CAT Roof Support Face-End Shield 21003800-2X6760-2050 Operating and Maintenance Manual

Media-ID: EM027415-00-EN Doc.-No.: 7420 274 000 BA 01 Jun. 2017

Operating and Maintenance Manual Face-End Shield 2100/3800-2X6760-2050 Part-No.:

4844969

Serial-No.:

ZZ700100 - ZZ700107

SAFETY.CAT.COM

© 2017 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of contents

Table of contents 1 About this manual ....................................................................................... 6 1.1 How to use this manual ........................................................................ 6 1.2 Signs and symbols used....................................................................... 8 2 Safety............................................................................................................ 9 2.1 General safety instructions ................................................................... 9 2.2 Personnel.............................................................................................. 9 2.3 Repair and servicing ............................................................................. 9 2.4 Operating conditions........................................................................... 10 2.4.1 Intended use ............................................................................ 10 2.4.2 Unauthorized use..................................................................... 10

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2.5 Using the machine and working on the machine ................................ 11 2.6 Notes on the hydraulic system............................................................ 12 2.6.1 Recommended storage and use period................................... 14 3 Storage and transport ............................................................................... 16 3.1 Storage ............................................................................................... 16 3.2 Transport ............................................................................................ 17 3.3 Transporting the entire shield support ................................................ 20 3.3.1 End shield ................................................................................ 20 3.3.2 Transport safety devices.......................................................... 22 3.3.3 Relay bar assembly ................................................................. 23 3.3.4 Side seal .................................................................................. 24 4 Installation.................................................................................................. 25 4.1 Pre-assembly of the shield units......................................................... 25 4.2 How to install the shield units ............................................................. 25 4.2.1 Shield units .............................................................................. 25 4.2.2 Pressure equalization of the electronic control system............ 27 4.2.3 Supply connections for auxiliary supply ................................... 28 4.3 Requirements for the face hydraulic system....................................... 33 4.4 Water spraying system requirements ................................................. 33 4.5 Commissioning ................................................................................... 34 4.5.1 To be observed prior to commissioning ................................... 34 4.5.2 How to put the support into operation ...................................... 36 4.5.3 Corrosion protection of hydraulic components......................... 36 5 Operation.................................................................................................... 37 5.1 Requirements ..................................................................................... 37 5.1.1 Operating conditions ................................................................ 37 5.1.2 Safety requirements................................................................. 39 5.2 Operation of the shield support........................................................... 42 5.3 Work safety......................................................................................... 48 5.4 Shield components ............................................................................. 49 5.5 Design of the ball valves..................................................................... 51 5.6 Hydraulic components on the shield................................................... 53 5.6.1 Location of hydraulic components ........................................... 53

Face-End Shield 2100/3800-2X6760-2050

Table of contents

5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.6.8 5.6.9 5.6.10

Control unit functions and pin assignment ............................... 60 Shield hydraulics...................................................................... 61 Hydraulic lines.......................................................................... 62 Hose lines ................................................................................ 64 Stecko parts ............................................................................. 68 Water spraying system and accessories ................................. 71 Bracket and accessories.......................................................... 73 Additional brackets................................................................... 79 Tools ........................................................................................ 84

5.7 Location of the hydraulic components ................................................ 87 5.8 Repair and emergency operation ....................................................... 99 5.9 Operation and functions of the electrohydraulic control unit............. 100 5.9.1 Shield functions - control unit, 12-function ............................. 100 5.9.2 Shield functions – water valve unit......................................... 103 5.11 Measuring coupling........................................................................... 104 5.12 Maintenance ..................................................................................... 105 5.13 Regular, scheduled damage assessment......................................... 107 5.14 Troubleshooting ................................................................................ 108 5.14.1 Instructions for troubleshooting.............................................. 108 5.14.2 3/2-way or pilot valve ............................................................. 111 5.14.3 Piloted check valves .............................................................. 111 5.14.4 Checking the leg check valves............................................... 111 5.14.5 Internal bypass in legs ........................................................... 111 5.14.6 Pressure relief valve defective ............................................... 112 5.14.7 Defective or clogged filter ...................................................... 112 6 Technical data.......................................................................................... 113 6.1 Technical description ........................................................................ 114 6.1.1 Main dimensions, end ............................................................ 114 6.1.2 Base frame with lemniscatic link and relay bar assembly...... 115 6.1.3 Relay bar assembly ............................................................... 121 6.1.4 Lemniscatic links.................................................................... 123 6.1.5 Canopy................................................................................... 125 6.1.6 Flipper .................................................................................... 127 6.1.7 Leg head with pin................................................................... 129 6.1.8 Canopy and caving shield side seals..................................... 130 6.1.9 Caving shield ......................................................................... 133 6.2 Accessories ...................................................................................... 135 6.2.1 Anti-topple device "canopy-canopy" ...................................... 135 6.2.2 Side flap ................................................................................. 143 6.3 Technical data, steel structure.......................................................... 145 6.4 Hydraulic system .............................................................................. 146 6.4.1 Shield hydraulics.................................................................... 146 6.5 Two-stage telescopic leg .................................................................. 147 6.5.1 Function ................................................................................. 148 6.6 Hydraulic cylinders............................................................................ 150 6.6.1 Layout .................................................................................... 150 6.6.2 Legs and cylinders ................................................................. 151 6.7 Pressure relief valves ....................................................................... 157 6.8 Angles of inclination of the canopy ................................................... 159 Face-End Shield 2100/3800-2X6760-2050

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5.10 Operating the double filter ................................................................ 103

Table of contents

6.9 Tightening torques ............................................................................ 159 6.9.1 Screws and bolts with ISO metric thread .............................. 159

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6.10 Permissible media ............................................................................ 161 6.10.1 Hydraulic fluids....................................................................... 161 6.10.2 Quality of the process water .................................................. 163 6.10.3 Greases and lubricating pastes ............................................. 164

Face-End Shield 2100/3800-2X6760-2050

About this manual

1

How to use this manual

1 About this manual This chapter contains important information that makes it easier for you to use this manual. You will also get information about the structure of the manual and the symbols, characters and abbreviations used and frequently used terms.

1.1 How to use this manual applicable operating manual

Using an operating manual that was not specifically written for the machine concerned can result in a safety hazard for yourself and others. Ensure that the data on the machine complies with the data given in the operating manual.

The operating manual must be accessible at all times to all persons working on or with the shield. It should always be available at the place of operation.

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

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields. All persons working on the face, at the edge of the face or at the entry must read this operating manual.

This includes persons who: are in charge of transport, set up the rise heading, perform installation/removal work, operate the shields, correct malfunctions, carry out daily routine work on the face or in the entry, monitor and look after for the hydraulic system, carry out maintenance work, carry out repair work.

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

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 product.

Take the time to read this operating manual in its entirety. Pay particular attention to the respective safety instructions. Familiarize yourself well with the appearance and meaning of the safety and information symbols.

Safety

Read the chapter “Your safety” especially carefully. This chapter contains important information, drawing your attention to possible hazards in the context of handling the product.

Carefully read through the chapter "Safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

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new operating manual

About this manual How to use this manual

Please contact your service partner for spare part requests or for the clarification of technical questions.

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service partner

1

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1

About this manual Signs and symbols used

1.2 Signs and symbols used DANGER The combination of the signal word DANGER and a corresponding symbol warns you of an immediate danger with a high personal risk.

If not observed, you or your coworkers will be seriously injured or killed.

1. Follow the described instructions.

WARNING The combination of the signal word WARNING and a corresponding symbol warns you of a potential danger with a moderate personal risk.

1. Follow the described instructions.

CAUTION The combination of the signal word CAUTION and a corresponding symbol indicates a potential personal risk.

If not observed, you or your co-workers could suffer minor to moderate injuries.

1. Follow the described instructions.

NOTICE The combination of the signal word CAUTION and the adjacent symbol indicates a potential risk of damage to the machine.

If not observed, material damage might occur on the machine.

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

This information will help you become more familiar with the machine and allow you to prepare your work more exactly.

1. Observe the provided tips and information.

Important information The combination of the signal words IMPORTANT INFORMATION and the adjacent symbol indicates important information or other operating manuals which must be observed at this place.

1. Observe the information and read the specified operating manuals.

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If not observed, you or your co-workers might be seriously injured or killed.

Safety General safety instructions

2

2 Safety This chapter provides you with important information about 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.

2.1 General safety instructions state of the art

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

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

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

Observe the safety and accident prevention regulations of the following parties: the mining company, the mines inspectorate and the mining supervisory authorities. additional operating manuals

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

2.2 Personnel The machine may only be operated by skilled or instructed personnel.

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

The following parts may only be installed or repaired by service technicians authorized by Caterpillar or mining professionals as defined below: safety components (pressure relief valves, etc.), the electrical system (controls, signaling devices, etc.), hydraulic system qualification

A skilled worker is someone who, based on his special training and experience, has sufficient knowledge and is familiar with the relevant regulations.

A skilled worker can carry out the work assigned to him. He can recognize potential hazards and take the necessary measures to eliminate them. He also has the required repair and installation knowledge.

An instructed person is someone who has been instructed with regard to the tasks assigned to him and the potential hazards which arise due to improper behavior, and, if applicable, has been trained/instructed concerning the necessary safety equipment and protective measures. The instructed person is able to work while looking ahead, recognize hazards and act accordingly.

2.3 Repair and servicing In general, repair work may only be performed by persons who have the knowledge and skills to meet the special requirements and have been adequately trained in the repair and servicing of the equipment.

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2

Safety Operating conditions

Repair work on and overhaul of: safety devices, as e.g. pressure relief valves, hydraulic props and cylinders control units, valves, and filters may only be carried out by Caterpillar service engineers or by specially trained personnel of the mining company.

2.4 Operating conditions 2.4.1 Intended use

Intended use includes: propping the roof up against the mine floor, ensuring an adequate travel way, the following shield operations: lowering, advancing, aligning and setting, the following conveyor operations: advancing, retracting, forming a thrust bearing for: the conveyor and mining equipment, conveyor steering devices, devices for raising the conveyor, conveyor steering cylinders.

Do not make any modifications or carry out changes which could impair safety.

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.

2.4.2 Unauthorized use Applications not expressly listed as intended use represent unauthorized use and are not permitted with the shield.

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

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The shield has been designed and manufactured exclusively for use as a shield unit for longwall faces.

Use the shield only as intended!

Safety Using the machine and working on the machine

2

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

Caterpillar assumes no liability for damage caused by unauthorized use.

2.5 Using the machine and working on the machine Each time before you turn on the machine, check that all protective devices are on the machine and functional.

Keep the signaling and lighting systems in proper working order.

Clean the operating plate at regular intervals. Make sure that the operating symbols are clearly recognizable.

Never reach into or enter areas between machine components which can move.

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

Secure the conveyor against being switched back on again while carrying out: Maintenance work Inspection work Repair work Notify the responsible personnel of the following prior to working on the longwall: your exact location, the work you are carrying out how much time you will probably need You may only carry out work in the mining area if: the roof has been secured against falling rock, the coal face has been secured against collapsing and the mining equipment and conveyor have been shut down and secured against being switched back on.

Refit any protective devices removed immediately after completing work, and check that they are working properly. emergency stop

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

Actuate the EMERGENCY STOP SWITCH also if safety equipment.

danger of explosion

Make sure to comply with the intervals specified for maintenance and inspections of the conveyor, as hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Observe the separate operating manuals for the components used.

disconnecting the conveyor

Before you disconnect the support from the conveyor, release the load from the components under hydraulic pressure or mechanical stress.

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2

Safety Notes on the hydraulic system

lifting the conveyor

If you raise the conveyor in the area of several shields, the shields to which lifting tackle is attached must not be located next to one another. Reset the shields in the area where the conveyor is to be raised. Check the setting pressure. Under no circumstances should you disengage the canopy from the roof.

It must always be in full contact over the entire length.

Only use the provided points of attachment and lifting tackle of adequate loadcarrying capacity. You must under no circumstances use cylinder brackets as they are not designed for tensile loads.

Only lift the conveyor using shields which are connected to the conveyor via the relay bar. Unattached shields could tip over forwards.

travel way

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

Storage and transport

Do not store any materials or components in the travel way or in your working area Only hook the lifting tackle into the lifting points provided for this purpose. Pay attention to the different load limits of the lifting points. Also observe the instructions on the transport sheets. Never attach lifting tackle to brackets and cylinder connections.

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

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

Do not damage any finished or polished surfaces, such as shaft surfaces, sealing surfaces, etc.

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

Secure all moving parts so that they are stationary.

When using floor conveying devices for transport make sure that the center of gravity is as low as possible.

Never walk or stay under unsecured components or suspended loads.

automatic mode

lubricants and chemicals

In automatic mode, the shield units of a face are controlled by an automatic program without any human intervention. When traveling along the face you should therefore always bear in mind that the shield units may move automatically.

Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals emitted by the control unit in the shield unit currently operated.

When working with oils, greases and other chemicals, pay attention to the safety regulations applicable to the product (manufacturer's safety data sheet).

Dispose of oil, grease and other chemicals as well as contaminated fluids in accordance with national environmental laws.

2.6 Notes on the hydraulic system hydraulic system protective devices

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

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

Safety Notes on the hydraulic system

pressure relief valves

handling hydraulic fluids

2

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

Avoid direct skin contact with hydraulic fluids. Hydraulic fluid can penetrate the skin and cause dangerous infections.

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

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

Carry out a visual inspection of all hydraulic components at regular intervals. In particular, please observe the following: the hoses are not pinched. the hoses have no bubbles or blisters. the hoses or the outer sheaths of the hoses are not abnormally hard.

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the outer sheath of the hose is not damaged. the connectors are securely inserted into the coupling sockets. the connections are leak-tight.

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

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

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Do not fail to depressurize the hydraulic line.

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

Never use nails, wire or similar materials.

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

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

Never try to repair damaged hose lines.

Replace hose lines at the first suspicion of damage. permissible hose lines

Only use hose lines approved for the prevailing pressures.

Do not use any hose lines with damaged connectors or worn O-rings.

Replace hose lines only with hose lines of the same or higher quality.

Germany / Europe

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure date of manufacture Caterpillar ID

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2

Safety Notes on the hydraulic system Fig. 1: Example: Hose line, identification

1

3

4

1

manufacturer ID

3

year

2

calendar week

4

working pressure in [bar]

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

For more concise information, follow the "Technical information on hydraulic components".

Australia

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure in [bar] date of manufacture (YY, MM) Caterpillar ID Additional writing on the label: manufacturer ID material number number of the test record, date of manufacture of the hose line, date of manufacture of the hose working pressure.

2.6.1 Recommended storage and use period The following recommendations apply to the use, storage and manufacture of hydraulic hoses and lines: hose storage period

length of storage time for hose lines

For the manufacture of a hose line, the used hose should not exceed a max. storage period of 4 years.

For hose lines, a maximum storage period of 2 years applies (starting from the time of manufacture).

To prevent signs of aging in hydraulic hoses and hose lines, aim for the following storage conditions: store in a dry, low-dust location in a lying position, the storage temperature should be between +15°C and +25°C at max. 65% relative humidity, avoid direct sunlight or exposure to UV radiation, do not use ozone-forming lights or electrical devices which form sparks in the direct vicinity, avoid contact with acids, bases or solvents,

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installing hose lines

2

Safety Notes on the hydraulic system

2

protect from nearby heat sources, when stored coiled up, the radius of the coils may not be smaller than the smallest bending radius indicated by the manufacturer. service life/period of use of hose lines

The service life of hose lines must meet the requirements of DIN 20066. Hose lines must be checked for damage daily by the operator. The test criteria of DIN 20066 must be observed.

The period of use of hose lines should not exceed a period of 2 years.

Guide values for service life

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Tab. 1: Service life Hydraulic hose

Hose line

Storage period

Storage period

Service life

max. 4 years (calculated from date of manufacture)

max. 2 years (calculated from date of manufacture)

max. 2 years

NOTICE Due to the cold-flow properties (creep) of the hose lines exhibited after installation of the fittings, preassembled hose lines should be stored for as short a period as possible prior to use.

