CAT Roof Support Water valve unit 4 functions Operation & Maintenance Manual - PDF DOWNLOAD

EM019321-0 (EN-US)

ID-Nr. BI001690_00_03_all_EN Dec. 2012

Operation and Maintenance Manual Water valve unit, 4 functions Typ Doc-No.: 8401 008 000 BA 00

SAFETY.CAT.COM SAFETY.CAT.COM

EM019321-0 (EN-US)

© 2003 CATERPILLAR ALL RIGHTS RESERVED

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

EM019321-0 (EN-US)

Translation of the original operating manual

Operating Manual Water valve unit, 4 functions Doc. no.: 8401 008 500 BA 00

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

EM019321-0 (EN-US)

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

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

Caterpillar declines any liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications as a result of technical developments without previous notice.

Caterpillar Global Mining Europe GmbH, Lünen 2012E A Caterpillar Inc. Company

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Contents

Contents 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.3 1.4

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

Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

Repair and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

E

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

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

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

2.3 2.3 2.4

2.4 2.4 2.4

2.5

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

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Transport boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.4

3.5 3.5 3.5 3.5

4. Installation Installation of the water valve unit . . . . . . . . . . . . .

Removing the water valve unit . . . . . . . . . . . . . . . . . . . . . . .

Installation of the water valve unit . . . . . . . . . . . . . . . . . . . .

4.3 4.3 4.4

5. Operation Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Operation and function of the pilot valves . . . . . .

5.4

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

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . .

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5.4 5.4 5.4

5.6 5.6 5.7

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Contents 6. Technical Data 6.3 6.3 6.4 6.4 6.4 6.4 6.5

Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . .

6.6

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Lubricating greases and pastes . . . . . . . . . . . . . . . . . . . . . .

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

Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.7

6.8 6.8 6.10 6.12

6.14 6.14

7. For your information Standards and guidelines . . . . . . . . . . . . . . . . . . . . .

Referenced standards and guidelines . . . . . . . . . . . . . . . . .

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

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

Materials used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2012

Technical description . . . . . . . . . . . . . . . . . . . . . . . . .

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1

About this manual

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Before starting work

About this manual This chapter contains important information to make it easier for you to use this manual. It also provides you with information on the structure of the manual and the symbols used.

Before starting work use the correct manual

Using an operating manual that was not specifically written for the water valve unit concerned can result in a safety hazard for yourself and others. Ensure that the specifications on the water valve unit comply with the specifications in the operating manual.

This operating manual is designed for: Water valve unit - 4 functions device number 8401 008 500 00 00

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and is only permitted to be used for water valve units of this type.

Only use the operating manual which applies to the respective water valve unit. Failure to do so will pose a danger to yourself and others. availability of operating manual

It is absolutely necessary to ensure that all persons working with or on the water valve unit always have unrestricted access to the contents of the current, applicable operating manuals.

Persons for whom this operating manual is intended This operating manual is intended for everyone concerned with installing, servicing, repairing, operating and removing the water valve unit.

The supervisors who ask initiate the above work or supervise it must also follow this operating manual.

Purpose of this operating manual efficiency

This operating manual is intended to help you work economically and safely with our product. It contains important information on all the activities related to the water valve unit.

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

safety

operating costs guarantee

Doc. no.: 8401 008 500 BA 00

Read chapter 2 “Your safety” closely. This chapter contains important information indicating potential hazards.

Observe this information and follow the instructions in this operating manual. This is the only way that you can keep the operating costs down and retain your rights to make a claim under the warranty.

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Before starting work Characters and symbols used The following characters and symbols are used for safety instructions and important information in this operating manual.

Try to memorize the symbols and their meanings.

Danger!

Points in the text marked with this symbol point out immediately impending danger. Possible consequences are: very serious injury or even death.

Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

Important!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

Items in lists are marked with bullets.

– Points in sub-lists are marked with a long dash at the start of the line.

. Points in the text that are marked in this way describe individual work steps. Follow this manual step-by-step. This will help you carry out your work faster and, more importantly, more safely.

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Notice!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: minor damage to the machine or damage in the immediate vicinity.

