CAT Shield support 1295/3048-2x4083-1750 Operating Manual - PDF DOWNLOAD

Translation of the original operating manual

Operating manual Shield support 1295/3048-2x4083-1750 Doc. No.: 7420 248 000 BA 00

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

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

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

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

We reserve the right to introduce modifications as a result of technical development without prior notice.

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

Table of content

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

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

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

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

1.3 1.3 1.4 1.4

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

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

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

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

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

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

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

2.3 2.3 2.4

2.5 2.5 2.5

2.6

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

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

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

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

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

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

Transporting the end shield . . . . . . . . . . . . . . . . . . . . . . . . .

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

Transport safety device, relay bar assembly . . . . . . . . . . .

Side seal transport safety device . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.4

3.5 3.5 3.5 3.8

3.9 3.9 3.10

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

4.3

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

4.3

Pressure equalization of the electronic control system . . .

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

Requirements for the face hydraulic system . . . .

4.9

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

4.10

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

4.11

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

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

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

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4.5 4.6

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4.11 4.13 4.13

Table of content 5. Operation 5.3 5.3 5.6

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

5.9

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

5.15

Overview of the shield components . . . . . . . . . . . .

5.16

Arrangement of the shield components . . . . . . . . . . . . . . . .

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

Functions of the HP ball valves on the shield . . . . . . . . . .

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

Arrangement of the hydraulic components on the end shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Internal bypass inside the prop . . . . . . . . . . . . . . . . . . . . . .

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

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

5.16

5.18 5.18 5.20 5.21 5.29 5.31 5.32 5.35

5.36 5.36 5.37 5.38 5.38 5.38

5.39 5.39 5.39 5.42 5.42 5.43 5.43 5.43

6. Technical data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Technical data of steel structure, end shield . . . . . . . . . . .

6.3 6.4 6.6 6.7 6.9 6.11 6.13 6.16 6.17

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

Table of content Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic prop, two-stage (Z1) . . . . . . . . . . . . . . . . . . . . . . .

Design of hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . .

Lifting cylinder (Z2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Shifting ram (Z4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal cylinder (Z5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18 6.18 6.21 6.22 6.23 6.24 6.25

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

6.26

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

6.28

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

6.29

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

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

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

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

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

6.29 6.31 6.33

6.35 6.35

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

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

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

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

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

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7.3 7.3

7.5 7.5 7.5

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Table of content

Shield support 1295/3048-2x4083-1750

1

About this manual

Before starting work

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

Before starting work applicable operating manual

shield type

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

This operating manual belongs to the Shield support 1295/3048-2x4083-1750 * ID no.: 7420 248 000 00 01 (end shield) and is only permitted to be used for shields of this type.

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

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

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

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

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

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

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

*

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

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1.3

Before starting work Purpose of this operating manual efficiency

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

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

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

service

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

safety

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

Observe this information and follow the procedural instructions.

Signs and symbols used

Danger!

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

Warning!

This symbol indicates information on hazardous situations.

Possible consequences include: death or very serious injuries.

Caution!

This symbol draws your attention to hazardous situations.

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

Notice!

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

Important!

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

They do not warn about harmful or hazardous situations.

Items in lists are marked with bullet points.

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

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

1.4

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Memorize the symbols and their meanings.

E

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

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

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

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

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

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

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

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

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

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

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

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

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2.3

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

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

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

2.4

Shield support 1295/3048-2x4083-1750

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

Use the shield only as intended!

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

the following conveyor operations: Caterpillar Global Mining Europe GmbH, Lünen 2012

– advancing, – retracting, forming a thrust bearing for: – the conveyor and mining equipment, – conveyor steering devices, – devices for raising the conveyor, – conveyor steering cylinders.

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

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

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

Caterpillar assumes no liability for damage caused by unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective equipment.

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

prerequisite

Only use shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

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

EMERGENCY STOP

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

support lock-out switch

- Only applies to the version with the electrohydraulic shield control system: Actuate the support lock-out switch (repair switch) before: maintenance work, inspection work, repair work, 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: skids and relay bar assemblies, canopies, lemniscatic links, side seals, front cantilevers, hydraulic props and cylinders, steering devices.

automatic mode

2.6

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

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signaling systems and safety equipment

Maintain the lighting systems in working condition.

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lighting system

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

Never stand under unsecured or suspended loads.

Observe the prescribed storage periods and the storage instructions.

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

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

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

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

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

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

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

Do not damage the polished surfaces of the cylinders and the props. Damage of this kind necessitates elaborate and expensive repair work.