Determination of the service life by the operator

Notice on work safety 1. The hydraulic hose line inspection intervals should be adapted to the operating conditions of the mine.

extension

The operator can define an extension of the guide values mentioned above.

This requires the following measures: The operator must write a risk and hazard analysis which takes into consideration the protective measures to be implemented in the event of hydraulic hose line failure.

Repeated checks for safe working conditions at appropriate and, if necessary, shortened intervals by qualified personnel.

Notice on work safety An extension of the replacement interval may not result in a dangerous situation which could cause harm to employees or other persons.

If hydraulic hose lines fail during operation or if damage or faults are found more frequently during regular checks, the checking and replacement intervals should be shortened in addition to finding the cause of the fault. reduction

The operator must define a reduction in the above-mentioned guide values if: inspections show there is significant wear on the hydraulic hose lines, indicating a reduced service life.

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3

Storage and transport Storage

3 Storage and transport 3.1 Storage General This chapter contains important information on correct storage and transport.

Following the instructions and notes will increase the life cycle and service life.

You will be able to carry out transport work more safely and quickly. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storing the equipment

avoid direct exposure to sunlight

dirt and moisture

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

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15oC to 25oC. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. by using tarpaulins.

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

short-term storage

long-term storage

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

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 our service technicians 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.

NOTICE When storing and removing machines and machine parts from storage with a limited service life, make sure to use old deliveries first.

Storing used equipment The above points, with the exception of the one concerning corrosion protection, similarly apply to the storage of equipment parts that have already been used. corrosion protection of hydraulic components

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If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor, e.g. MinetechTM Protection Fluid (Quaker). If this is

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corrosion protection

Storage and transport Transport

3

not done, then the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation. corrosion protection of waterconducting components

Equipment parts for conveying water, such as the parts for the water spraying system or motor cooling circuit, must be completely drained, or also filled with antifreeze if required.

3.2 Transport Load Units, Dimensions and Weights Make sure to pay attention to the transport sheet. It includes information on: dimensions weight Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

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

DANGER Suspended loads Not observing the rules for safely lifting or transporting may cause injury or death to your colleagues.

1. To lift and transport loads, only use serviceable load handling devices that are sufficiently large.

2. Only attach the loads to the provided lifting points.

3. Make sure that boltable lifting points such as lifting eyes are completely bolted in.

4. Never stand under suspended loads.

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3

Storage and transport Transport Fig. 2: Lifting eye and load ring example

A

B

b

c

a

a

A

Lifting eye

B

Load ring

a

Load capacity 5000 kg

b

Eye

c

Welded onto component

d

Screwed onto component

Before transport temperatures below freezing

It is only permitted to transport equipment at temperatures of -21oC to -40oC 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 floor-mounted vehicles 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.

hydraulic component frost protection

electrical and electronic components

Before transporting the equipment at temperatures below freezing, all hydraulic components that are operated with emulsion (HFAE or HFAS) must be completely drained and filled with a corrosion inhibitor such as MinetechTM Protection Fluid (Quaker).

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the entire equipment are protected against harmful environmental influences by suitable packaging. The electrical cables remain in the equipment. They must be protected carefully from transport damage and the connectors must be protected from dirt.

Transporting the components Use machine parts are equipped with lifting eyes or load rings for transportation.

In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport.

Use suitable transport equipment such as belts, chains, etc. to transport components without load attachment points.

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d

Storage and transport Transport

3

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Fig. 3: Correct transport of machine parts

Transport boxes Machine parts for hydraulic components can be packed in transport boxes.

They should stay in these transport boxes until they reach their final place of operation. This protects them from external damage.

Make sure that the transport boxes are not damaged during transport.

Protect the transport boxes from moisture.

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3

Storage and transport Transporting the entire shield support

3.3 Transporting the entire shield support 3.3.1 End shield

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Fig. 4: Transport of the shield support as a complete unit

Dimensions and weights Tab. 2: Type specification for shield support 2100/3800-2X6760-2050

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Device number

Prop x prop force

Year of manufacturing

Use

7420 274 000 00 01

2X6760

2016

Face end shield

Face-End Shield 2100/3800-2X6760-2050

Storage and transport Transporting the entire shield support

3

Tab. 3: Transport dimensions and weights Device number

Length L in mm

Width W in mm

Height H in mm

Sx/Sy in mm

Weight in kg

7420 274 000 00 01

8 535

1 950

2 100

1 185 x 1 435

46 500

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Fig. 5: Transport Face end shield

S1

Long slot, on the side of the base, load capacity: 25 000 kg

S2

Long slot, 2x at the front of the base, load capacity: 30 000 kg

S3

Through hole, 2x on the rear of the base, load capacity: 25 000 kg

S4

Load ring 2x on the caving shield, gobside load capacity: 8 000 kg

S0

Center of gravity

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a

Filler piece not installed

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3

Storage and transport Transporting the entire shield support

DANGER Lifting points If you do not use the marked lifting points for lifting components, you or your colleagues could be severely injured or killed due to a falling load.

1. Only use the marked lifting points for transporting components!

2. Heed the information in the safety chapter.

3.3.2 Transport safety devices

Tab. 4: Transport safety devices Component

Transport safety device

Number

Side seal, movable

Pin and securing device

4

face side

Transport safety device

1

Hydraulic System

Unused hydraulic connections are protected by protective caps or plugs

Relay bar assembly

Notice on work safety Make sure that you observe the safety regulations of your mine for shield transport underground under all circumstances!

NOTICE Transport safety devices Transport safety devices can be damaged during transport and cause severe damage to the transport unit.

1. Check all transport safety devices for damage before each new load handling!

2. Immediately replace damaged transport safety devices with new ones!

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

Storage and transport Transporting the entire shield support

3

3.3.3 Relay bar assembly A transport safety device is to be attached to the relay bar assembly during face-side transportation. The transport safety device fixes the relay bar assembly to the canopy.

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Fig. 6: Transport safety device, relay bar assembly, face side

1

Transport rod

2

Spring clip 6

On the gobside, the relay bar assembly is equipped with a chain under the caving flap for transport. The chain is fastened with a hex. head screw and nut.

Fig. 7: Relay bar assembly, transport safety device, gobside

c

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Transport chain

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3

Storage and transport Transporting the entire shield support

3.3.4 Side seal For transport, the movable side seals are retracted and locked mechanically with pins. The pins are secured with staples or locking clips.

11

Pin 30/22x120

12

Spring clip 3.2

14

Pin 30/22x120

15

Spring clip 3.2

Important information More information is available information in chapter 6 in the section "Side seal".

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Fig. 8: Side seal transport safety device, principal

Installation Pre-assembly of the shield units

4

4 Installation In this chapter, you will be given information about installing the shield units.

Please pay special attention to the warnings and tips.

NOTICE Slide surfaces Before putting subassemblies of the steel structure together, slide surfaces must be treated with the molybdenum disulfide-free lubricating paste B3 in accordance with EWN 7068 (see "Lubricating greases and pastes" for more information).

Important information

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Follow the additional information in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

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

4.2 How to install the shield units 4.2.1 Shield units Installing the shield units

DANGER Lifting points If you do not use the marked lifting points for lifting components, you or your colleagues could be severely injured or killed due to a falling load.

1. Only use the marked lifting points for transporting components!

2. Heed the information in the safety chapter. installation plan

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

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

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Installation How to install the shield units

identification for installation in the face

shield number

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

The shield number serves as an identification feature. All shields are numbered consecutively. Firmly attached tags with the respective shield number are On the left base of the shield.

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a

Shield number

c

Weight sign

b

Serial number plate

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Fig. 9: Numbers on the shield

Installation How to install the shield units

4

4.2.2 Pressure equalization of the electronic control system The shields can be utilized in a number of different height positions at various prevailing air pressure levels. These are equipped with a vent screw in order to enable pressure equalization between the internal and external pressure of the housing of electronic controls.

1. Release the vent screw (hex. socket 4 mm spanner gap) on the control with several turns.

Pressure equalization is indicated by an audible hissing.

NOTICE PMC pressure equalization

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If the pressure is too high, the foil displays of the electronic control can be severely damaged!

1. Release the vent screw for pressure equalization on the control at the beginning of the transport.

2. Retighten the vent screw when the control is installed at the place of operation.

Fig. 10: Example of a vent screw on an electronic control

a

Vent screw

b

Electronic control PMC®R

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

NOTICE Tightening the vent screw If the vent screw is not retightened, then dirt and moisture can penetrate the control unit and firedamp protection is no longer ensured!

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

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Installation How to install the shield units

4.2.3 Supply connections for auxiliary supply During installation, the individual shield can be pressurized and operating by using the so-called auxiliary supply. The shield is equipped with an auxiliary supply on the supply block.

The shield functions must then be operated using an additional, external PMC®R control unit. A corresponding cable is used to connect it to the internal PMC®R control unit.

Important information With regard to this, observe the separate operating manual for the PMC®-R.

Lever position on the supply block During installation via the auxiliary supply, the lever (1) on the supply block (5/3way ball valve) must be moved to the PTO (Power take off) position. Only in this position is the shield is depressurized and the return line is blocked.

A sign is on the supply block that explains the lever positions.

Fig. 11: Supply block with 5/3-way ball valve

P

Pressure line connection

D

W

Water line connection

1

Distributor block

2

5/3-way ball valve

10

Name plate

15

Sign

a

Lever

LSP

Return line connection Connection

Lever position

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ON

Working position (pressure and return lines open)

OFF

Depressurized (return line open)

PTO

Depressurized (pressure and return lines blocked)

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

Installation How to install the shield units

4

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

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

Connecting the auxiliary supply The auxiliary supply connections are located at the right beneath the canopy in the vicinity of the shield's side seal. There is an HP ball valve in the pressure line of the auxiliary supply which must remain open during the procedure.

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Fig. 12: Auxiliary supply, closed

26

PRV, 80 bar

30

Measuring coupling

33

HP ball valve DN 12 for auxiliary supply

43

Through sleeve DN20/DN12

P

Connection for pressure line, auxiliary supply

D

Connection for return line auxiliary supply

a

Pressure line for auxiliary supply

b

Return line for auxiliary supply

c

Plugs

Notice on work safety The connections of the auxiliary supply must be sealed with plugs during normal operation.

connecting the auxiliary supply

1. Check if the lever on the supply block is in the PTO position.

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Installation How to install the shield units

2. Open the HP ball valve.

3. Remove the plugs from the connections P and T of the auxiliary supply.

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

5. Secure the connections with staples.

The shield can now be moved via the external control units PMC®-R. 1. Move the shield to the desired position.

disconnecting the auxiliary supply

26

PRV, 80 bar

30

Measuring coupling

33

HP ball valve DN 12 for auxiliary supply - open

43

Through sleeve DN 20

P

Connection for pressure line, auxiliary supply

D

Connection for return line auxiliary supply

a

Plugs

b

Pump pressure and return lines

Once the shield is in the desired position, the auxiliary supply can be disconnected as follows: 1. To relieve the pressure line, close the pressure line to the pump. The return line of the pump must remain open.

2. Move the lever on the supply block to the OFF position. This relieves the pressure by means of the return line.

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

4. Close the HP ball valve.

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

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Fig. 13: Auxiliary supply, open

Installation How to install the shield units

4

Notice on work safety The connections of the auxiliary supply must be sealed with plugs during normal operation.

The hydraulic connections to the shield units are designed as plug-type connections in accordance with DIN 20043. hydraulic system

The supply block for supplying the shield hydraulics is located in the middle beneath the canopy.

Connection to the supply block of the neighboring shield is made with the aid of four hose lines: one pressure line P (DN 50 SSKV-HP),

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one return line T (DN 63 SSKV-HP), one water line W (DN 50 SSKV-LP) and one LSP line (DN 25 SSKV-HP).

Proceed as follows to join the shields to one another: 1. Remove the plugs from the connections P, D, W, LSP of the shields to be connected.

2. Install the connection lines in the connections P, D, W, LSP on the supply block and connect them to the supply block of the neighboring shield.

Fig. 14: Connection lines to the neighboring shield (principle diagram)

control unit

The shield units are equipped with a type PMC®-R electronic control system.

The control unit and the electrohydraulic control unit are connected via a solenoid driver module. The connection cables required for this are included in the delivery of the PMC®-R control system.

Important information For details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control!

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

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Installation How to install the shield units

additional equipment

The shield units are prepared for the fitting of additional equipment. For example: lighting system, two-way intercom system.

Important information

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

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Installation Requirements for the face hydraulic system

4

4.3 Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulic components included in the Caterpillar scope of delivery: Pressure fluid according to list of approved products. See the section "Operating media" in chapter 6 of this operating manual.

Contamination class 18/14 as per ISO 4406

permissible pressure

Nominal pressure

320 bar

Tolerance range

± 10 % of the nominal pressure

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

In the event that the pressure falls to 180 bar or less, there is a risk of malfunctions occurring in the electrohydraulic control. In this case, valve functions might not be executed. It can even result in valves starting to vibrate, which could lead to valve damage.

WARNING Pressure drop with the face hydraulic system In the case of a pressure drop in the face hydraulic system, dangerous situations can arise that cause accidents involving injuries to personnel and damage to property!

1. Make sure that the system pressure never falls below 180 bar anywhere in the face hydraulic system.

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

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

For the shield support 2100/3800-2X6760-2050 ID no. 7420 274 000 00 01 a minimum pressure of 30 bar applies to the water spraying system!

The minimum pressure applies to all shields.

WARNING Insufficient water spraying system Insufficient water spraying can cause the ignition of explosive atmospheres (air) and dust. This could seriously injure or kill you or your associates.

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

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4

Installation Commissioning

4.5 Commissioning Notice on work safety Initial commissioning and trial run The initial commissioning of a shield or the trial run may only be carried out by a well trained crew. The crew must also be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

NOTICE Transport safety device

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

Please observe the following: Mechanical system: 1. Make sure that all transport safety devices have been removed.

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

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

4. Check all mechanical connections on the shield units.

5. Check the plugs of the relay bar assembly. If the relay bar assembly is designed with a plug-in crawl pan, it must be made sure that it is plugged in correctly. Under no conditions is the crawl pan permitted to be plugged in for normal operation while in the "withdrawal position" 1).

1)

Maximum possible plugging Hydraulic system:

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

2. Especially check whether hinges and hoses can be damaged due to movements of the support.

WARNING Work on hydraulic lines During work on pressurized hydraulic lines, you can be severely injured due to moving hydraulic hoses or liquid escaping under pressure.

1. Always depressurize the hydraulic line before starting with your work.

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

See chapter 3, section "Transport".

Installation Commissioning

4

1. Check the hydraulic supply pressure.

2. Check the load-carrying function of the props. The current pressure under the piston of a prop can be queried at the PMC®-R control unit. Here, you can query the pressure for a neighboring support or the support in which you are currently located. The pressure gauge on the prop control valve of the prop indicates the pressure directly.

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

Signaling and lighting systems, information plates 1. Check all signaling devices.

Important information

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Follow the additional information in the separate operating manuals or spare parts documentation from the respective manufacturer or supplier.

1. Make sure that the face lighting is sufficient.

2. Check whether the face area, especially the travel way, is sufficiently marked with signs. It is imperative that you observe the regulations of the responsible mines inspectorate.

EMERGENCY STOP systems: 1. Check that all EMERGENCY STOP systems are working properly.

NOTICE Inclination of the canopy An excessive inclination of the canopy can lead to severe damage to your support shield. This damage is not covered by the guarantee!

1. Avoid the canopy being excessively inclined by filling out small roof falls, for example, or by underpinning them with a horizontally positioned shield!

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Installation Commissioning

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

Check the support for any installation errors or other sources of error: 1. Check all line connections established during the installation of the shields, especially all supply lines of the shield hydraulics, for completeness and correctness.

WARNING Shut-off valves may not be installed in the return lines for the shield hydraulics.

Otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst. This may result in persons being seriously injured or even killed.

1. Only release the shield for use once you have checked that all of it works properly and have not found any malfunctions.