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Caution!

This symbol draws attention to dangerous situations. Possible consequences are: minor to moderately serious injuries and damage to the machine.

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2

Your safety

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Personnel

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. residual risk

supplementary regulations

The water valve unit was manufactured in accordance with state of the art and generally recognized safety standards and regulations.

However, a residual risk still exists which may involve you getting into hazardous situations when working with or on the water valve unit. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

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

Observe the safety and accident prevention regulations: of the mining company,

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of the mines inspectorate, and of the mining supervisory authorities.

Personnel Persons employed in the operation, repair and overhaul of hydraulic and/or electrohydraulic control components must be specially qualified. In addition to having had training in mining technology, the following minimum requirements must be met.

Operation and maintenance qualification

Operation and maintenance of the shield control system may only be performed by trained personnel.

The training must be specially tailored to the type of water valve unit actually being used.

The content of the operating manual, especially the chapter on safety, must constitute a part of this training.

They must possess and furnish proof of sufficient familiarity with the mechanical, hydraulic and control systems.

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Operating conditions Repair and maintenance 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 of the equipment.

Repair work on and overhaul of: water valve units, working valves, pilot valves, safety components such as pressure relief valves etc. shall be performed only by Caterpillar service technicians or by specially trained personnel of the mining company.

Operating conditions

water spraying system

The water spraying system serves to actively counteract dust.

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 pushing the shield and when the mining equipment passes the support.

The water spraying valves are controlled by the program of the electronic shield control or directly by means of the hydraulic shield control system.

Unauthorized use All use, which is not expressly declared as intended, is regarded as unauthorized use Unauthorized use can endanger yourself and others. You might be killed or seriously injured.

You should thus only use the electrohydraulic water valve unit as intended.

Caterpillar will accept no responsibility for the consequences of unauthorized use.

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The water valve unit serves to control the water spraying system.

It is only used in conjunction with an electronic control system, for example a PMC®-R control system.

Only use the water valve unit as intended.

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Intended use

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Safety instructions Safety instructions The following always applies: general

Always concentrate on your work.

It is also imperative that you follow the operating manual for the support and the water valve unit.

Always familiarize yourself with the working environment before starting work.

Always keep out of any shield which is not set.

Always wear your personal protective clothing and equipment.

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

requirements

EMERGENCY STOP

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

support lock-out switch

If the shield is equipped with an electrohydraulic water valve unit, you must lock-out the shield by pressing the support lock-out switch (repair switch). This means the shield can not be controlled via the water valve unit.

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Only use water valve units which are in a technically flawless condition.

Press the support lock-out switch when performing: maintenance work, inspection work, repair work, and during prolonged presence in the shield. moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: side seals, skids, relay bar assemblies, lemniscatic links, hydraulic props and cylinders, canopies and flippers.

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Safety instructions Storage and transport Never store materials of any kind in the travel way or in your working area.

To avoid hindering or endangering the face crew, immediately remove any faulty components from the face.

Never store faulty parts with good parts. This way you can avoid inadvertent reinstallation of these faulty components somewhere else. Have these faulty components repaired.

Observe the specified storage periods and the storage instructions.

Installation Mechanically secure all moving parts before you depressurize the hydraulic system.

As a matter of principle, only work on depressurized hydraulic systems.

Operation Only work in repair mode if it is absolutely necessary. If possible control the shields from the water valve unit of the neighboring shield.

Check to determine whether all protective devices on the shield are present and functional.

Make sure that no one is in the area of the shield being actuated.

Watch the shield's range of motion so that potential hazards can be recognized in time and preventative action can be taken.

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

Keep your working area clear to avoid danger to yourself and other persons.

Block off the working area for the mining equipment or stop the equipment and the conveyor and lock the system, to prevent it from being turned on again.

Before performing work, mechanically secure the shield to prevent it from accidentally sinking into the floor, e.g. by: propping up or supporting the canopy, placing wooden wedges between the lemniscatic links.

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Only remove the protective caps from the connections immediately before installing the water valve unit.

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Make sure that no dirt or impurities can get into the hydraulic system.