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

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

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

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

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2.7

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

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

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

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

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

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Fig. 1:

transport safety device

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

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

travel way

Make sure that the minimum dimensions specified for the travel way with the shield are maintained at all times. The minimum dimensions are: width: 600 mm, height: 400 mm.

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

2.8

Shield support 1295/3048-2x4083-1750

Safety instructions Operation shield control

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

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

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

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

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

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

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

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

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

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

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

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

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2.9

Safety instructions shield alignment

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

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

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

roof falls

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

Never set the tip of the canopy into a roof fall so that the maximum admissible angle of inclination of the canopy is exceeded, the canopy is loaded excessively in the longitudinal direction, as this may cause damage due to excessive stress and strain on the components.

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

residual stroke

retracting the conveyor

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

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

Secure all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the lifting points intended for that purpose.

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

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

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

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

2.10

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the stabilizing cylinder locks,

Safety instructions For raising the conveyor, use only: high-strength, undamaged chain slings, the lifting points provided for the purpose.

Check that the lifting points are undamaged before attaching the load. lifting gear of adequate load-carrying capacity.

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

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

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

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

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

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

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

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

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

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

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

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2.11

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

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

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

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

Hydraulic system handling hydraulic fluids

Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

protective devices - hydraulic system

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

maintenance, repairs

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

pressure relief valves

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

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

2.12

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

E

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

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

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

Never use nails, wire or similar materials.

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

Only use hydraulic hoses approved for the prevailing pressures.

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

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

Fig. 2:

Example of a hose line, marking 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 section in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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2.13

Safety instructions laying hydraulic hoses

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

Lay hydraulic hoses so that: they are always slightly slack, Fig. 3:

Laying a hydraulic hose, slack RIGHT

WRONG

they are not twisted, Fig. 4:

Laying a hydraulic hose, twisted WRONG

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

Laying a hydraulic hose, bending RIGHT

WRONG

they cannot chafe, Fig. 6:

2.14

Laying a hydraulic hose, crossing RIGHT

WRONG

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Caterpillar Global Mining Europe GmbH, Lünen 2012

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RIGHT

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

Only push hydraulic hoses into the connector sockets by hand.

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

When laying hydraulic hoses, ensure that they cannot be: torn out, kinked, pinched, driven over or twisted (Fig.: 7).

Fig. 7:

Laying a hydraulic hose, connections on moving parts WRONG

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RIGHT

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2.15

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Safety instructions

2.16

Shield support 1295/3048-2x4083-1750

3

Storage and transport

Storage

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

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

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

Storage Storing the equipment

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anticorrosion protection

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

no direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

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

dirt and moisture

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

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

short-term storage

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

long-term storage

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

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

This inspection can be carried out by Caterpillar upon request.

natural aging

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

Important!

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

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3.3

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

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

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

*

3.4

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

Shield support 1295/3048-2x4083-1750

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

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

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Warning!

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

Falling components can cause serious injury and death.

Only use suitable load handling devices.

Before transport temperatures below freezing

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

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

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

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

electrical and electronic components

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

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

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3.5

Transport transport units

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

Tab. 1: Transport units

transport safety devices

Designation

Alignment

Complete shield unit

As for normal use

Note

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

Tab. 2: Transport safety devices Component

Transport safety device

Quantity

Face side

Transport rod and cable ties

1

Gob side

Chain

1

Side seal, movable

Pin and securing device

4

Hydraulic system

Unused hydraulic connections are protected by protective caps or plugs

-

3.6

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Caterpillar Global Mining Europe GmbH, Lünen 2012

Caution!

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

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

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Relay bar assembly

Transport collision of components

Fittings, such as hydraulic components, shut-off valves or electronic parts, can potentially collide in the transport position of the support.

Caution!

When retracting the shield, watch out for potential collisions in the transport position. Turn or fasten any fittings before you move the shield into its transport position.

Move the following components into their corresponding position, as illustrated, to avoid collisions in the transport position.

HP ball valves on the prop Transport position of the HP ball valves on the prop

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Fig. 8:

HP ball valve behind the electrohydraulic control unit Fig. 9:

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Transport position of the HP ball valve behind the electrohydraulic control unit

3.7

Transport Transporting the end shield Transport as a complete unit

1295 transport height

Fig. 10:

740

So

1637

S1

S1

8065 transport length

S3

S4

S3 8202

1700

1650

S2

S2

S1 transport hole, capacity 15,000 kg S2 transport hole, capacity 15,000 kg S3 transport hole, 2 x on the canopy, capacity: 15,000 kg S4 load ring, 2 x on the caving shield, capacity: 15,000 kg So center of gravity

Important!

Use the lifting points S1 for transport.