1. Check the function of the hydraulic system and water supply for the face.

2. Check all functions of the shield control unit.

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

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

When these components are put into operation, no special measures have to be taken with regard to corrosion protection since the testing and anti-corrosion medium used is completely compatible with the approved operation fluids of the group HFA.

Important information Additional information can also be found in chapter 6 in the section "Permissible media".

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Shield release

Operation Requirements

5

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

5.1 Requirements 5.1.1 Operating conditions

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face crew

face equipment

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

The face must be sufficiently illuminated.

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

travel way

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

CAUTION Minimum dimension for the travel way Be sure to follow national regulations.

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

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

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

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

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5

Operation Requirements

roof support work

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

work in the mining area

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

The conveyor and the space above the conveyor may only be entered if the roof has been secured against falling rock. In thick seams, the coal face must also be protected against collapsing in these places. On faces equipped with shield supports, this is best done by using flippers.

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

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

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

With inclined faces, additional barriers such as air cushions must be set up above the work area in the conveyor to protect against the following material.

The design and amount of required safety equipment depends on the local conditions.

repair work

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

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Fig. 15: Minimum dimension for the travel way, schematic diagram

Operation Requirements

5

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

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

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

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

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water spraying system

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

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

conveyor steering device

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

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

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

5.1.2 Safety requirements automatic mode

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

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

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

operating the shield unit

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

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

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

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5

Operation Requirements

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

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

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

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

Advancing should be started from bottom to top in the case of inclined faces.

The neighboring control offers the operator in the shield unit above protection and allows the shield unit being advanced to be monitored.

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

Fig. 16: W r o n g, support advanced too late

Fig. 17: R i g h t, support advanced in time

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

Before a shield unit can be advanced, the flipper must be completely folded in.

Under no circumstances may the support be advanced against the coal face with the flipper extended. Failure to observe this can lead to serious damage, especially to the flipper cylinders and the flipper suspension.

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

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

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

Operation Requirements

5

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

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

Damaged hydraulic hoses and hose connections must be replaced immediately.

This work may only be carried out by skilled personnel.

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

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

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

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

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

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5

Operation Operation of the shield support

5.2 Operation of the shield support definition of viewing direction

In the following figure, the sides are defined on a support shield. If the right or left side is named in the following document, the view toward the coal face is considered to be standard.

general

A

Looking towards the coal face

1

Right side, face side

B

Looking towards the gob

2

Right side, gobside

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

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

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

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

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

shield canopy position

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The shield units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible. In the context of the maximum inclination and swivel angles specified on the technical data sheet, however,

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Fig. 18: Definition of viewing direction, schematic diagram

Operation Operation of the shield support

5

steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

NOTICE Permissible angle of inclination of the canopy If the angle of inclination of the canopy is exceeded (angle between the shield canopy and the caving shield), severe damage to the shield support, especially of the hydraulic cylinders and legs, can occur!

1. Be sure to observe the permissible angle of inclination of the canopy (see section "Technical data")!

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Fig. 19: Shield support in normal position

M

Height of the set shield support

α

Angle of inclination of the canopy

NOTICE Residual stroke of stabilizing cylinders or adjusting cylinders When stabilizing cylinders or adjusting cylinders are completely extended, any load peaks that occur cannot be absorbed. This can lead to damage to the steel structure.

1. Make sure that stabilizing cylinders or adjusting cylinders always have a residual stroke of min. 20 mm.

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

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

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5

Operation Operation of the shield support

M

Height of the set shield support

α

Angle of inclination of the canopy

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

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

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

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Fig. 20: Shield support with extremely inclined shield canopy

Operation Operation of the shield support

5

Fig. 21: W r o n g, do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended!

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

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Fig. 22: R i g h t, fill out roof falls

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

Accumulation on the shield canopy can be avoided by grinding while advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy.

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5

Operation Operation of the shield support

range of adjustment of the support/changing face thickness

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

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

The minimum residual stroke required for lowering the shield unit can be maintained by: keeping the longwall opening sufficiently large using the mining equipment, avoiding the accumulation of debris and fine coal on the floor,

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

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

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

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

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

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

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

On an inclined face, the conveyor must be anchored with respect to the support.

You can thus prevent the conveyor from shifting to the side compared to the support. That reduces the danger of jamming the relay bar assembly in the base frame, which would hinder advancing the shield.

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

unfavorable floor conditions

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

Face-End Shield 2100/3800-2X6760-2050

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removing accumulated piles of rock on the shield canopies.

Operation Operation of the shield support

5

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

For shield units without a lifting device, the procedure is different, depending on the design: Individual skids on two-leg shields can usually be lifted hydraulically by actively lowering a leg.

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

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5

Operation Work safety

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

DANGER Staying in the shield support Staying in a moving shield support can lead to severe or fatal injuries!

1. Before entering a shield support, e.g. for maintenance purposes, be sure to actuate the "Support locking switch"!

2. It is not permitted to stay in the shield support in automatic mode!

Buttons / levers on pilot valves / control units Sticking or locked buttons on pilot valves can cause undesired motions. This could seriously injure or kill you or your associates!

1. Never lock buttons / levers on control units!

2. Always keep the control units free from dust and dirt!

3. Regularly check valves and control units for correct functioning!

Observe the following safety regulations: Make sure that your body is completely under a set shield.

Keep away from shields which are in the process of being moved or which are to be moved soon.

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

Observe the following instructions if a support has failed to advance: Determine the cause. Check the following possibilities: malfunction of the electronic control, external jamming: Shield is wedged in between the neighboring shields.

Tip of the canopy is stuck in the roof.

Floor step or debris is blocking the skid.

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

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

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WARNING

Operation Shield components

5

5.4 Shield components Main components

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Fig. 23: Face end shield layout

1

Base frame

2

Relay bar assembly

5

Lemniscatic links, front

7

Lemniscatic links, rear

11

Canopy 2x6521-1080-2050

12

Flipper

21

Side seal, canopy

22

Caving shield side seal

31

Caving shield

41

Leg

51

Stabilising cylinder

52

Advancing cylinder

53

Lifting cylinder

61

Hydraulic system

81

Sign

82

Sign

86

Rubber covering

87

Rubber covering, center

88

Pin retainer

a

PMC®-R control unit

b

Electro-hydraulic control unit, 12-function

c

Water valve unit, 2 function

d

Flipper cylinder

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5

Operation Shield components

Tab. 5: Shield support 7420 274 000 00 01, subassemblies used Description

ID no.

SAP no.

Approx. weight in kg

Note

1

Base frame 2X6521

7420 273 300 00 01

4835979

10 788 Length: 4 025

2

Relay bar assembly

7420 274 330 00 01

4852394

5

Lemniscatic links, front

7420 273 303 00 00

4835741

650 Length: 2 040

7

Lemniscatic links, rear

7420 273 305 00 00

4835800

695 Length: 1 880

11

Canopy

7420 274 400 00 01

4842021

14 543 Length: 6 260

12

Flipper

7420 273 480 00 01

4845663

21

Side seal, canopy

7420 274 710 00 01

4844725

1 409 Seal cylinder: 8241 352 000 00 00

22

Caving shield side seal

7420 274 750 00 01

4848125

941 Seal cylinder: 8241 352 000 00 00

31

Caving shield

7420 274 800 00 01

4848122

6 173 Length: 2 809

41

Leg SD-6500-450-1565/3175

8250 231 000 00 00

4839527

2 811 with PRV 520 bar

51

Stabilizing cylinder ZE-200/125-630

8241 615 000 00 00

4839751

248

52

Advancing cylinder ZE-200/125-1080

8241 614 000 00 00

4843663

380

53

Lifting cylinders ZE-150/90-300

8241 616 000 00 00

4837899

90

61

Hydraulic system 2-leg shield

8112 427 000 00 00

4852755

1 147

838

Flipper cylinder: 8241 618 000 00 00

EHS: 8154 167 000 00 00 WVE: 8401 008 150 00 00 Lines: 8154 427 010 00 00 Water spraying system: 8154 427 020 00 00 Holder: 8154 427 030 00 00

86

Rubber covering

7420 273 050 00 00

4849120

10.1

87

Rubber covering, center

7420 273 060 00 00

4849038

20.1

88

Pin retainer

7420 242 030 00 00

4121216

1.1

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

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Item

Operation Design of the ball valves

5

5.5 Design of the ball valves To open the ball valve the lever needs to be lifted to disengage from the detent.

Only then the lever can be turned to the open position.

NOTICE Operation of a ball valve An incorrect lever position will cause damage to the ball valve over the long term.

1. When operating a ball valve, always make sure that the lever is completely engaged in its respective position.

2-way ball valve

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

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

Fig. 24: 2-way ball valve, open and closed

a

Through-flow for medium enabled

b

Through-flow for medium stopped

5/3-way ball valve The 5/3-way ball valve has three switching or lever positions.

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

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

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5

Operation Design of the ball valves

1

lever

2

PTO Depressurized

Locking bolt

OFF Depressurized

(pressure and pressure release blocked) medium flow stopped

ON

(pressure release for output side to the tank) medium flow stopped

Working position (pressure open) medium flow open

Change the lever position by 1. pulling/lifting the locking bolt (2), 2. turning the hand lever (1) to the respective position until the lever locks in place.

Functions of the HP ball valves The following ball valves are open during normal operation: 21a, 21b, 21c, 21d, 21e, 21f, 22a, 22b, 32 The following ball valves are closed during normal operation: 31, 33

Tab. 6: HP ball valves Item SAP no.

Colo r

Designation

21a

961254

Red

HP ball valve DN 10

For shutting off the rear leg. The leg is not retracted during lowering.

During maintenance work and repairs on the leg and possible disassembly.

21b

961254

Red

HP ball valve DN 10

For shutting off the rear leg. The leg is not retracted during lowering.

During maintenance work and repairs on the leg and possible disassembly.

21c

961254

Red

HP ball valve DN 10

For shutting off the piston space of the lifting cylinder. Lifting cylinder is not retracted while setting legs

During maintenance and repair work.

21d

961254

Red

HP ball valve DN 10

For shutting off the annular spaces of the seal cylinders.

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

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Function

Use

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Fig. 25: 5/3-way ball valve, with three lever positions

Operation

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Hydraulic components on the shield

Function

5

Item SAP no.

Colo r

Designation

Use

21e

961254

Red

HP ball valve DN 10

For switching off the automatic function of The canopy remains inclined towards the the stabilizing cylinder. While the legs are roof for any maintenance work. During being set, a canopy that has too steep a maintenance and repair work setting angle will automatically align itself to the roof as long as the ball valve for the stabilizing cylinder is not blocked.

21f

961254

Red

HP ball valve DN 10

For shutting off the pressure supply to the During maintenance and repair work on piston space of the flipper cylinder. the flipper.

22a

961255-SS

Red

HP ball valve DN 20

For shutting off the pressure supply to the During maintenance work and repairs on piston space of the leg. the leg and possible disassembly.

22b

961255-SS

Red

HP ball valve DN 20

For shutting off the pressure supply to the During maintenance work and repairs on piston space of the leg. the leg and possible disassembly.

31

961892

Blue

HP ball valve DN 10

For shutting off the water hose.

Spraying or cleaning of soiled components.

32

961256

Blue

HP ball valve DN 20

For shutting off the water spraying system.

The water spraying function is deactivated.

33

961257

Red

HP ball valve DN 12

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

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

5.6 Hydraulic components on the shield 5.6.1 Location of hydraulic components The following table indicates the hydraulic components of the Face end shield 7420 274 000 00 01.

Item

Qty.

Designation

Arrangement

Note

Z1

2

Leg

Z2

1

Shifting ram

Z3

1

Stabilizing cylinder

Z4

4

Seal cylinder

Z5

1

Lifting cylinder

Z6

1

Flipper cylinder

1

1

Electrohydraulic control unit, 12-function

1x centered between the front lemniscatic links

Fastening with support See separate operating manual

2

1

Leg POCV DN 20 SSO

1x on the left-hand gobside leg

3

1

Leg POCV DN 20 SSO

1x on the right-hand gobside leg

4

1

Water valve unit

1x on the left next to the control unit (1)

Fastening with support See separate operating manual

5

1

POCV DN 12

1x in the middle between the legs

For shifting ram (Z2)

7

2

PRV 410 bar

2x on the stabilizing cylinder

For piston space side and annular space side

8

2

PRV 410 bar

1x on each leg POCV

In the piston space of the legs

9

3

CV NW 25

3x on the supply manifold (16)

10

1

Double POCV DN 10

1x flanged to the flipper cylinder (Z6)

For flipper cylinder (Z6)

11

1

Double POCV

1x flanged to the stabilizing cylinder

For stabilizing cylinder (Z3)

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Operation Hydraulic components on the shield

Item

Qty.

Designation

Arrangement

12

Note

6

Pressure gauge

a) 2x1 on each leg (Z1) b) 1x on the control unit (1) c) 1x on the right-hand supply manifold (16) d) 1x the on left-hand supply manifold (16) e) 1x on the HP ball valve (32)

13

1

Hose lines

Subassembly

14

1

Water spraying system accessories

Subassembly

15

1

Brackets and accessories

Subassembly

16

1

Supply manifold SSKV 63; 50; 50; 25

1x between the front lemniscatic links

17

1

Accumulator cartridge

1x on the electrohydraulic control unit (1)

18

5

PRV DN 10, 380 bar

With 5/3-way ball valve DN 25-SS/DN 12

a) 1x on the hydraulic distributor (27) b) 1x on the shifting ram (Z2) c) 1x on the distributor (37) d) 2x on the flipper cylinder (Z6)

Centered under bracket a) for the seal cylinder (Z4) b) for the shifting ram (Z2) c) for the lifting cylinder (Z5) d) for the flipper cylinder (Z6)

20

1

RS double filter DN 25 SS

1x beneath the canopy

In front of leg (Z1 le.)

21

6

HP ball valve DN 10

a) 1x centered under bracket b) 1x centered under bracket c) 1x behind the control unit (1) on the right d) 1x behind the control unit (1) on the left e) 1x centered under bracket

a) shuts off the right-hand leg b) shuts off the left-hand leg c) for the lifting cylinder (Z4) function 11

Red

f) 1x in the hose line to the flipper cylinder (Z6)

d) for the seal cylinder (Z4) function 5 e) automatic operation of the stabilizing cylinder (Z3) f) in the pressure line to the flipper cylinder (Z6)

22

2

HP ball valve DN20-SS

a) 1x on the left-hand leg (Z1) b) 1x on the right-hand leg (Z1)

Red

23

3

Through sleeve DN 10, 3 times

a) 1x in front of leg (Z1 re) b) 1x in front of leg (Z1 left) c) 1x between canopy and side seal

a) for the water spraying system b) for the water spraying system c) for the side seal water spraying system

24

1

EC inline filter DN 20

1x on the supply manifold (16)

25

1

Distributor

1x behind the electrohydraulic control unit

26

1

PRV, 80 bar

1x on the auxiliary supply

27

2

Hydraulic distributor DN 10 7-way

2x beneath the canopy on the left

29

2

Pressure gauge port

2x1, on each leg (Z1)

30

16

Measuring coupling SMK20

a) 2x on the double POCV (11) for the stabilizing cylinder b) 1x on the water valve unit (4) c) 1x on the distributor (38c) d) 1x on the distributor (37) e) 1x on the HP ball valve (21c) f) 1x on the hydraulic distributor (27) g) 1x on the control unit (1) h) 1x on the double filter (20) i) 1x on the water filter (39) k) 2x on the auxiliary supply l) 1x on the POCV (5) m) 2x on the double POCV (10) n) 1x on the HP ball valve (21f)

31

1

HP ball valve DN 10

1x behind the lifting cylinder (Z5)

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For seal cylinder (Z4)

Blue

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5

Operation

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Hydraulic components on the shield

Item

Qty.