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Safety instructions Immediately discontinue any work on the shield, if conveying and mining operations are in progress in your working area.

Immediately after completing work, refit any removed protective devices and check that they work properly.

Make sure that the prescribed maintenance and inspection intervals are observed. original parts

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

Please refer to the spare parts folder for the order numbers.

Do not make any modifications or changes. All modifications and changes must be approved by Caterpillar.

Never use the water valve unit without a filter cartridge. If the filter is missing or if it is not fine enough, this can lead to malfunctions and damage to the water valve unit.

Hydraulic system

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handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

protective devices hydraulic system

Note that when dismantling protective equipment that includes hydraulic components, that they can be pressurized. You could be severely injured by hydraulic fluid jetting out wildly. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

maintenance, repair

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

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace defective caps without delay.

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

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Safety instructions Ensure that no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage in the whole system. Flush out the hydraulic lines thoroughly before connecting.

Before removing the coupling clips for disconnecting the hydraulic hose lines, turn the hose at the coupling socket to check whether the line is 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 line.

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

Only secure the coupling sockets of the hydraulic elements with the proper coupling clips. Always fasten the clips completely with both sides.

Never use nails, wire or similar materials to secure the connectors.

After finishing repair work, check all connectors and connections for leaks before pressuring the system again.

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

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Fig. 1:

Example hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged.

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Use only hydraulic hoses approved for the prevailing pressures.

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permissible hoses

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Safety instructions laying hydraulic hoses

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

Always lay hydraulic hoses so that they: always have a little slack, Fig. 2:

Laying hydraulic hoses, slack RIGHT

WRONG

are not twisted Fig. 3:

Laying hydraulic hoses, twisting WRONG

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RIGHT

are not bent directly behind the connections (distance minimum 1.5 x nominal diameter) Fig. 4:

Laying hydraulic hoses, bending RIGHT

WRONG

cannot chafe Fig. 5:

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Laying hydraulic hoses, crossing RIGHT

WRONG

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

Only push hydraulic hoses into the connectors by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: torn out, kinked, crushed, driven over or twisted by the movement of the equipment (Fig. 6).

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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Fig. 6:

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3

Storage and transport

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Storage

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

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

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

Storage Storage of the equipment anticorrosion protection

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

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The hydraulically actuated equipment is run with a test fluid before delivery and is emptied as thoroughly as possible before shipping.

The internal parts are also protected against corrosion by the residual film for at least six months. avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store all electrical equipment, electronic components, replacement parts made from rubber or plastic such as seals and hoses and hydraulic fluids in closed rooms at 15 C to 25 C.

moisture and dirt

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

You need to protect the connecting faces of hydraulic components from corrosion and seal them with blind plates. Protect the hydraulic plug-type connections and the connectors 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 particularly protected against excessive temperatures, dirt and moisture.

During 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, a random sample inspection must be performed to determine whether the measures taken and the method of storage have prevented damage.

This inspection can be carried out by Caterpillar upon request.

natural aging

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

Important!

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

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Storage Used equipment If there is any need to store hydraulic equipment that has been in use before the items specified above apply analogously, with the exception of the item corrosion protection.

In case the hydraulic system is to be put out of operation temporarily the complete system has to be flushed thoroughly and filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50)*). If this is not done, considerable damage to the hydraulic components may be caused within a short time since the properties of the medium used may change very fast and negatively, e.g. due to microbial attack.

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corrosion protection

*) HYDROCOR® CV50 is a trade name of Theunissen, Chemische Fabriken GmbH, Wuppertal / Germany

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Transport Transport Transport boxes The water valve units are packed in several transport boxes. They should stay in these boxes until they reach their final operating location. This protects them from external damage.

Make sure that the boxes are not damaged during transport. During transport, make sure that they are not: dropped, broken open.

Protect the transport boxes from moisture. avoid frost damage

Before transporting the equipment at temperatures below freezing, all of the hydraulic components must be completely emptied and then completely filled with a corrosion inhibitor (e.g. HYDROCOR® CV50).

