 320 bar . . . . . . . . . . . . . . kN

1005

Pulling force at 320 bar . . . . . . . . . . . . . . kN

512

VESP / 02

6.5

Hydraulic cylinder Lock cylinder Fig. 28:

Hydraulic cylinder ZE-80/50-170-AB-CR

40 L

a

b

1

1 cylinder tube 2 piston rod lock cylinder double-acting

6.6

a piston space connection b annular space connection

Type ZE-80/50-170-AB-CR, device number 8241 555 000 00 00 Length L retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm extended . . . . . . . . . . . . . . . . . . . . . . . . . . mm

455 625

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

170

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

80

Piston rod diameter . . . . . . . . . . . . . . . . . mm

50

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

50.3

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

30.6

Thrust force at 320 bar . . . . . . . . . . . . . . kN

161

Pulling force at 320 bar . . . . . . . . . . . . . . kN

98

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

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2

Hydraulic cylinder Measuring cylinder Fig. 29:

Hydraulic cylinder ZE-35/33-1350-ME-W-BN

20

L1 L

21 24 3

1

b

a

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1 cylinder tube 3 reed rod 21 piston rod 24 threaded ring measuring cylinder electrical connection

Doc. no.: 5445 001 800 BA 00

a peg b ventilation

Type ZE-35/33-1350-ME-W-BN, device number 8241 537 000 00 00 version with reed rod Length L retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm extended . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1360.5 2710.5

Length L retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm extended . . . . . . . . . . . . . . . . . . . . . . . . . . mm

15010.5 3010.5

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1350

VESP / 02

6.7

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as 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 Rock Feeder. Also refer to the hydraulic circuit diagram and spare parts catalog.

Design

Setting pressure in bar

Device no.

General cylinder use

Spring-loaded

350

4318375

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!

Defective seals will result in leaky connections and impair the operational safety of the hydraulic system.

Always fit new seals when replacing a pressure relief valve. identification

Pressure relief valves are color-coded and text-coded according to DIN 21557.

The text code includes the following information: setting pressure, target value week setting was made year setting was made last person who made changes Tab. 8: Text code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

1)

6.8

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” corresponds to 420 bar, “08” corresponds to 80 bar

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

Application

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Tab. 7: Pressure relief valves, use of the various types

Pressure relief valves Color coding is with either one or two colors. It indicates the range within which the setting pressure is. The following figure 30 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.

Fig. 30:

Pressure relief valve, example

b

a

a color code b protective cap

The following table shows the relationship between the color code and the pressure range.

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Tab. 9: Color codes for pressure relief valves, overview

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VESP / 02

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

6.9

Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 10: Tightening torques at tot. = 0.14 Tightening torque 4)

Pitch P

(mm)

(mm) 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

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d

Important!

The tightening torques listed in the spare parts lists must also be observed during installation and maintenance work.

1) 2) 3)

The dimensions listed in parentheses are used in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

Only for expansion bolts with a reduced shaft cross-section of 24.2 mm.

4) The tightening torques comply with the works standard (EWN 6003).

6.10

E

Thread 1)

Rock Feeder RF300

Permissible media Permissible media Hydraulic oil Permissible hydraulic oil Hydraulic oil: HLP 46 operating temperature

The maximum permissible temperature of the hydraulic fluid is 60C. During normal operation, however, an operating temperature of 45C should not be exceeded. A higher operating temperature will reduce the service life of the sealing material.

Quality of the process water for use as spraying water

E

limit values

The water used 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 m. In order to protect the components, the limit values listed in the table must not be exceeded.

The following table lists limit values for the main properties and components of the process water.

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Caution!

Using water that is not of the specified quality can cause serious damage to component surfaces and the entire system.

Only use water that complies with the specified limit values!

Tab. 11: 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 S/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)

Solid foreign matter share with 1.2 m filtering  in accordance with DIN EN 12662 Contamination class according to ISO 4406: 1999

1)

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10 mg/l1)

- / 18 / 14 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.

VESP / 02

6.11

Permissible media 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. 12: 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. 13: Grease A2 Supplier

Make

Base

NLGI class

Flashpoint in °C

Shell

Alvania E.P. grease 2

Lithium soap

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. 14: Grease A8 Supplier

Make

Base

NLGI class

Flashpoint in °C

Castrol

Molub-Alloy 3036/680-1

Lithium soap

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

6.12

Rock Feeder RF300

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Behavior in the presence of water: . . . practically insoluble in water

Permissible media Lubricating pastes lubricating paste B1

Lubricating paste as spray with solid lubricant molybdenum disulfide and adhesive active agents. To lubricate fixed and sliding fits, heavy-duty dowel pins for facilitate installation. Reduced friction and wear.

Tab. 15: Lubricating paste B1 Supplier

Make

Gleitmolybdän

gleitmo 100 S Spray Mineral oil

-

Molykote

Paste G Rapid Spray

-

Lubricant carrier

NLGI class

Mineral oil

Static penetration: . . . . . . . . . . . . . . . . . . 250 to 270 (0.1 mm) Behavior in the presence of water: . . . . no information Temperature range of application: . . . . -35 to +450C, when air is excluded, up to 630C

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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. 16: 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 lubricant B6

Parting agents and lubricants with organic lubricating media on synthetic carrier material for lubricating threaded areas and fitting points on props and hydraulic cylinders, on pin connections and similar connecting elements.

Tab. 17: 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

Doc. no.: 5445 001 800 BA 00

VESP / 02

6.13

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Permissible media

6.14

Rock Feeder RF300

7

For your information

Standards and directives

For your information Should you require spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.mining.cat.com).

Standards and directives Applied standards and directives Tab. 17: Standards and directives, excerpt

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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 2004-04 Safety of machinery 12100-1/A1 2009-10 DIN EN ISO 12100-2 Safety of machinery 2004-04 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 DIN EN 60445 Basic and safety principles for man-machine interfaces 2007-11 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 plow 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 neutralization number 1979-07 DIN 51575 Determination of the sulfate ash 2011-01

Doc. no.: 5445 001 800 BA 00

VESP / 02

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

E

EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = works standard

7.4

Rock Feeder RF300