Designation

Arrangement

Note

32

1

HP ball valve DN 20

1x on the supply manifold (16)

Blue

33

1

HP ball valve DN 12 NIRO

1x on the auxiliary supply

Red

34

1

Throttle - CV DN 10/1

1x behind the electrohydraulic control unit (1)

Red

36

1

Screw-in socket, DN 10 with throttle 0.8

1x on the control unit (1)

37

1

Distributor

1x behind the lifting cylinder (Z5) centered under the bracket

Centered under the bracket

38

3

Distributor

a) 1x behind the lifting cylinder (Z5) on the right b) 1x behind the lifting cylinder (Z5) on the left c) 1x behind the lifting cylinder (Z5) at the center

Centered under the bracket

39

1

Water filter DN 10

1x CV (40)

40

1

POCV DN 10

1x on the distributor (38a)

41

2

CV DN 10

2x1, on each leg (Z1)

42

1

Through sleeve DN 10

1x in the hose line to the flipper cylinder (Z6)

43

1

Through sleeve DN20/DN12

1x on the auxiliary supply

44

1

Plug DN 10

1x on the water valve unit (4)

45

1

Diffusor DN 12

1x on left-hand side seal

47

2

Rock burst valve, DN 40, 440 bar

1x, on each leg

S1

2

Pressure sensor

1x on each leg POCV (2, 3)

5

Centered under the bracket

In the pressure line to the flipper cylinder (Z6)

CV = check valve, PRV = pressure relief valve, HP = high pressure, EHS = electrohydraulic control unit

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5

Operation Hydraulic components on the shield

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Fig. 26: Shield hydraulics, arrangement on top

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Operation Hydraulic components on the shield

5

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Fig. 27: Shield hydraulics, arrangement of leg and flipper cylinder

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5

Operation Hydraulic components on the shield

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Fig. 28: Shield hydraulics, arrangement of ball valves in bracket

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Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

5

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Fig. 29: Shield hydraulics, arrangement of control unit front and rear

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5

Operation Hydraulic components on the shield

5.6.2 Control unit functions and pin assignment

Tab. 7: Electrohydraulic control unit with 12 functions, pin assignment of functions Function no.

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Function, designation

1

Advance shield

2

Set leg

3

Push conveyor

4

Leg setting pressure LSP

5

Retract seal cylinder

6

Extend seal cylinder

7

Retract flipper cylinder

8

Extend flipper cylinder

9

Retract compensation cylinder

10

Extend compensation cylinder

11

Extend lifting cylinder

12

Lower leg

W1

Canopy tip water spraying system

W2

Side seal spraying system

Face-End Shield 2100/3800-2X6760-2050

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Fig. 30: Electrohydraulic control unit, 12-function

Operation Hydraulic components on the shield

5

5.6.3 Shield hydraulics

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Fig. 31: Shield hydraulics Face end shield 7420 274 000 00 01

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5

Operation Hydraulic components on the shield

5.6.4 Hydraulic lines

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Fig. 32: Hose plan Face end shield 7420 274 000 00 01

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Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

Hose lines

2

Plug-in parts

16

Hose restraining cable DN 32

17

Hose restraining cable DN 40

18

Hose restraining cable DN 25

22

Shackle

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1

5

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5

Operation Hydraulic components on the shield

5.6.5 Hose lines

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Fig. 33: Hose lines Face end shield 7420 274 000 00 01

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Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

5

Tab. 8: Colour coding hose lines System pressure

Yellow

Water pressure

Red/yellow

High pressure

Orange

Return

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Red

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Operation

5

Hydraulic components on the shield

Tab. 9: Hose lines Designation

Colour

Item

Designation

Colour yellow

2

2 x Hose line 4SP DN6x1800, connections galvanized

red / yellow

3

1 x Hose line 4SP DN6x2100, connections galvanized

10

1 x Hose line 2SC DN10x350, connections galvanized

red

11

2 x Hose line 2SC DN10x800, connections galvanized

13

4 x Hose line 2SC DN10x1100, connections galvanized

14

1 x Hose line 2SC DN10x1100, connections galvanized

15

1 x Hose line 2SC DN10x1400, connections galvanized

17

1 x Hose line 2SC DN10x1500, connections galvanized

19

1 x Hose line 2SC DN10x3800, connections galvanized

20

1 x Hose line 2SC DN10x1600, connections galvanized

red

21

4 x Hose line 2SC DN10x1700, connections galvanized

22

2 x Hose line 2SC DN10x1700, connections galvanized

red

23

4 x Hose line 2SC DN10x2000, connections galvanized

24

2 x Hose line 2SC DN10x2100, connections galvanized

25

1 x Hose line 2SC DN10x2300, connections galvanized

26

1 x Hose line 2SC DN10x2400, connections galvanized

27

2 x Hose line 2SC DN10x2500, connections galvanized

28

1 x Hose line 2SC DN10x3000, connections galvanized

29

2 x Hose line 2SC DN10x3500, connections galvanized

31

4 x Hose line 2SC DN10x3600, connections galvanized

37

2 x Hose line 4SP DN12x1200, connections galvanized

38

1 x Hose line 4SP DN12x1400, connections galvanized

39

2 x Hose line 4SP DN12x1600, connections galvanized

43

1 x Hose line 4SP DN12x1800, connections galvanized

45

1 x Hose line 4SP DN12x3600, connections galvanized

49

2 x Hose line 4SP DN20x1000, connections galvanized

orange

50

2 x Hose line 4SP DN20ST/STX1300, connections galvanized

51

1 x Hose line 4SP DN20x1500, connections galvanized

orange

52

2 x Hose line 4SP DN20x3200, connections galvanized

55

1 x Hose line 4SH DN20x1300, connections galvanized

56

2 x Hose line 4SH DN20x1600, connections galvanized

57

2 x Hose line 4SH DN20x1800, connections galvanized

58

3 x Hose line 4SH DN20x3600, connections galvanized

61

1 x Hose line 4SP DN25x335, connections galvanized

66

1 x Hose line 4SH DN25x2700, connections galvanized

red

67

1 x Hose line 4SH DN25x3400, connections galvanized

red

69

1 x Hose line 2SC DN10x600, connections NIRO

yellow

70

1 x Hose line 2SC DN10x1100, connections galvanized

yellow

71

1 x Hose line 2SC DN10x1000, connections NIRO

yellow

72

1 x Hose line 2SC DN10x1400, connections NIRO

yellow

73

1 x Hose line 2SC DN10x1800, connections NIRO

yellow

74

1 x Hose line 2SC DN10x2000, connections NIRO

yellow

75

2 x Hose line 2SC DN10x2600, connections NIRO

yellow

76

2 x Hose line 2SC DN10x3900, connections NIRO

yellow

77

1 x Hose line 2SC DN10x3600, connections NIRO

yellow

78

2 x Hose line 2SC DN10x4300, connections NIRO

yellow

79

1 x Hose line 2SC DN10x3700, connections NIRO

yellow

81

1 x Hose line 4SP DN20x800, connections NIRO

yellow

90

1 x Hose line 4SP DN63x28000-SSVK, connections galvanized

orange

91

1 x Hose line 4SP DN50x28000-SSVK, connections NIRO

yellow

66 / 165

orange

red

red

orange

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Item

Operation Hydraulic components on the shield

1 x Hose line R13 DN50x27000-SSVK, connections galvanized

100

2 x Hose line 2SC DN10x1000, connections galvanized

102

1 x Hose line 2SC DN10x3800, connections galvanized

red

93

1 x Hose line 4SH DN25x2700-SSKV, connections galvanized

101

1 x Hose line 2SC DN10x3700, connections galvanized

red

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

92

5

Face-End Shield 2100/3800-2X6760-2050

67 / 165

5

Operation Hydraulic components on the shield

5.6.6 Stecko parts

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 34: Stecko parts Face end shield 7420 274 000 00 01

68 / 165

Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

5

Tab. 10: Stecko parts

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Item

Designation

Item

Designation

1

1 x Straight socket DN 6

2

1 x Plug-in elbow socket DN 6

3

1 x Sleeve DN 6

7

3 x Sleeve DN 10

8

2 x Double nipple DN 10

9

1 x Plug-in elbow socket DN 10 long

10

3 x Plug-in elbow socket DN 10

11

6 x Straight socket DN 10

12

22 x Plug-in elbow socket DN 10

13

2 x T-socket DN 10

14

1 x Double nipple DN 10 100 lg.

15

7 xPlug-in L-socket DN 10

16

1 x Connector DN 10 155 lg.

17

1 x Plug-in T-socket DN 10

18

2 x Screw-in socket DN 10

19

3 x Plug-in elbow socket DN 10/135°

20

10 x Plug DN 10

30

1 x T-socket DN 12

31

2 x Plug-in elbow socket DN 12

32

4 x Plug-in elbow socket DN 12/135°

34

1 x Straight socket DN 12

35

1 x Plug DN 12 with chain

36

1 x Double nipple DN 12 82 lg.

39

1 x Connector DN 20 102 lg.

40

1 x Plug-in elbow socket DN 20/135°

41

4 x Plug-in elbow socket DN 20

42

2 x Straight socket DN 20 - angled version -

43

2 x Plug DN 20

44

1 x Plug DN 20 with chain, NIRO

45

4 x Plug-in elbow socket DN 20

50

3 x Straight socket DN 20 SS-O

51

2 x Connector DN 20 SS-O 145 lg.

52

4 x Plug-in elbow socket DN 20 SS-O

53

4 x Plug-in elbow socket DN 20 S-SO 90°

54

2 x Plug DN 20 SS-O

55

3 x Plug-in elbow socket DN 20 S-SO 135°

60

2 x Plug-in elbow socket DN 25, rigid

63

1 x Plug-in elbow socket DN 25/135°

64

1 x Plug-in L-socket DN 25

67

1 x Plug-in elbow socket DN 25 S-SO

69

2 x Double nipple DN 25 SS 260 lg.

70

2 x T-socket DN 25 S-SO

71

1 x Double nipple DN 25 S-SO 110 lg.

72

1 x Double nipple DN 25 SS 120 lg.

74

3 x Plug-in elbow socket DN 25 SS-O

76

1 x Sleeve DN 10/6

77

1 x Plug-in reducing socket DN 25/20

78

1 x Plug-in reducing socket DN 25 S-SO/12

79

1 x Plug-in reducing L-socket DN 25SS/10

80

1 x Plug-in reducing T-socket DN 25SS/DN10

81

2x Plug-in reducing elbow socket DN 10/6

83

1 x Plug-in reducing L-socket DN 12/10/12

84

2 x Plug-in reducing L-socket DN 20 SS-O/DN 10

85

1 x Plug-in reducing socket DN 20 S-SO/DN 12

86

1 x Plug-in reducing socket DN 25 S-SO/DN 10

87

2 x Plug-in reducing elbow socket DN 25/20

88

1 x Special plug-in L-socket

90

1 x Connector DN 10, 85 lg.

91

2 x Screw-in socket DN 10

92

10 x Plug-in elbow socket DN 10

93

6 x Plug-in elbow socket DN 10/135°

94

3 x Plug-in L-socket DN 10

95

1 x Plug-in elbow socket DN 20

96

3 x Double nipple DN 20

97

4 x Sleeve DN 12/10

98

1 x Plug

99

3 x Plug-in reducing L-socket DN 20/10/20

100

10 x Staple DN 6

101

220 x Staple DN 10

102

15 x Staple DN 10, 82 lg.

103

5 x Staple DN 10

104

32 x Staple DN 12

105

42 x Staple DN 20 D-type with Si

106

40 x Staple SSO-DN 20

107

14 x Staple DN 25 D-type

108

20 x Staple SSO-DN 25 D-type with Si

110

2 x Clamp collar DN 25 SSKV HD

111

2 x Clamp collar DN 50 SSKV HP

112

2 x Clamp collar DN 50 SSKV LP

Face-End Shield 2100/3800-2X6760-2050

69 / 165

Operation

5

Hydraulic components on the shield

2 x Clamp collar DN 63 SSKV LP

114

2 x Retaining ring DN 25 SSKV-HD

115

2 x Retaining ring DN 50 SSKV-HP

116

2 x Retaining ring DN 50 SSKV-LP

117

2 x Retaining ring DN 63 SSKV-LP

118

2 x Plug DN 25 SSKV-HP

119

2 x Plug DN 50 SSKV-HP short

120

2 x Plug DN 50 SSKV-LP

121

2 x Plug DN 63 SSKV-LP

124

1 x Sleeve elbow DN 10

125

1 x Plug-in elbow socket DN 10

126

2 x Straight socket DN 10 NIRO

127

2 x Plug-in elbow socket DN 20

130

1 x Adapter DN 25 SSKV-HP

131

1 x Straight socket DN 50 SSKV-LP NIRO

132

1 x Straight socket DN 50 SSKV-HP

133

1 x Straight socket DN 63 SSKV-LP

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113

70 / 165

Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

5

5.6.7 Water spraying system and accessories

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 35: Water spraying diagram

Face-End Shield 2100/3800-2X6760-2050

71 / 165

5

Operation Hydraulic components on the shield

1

Spray distributor

2

Spray distributor

3

Nozzle head

6

Spray distributor

7

Water spraying system fitting

10

Nozzle

11

Full cone spray nozzle

12

Full cone spray nozzle

Location of the water spraying system

72 / 165

1

Spray distributor

2

Spray distributor

3

Nozzle head

6

Spray distributor

7

Water spraying system fitting

10

Nozzle

11

Full cone spray nozzle

12

Full cone spray nozzle

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 36: Water spraying system accessories

Operation Hydraulic components on the shield

5

5.6.8 Bracket and accessories

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 37: Brackets and accessories, component positions

Face-End Shield 2100/3800-2X6760-2050

73 / 165

Operation Hydraulic components on the shield

74 / 165

1

Bracket for electrohydraulic control unit, 12-function

2

Supply manifold bracket

3

Bracket for PMCR, long

4

Center bracket (ball valves)

5

Support for spraying block

6

Cover

8

Bracket

9

Bracket

10

Hose guide

11

Bracket

12

Bracket for nozzle head

13

Hose holder

14

Hose holder

15

Lamp bracket, front

16

Hose cover

17

Handle for leg

18

Bracket for leg

19

Bracket, complete

20

Fastening for lamp distributor

21

Bracket

22

Bracket PTO

23

Support for nozzle head

24

Water spraying system bracket

25

Stabilizing cylinder clamp lock

26

Pressure relief valve cover

27

Support for nozzle head

28

Leg valve fastening

29

Flipper cylinder staple clip

30

Bracket, compl.