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If, during transport, the water valve unit is exposed to temperatures below -20 C, then special measures may have to be taken. In this case, before starting transport, contact Caterpillar's service department to clarify the necessary measures.

Dimensions and weight Depth: . . . . . . . . . . . . . . . . . . .

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

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

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

196 mm 132 mm 110 mm 11 kg

Plugs The connections for the individual water valve units are closed off with plastic plugs. This protects them from moisture, dirt and damage.

Notice!

Impurities in the hydraulic system can lead to the failure of the entire system, making expensive repairs necessary.

For this reason, you should only remove the plugs just before the water valve unit is connected.

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Transport

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4

Installation

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Installation of the water valve unit

Installation This chapter contains information on the installation and deinstallation of electrohydraulic water valve units. Please pay special attention to the warnings and tips.

Warning!

Improper or faulty installation can endanger yourself and others.

You may only carry out the installation if you can demonstrate that you have the requisite, special knowledge.

Installation of the water valve unit Removing the water valve unit Before you can start with the installation or exchange of the water valve unit, you must take safety precautions: safety

. Have mining stopped in this area.

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. Seal off your working area to keep all other personnel out. . Inform your colleagues about the nature and duration of the repair work and about your exact location.

switch hydraulic pressure off

. Depressurize the hydraulic system of the shield concerned. . Check that the hydraulic lines are really depressurized.

removing water valve unit

If everything is OK so far, then you can continue with the next step.

. Label the connecting cables and hydraulic hoses to avoid mixups later on.

. Pull off the connecting cable from the cover of the pilot valve.

Danger!

Never work on a hydraulic line, if you are not sure that the line is completely depressurized.

If loose hydraulic hoses are thrashing about and hydraulic fluid is escaping under pressure, you could be seriously injured or even killed.

It is thus vital that you depressurize hydraulic components before you start to dismantle them.

If a coupling clip can't be pulled out, or is very stiff, then you should be very careful. It is possible that the hydraulic line is still under pressure.

. Undo all of the hydraulic connections on the rear side of the water valve unit and make sure that the connections are not damaged or soiled when doing this.

. Undo the screws on the mounting of the water valve unit. . Pull the water valve unit out of the mounting.

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Installation of the water valve unit Installation of the water valve unit To install the water valve unit,

. place the water valve unit in the mounting and tighten the screws (M10) by hand.

Fig. 7:

Example M10

Caution!

Before the hydraulic connections are made, the sockets and nipples of the connectors must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, section “Lubricating greases and pastes”.

. Connect the hydraulic hoses. Ensure that you do not mix up the connections.

Follow the hose plan and the labeling of the hoses.

Danger!

You could be seriously injured or even killed by a hydraulic hose that is thrashing about!

Only use the correct size of coupling clip to secure connectors. Push the clips on completely, using both sides of the clip.

Never use nails, wire or similar materials.

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M10

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Installation of the water valve unit safety

. Check the hose connections again. The hose nipples must be firmly seated in the connector and must be locked in place with a coupling clip. Both arms of the clip must fit in the connector.

Ensure that the connections don't leak.

. After you have connected and checked the hoses, plug in the connecting cable from the electrohydraulic water valve unit into the connection on the pilot valve. Follow the circuit diagram and the labeling of the cables.

. Check all of the connections again using the wiring plan. . Test all of the water valve unit functions and remove all of the safety measures used.

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Warning!

Only release the water valve unit for use once you have checked that it works properly and did not find any malfunctions.

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4.5

EM019321-0 (EN-US)

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Installation of the water valve unit

4.6

Water valve unit - 4 functions

EM019321-0 (EN-US)

5

Operation

EM019321-0 (EN-US)

EM019321-0 (EN-US)

Main components

Operation This chapter provides you with information on the operation of the water valve unit.

Main components Fig. 8:

Water valve unit, 4 functions

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4

2 1

3 1 connection plate 2 double 3/2-way magnetic pilot solenoid valve 3 valve cartridge

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4 filter cartridge components not listed can be found in the spare parts catalog supplied.

5.3

EM019321-0 (EN-US)

Operation and function of the pilot valves Operation and function of the pilot valves Operation There are two pushbuttons on the cover of each pilot valve. If you push one of these buttons, the corresponding valve is immediately operated.

As soon as you release the button, the function is ended.

Pushbutton

Function variable functions

The function of each pilot valve is variable and depends on the external circuitry of the water valve unit. A symbol strip shows the function of the buttons.

The symbol strip is mounted near the pilot valve.

Replacing the pilot valve Preparatory work

. Mechanically secure the shield against involuntary lowering.

Warning!

The pilot valve is permanently pressurized. You could be seriously injured or even killed by pressurized components and escaping hydraulic fluid. Before starting work you must thus be absolutely certain that the hydraulic system is depressurized.

. Close the shut-off valve in the shield hydraulics pressure supply line.

. Alternately operate both manuel pushbuttons of each pilot valve ten times, to reduce the pressure in the shield hydraulic system.

. Check if there is any residual pressure in the control unit. Consider the hydraulic lines and the hydraulic circuit diagram when doing this.

If the shield hydraulics is depressurized, then you can continue with the next step.

5.4

Water valve unit - 4 functions

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Fig. 9:

EM019321-0 (EN-US)

Operation and function of the pilot valves Removing the pilot valve Caution!

Contamination in the hydraulic fluid can cause serious damage to the whole system!

You should thus always ensure that your working area is clean.

. Clean dust and other loose debris from the immediate vicinity of the water valve unit, so that no contaminants get into the hydraulic system during the removal / installation of the pilot valve.

. Unscrew two hex. head screws (a). . Pull the pilot valve (b) forwards out of the control unit.

Fig. 10:

Exchanging the pilot valve a

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b

a a hex. head screw M 6X20-A 4-80

b pilot valve

Installing the pilot valve The new pilot valve is installed in the reverse sequence to the removal of the old one.

Before installing, treat the contact surfaces with a separating/lubricating agent (B6 to EWN 7068), see also chapter 6, the section “Lubricating greases and pastes”.

If you have checked the hydraulic circuit and found no faults, then you can reapply pressure to the water valve unit.

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5.5

EM019321-0 (EN-US)

Filter cartridge Filter cartridge A filter cartridge is located in the distributor block of the control unit.

It protects the control unit's valves from damage caused by impurities in the hydraulic fluid.

Maintenance intervals Important!

The recommended maintenance intervals are for guidance only. Particular operating conditions may require other maintenance intervals. Be sure to modify the maintenance intervals to the specific operating conditions.

After working on a hydraulic system, you can assume that dirt has gotten into the hydraulic system. Depending on the degree of contamination, this can cause the filters in the system to block up.

As a result, functions are slowed down, performed incorrectly, or not performed at all. according to a schedule

5.6

If problems occur in the preparation of the hydraulic medium, there will be an increased risk of failures due to clogged filters. Measures which have to be carried out regularly may become necessary to ensure reliable and safe operation. If necessary, the filter cartridges should be replaced at regular intervals, as a precaution.

Water valve unit - 4 functions

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

after startup

EM019321-0 (EN-US)

Filter cartridge Replacing the filter cartridge Caution!

Only use each filter cartridge once and do not attempt to clean it.

Contamination in hydraulic systems is a common reason for expensive repairs.

You must always only use new filter cartridges and seals.

Preparatory work

. Mechanically secure the shield against involuntary lowering.

Warning!

The filter cartridge is permanently pressurized. You could be seriously injured or even killed by pressurized components and escaping hydraulic fluid. Before starting work you must thus be absolutely certain that the hydraulic system is depressurized.

. Close the shut-off valve in the

shield hydraulics.

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. Alternately operate both manuel pushbuttons of each pilot valve ten times, to reduce the pressure in the shield hydraulic system.

. Check if there is any residual pressure in the control unit. Consider the hydraulic lines and the hydraulic circuit diagram when doing this.

If the hydraulic circuit is depressurized, then you can continue with the next step.

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5.7

EM019321-0 (EN-US)

Filter cartridge Removing the filter cartridge

. Remove dust and other contaminants from the control unit.

Caution!