31

Hose holder

32

Hose holder

33

Pin retainer

34

Symbol plate

36

Guide

37

Guide

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

5

Operation Hydraulic components on the shield

5

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 38: Bracket for Electrohydraulic control unit, 12-function

1

Bracket

2

Staple for locking piece

3

Symbol plate support

4

Staple for locking piece

5

Staple for locking piece

6

Symbol plate

7

Symbol plate

8

Solenoid driver module fastener

9

Locking plate staple

11

Flat-head screw M 12x50-A 2-70

12

Hex. head screw M 10x20-A 2-70

13

Hex. head screw M 10x30-A 2-70

14

Hex. head screw M 6x16-A 2-70

15

Hex. nut M 12-A 4-80

16

Hex. nut M 10-A 2-70

17

Hex. nut M 6-A 4-80

a

Stud bolt M 10

b

Hex. nut M 10-A 2-70

c

Spring clip 2.5

Face-End Shield 2100/3800-2X6760-2050

75 / 165

5

Operation Hydraulic components on the shield

1

Bracket

2

Pin 30/25X60

3

Spring clip 3.2

4

Hex. head screw M 20x50-A 2-70

5

Support

6

Hex. head screw M 10x20-A 2-70

7

Bracket

8

Hex. head screw M 16x20-A 2-70

Fig. 40: Bracket for PMC®-R

76 / 165

1

Support I

2

Support II

3

Support IV

4

Plate

5

Tube 25x5 - 32 long

6

Countersunk screw M 12x50-A2-70

7

Cyl. head screw M 12x110-A 2-70

8

Flat-head screw M 12x50-A 2-70

9

Hex. nut M 12-A 4-80

a

Chain 6x42

b

Screw holder M 8

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 39: Supply unit bracket

Operation Hydraulic components on the shield

5

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 41: Holder for bracket, center

1

Bracket, center

2

Running board, front center

3

Running board, rear center

4

Retainer

5

Bracket for shifting ram valve

6

Cover LSP

7

Running board

8

Running board

9

Retainer

10

Retainer

11

Cover plate

12

Pin 20/12.5x30

13

Hex. head screw M 16x40-A 2-70

14

Washer 12

15

Hex. head screw M 12x20-A 2-70

16

Hex. head screw M 12x30-A 2-70

17

Hex. head screw M 12x40-A 2-70

18

Hex. head screw M 8x70-A 2-70

19

Hex. head screw M 8x60-A 2-70

20

Hex. head screw M 6x50-A 2-70

21

Hex. nut M 16-A 2-70

22

Hex. nut M 12-A 2-70

23

Hex. nut M 8-A 4-80

24

Hex. nut M 8-A 4-80

25

Hex. nut M 6-A 4-80

26

Spring cotter 3.2

27

Washer 8-A2

28

Sign

Face-End Shield 2100/3800-2X6760-2050

77 / 165

5

Operation Hydraulic components on the shield

1

Bracket for shifting ram valve

2

Clip

3

Hex. head screw M10x85-A 2-70

4

Hex. nut M 10-A 2-70

5

Hex. head screw M 10x80-A 2-70

a

Sign

b

Screw holder M 10

Fig. 43: Hose guide

78 / 165

1

Hose guide

2

Hose guide

3

Support

4

Support

5

Hose holder

6

Cyl. head screw M 12x35-A 2-70

8

Hex. nut M 12-A 4-80

9

Spring clip 2.5

10

Spring cotter 5

a

Locking pin

b

Locking pin

c

Countersunk screw M 8x20-A 4-80

d

Hex. head screw M 12x25-A 2-70

e

Hex. head screw M 12x35-A 4-80

f

Hex. nut M 12-1.4571

g

Hex. nut M 12-A 4-80

h

Load ring 1000 kg

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 42: Bracket for shifting ram valve

Operation Hydraulic components on the shield

5

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 44: Lamp bracket

1

Lamp bracket

2

Lamp mount

3

Hex. head screw M 10x25-A 2-70

4

Hex. nut M 10-A 2-70

5

Hex. head screw M 12x30-A 2-70

6

Hex. nut M 12-A 4-80

7

Hex. head screw M 12x20-A 2-70

a

Lamp

5.6.9 Additional brackets Belt guide Fig. 45: Belt guide, component positions and dimensions

1

Belt guide

2

Idler roller

5

Hex. head screw M 10x80-A 2-70

6

Hex. nut M 12-A 2

7

Hex. head screw M 12x30-A 2-70

8

Hex. nut M 12-A 4-80

Face-End Shield 2100/3800-2X6760-2050

79 / 165

5

Operation Hydraulic components on the shield

Belt guide

1

Belt guide

2

Idler roller

5

Hex. head screw M 10x80-A 2-70

6

Hex. nut M 12-A 2

7

Hex. head screw M 12x30-A 2-70

8

Hex. nut M 12-A 4-80

Winch holder Fig. 47: Winch holder, component positions and dimensions

80 / 165

1

Winch holder

2

Hex. head screw M 12x50-A 2-70

3

Hex. nut M 12-1.4571

4

Hex. head screw M 10x30-A 2-70

5

Hex. nut M 10-A 2-70

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 46: Belt guide, component positions and dimensions

Operation Hydraulic components on the shield

5

Fire extinguisher holder

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 48: Fire extinguisher holder, component positions and dimensions

1

Fire extinguisher holder

2

Hex. head screw M 10x30-A 2-70

3

Hex. nut M 10-A 2-70

4

Hex. head screw M 12x50-A 2-70

5

Hex. nut M 12-1.4571

Multi-purpose holder Fig. 49: Multi-purpose holder, component positions

1

Multi-purpose holder

2

Support

3

Hex. head screw M 10x70-A 2-70

4

Hex. head screw M 12x40-A 2-70

5

Hex. nut M 10-A 2-70

Face-End Shield 2100/3800-2X6760-2050

81 / 165

5

Operation Hydraulic components on the shield

Shear pin holder Fig. 50: Shear pin holder, component positions and dimensions

Shear pin holder

3

Hex. nut M 12-A 2

2

Countersunk screw M 12x25-A 2-70 Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

1

Support for IMAC box Fig. 51: Support for IMAC box and screw holder, dimensions

82 / 165

Face-End Shield 2100/3800-2X6760-2050

Operation Hydraulic components on the shield

5

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 52: Support for IMAC box and screw holder, component positions

1

Support I

2

EMERGENCY STOP support

3

Hose holder

4

Pin 15/12x55

5

Hex. head screw M 10x40-A 2-70

6

Countersunk screw M 12x30-1.4301

7

Hex. nut M 12-A 4-80

8

Hex. nut M 10-A 2-70

9

Spring clip 2.5

a

Hose holder

b

Hex. head screw M 12x25-A 2-70

c

Hex. head screw M 12x35-A 4-80

d

Hex. nut M 12-A 4-80

e

Hose clip, 3-position

f

Countersunk screw M 8x20-A 4-80

g

Hex. nut M 12-A 4-80

Face-End Shield 2100/3800-2X6760-2050

83 / 165

5

Operation Hydraulic components on the shield

5.6.10 Tools Testing device for hydraulic legs and valves The testing device is a pressure intensifier with which the function of the pressure relief valves can be checked. The pressure relief valve is charged with the setting pressure of the pressure relief valve via the pressure intensifier of the testing device to check the function (pressure relief by draining the liquid).

Via the lever, the pressure relief valve is charged with steadily increasing pressure until the draining pressure is reached.

2

Ball detent

9

Screw plug

13

Throttle screw M 8x1

14

Check valve, DN 10

15

Plug DN 10 with pressure relief

16

Booster connection

17

Plug-in elbow socket DN 10

19

Testing device body

21

Threaded plug-in socket

22

Cross socket DN 10

26

Dial with angle scale

27

Valve hood

30

Plate

31

Cylinder head screw M 6x10-8.8

33

Cylinder head screw M 6x40-8.8

34

Cylinder head screw M 6x16-8.8

36

Screw plug M 30 x 1

38

Spring dowel pin 6x12

46

Washer 30

48

Staple DN 10 D-type

55

Pressure gauge NG 50

57

Wrench 14x17

81

Screw plug M 8 x 1

83

Hose line 4SP DN10x800, connections galvanized

84

Hose line 4SP DN10x1200, connections galvanized

87

Sintered plug

84 / 165

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 53: Testing device for hydraulic legs and valves, component positions

Operation Hydraulic components on the shield

5

Lever positions The testing device has three lever positions. When the lever is in position (3), the pump fills with hydraulic fluid and presses it into the leg of the pressure relief valve being tested at a 1.75x higher pressure.

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 54: Lever positions

Tab. 11: Lever positions Lever position

Effect

1

Pump fills with hydraulic fluid

2

Pump fills and pressure intensification = zero

3

Hydraulic fluid is pressed into the pressure relief valve (pressure intensifier)

Booster Fig. 55: Booster connection, component positions

1

Plug-in nipple

2

Nut

3

Threaded socket

4

Socket DN 10

7

O-ring 8x2

8

O-ring

9

Wire MW 8/10

10

Plug protective (not illustrated)

Face-End Shield 2100/3800-2X6760-2050

85 / 165

5

Operation Hydraulic components on the shield

Fitting tool

1

Rod

2

Retaining nut

3

Slide piece

4

Mounting

5

Spring dowel pin 5x20

6

Cylinder head screw M 5x30-8.8

Measuring adapter Fig. 57: Fitting tool for valve cartridges, component positions

86 / 165

1

Measuring adapter DN 10 with bleeder

2

Pressure gauge

4

Staple DN 10 D-type

5

SHL-LTG 4SP-DN10ST

6

Measuring hose

7

Measuring coupling

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 56: Fitting tool for valve cartridges, component positions

Operation Location of the hydraulic components

5

5.7 Location of the hydraulic components The shield is equipped with the following control units: Electrohydraulic control unit, 12-function , Water valve unit, 2-function, Supply manifold, PMC®-R control unit.

Important information Observe the additional instructions in our operating manuals for the electronic shield control system!

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Control units Fig. 58: Control units on the shield

1

Electrohydraulic control unit 12-function

a

PMC®-R control unit

Face-End Shield 2100/3800-2X6760-2050

4

Water valve unit 2-function

87 / 165

5

Operation Location of the hydraulic components

Supply manifold

9

CV, NW 25

12

Pressure gauge

16

Supply block

30

Measuring coupling SMK 20

39

Line filter DN 10

Z3

Stabilizing cylinder

a

5/3-way ball valve DN 25-SS/DN 12

Fig. 60: Supply manifold right

88 / 165

9

CV, NW 25

12

Pressure gauge

16

Supply block

32

HP ball valve DN 20

Z3

Stabilizing cylinder

a

5/3-way ball valve DN 25-SS/DN 12

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 59: Supply manifold side

Operation Location of the hydraulic components

5

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 61: Supply manifold bottom

9

CV, NW 25

12

Pressure gauge

16

Supply block

21

HP ball valve DN 10

32

HP ball valve DN 20

39

Line filter DN 10

Z3

Stabilizing cylinder

a

5/3-way ball valve DN 25-SS/DN 12

b

Face-End Shield 2100/3800-2X6760-2050

Support II

89 / 165

5

Operation Location of the hydraulic components

1

Electrohydraulic control unit

16

Supply manifold

21

HP ball valve DN 10

Z1

Leg

Z3

Stabilizing cylinder

a

Hose connections

Z3

Stabilizing cylinder

Fig. 63: Supply manifold Hose connections, left

90 / 165

16

Supply manifold

a

Hose connections

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 62: Supply manifold Hose connections, right

Operation Location of the hydraulic components

5

PMC®-R control unit

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 64: PMC®-R control unit

a

PMC®-R control unit

b

EMERGENCY STOP switch

c

Support lock-out switch

d

Bracket

Electrohydraulic control unit and water valve Fig. 65: Electrohydraulic control unit and Water valve unit, detail

1

Electrohydraulic control unit, 12-function

4

Water valve unit, 2-function

12

Pressure gauge

17

Accumulator cartridge

a

Symbol plate

b

Sign

Face-End Shield 2100/3800-2X6760-2050

91 / 165

5

Operation Location of the hydraulic components

Double filters

12

Pressure gauge

20

Double filter

30

Measuring coupling

a

Support for lamp

*

concealed

CAUTION Changing the double filter Generally, double filters are equipped with rotation prevention for the filter cartridges. The filters can only be loosened when depressurized.

1. First depressurize the hydraulic system before replacing the filters!

92 / 165

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 66: Double filter

Operation Location of the hydraulic components

5

Leg

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 67: Leg with cover

a

Cover, right

c

Bracket, center

Face-End Shield 2100/3800-2X6760-2050

b

Cover, left

93 / 165

5

Operation Location of the hydraulic components

2

Leg POCV DN 20

3

Leg POCV DN 20

8

PRV 410 bar

12

Pressure gauge NG 50

29

Pressure gauge port

41

CV DN 10

47

Rock burst valve, DN 40 - 440 bar

S1

Pressure sensor

a

Compensating valve

c

PRV 520 bar

Z1 left

94 / 165

Leg, left

b

Z1 right

Cover PRV

Leg, right

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 68: Leg

Operation Location of the hydraulic components

5

Stabilizing cylinder

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 69: Stabilizing cylinder

7

PRV 410 bar

11

Double POCV

30

Measuring coupling

Z3

Stabilizing cylinder

Bracket with hydraulic components A bracket with hydraulic components is located between the two legs: The HP ball valves are located on the front section of the bracket.

The distributors and water filters are located on the rear section of the bracket.

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5

Operation Location of the hydraulic components

31

HP ball valve DN 10

a

Walkway plate, front

b

Walkway plate, rear

c

Cover

Z1 re Leg, right

Z1 li

Leg, left

Fig. 71: Bracket, front

21

HP ball valve DN 10

38

Distributor

Z1 re Leg, right

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22

Z1 li

HP ball valve DN 20

Leg, left

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Fig. 70: Bracket, center; side view

Operation Location of the hydraulic components

5

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Fig. 72: Bracket, rear

5

POCV, hydraulically piloted DN 12

30

Measuring coupling

38

Distributor

39

Line filter DN 10

40

POCV, hydraulically piloted DN 10

a

Walkway plate, rear

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Operation Location of the hydraulic components

Flipper

1*

Face end shield7420 274 000 00 01

2*

Flipper

3*

Flipper extension

4*

Hydraulic system for flipper

Z6

Flipper cylinder

Fig. 74: Flipper cylinder

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1*

Double POCV DN 10

6*

PRV 380 bar DN 10

7*

Measuring coupling

Z6

Flipper cylinder

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Fig. 73: Flipper

Operation Repair and emergency operation

5

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

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

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

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

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

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WARNING The buttons on the control unit 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 or death.

Notice on work safety The shield support is operated in normal operation by means of the electronic control only.

It is imperative that you observe the separate operating manual for the PMC®-R control unit.

Fig. 75: PMC®-R control unit

a

PMC®-R control unit

c

Support lock-out switch

b

EMERGENCY STOP switch

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

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

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5

Operation Operation and functions of the electrohydraulic control unit

5.9 Operation and functions of the electrohydraulic control unit This chapter provides you with information on the functions of the electrohydraulic control unit. It is also imperative that you follow the operating manuals for the support and the control unit.

DANGER Operating the control Incorrect or negligent operation of the control system can result in serious injury or death!

1. Only operate the control system if you have detailed knowledge of the operating controls and their method of operation!

Locking of operating levers Shield motions cannot be stopped when operating elements of the control are intentionally or unintentionally locked. This could fatally injure you or others.

1. Never lock operating levers of controls!

2. Regularly check the correct function of the operating levers.

3. Shut down the machine immediately if you notice a malfunction or locked levers.

DANGER Manual operation of a button 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.

1. Always make sure to execute the functions in the correct sequence!

For example, the function "Advance shield" can be activated without previously activating the functions "Retract side seal" and "Actively lower support". This can cause dangerous situations which can result in very serious injuries.

The symbol plate is located on the electrohydraulic control unit above the pilot valves. The displayed symbols directly correspond to the various functions which are initiated by actuating the respective button.

The meaning of the symbols and functions are described below.

5.9.1 Shield functions - control unit, 12-function Fig. 76: Functions of the electrohydraulic control unit, 12-function, symbol plate

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DANGER

Operation Operation and functions of the electrohydraulic control unit

5

Advance shield Before executing this function, the side seal of the shield unit must be released and the function "Retract leg" must have been executed for both legs.

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

As long as the function is activated, the piloted check valve, which hydraulically blocks the annular space of the advancing cylinder, is opened automatically.

Set the leg (compensating valve) Before this function is actuated, the shield canopy must be correctly aligned.

While this function is being executed, the baselift cylinder is actively retracted and the dust control system is activated.

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

While the legs are being set, a canopy, which has too steep a setting angle, aligns itself automatically to the roof as long as the function of the compensating valve is not blocked. The canopy might then have to be realigned.

Compensating valve (KN valve) The compensating valve and the associated shut-off valve are on the right leg when looking at the coal face. When the shut-off valve is open (lever in the direction of flow), the compensating valve is activated. When the shutoff valve is closed (lever perpendicular to direction of flow), the compensating valve has no function.

While the legs are being set, the compensating valve limits the pressure of the stabilizing cylinder to 200 bar as long as the pressure under the piston of the leg does not exceed 100 bar. This means that the stabilizing cylinder retracts if the canopy is set too steeply. The canopy only presses with the tip against the roof and aligns itself to it automatically.

Conveyor push Before executing this function, ensure that the shield unit is completely set.

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

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

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

While the legs are being set, a canopy, which has too steep a setting angle, aligns itself automatically to the roof as long as the ball valve for the stabilizing cylinder is not blocked.

Retract seal cylinder The seal cylinders continue to retract as long as the button is held down or until the end position is reached.

In idle state, the side seal is always pushed outwards due to the force of the compression springs.

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Operation Operation and functions of the electrohydraulic control unit

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

The function serves to align the shield unit to the neighboring support.

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

In idle state, the side seal is always pushed outwards due to the force of the compression springs.

Retract stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy.

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

Extend stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy.

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

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

NOTICE Residual stroke of stabilizing cylinders or adjusting cylinders When stabilizing cylinders or adjusting cylinders are completely extended, any load peaks that occur cannot be absorbed. This can lead to damage to the steel structure.

1. Make sure that stabilizing cylinders or adjusting cylinders always have a residual stroke of min. 20 mm.

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

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

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

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

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

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

Operation Operating the double filter

5

5.9.2 Shield functions – water valve unit Fig. 77: Functions of the water valve unit, symbol plate

Canopy tip water spraying system Pressing the button causes the spraying valve on the canopy tip to open. It is locked in idle status.

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

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The water feed line to the spraying valve can be interrupted with the shut-off valve which is aligned in the water circuit.

Side seal spraying system Pressing the button causes the spraying valve on the side seal to open. It is locked in idle status.

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

The water feed line to the spraying valve can be interrupted with the shut-off valve which is aligned in the water circuit.

5.10 Operating the double filter NOTICE Putting the double filter into operation Do not put the filter into operation before making sure that all connections have been properly established. normal operation

backflushing

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

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

NOTICE Putting the double filter into operation The filter can be damaged by an incorrect sequence of operation or sudden actuation of the shut-off valves in succession.

1. First, slowly open the shut-off valve on the inlet side and then that on the outlet side.

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

Then repeat the procedure with the other lever.

Note that for backflushing a volume flow of at least 70 L/min is required.

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5

Operation Measuring coupling

A

Normal operation: Both levers in position "A"

B

Backflushing: One of the levers in position "B"

5.11 Measuring coupling The measuring coupling (SMK20) is used for monitoring and checking the pressure in the system. Measuring couplings are installed on cylinders and legs, for instance.

By connecting measuring and checking devices, the pressure can be read and the system depressurized.

Fig. 79: Pressure relief measuring coupling

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1

Connection

3

Protective cap

2

Pressure relief measuring device connection

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Fig. 78: Operating the double filter

Operation Maintenance

5

5.12 Maintenance WARNING Release Installation errors after repair or maintenance work can severely injure you or your associates!

1. Only release the shield or machine for use once you have checked that all of it works properly and have not found any malfunctions. electronic control system

NOTICE

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

After working on a hydraulic system, you can assume that dirt has penetrated the hydraulic system. Depending on the degree of contamination, this can clog the filters in the system.

As a result, functions are slowed down, performed incorrectly, or not performed at all. filter cartridges

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

It is therefore very important to ensure quality when preparing the hydraulic medium!

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

replacing filters

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

We recommend:

water filters

Replace the water filter directly.

piston rods

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

pressure relief valves

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

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

We recommend such spot checks at 3-month intervals.

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5

Operation Maintenance

Daily maintenance hydraulic system

Check the shields by visually inspecting them for any escaping hydraulic fluid at the following components: Hose lines Electrohydraulic control unit Valves Legs All installed cylinders Check the pressure gauges on the legs for visible damage and correct function.

support unit

Check the shields by visually inspecting them for damage to the steel structure at the following components: Relay bar assembly

Side seal Brackets, etc.

Weekly maintenance 1. Check each control for correct functioning.

2. Replace defective controls or individual components immediately.

3. Clean the controls, especially the control panel.

WARNING It is important that the control system symbols are easily legible.

This reduces the danger of operating errors and resulting accidents.

Six-monthly maintenance hydraulic leg

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Lubricate the dirt strippers of both telescope stages via the lubricating nipple with grease A2 acc. to EWN 7068, see chapter 6, section "Lubricating greases and pastes".

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Pin connections and retaining devices

Operation Regular, scheduled damage assessment

5

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Fig. 80: Lubricating nipples on the hydraulic leg

a

Lubricating nipples on the guide bushing

b

Grease escaping at dirt stripper

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

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5

Operation Troubleshooting

5.14 Troubleshooting 5.14.1 Instructions for troubleshooting The shield hydraulics of a shield unit consists of a number of individual components. The linking of the components with each other is shown in the diagrams and hose diagrams for the shield hydraulics.

Refer to the section "Operating the shield hydraulics" in this chapter or the spare parts catalog.

Malfunctions can basically occur on all components. Most faults on hydraulic valves, however, are caused by hydraulic bypass flows. These are normally audible to the operator.

support cannot be lowered

support cannot be set

Possible cause

Measure required

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

Open the shut-off valve! Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

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

Control piston on the leg control valve is not working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

Leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

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

Leg is defective

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

Possible cause

Measure required

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

Open the shut-off valve! Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

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Control piston on the leg control valve is not working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

Leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

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

Leg is defective

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

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

Operation Troubleshooting

support cannot be advanced

5

Possible cause

Measure required

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

Open the shut-off valve! Valves can only be switched when the supply line is open.

The support is stuck between the neighboring supports.

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

Step on roof or floor blocking the support.

Lower the canopy sufficiently to clear the step or lift the base frame one step.

The pressure of the hydraulic supply is too low.

Check whether - all shut-off valves are open,

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- the system pressure is sufficient.

Control piston on the piloted check valve is not working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

Leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked advancing cylinder hose lines. Replace the hose line if necessary. Make sure hose lines are laid properly.

Advancing cylinder is defective.

Check whether - advancing cylinder is damaged, - piloted check valve works correctly.

Remove the hose from the connection on the piston side and execute the function "Advance conveyor". If pressurized fluid escapes, replace the advancing cylinder.

setting pressure is not reached / leg pressure drops again after

Possible cause

Measure required

Leg control valve is defective.

Replace leg control valve. Continue troubleshooting if the pressure continues to drop.

Legs are damaged.

Check legs for damage and replace, if necessary. Remove hose from leg lowering connection and check whether pressurized fluid is escaping even though the leg is no longer being extended. If applicable: piston packing defective, replace leg.

Pressure relief valve defective

Monitor pressure drop on the pressure gauge.

Is pressurized fluid leaking from the pressure relief valve? Replace the pressure relief valve and retest the function.

setting

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Operation Troubleshooting

canopy cannot be positioned

Possible cause

Measure required

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

Open the shut-off valve! Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply works correctly, - all shut-off valves are open,

canopy cannot be lowered

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approximately 80 bar. Check valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Measure required

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

Open the shut-off valve! Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

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Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approximately 80 bar. Check valve may be defective.

Damaged or trapped hose line.

Check hose lines for controlling the leg / stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

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- the system pressure is sufficient.

Operation Troubleshooting

5

5.14.2 3/2-way or pilot valve The valve is jammed or a bypass has formed due to internal leakage. The latter can normally be detected on the working valves of the electrohydraulic control unit by a clearly audible hissing noise.

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

The 3/2-way valve or the pilot valve may therefore be faulty. valve sticks

internal leakage

1. Try to solve the problem by actuating the function several times at the electrohydraulic control unit or control unit.

1. Locate the faulty valve by actuating the functions individually in sequence.

If the noise goes away while a function is being actuated, this valve is faulty.

You might have to press the button for the faulty function for several seconds before the noise goes away.

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valve replacement

1. Close the main shut-off valve in the pressure feed line for the shield at the pipe distributor.

2. Then actuate the functions manually to depressurize the system.

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

5.14.3 Piloted check valves The formation of a bypass is indicated by a drop in pressure.

1. 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.

1. Check the valve and, if it is faulty, replace it.

5.14.4 Checking the leg check valves To check the leg check valves please proceed as follows: 1. Set the leg until the setting pressure has been reached.

2. Remove the "set leg" hose line on the piloted check valve.

If fluid escapes from the connection of the piloted check valve, it is defective.

5.14.5 Internal bypass in legs If you suspect an internal bypass in a leg, follow this procedure: Set the leg until the setting pressure has been reached.

Make sure that the annular space of the leg is depressurized.

Release the hose of the leg annular space connection at the leg.

Actuate the "Set leg" function at the neighboring support.

1. If there is an internal bypass in the leg, for example due to damaged piston packing, fluid will flow out of the leg's lower connection.

Replace the leg in this case.

If fluid escapes from the detached hose lines, the piloted check valve is defective.

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Operation Troubleshooting

5.14.6 Pressure relief valve defective Leaking pressure relief valves can normally be detected by the discharge of fluid, or a pressure drop is displayed on the pressure gauge. If fluid is already discharged at working pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

In the hydraulic circuit of a shield unit, various types of pressure relief valves are used. For example, pressure relief valves with a high flow rate are used on the legs. However, the pressure relief valves for securing advancing cylinder, stabilizing cylinders etc. are designed for a lower flow rate.

Pressure relief valves for different cylinders or for the piston and ring sides of a cylinder can be set to different maximum pressure values. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

Operation of the shield is slow although the system pressure lies in the normal range. It is also possible that the hydraulic system has been contaminated, for example during repair work on the hydraulic system.

1. Check the filters in the hydraulic system.

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

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5.14.7 Defective or clogged filter

Technical data Troubleshooting

6

6 Technical data This chapter contains the technical description of the support and its main subassemblies as well as the technical data for the described subassemblies.

Type 2100/3800-2X6760-2050 The Two-leg shield consists essentially of the following main subassemblies: base frame with lemniscatic links and relay bar assembly, canopy caving shield caving flap canopy and caving shield side seals hydraulic legs

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hydraulic equipment with hose lines and control Tab. 12: Shield support variants, dimensions and weight Use

Face end shield

Device number

7420 274 000 00 01

Dimensions

Weight

LxWxH

Approx. in kg

8 535 x 1 950 x 3 000

46 500

Special design

Tab. 13: Shield support, numbering

base frame

caving shield

canopy

hydraulic system

SAP number

Serial number

Shield number

4844969

ZZ700100 to ZZ700107

GE001 to GE008

The shield is equipped with a one-piece base frame. This consists of two skids which are tightly connected to each other, in the middle of which is the channel for the relay bar assembly.

The caving shield is a one-piece steel construction; it is hinged to the canopy and also to the base frame by means of the so-called lemniscatic link.

The shield canopy transmits the bearing strength of the legs to the roof. The caving shield has a hinged connection through use of pin connections. The hinge is reinforced by the the lemniscatic links.

Programmed methods of calculation ensure the best possible support. This ensures that the support resistance and range of vertical adjustment is coordinated in optimum fashion. The multi-stage hydraulic legs have the same load capacity at any stage and act on both sides.

The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

The shield units are equipped with all components required for implementing an electrohydraulic neighboring control with the electronic PMC®-R control system.

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Technical data Technical description

6.1 Technical description 6.1.1 Main dimensions, end

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Fig. 81: Face end shield, dimensions

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Face-End Shield 2100/3800-2X6760-2050

Technical data Technical description

HG

Height, extended

HE

Height, retracted

LT

Transport length

M

Support center distance

B

Width

6

Tab. 14: Shield, dimensions LT

L

L1

L2

L3

M

H

HG

HE

B

W1

W2

W3

8 535

6 160

3 299

4 660

1 690

2 050

3 000

3 800

2 100

1 950

1 900

1 080

390

6.1.2 Base frame with lemniscatic link and relay bar assembly

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The one-piece base frame transmits the shield load of the hydraulic legs to the floor. The legs are mounted on hinges in the ball sockets in the skids and are held on both sides by leg retainers.

Both pairs of lemniscatic links are hinged to the base frame with a pin connection.

Characteristic for the base frame is the arrangement of the relay bar assembly in the middle between the two skids. The relay bar assembly is reversemounted. This means that the force applied to the piston surface of the shifting ram is used to advance the shield. Correspondingly, the conveyor is advanced with the smaller force generated by the annular surface.

The clevis joint of the relay bar assembly establishes the connection to the conveyor. With the help of the lifting cylinder, the shield can be lifted during shield advance.

The shifting ram can be equipped with a reed rod for measuring forward movement.

The relay bar assembly is fastened to the conveyor using the clevis assembly for conveyor on the crawl pan.

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Technical data Technical description

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

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Fig. 82: Base frame with lemniscatic link and relay bar assembly, dimensions

Technical data Technical description

6

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Fig. 83: Base frame, component positions

1

Base frame

2

Cylinder bearing

3

Leg retainer, right

4

Leg retainer, left (not visible)

5

Lemniscatic link pin 184.3 x 677

6

Lemniscatic link pin 154.3 x 677

7

Safety segment

8

Safety segment

9

Mounting link

10

Subassembly cover plate

12

Running board, right

13

Running board

14

Running board, left

15

Pin 22/16x52

17

Cover

18

Plug, side

19

Pin 60/50x135

20

Pin 35/29x66

21

Pin 25/16x154

22

Pin 25/16x138

24

Washer

25

Hex. head screw M 30x50-A 4-80

26

Hex. head screw M 16x80-A 4-80

27

Hex. nut M 16-1.4571

28

Hex. head screw M 12x70-A 4-80

29

Hex. nut M 12-A 4-80

30

Spring clip 2.5

31

Spring clip 4

32

Spring clip 3.2

34

Spring cotter 5

*

Concealed

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Technical description

Running boards

1

Running board, right

2

Running board

3

Hex. head screw M 12x30-A 4-80

4

Washer 24

5

Hex. nut M 12-A 2-70

Fig. 85: Running board, component positions and dimensions

1

Running board

2

Running board

3

Hex. head screw M 12x30-A 2-70

4

Hex. nut M 12-1.4571

Fig. 86: Running board, left, component positions and dimensions

118 / 165

1

Running board, left

2

Running board

3

Hex. head screw M 12x30-A 4-80

4

Washer 24

5

Hex. nut M 12-A 2

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 84: Running board, right, positions and dimensions

Technical data Technical description

6

Covers

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 87: Subassembly cover plate, component positions and dimensions

1

Cover plate

2

Cover plate

3

Hex. nut M 12-A 2

a

Hex. head screw M 12x30-A 2-70

b

Hex. head screw M 12x35-A 4-80

c

Hex. nut M 12-1.4571

d

Screw holder M 12

Fig. 88: Cover, component positions and dimensions

1

Plate

2

Rubber covering

3

Mounting

4

Hex. head screw M 12x45-A 2-70

5

Hex. head screw M 12x30-A 2-70

6

Hex. nut M 12-A 4-80

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Technical description

1

Locking section

5

Spring dowel pin 10x36-1.4310

Rubber covering Fig. 90: Rubber covering, component positions and dimensions

1

Rubber covering

2

Mounting

3

Hex. head screw M 12x40-A 2-70

4

Hex. nut M 12-1.4571

Fig. 91: Rubber covering, center, component positions and dimensions

120 / 165

1

Mounting

2

Rubber covering

4

Hex. head screw M 12x60-A 4-80

6

Hex. nut M 12-1.4571

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 89: Locking section, component positions and dimensions

Technical data Technical description

6

6.1.3 Relay bar assembly The relay bar assembly is arranged in the middle of the base frame. It consists mainly of the relay bar, shifting ram, lifting cylinder and the required connecting elements. It serves to advance the conveyor and the shield.

The force of the reverse-mounted shifting ram is applied directly to the relay bar. Here, the force on the piston surface side is used to advance the shield, while the smaller force of the annular surface is used to advance the conveyor.

With the help of the base-liftung device , the base frame can be lifted from the floor during advancing. The lifting cylinder is located in the center of the base frame. The force of the lifting cylinder acts on the floor via the relay bar.

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 92: Relay bar assembly, dimensions

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Technical description

122 / 165

1

Point of attachment for the conveyor

2

Beam

3

Relay bar

4

Shear pin 60/53x201

5

Pin 70/53x205

6

Threaded pin 60x273/361

7

Nut M48

8

Locking clip, 8x42

9

Pin 70/63x203

10

Pin 15/12x105

11

Hex. head screw M 16x20-A 2-70

11

Hex. nut M 12-A 4-80

13

Spring clip 2.5

a

Locking piece

b

Load ring, beam load capacity 3 000 kg

c

Name plate, beam

d

Cylinder bearing

e

Load ring, relay bar load capacity 3 000 kg

f

Name plate, relay bar

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 93: Relay bar assembly, component positions

Technical data Technical description

6

6.1.4 Lemniscatic links The front and rear lemniscatic links of the shields differ in: the length, the design.

Lemniscatic links, front The front lemniscatic links have the same dimensions and components.