Contamination in the hydraulic system can cause serious damage to the whole system!

Always ensure that your working area is clean.

. Unscrew the filter cartridge using a screwdriver.

Unscrewing the filter cartridge

Important!

The filter cartridge has been soiled by residual emulsion and deposits.

Make sure that you dispose of the filter cartridge in an environmentally acceptable way!

Screwing in a new filter cartridge

. Screw the new filter cartridge in. . Hand-tighten the cartridge (15 Nm). . Check whether this connection leaks.

If you have checked the hydraulic circuit and found no faults, then you can reapply pressure to the control unit. Only remove the security measures which you introduced to carry out the work when you are sure that the hydraulics are working perfectly.

5.8

Water valve unit - 4 functions

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Fig. 11:

EM019321-0 (EN-US)

6

Technical data

EM019321-0 (EN-US)

EM019321-0 (EN-US)

Technical description

Technical Data This chapter contains important and useful information about the type of construction of the control unit and the materials used. At the end of this chapter, you will find information about permissible hydraulic fluids and recommendations on lubricants.

Important!

Please refer to the corresponding spare parts catalogue for the details necessary to order spare parts.

Technical description Functions Four functions can be controlled independently of one another using the water valve unit. The control unit's working valves are driven via electromagnetic pilot valves. An electronic control unit is required to control the pilot valves, for example a PMC®-R, type control unit.

View of the water valve unit, example

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Fig. 12:

1

3

a connector (DN20) for accumulator cartridge b distributor block

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2 c pilot valve

6.3

EM019321-0 (EN-US)

Technical description Main components The main parts of the electrohydraulic water valve unit are: connection plate with – working valves, – connection socket, – filter cartridge. pilot valves.

Water valve unit, 4 functions 4

b

a

2 1

3 1 connection plate 2 double 3/2-way magnetic pilot solenoid valve 3 valve cartridge 4 filter cartridge

a pushbutton b connecting sockets for control unit c connection socket on the rear side

Materials used The control unit is made of corrosion resistant materials such as stainless steel, brass, bronze, etc.

The seal materials are designed for operation with HFA hydraulic fluids (oil in water emulsions).

Dimensions and weight Depth: . . . . . . . . . . . . . . . . . . . .

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

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

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

196 mm 132 mm 110 mm 11 kg

Pressures Permissible working pressure: 350 bar Test pressure: . . . . . . . . . . . . . 400 bar

6.4

Water valve unit - 4 functions

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c

Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 13:

EM019321-0 (EN-US)

Technical description Valves Working valves: 4 x 2/2-directional control valves (UG) They are driven via pilot valves.

Pilot valves: 2 x double -3/2 directional control valves (NG 0.5) The pilot valves are driven by a control unit (e.g. PMC®-R). In an emergency, or for repairs, they can also be operated directly. For this, two pushbuttons are fitted in the valve cover.

The power supply to the pilot valve comes from the electronic control unit. In the housing cover of each pilot valve there are 4 contacts, which serve to attach a suitable connecting cable.

Double 3/2-directional control valve parameters

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Classification according to guidelines 94/9/EC (ATEX): . . . . . . . . . . . . . . . . . . .

Protection class: . . . . . . . . . . . . . . . . . . . .

Connector type: . . . . . . . . . . . . . . . . . . . .

Type of magnet: . . . . . . . . . . . . . . . . . . . .

Nominal voltage: . . . . . . . . . . . . . . . . . . .

Perm. variation: . . . . . . . . . . . . . . . . . . . .

Switching current: . . . . . . . . . . . . . . . . . .

Lowest current: . . . . . . . . . . . . . . . . . . . . .

Group I, category M2 EExib l OS4 Electromagnet, around 57 Ohm Type: DMA3-1 12 V, DC -2%/+10% approximately 190 mA at most, down to 40 mA

Warning!

As soon as the current falls to a level below 40 mA, the switch settings will become unstable. This can lead to malfunctions or to the failure of the control unit.

Tab. 1: Mining approvals

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Apply in

Approval authority

Approval no.