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 94: Front lemniscatic links, dimensions

Tab. 15: Lemniscatic links, dimensions Item

Lemniscatic links

Drawing no.

Qty.

L

L1

L2

L3

B

5

front

7420 273 303 00 00

2

2 040

1 690

845

30

530

D

Note

185 1x load ring 1x stripper

1x name plate 4x screw holder M12

Fig. 95: Lemniscatic links, front

1

Lemniscatic links, front

2

Stripper

5

Name plate

10

Load ring capacity 3000 kg

15

Screw holder M 12

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Technical description

Lemniscatic links, rear The rear lemniscatic links have the same dimensions and components.

Tab. 16: Lemniscatic links, dimensions Item

Lemniscatic links

Drawing no.

Qty.

L

L1

L2

L3

B

7

rear

7420 273 305 00 00

2

1 880

1 510

750

250

530

D

Note

155 1x load ring

1x name plate

Fig. 97: Lemniscatic links, rear

124 / 165

1

Lemniscatic links, rear

10

Load ring capacity 3000 kg

5

Name plate

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 96: Rear lemniscatic links, dimensions

Technical data Technical description

6

6.1.5 Canopy The canopy transfers the bearing strength of the legs to the roof. It is hinged to the caving shield by means of pin connections. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the legs are hinged to the canopy.

NOTICE Permissible angle of inclination of the canopy If the angle of inclination of the canopy is exceeded (angle between the shield canopy and the caving shield), severe damage to the shield support, especially of the hydraulic cylinders and legs, can occur!

1. Be sure to observe the permissible angle of inclination of the canopy (see section "Technical data")!

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Tab. 17: Canopy, dimensions and weight Description

Canopy

ID number

7420 274 400 00 01

Note

Face end shield

Dimensions

Weight approx.

LxWxH

in kg

6 160 x 1 930 x 830

14 543

Fig. 98: Canopy for face shield, dimensions

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

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6

Technical data Technical description

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 99: Canopy, component positions

1

Canopy

2

Cover plate

3

Cover

4

Peg 69X158

5

Pin 15x150

6

Joint pin Ø154.3x660

7

Locking piece

8

Pin 15/12X120

9

Pin 63x240

10

Retaining ring

11

Hex. head screw M 10x110-A 2-70

12

Hex. nut M 10-A 2-70

13

Hex. head screw M 12x35-A 4-80

14

Hex. nut M 12-A 4-80

15

Spring clip 2.5

16

Hex. head screw M 12x50-A 2-70

17

Pin 50/44X92

18

Hex. head screw M 12x30-A 2-70

19

Spring cotter 5

20

Clevis

21

Clevis holding plate

22

Sealing rubber

23

Locking piece

24

Staple DN 32-130 lg

a

Load ring 3 000 kg

b

Safety peg 5 t

c

Load ring 3000 kg

d

Safety peg 3 t

e

Water spraying system holder

f

Clip 8 t

g

Name plate

h

Clamping plate

k

Screw holder M 16

126 / 165

Face-End Shield 2100/3800-2X6760-2050

Technical data Technical description

6

6.1.6 Flipper The flipper shields off the area in front of the relay bar assembly. It is connected to the canopy via the flipper cylinder.

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Fig. 100: Flipper, dimensions

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Technical description

128 / 165

1

Flap

2

Flange plate

3

Fork control arm

4

Flipper cylinder

5

Locking piece

6

Fork control arm

7

Plate

8

Damper

9

Pin 55/43.5x148

10

Pin 58.5X300

11

Pin 58.5X240

12

Pin 58.5X270

13

Pin 45/38.5x160

14

Hex. head screw M 10x60-A 2-70

15

Hex. head screw M 10x75-A 2-70

16

Hex. head screw M 10x70-A 2-70

17

Hex. head screw M 30x80-10.9

18

Hex. head screw M 16x170-A 2-70

19

Cylinder head screw M 16x80-1.4301

20

Hex. nut M 10-A 2-70

21

Hex. nut M 30-10

22

Hex. nut M 16-A 2

23

Hex. nut M 16-A 2-70

24

Washer 17

26

Spacer sleeve 25x4, 32 lg

27

Hex. head screw M 12x90-A 4-80

28

Hex. nut M 12-A 4-80

a

Name plate, canopy

b

Name plate, flange plate

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 101: Flipper, component positions

Technical data Technical description

6

6.1.7 Leg head with pin 1. Before installing the leg head, put the pins of the leg head fixture into the bore holes of the mounting device.

2. Secure the pins with the securing devices (pins, locking clips) in the second groove.

3. After installing the leg, push the pins in the bore holes of the leg head.

4. Secure the pins in the first groove by using the securing devices.

Hydraulic leg SD-6500-450-1565/3175

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 102: Fastening the leg head

1

Pin 69x158

2

Pin 15x150

3

Spring clip 2.5

a

Leg

NOTICE Installation Before the leg heads are installed in the ball sockets of the canopy, they must be lubricated with lubricant B6.

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6

Technical data Technical description

6.1.8 Canopy and caving shield side seals The side seals seal the gaps between neighboring shield units. They can also be used to align a shield unit to the adjacent shield units.

The side seals are arranged on the canopy and the caving shield and can be moved on the right side. They are guided by means of guiding pins and pressed permanently against the neighboring shield by compression springs. The side seals can be extended and retracted using hydraulic legs.

WARNING Side seal Movable side seals are under spring pressure! Increased risk of injury due to unexpected movements of the side seal!

2. Reattach all connecting elements before removing the clamp clips!

Side seal, canopy Fig. 103: Canopy side seal, dimensions

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

NOTICE Transport safety devices To transport the shield unit, the movable side seals are retracted and locked mechanically with pins. These pins are secured with staples that must be removed prior to commissioning in order to prevent damage.

1. Before the shield unit is commissioned, it is necessary to remove the transport safety devices of the side seal!

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Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

1. Never remove connecting elements of the side seal before the side seal is pulled together and secured using clamp clips!

Technical data Technical description

6

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 104: Canopy side seal, component positions

1

Side seal, CRH

2

Seal cylinder ZE-63/50-215

3

Guiding pin Ø133x715

4

Compression spring 12x79x560

5

Guiding pin Ø133x1355

6

Pin 35/28x232

7

Staple DN 12-100 lg.

8

Pin Ø28x93

9

Split pin 6.3x40-ST

10

Cover

11

Locking piece

12

Pin 15/12x120

13

Spring clip 2.5

14

Pin 30/22x120

15

Spring clip 3.2

16

Cylinder liner 133x105

17

Screw pin M 10x12

Caving shield side seal Fig. 105: Caving shield side seal, dimensions

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

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6

Technical data Technical description

NOTICE Transport safety devices To transport the shield unit, the movable side seals are retracted and locked mechanically with pins. These pins are secured with staples that must be removed prior to commissioning in order to prevent damage.

1. Before the shield unit is commissioned, it is necessary to remove the transport safety devices of the side seal!

132 / 165

1

Side seal, CSRH

2

Cover plate D 205

3

Guiding pin Ø103x1350

4

Seal cylinder ZE-63/50-215

5

Guiding pin Ø103x695

6

Compression spring 12x79x560

7

Pin 30/25x175

8

Staple DN 12-97 lg.

9

Pin Ø28x93

10

Split pin 6.3x40-ST

11

Pin 30/22x120

12

Spring clip 3.2

13

Cylinder liner 133x105

14

Screw pin M 10x12

15

Hex. head screw M12x35-A 4-80

16

Hex. nut M 12-A 4-80

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 106: Caving shield side seal, component positions

Technical data Technical description

6

6.1.9 Caving shield The caving shield protects the face area toward the caving area. It is connected to the shield canopy and to the base frame via the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the shield canopy to provide stability for the hinge.

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 107: Caving shield, dimensions

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

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6

Technical data Technical description

134 / 165

1

Caving shield

2

Cover plate

3

Cover plate D 205

4

Locking piece

5

Bar

6

Locking piece

7

Lemniscatic link pin 184.3 x 673

8

Lemniscatic link pin 154.3 x 673

9

Pin 63x240

10

Pin 40/34x64

11

Pin 15/12x120

12

Retaining ring

13

Sealing rubber

14

Sealing rubber

15

Hex. head screw M 10x110-A 2-70

16

Hex. head screw M 12x35-A 4-80

17

Hex. head screw M 12x25-A 2-70

18

Hex. head screw M 12x40-A 4-80

19

Hex. nut M 10-A 2-70

20

Hex. nut M 12-A 4-80

21

Hex. nut M 12-A 2-70

22

Staple DN 25 - 105 long

23

Spring cotter 5

24

Spring clip 2.5

a

Load ring 3 000 kg

b

Safety peg 3 000 kg

c

Transport ring 8 000 kg

d

Spacer plate

e

Plate

f

Screw holder M12

g

Screw holder M8

h

Name plate

i

Stabilizing cylinder bearing

k

Bearings

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 108: Caving shield, positions

Technical data Accessories

6

6.2 Accessories 6.2.1 Anti-topple device "canopy-canopy" The anti-topple device “canopy / canopy” according to drawing number 7427 174 000 00 01 can be used only for the end shield on the Tail gate.

Before aligning, the shield to be aligned should be lowered. The neighboring shield to which the alignment cylinder is attached must be set. By actuating (pushing or pulling) the lever "Z", the corresponding alignment cylinder is retracted and the shield is aligned.

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

It may be necessary to also use the corresponding side seal or pusher cylinder to align more precisely.

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Accessories

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Fig. 109: Anti-topple device "canopy-canopy"

136 / 165

Face-End Shield 2100/3800-2X6760-2050

Technical data Accessories

6

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 110: Anti-topple device "canopy-canopy"

a

Anti-topple device "canopy-canopy"

NOTICE Observe the sequence of steps An incorrect sequence of steps when advancing the shields can lead to serious damage!

1. Advance the shields only in the sequence 2-1-3 or 2-3-1!

DANGER Offset shield 1 to shield 2 If the permissible offset dimension is exceeded, the alignment cylinders or their brackets could be seriously damaged. You or your colleagues could be seriously injured or even killed by falling components!

1. The offset from shield 1 to shield 2 must never exceed 200 mm!

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Accessories

138 / 165

1

Terminal bracket

2

Pin 69.8x220

3

Universal joint

4

Universal joint

5

Hinge piece

6

Hydraulic cylinder ZE-135/80-800

7

Pin 16x150

8

Spring clip 3.2

9

Pin 55/40x125

10

Spring clip 4

a

Hammer head bolt M 24x80-12.9

b

Hex. nut M 24-8

c

Load ring 1 000 kg

d

Screw holder M 12

e

Screw holder M 16

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 111: Anti-topple device "canopy / canopy", positions

Technical data Accessories

6

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 112: Hydraulic control for anti-topple device "canopy / canopy" 1, positions

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Accessories

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 113: Hydraulic control for anti-topple device "canopy / canopy", positions

140 / 165

1

Bracket

2

Symbol plate, 2-function

3

Electrohydraulic control unit 2-function

4

Plug-in elbow socket DN 10

5

Plug-in elbow socket DN 10/135°

6

Plug DN 10

Face-End Shield 2100/3800-2X6760-2050

Technical data Accessories

6

7

Plug-in reducing L-socket DN 25/DN10

8

Plug-in reducing L-socket DN 10

9

HP ball valve DN 10, Red

10

CV DN 10

15

Hose line 2SC DN10x2100, connections galvanized

16

Hose line 2SC DN10x3000, connections galvanized

17

Hose line 2SC DN10x800, connections galvanized

18

Hose line 2SC DN10x1500, connections galvanized

20

Staple DN 10

21

Staple DN 25

a

Reposition existing measuring coupling

b

P-control

c

T-supply block

d

Connection, 2-control

e

glued

f

P-filter

g

Annular space

h

Piston space

i

T-control

2

Hydraulics for anti-topple device "canopy-canopy"

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 114: Hydraulics for anti-topple device "canopy-canopy"

a

Face-End Shield 2100/3800-2X6760-2050

Anti-topple device "canopy-canopy"

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6

Technical data Accessories

142 / 165

1

Support

3

Electrohydraulic control unit

9

HP ball valve DN 10

10

CV DN 10

a

Anti-topple device "canopy-canopy"

b

Double filters

15

Hose line 2SC DN10x2100, connections galvanized

16

Hose line 2SC DN10x3000, connections galvanized

17

Hose line 2SC DN10x800, connections galvanized

18

Hose line 2SC DN10x1500, connections galvanized

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 115: Anti-topple device "canopy-canopy"

Technical data Accessories

6

6.2.2 Side flap

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Fig. 116: Side flap, dimensions

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6

Technical data Accessories

144 / 165

1

Bracket

2

Bracket

3

Bracket

4

Hammer head bolt M 24x80-8.8

5

Washer 24

6

Hex. nut M 24-8

7

Flap

8

Side flap

9

Pin 50/40x130

10

Cyl. head screw M 6x50-A 2-70

11

Hex. nut M 6-A 4-80

12

Pin 40/30x110

13

Cylinder head screw M 6x40-1.4301

14

Fork

a

Clevis

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 117: Side flap 7420 274 070 00 00, component positions

Technical data Technical data, steel structure

6

6.3 Technical data, steel structure Face end shield, device number 7420 274 000 00 01

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Securing from tipping, permissible inclination, omnidirectional

Degrees

15

Height, retracted

mm

2 100

Height, extended

mm

3 800

Height adjustment

mm

1 700

Advance stroke

mm

1 000

Shifting ram stroke

mm

1 080

Leg clearance in inclines

mm

1 080

Forepole of canopy

mm

4 660

Rear projection of canopy

mm

1 500

Canopy width with side seal

mm

1 950

Canopy length

mm

6 160

Support retracted

Degrees

21.1

Support extended

Degrees

56.1

Caving shield width, with side seal

mm

1 950

Base frame width

mm

1 900

Total area of the base frame

cm

2

47 550

Support center distance

mm

2 050

Supporting force for average seam of

mm

3 000

a) at 350 bar setting pressure

kN

10 761

kN

12 605

mm

3 000

Caving shield inclination:

b) at 410 bar nominal pressure 2

Support resistance for each m of roof surface with medium seam thickness of Face end shield a) at 350 bar setting pressure b) at 410 bar nominal pressure

kN/m2

781

2

796 / 915

kN/m

(KAKO large / small)

Face-End Shield 2100/3800-2X6760-2050

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6

Technical data Hydraulic system

6.4 Hydraulic system The following section provides an overview of the parts of the shield hydraulics.

Additional information can be found in the spare parts catalog for the shield support or the hydraulic components listed in the "Operation" chapter. normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

6.4.1 Shield hydraulics Electrohydraulic control unit The pilot valves of the electrohydraulic control unit are equipped with buttons which allow the shield functions to be actuated manually. A symbol plate shows the function of the buttons.

Control unit 8154 167 000 00 00 with 12 functions,

WARNING The buttons on the control unit 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 or death.

Fig. 118: Electrohydraulic control unit, 12 functions

146 / 165

1

Distributor block

2

Double 3/2 way magnetic pilot solenoid valve

3

Control valve cartridge NG 20

4

Control valve cartridge NG 13

5

Check valve NG 2

6

Filter cartridge

7

Screw fitting

8

Screw fitting

9

Plug M 16x1

10

Plug M 18x1

Face-End Shield 2100/3800-2X6760-2050

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Shield 7420 274 000 00 01 is equipped with an electrohydraulic control unit:

Technical data Two-stage telescopic leg

6

6.5 Two-stage telescopic leg The double-telescopic leg is double acting and designed for the same loadbearing capacity in both stages. Identical load-bearing capacity is ensured by a piloted check valve (floor valve) which is installed in the piston pipe.

The bottom and top of the leg are designed as a spherical joint. This allows the leg to be joined to the support via a rotatable fastening.

The head is fastened using two pins each that are inserted into the holes in the retainer before the leg head is installed. The pins are secured in the second groove by a pin and locking clip. After the leg head is installed, the pins are pushed into the holes of the leg head and secured in the first groove with a pin and locking clip.