Europe

INERIS, ATEX

05 ATEX 0049

USA

MSHA

18-ISA050002-0

Australia

Testsafe, ANZEx

05.4015X

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EM019321-0 (EN-US)

Hydraulic circuit diagram Hydraulic circuit diagram Fig. 14:

Water valve, 4 functions W

P

W2 W2

W1 W1 W4 W4

W3

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W3 LK

W (input) = DN 20 P, W1, W2, W3, W4 and leakage = DN 10

6.6

Water valve unit - 4 functions

EM019321-0 (EN-US)

Connections Connections The connection sockets for the hydraulic lines are on the rear side of the control unit.

Fig. 15:

Control block, rear view

W3

W1

P

W4

W2

L

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W

W input L leakage P pressure

Hydraulic connections consumer of medium quantities

Connections: . . . . . . . . . . . .

Identification: . . . . . . . . . . . .

Flow rate: . . . . . . . . . . . . . . .

Use: . . . . . . . . . . . . . . . . . . . .

4 x DN 10, socket, Steck-0 DN 10: W1, W2, W3, W4 max. 180 l/min at p = 100 bar Consumer of medium quantities

connections for water supply

Connections: . . . . . . . . . . . .

Identification: . . . . . . . . . . . .

Flow rate: . . . . . . . . . . . . . . .

Use: . . . . . . . . . . . . . . . . . . . .

1 x DN 20 socket, Steck-0 W max. 340 l/min at p = 100 bar Water supply

connections for pressure feed

Connections: . . . . . . . . . . . .

Identification: . . . . . . . . . . . .

Flow rate: . . . . . . . . . . . . . . .

Use: . . . . . . . . . . . . . . . . . . . .

1 x DN 10 socket, Steck-0 P max. 180 l/min at p = 100 bar Pressure feed

leakage connection

Connections: . . . . . . . . . . . . 1 x DN 10 socket, Steck-0 Identification: . . . . . . . . . . . . L Use: . . . . . . . . . . . . . . . . . . . . Leakage Important!

The Leakage connection must not be connected to the return, it must be arranged so that it can discharge freely.

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6.7

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Caterpillar. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

For the operation of hydraulic components from Caterpillar, generally only such hydraulic fluids may be used for which there is a valid certificate in accordance with EWN 8350 or an exemption permit from Caterpillar is available to the respective operator. Caterpillar will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

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 and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by Caterpillar. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: stability, sealing materials, corrosion.

In addition, a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive the respective Caterpillar certificate.

6.8

Water valve unit - 4 functions

Caterpillar Global Mining Europe GmbH, Lünen 2012

If a mine only uses individual hydraulic components without using 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 drive units, etc. The respective exemption permit will be issued by Caterpillar on request.

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In addition, when operating this equipment national and sometimes also regional health and safety at work regulations and any environmental regulations must be observed.

EM019321-0 (EN-US)

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Caterpillar hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can respectively be extended for an additional year. The certificate will no longer be 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.

Typical certificate

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Fig. 16:

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6.9

EM019321-0 (EN-US)

Permissible media Hydraulic fluid maintenance The 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 but 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 ratio and microbial load.

The operator must draw up a maintenance concept for the hydraulic fluid that relates to the respective conditions of use. The maintenance concept 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 in the following should be checked at least once every week: pH value Concentrate ratio – Target value: see certificate Microbial load – Target value:  105 col/ml.

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 life of the sealing material.

Quality of the process water using hydraulic fluids

The quality of the water used to make 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 limits shown in the Table 2 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing 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.

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– Target value: 7.5 to 9.5

EM019321-0 (EN-US)

Permissible media using as spraying water

limit values

Water used for this purpose may not contain aggressive components and dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100 m. In order to protect the components, the limit values listed in the table must not be exceeded.

The following table lists limit values for the essential properties of the process water.

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Use only water that conforms to the specified limit values.

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Tab. 2: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 S/cm

pH value

6.5 to 8.5

Na+ content

Not specified

Mg+

Not specified

content

Water hardness

< 750 mg/l CaCO3 equivalent ( 42° dH)

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 mfiltering in conformity with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1 mg/l

1) The values listed must be observed during the production of hydraulic liquids.