Leg

Media-ID: EM027415-00-EN / Caterpillar Global Mining Europe GmbH 2017 ©

Fig. 119: Two-stage telescopic leg, 6870-480-1465/2950

1

Leg base

2

Piston pipe

5

Burst protection

6

PRV 520 bar

10

Piston rod

29

Screw pin M 12x20-A 4-80

31

König expander

32

Lubricating nipple

a

Load ring 3000 kg

b

Valve connection plate

c

Protective plate

d

Weld-on socket DN 10

e

Valve port

f

Ball foot

g

Screw holder M 12

x

Piston space connection

y

Annular space connection

ID number

Length in mm

Stroke in mm

Telescopic leg

retracted

extended

upper stage

lower stage

8250 231 000 00 00

1 565

3 175

726

884

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6

Technical data Two-stage telescopic leg

Leg double-acting 2-stage

Tab. 18: Technical data Type ST-6870-480-1465/2950

Device number 8250 231 000 00 00

Cylinder stroke

1 610

mm

Piston diameter

450 / 320

mm

Piston rod diameter

415 / 295

mm

1 590 / 804

cm2

238 / 121

cm2

Prop force at 320 bar

5 089

kN

Prop force at 410 bar

6 521

kN

762

kN

Piston surface Annular surface

Retracting force at 320 bar

DANGER When lowering connections on hydraulic legs are closed, a dangerous overpressure can build up in the leg that can lead to fatal injuries due to pressurized fluids escaping.

1. Never close the lowering connections on double acting legs so that they are pressure-tight!

2. Before starting up a leg, make sure that all protective caps and plugs have been removed!

6.5.1 Function set leg

load leg

Pressurized fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, while the pressurized fluid in the annular space is discharged into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressurized fluid is supplied at the same time via the check valve in the bottom of the piston pipe 1. Only piston pipe extended: The force is transferred mechanically from the shield canopy via the leg head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. Further transmission of the force takes place hydraulically via the pressurized fluid under the piston pipe in the leg base and from there, mechanically into the base frame (skid). The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the corresponding check valve. If the pressure set on the pressure relief valve is exceeded, the pressurized fluid flows out of the leg and the leg is pushed in by the nominal leg force.

2. Piston pipe and piston rod extended: The force is transferred mechanically from the shield canopy via the leg head to the piston rod. The piston rod supports itself on the pressurized fluid, which is blocked by the check valve in the bottom of the piston pipe.

Further transmission of force up to the setting of the piston pipe is as described under 1).

lower leg

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The pressurized fluid is connected to the return line under the piston pipe via the control valve for the leg.

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Lowering connections on double acting legs

Technical data Two-stage telescopic leg

6

Both stages of the leg can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston rod can then retract.

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A few millimeters before the piston pipe is "fully retracted", the check valve is opened by a tappet, whereby the pressurized fluid underneath the piston pipe acts like a spring lifting the piston pipe to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

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6

Technical data Hydraulic cylinders

6.6 Hydraulic cylinders 6.6.1 Layout The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be basically divided into two groups: Type a) arrangement of the connections in the outer cylinder Type b) arrangement of the connections on the end of the piston rod.

1

Outer cylinder

2

Cylinder bottom

3

Piston rod

4

Guide bushing

5

Connection

6

Connection

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against loosening using clamping screws or a spring pin connection.

The pressurized fluid is fed through the connections either on the outer cylinder (type a) or on the piston rod (type b).

If a double-acting cylinder is only to be operated as a single-acting cylinder, the annular space connection must be protected against the penetration of dirt with a filter screw. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

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Fig. 120: Hydraulic cylinder, typical example

Technical data Hydraulic cylinders

6

6.6.2 Legs and cylinders

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Fig. 121: Component positions of the legs and hydraulic cylinders

Tab. 19: Component positions of the legs and hydraulic cylinders ID

Qty. Name

Location

Drawing no.

Type

8250 231 000 00 00

SD-6500-450-1565/3175

Z1

2

Leg

base frame

Z2

1

Advancing cylinder

on the relay bar assembly 8241 614 000 00 00

ZE-200/125-1080

Z3

1

Stabilizing cylinder

caving shield canopy

8241 615 000 00 00

ZE-200/125-630

Z4a

2

Seal cylinder

on the canopy

8241 352 000 00 00

ZE-63/50-215

Z4b

2

Seal cylinder

on caving shield

8241 352 000 00 00

ZE-63/50-215

Z5

1

Lifting cylinders

on the base frame

8241 616 000 00 00

ZE-150/90-300

Z6

1

Flipper cylinder

Canopy-flipper connection

8241 618 000 00 00

ZE-165/100-555

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6

Technical data Hydraulic cylinders

Stabilizing cylinder

1

Cylinder tube

11

Piston rod

a

Piston space connection

b

Annular space connection

c

Valve connection

d

Load ring 1000 kg

L

Retracted 1 075

Strok 630 e

Stabilizing cylinder double-acting

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Extended 1 705

Tab. 20: Technical data Type ZE-ZE-200/125-630

Device number 8241 615 000 00 00

Cylinder stroke

630

mm

Piston diameter

200

mm

Piston rod diameter

125

mm

Piston surface

314.2

cm2

Annular surface

191.4

cm2

Thrust force at 320 / 500 bar

1 005 / 1 571

kN

Pulling force at 320 / 500 bar

613 /958

kN

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Fig. 122: Hydraulic cylinder ZE-200/125-540

Technical data Hydraulic cylinders

6

Advancing cylinder

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Fig. 123: Hydraulic cylinder, type ZE-200/125-1080

1

Cylinder tube

2

Reed rod 1050 lg.

3

Piston rod 125

6

Screw fitting

a

Piston space connection

b

Annular space connection

c

Load ring 1 000 kg

d

Weld-on socket NW 20

L

Retracted: 1 460 Extended: 2 540

Advancing cylinder double-acting

Strok 1 080 e

Tab. 21: Technical data Type ZE-200/125-1080

Device number 8241 614 000 00 00

Cylinder stroke

1 080

mm

Piston diameter

200

mm

Piston rod diameter

125

mm

Piston surface

314

cm2

Annular surface

191

cm2

Thrust force at 320 bar

1 005

kN

Pulling force at 320 bar

612

kN

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6

Technical data Hydraulic cylinders

Lifting cylinders

1

Cylinder tube

2

Piston rod

3

Wearing bottom

17

Hex. nut M 16-1.4571

20

Hex. head screw M 16x90-A 2-70

21

Washer 16

a

Piston space connection

b

Annular space connection

c

Load ring 1000 kg L

Retracted 588

Strok 300 e

Lifting cylinders double-acting

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Extended 888

Tab. 22: Technical data Type ZE-150/90-300

Device number 8241 616 000 00 00

Cylinder stroke

300

mm

Piston diameter

150

mm

Piston rod diameter

90

mm

Piston surface

177

cm2

Annular surface

113

cm2

Thrust force at 320 / 420 bar

566 / 742

kW

Pulling force at 320 / 420 bar

362 / 475

kW

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Fig. 124: Hydraulic cylinder, type ZE-150/90-300

Technical data Hydraulic cylinders

6

Seal cylinder

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Fig. 125: Hydraulic cylinder ZE-63/50-215

1

Cylinder tube

2

Piston rod

a

Piston space connection

b

Annular space connection

L

retracted 440 extended 655

Seal cylinder double-acting

Tab. 23: Technical data Type ZE-63/50-215

Device number 8241 352 000 00 00

Cylinder stroke

215

mm

Piston diameter

63

mm

Piston rod diameter

50

mm

Piston surface

31.2

cm2

Annular surface

11.5

cm2

Thrust force at 320/380 bar

100 / 118.6

kN

Pulling force at 320/380 bar

37 / 43.7

kN

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6

Technical data Hydraulic cylinders

Flipper cylinder

1

Cylinder tube

2

Piston rod 100

25

Reed rod

28

Screw fitting

a

Load ring 1000 kg

b

Valve connection plate

c

Cylinder bottom

Strok 535 e

Flipper cylinder double-acting

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Reed rod L

Retracted 865 Extended 1 400

Tab. 24: Technical data Type ZE-165/100-555

Device number 8241 618 000 00 00

Cylinder stroke

535

mm

Piston diameter

165

mm

Piston rod diameter

100

mm

Piston surface

213.8

cm2

Annular surface

135.3

cm2

Thrust force at 32ß bar

684

kW

Pulling force at 320 bar

432.9

kW

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Fig. 126: Hydraulic cylinder ZE-125/90-615

Technical data Pressure relief valves

6

6.7 Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves listed in the following table can be used in the hydraulic circuit of the shield support.

Important information Observe the additional information in the hydraulic diagram and spare parts catalog.

Tab. 25: Pressure relief valves, use of the various types

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Application

Design

Setting pressure in bar

Device number

gen. use, not for leg and stabilizing cylinders

spring-loaded

80

8220 042 080 00 00

gen. use, not for leg and stabilizing cylinders

spring-loaded

380

7337 486 380 00 00

For stabilizing cylinders

spring-loaded

410

8220 027 410 00 00

for legs

spring-loaded

410

7337 486 410 00 00

Rock burst valve

gas charged

440

8220 148 440 00 00

NOTICE Setting pressure of pressure relief valves Incorrectly set pressure (overpressure) of pressure relief valves leads to machine damage.

1. The setting pressure of pressure relief valves must not be changed.

2. Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code. identification

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

The text code includes the following information: The setting pressure, setpoint The week the setting was made The year the setting was made The last person who made changes Tab. 26: Text code, example 420 or 42 1)

09

13

xy

Setting pressure

Week

Year

Last person who made changes

1)

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

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6

Technical data 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 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

a

Color code

b

Protective cap

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

Tab. 27: Color codes for pressure relief valves, overview

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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

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Fig. 127: Pressure relief valve, example

Technical data Angles of inclination of the canopy

6

6.8 Angles of inclination of the canopy The angles of inclination of the canopy relative to the mine floor level are at least 15 degrees unless limited by the retracted/extended state of legs or stabilizing cylinders or by the limited articulation of the hinged joint between the shield canopy and caving shield.

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Fig. 128: Angle α 1 / α 2

NOTICE Permissible angle of inclination of the canopy If the angle of inclination of the canopy is exceeded (angle between the shield canopy and the caving shield), severe damage to the shield support, especially of the hydraulic cylinders and legs, can occur!

1. Be sure to observe the permissible angle of inclination of the canopy (see section "Technical data")!

Tab. 28: Angle α 1 / α 2 at height M Shield

Inclination α at height M

ID no.

α1 in °

α2 in °

M in mm

15

15

2 100 to 3 800

7420 274 000 00 01

6.9 Tightening torques 6.9.1 Screws and bolts with ISO metric thread Tab. 29: Tightening torques at µtot. = 0.14 Thread (mm) d

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Pitch P (mm) Coarse thread

Tightening torque MA (Nm) Fine thread

8.8

10.9

12.9

A 2-70

A 4-80

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Technical data Tightening torques

Thread (mm)

Pitch P (mm)

Tightening torque MA (Nm)

M8

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

2

DM 24

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27)

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

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

NOTICE Tightening torques Incorrect torque may cause considerable machine damage.

1. Also follow the tightening torques for installation and maintenance stated in the spare parts lists.

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6

Technical data Permissible media

6

6.10 Permissible media 6.10.1 Hydraulic fluids Permissible hydraulic fluids

NOTICE Hydraulic fluid If impermissible hydraulic fluids are used, and the warranty expires and serious machine damage may arise.

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1. Use only hydraulic fluids and gear oils approved by Caterpillar.

Only those hydraulic fluids for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Caterpillar may be used for the operation of hydraulic components from Caterpillar. Caterpillar will not accept any warranty claims for any components which have been or are operated with a different hydraulic fluid.

In addition, national – and sometimes also regional – regulations on health and safety at work and any environmental regulations must be observed for operation.

If a mine only uses individual hydraulic components without using Caterpillar shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Caterpillar. The same applies for example to hydraulic chain tensioners, hydraulically tensionable drives etc. A corresponding certificate of exemption will be issued by Caterpillar upon request.

Suitability test Before the certificate of Caterpillar is issued for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health, safety and environmental protection.

To perform the suitability test, original samples are required of the concentrate and the water that will be subsequently used when preparing the hydraulic fluid at the mine.

The suitability test is carried out by an independent testing institute authorized

by Caterpillar. The criteria as specified in EWN 8350 are applied for the test.

The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: stability, sealing materials, corrosion.

Furthermore, a chemical "fingerprint" of the concentrate is created in order to rule out or verify any possible changes in the composition of the concentrate if necessary.

If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive a corresponding certificate from Caterpillar.

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6

Technical data Permissible media

Certificate The customer will be issued a certificate attesting the suitability of the hydraulic fluid for the operation of Caterpillar hydraulic systems for each product tested.

Certificates are valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate is no longer valid if one or several of the requirements for obtaining the certificate are no longer fulfilled.

This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

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Fig. 129: Certificate, example

Maintenance of the hydraulic fluid Consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH value, concentrate content and microbial load.

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Technical data Permissible media

6

The operator of the equipment must compile a hydraulic fluid maintenance plan for the specific application. The maintenance plan should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed below should be checked at least once every week: pH value setpoint: 7.5 to 9.5 concentrate content setpoint: see certificate microbial load setpoint: ≤ 105 Kol/ml

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In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55°C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the service life of the sealing material.

6.10.2 Quality of the process water for use for hydraulic fluids

The quality of the water used to create the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limit values shown in the table are complied with, it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not complied with this should be taken into consideration when selecting a concentrate. Furthermore, water treatment may also be necessary.

However, the customer shall in any case provide a sample of the original water to permit the conduction of the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

for use as spraying water

limit values

Water used for this purpose may not contain aggressive components or dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100 µm. 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.

NOTICE Quality of the process water Poor quality process water can seriously damage the surface of the components and the hydraulic components of the machine.

1. Only use water that complies with the specified limit values.

Tab. 30: Properties of the process water, limit values Test criterion

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Limit value

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6

Technical data Permissible media

Appearance, color, odor

No peculiarities permissible, e.g. turbidity, bad smell, etc.

electrical conductivity

< 1800 mS/cm

pH

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

2-

SO4 content

≤ 145 mg/l

NO3- content

≤ 20 mg/l

Fe content

≤ 1 mg/l

Bacteriological requirements

≤ 105 col/ml

- / 18 / 14 1)

Contamination class according to ISO 4406: 1999

The values listed for bacteriological requirements, the amount of solids and contamination class must be observed during the production of hydraulic fluids.

They do not apply if the water is used exclusively as spraying water.

6.10.3 Greases and lubricating pastes Only the recommended lubricants or products certified as equivalent may be used.

Important information 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. 31: Greases A1

grease A2

Supplier

Type

Base

NLGI class

Fuchs

Renolit MP

lithium soap

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-40 to +120 °C

Greases containing additives for high pressure applications, e.g. for roller bearings and other bearings subject to extreme load.

Tab. 32: Grease A2

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Supplier

Type

Base

NLGI class

Flashpoint °C

Shell

Alvania E.P. grease 2

lithium soap

2

205

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Ratio of solid foreign matter at 1.2 mm - ≤ 10 mg/l 1) filtering in conformity with DIN EN 12662

Technical data Permissible media

grease A8

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-15 to +120°C

6

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.

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Tab. 33: Grease A8 Supplier

Type

Base

NLGI class

Flashpoint °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 at 90°C

temperature range of application:

-20 to +120°C

Lubricating pastes lubricating paste B3

Lubricating pastes free of molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 34: Lubricating paste B3 Supplier

Type

Lubricant carrier

NLGI class

Flashpoint °C

Gleitmolybdän

gleitmo 805

lithium soap

2

220

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

insoluble

temperature range of application:

-20 to +120°C

Lubricants lubricant B6

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

Tab. 35: Lubricant B6 Supplier

Type

Lubricant carrier

Flashpoint °C

Chesterton

parting agent/lubricant 785

petroleum base

132

behavior in the presence of water:

insoluble

temperature range of application:

-34 to +120°C

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