They do not apply when the water is used exclusively as spraying water.

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Permissible media Lubricating greases and pastes Only the recommended lubricants or products certified as equivalent may be used.

Important!

The lubricants to be used are specified in the respective chapters.

Greases grease A1

Greases for general application, e.g. for roller bearings subject to normal load, for labyrinths, and for installation.

Tab. 3: Greases A1 Supplier

Type

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm)

Temperature range of application: . . . -40 to +120C grease A2

Greases containing additives for high pressure applications, e.g. for roller bearings and other bearing points exposed to extreme load.

Tab. 4: Grease A2 Supplier

Type

Base

Shell

Alvania E.P. grease 2

Lithium soap

NLGI class

Flashpoint in °C

2

205

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . practically insoluble in water Temperature range of application: . . . -15 to +120C grease A8

High-load grease for high loads and low speeds, e.g. for roller bearings in drive frame and crusher, for installation and corrosion protection purposes, suitable for central lubrication.

Tab. 5: Grease A8 Supplier

Type

Base

Castrol

Molub-Alloy 3036/680-1

Lithium soap

NLGI class

Flashpoint in °C

1

210

Worked penetration: . . . . . . . . . . . . . . . 310 to 340 (0.1 mm) Behavior in the presence of water: . . . insoluble in water at 90C Temperature range of application: . . . -20 to +120C

6.12

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

EM019321-0 (EN-US)

Permissible media Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 6: Lubricating paste B3 Supplier

Type

Base

gleitmolybdän

gleitmo 805

Lithium soap

NLGI class

Flashpoint in °C

2

220

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . insoluble in water Temperature range of application: . . . -20 to +120C Lubricants Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support.

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lubricant B6

Tab. 7: Lubricant B6 Supplier

Type

Base

Chesterton

parting and lubricating material 785

Petroleum

Flashpoint in °C 132

Behavior in the presence of water: . insoluble in water Application temperature range: . . . . -34 to +120°C

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Tightening torques Tightening torques Screws with ISO metric thread Tab. 8: Recommended tightening torques at ges. = 0.14 Tightening torque 4)

Pitch P (mm)

d

coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

3

535

-

-

3

965

1360

1630

-

1600

-

M 24 DM 24

2 2)

(M 27) (M 27) (DM 27

fine thread

2))

M 30

2 3

580

-

-

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

1) 2) 3) 4)

6.14

dimensions in brackets in exceptional cases only according to works standard (EWN 6110), February 1985 edition only for expansion screws having a reduced shaft cross-section of 24.2 mm the tightening torques comply with EWN 6003 works standard.

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(mm)

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Thread 1)

EM019321-0 (EN-US)

7

For your information

EM019321-0 (EN-US)

EM019321-0 (EN-US)

Standards and guidelines

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

Standards and guidelines Referenced standards and guidelines Tab. 9: Standards and guidelines, extract

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Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 2006/42/EC the approximation of the laws of the Member States relat2006-05-17 ing to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and Directive 94/9/EC 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 2004-04 Safety of machinery 12100-1/A1 2009-07 DIN EN ISO 12100-2 Safety of machinery 2004-04 Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water - Distillation method Non-electrical equipment for potentially explosive atmoDIN EN 13463-1 2009-07 spheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079-0 2010-03 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface 2007-11 Underground mining machinery - Specification for the DIN EN 12321 2009-07 safety requirements for armoured face conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shear loaders and plough systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic powered roof supports 2010-05 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation DIN 2000 Quality of drinking water 2000-10 DIN 6789 Documentation System 1990-09 DIN 20043 Plug connectors for hydraulics 2003-09 DIN 24320 Fire-resistant hydraulic fluids 2006-12 DIN 24343 Maintenance and inspection list for hydraulic systems 1982-02 DIN 51558-1 Determination of the acid number 1979-07 DIN 51575 Determination of sulfated ash 2011-01

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Standards and guidelines Date of issue

Designation

Title

EWN 6003 1)

Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

1985-02 1992-06 1985-02 2008-01

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

1985-02

1) EWN = works standard

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