Tab. 3: Shield support 7420 248 000 00 01, dimensions and weights

3.8

Device number

Length L in mm

Width W in mm

Height H in mm

Weight in kg

7420 248 000 00 01

8065

1700

1295

28400

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S4

Transport safety device Transport safety device Transport safety device, relay bar assembly The skids are secured on the face side with a transport rod during transport. The transport rod is secured with cable ties.

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Fig. 11:

Transport safety device, skids, face side

Caterpillar Global Mining Europe GmbH, Lünen 2012

1

1 transport rod fastened with cable ties

The relay bar assembly is secured on the gobside with a chain during transport. The chain is secured with bolted connections.

Fig. 12:

Transport safety device, relay bar assembly, gobside

1, 2, 3

1 chain 6x42 2 hex. head screw M 12x40-8.8

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3 hex. nut M 12-8

3.9

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

Fig. 13: Transport safety device, side seal 13

side seal, canopy

12 24

side seal, caving shield 11

24 20

Canopy side seal 12 pin 40/34x307 13 pin 40/34x257 20 staples DN 25

3.10

Caving shield side seal 11 transport safety devices 22x128 24 staples DN 12

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20

11

4

Installation

Preassembly of the shield units

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

Warning!

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

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

Caution!

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

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Caution!

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

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

Installation of the shield units Caution!

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

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

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

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

Important!

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

identification for installation in the face

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

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4.3

Installation of the shield units shield number

The shield number serves as an identification feature. All shields are numbered consecutively. The shield numbers are on the skid, caving shield and canopy.

Fig. 14:

Example of shield number

Tab. 4: Shield support, numbering

4.4

Use

Shield number

Special design

End shield

BG-01 to BG-16

Moving side seal

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BG-01

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

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

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

Pressure equalization is indicated by an audible hissing.

Caution!

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

Fig. 15:

Example of a vent screw on an electronic control system b

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a

a vent screw

b electronic control system PMC®-R

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

Caution!

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

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

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4.5

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

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

Important!

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

Important!

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

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

Important!

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

. Close the HP ball valve.

Fig. 16:

Compact distributor with 3/2-way ball valve (shown: lever in CLOSED position)

OPEN

CLOSED

Lever position OPEN working position (pressure open) CLOSED depressurized (pressure relief for output side for return line)

4.6

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During installation via the auxiliary supply, the 3/2-way ball valve on the compact distributor must be closed.

E

Lever position on the compact distributor

Installation of the shield units Connecting the auxiliary supply The auxiliary supply is connected to the ports of the through sleeve. The connections are on the coal face, on the right side of the shield. There is an HP ball valve in the pressure line of the auxiliary supply, which must remain open during the procedure.

Fig. 17:

Auxiliary supply, displayed without hoses

27

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23

P 11a

27

T

13

11a HP ball valve in the pressure line of the auxiliary supply 13 PRV 80 bar 23 through sleeve

connecting the auxiliary supply

27 plug DN 10 with pressure relief P connection for pressure line, auxiliary supply (DN 12) T connection for return line, auxiliary supply (DN 20)

. Check that the HP ball valve on the compact distributor is closed.

. Open the HP ball valve, item 11a. . Remove the plugs from the connections P and T of the auxiliary supply.

. Connect the auxiliary supply to the pump's pressure and return lines.

. Secure the connections with staples.

The shield can now be moved via the external control units PMC-R.

. Move the shield to the desired position.

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4.7

Installation of the shield units disconnecting the auxiliary supply

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

. To relieve the pressure line, switch off the pump and close the pump's pressure supply line. Make sure that the pump's return line remains open.

. Relieve the pressure in the pressure line via the plug with pressure relief, item 27.

See additional information on page 5.35.

. Close the HP ball valve, item 11a.

Notice!

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

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

Fig. 18:

The compact distributor for supplying the shield hydraulics is arranged centered under the canopy. The connection to the compact distributor of the neighboring shield is established with the aid of three hose lines: one pressure line P (DN 40 SS), one return line T (DN 50) and one water line W (DN 50).

Connection lines to the neighboring shield (schematic diagram)

DN40 SS

P T

T T DN50 W

W W DN50

P pressure line connection T return line connection

W water line connection

Proceed as follows to join the shields to one another:

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

. Fit the connection lines in the connections P, T, W on the compact distributor and connect them to the compact distributor of the neighboring shield.

4.8

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hydraulic system

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Establishing a connection between the shields

Requirements for the face hydraulic system control unit

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

For details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control. An overview of the design of the control is also given in chapter 6 of this operating manual in the section “Shield control system”.

additional equipment

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

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

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Requirements for the face hydraulic system hydraulic medium

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

permissible pressure

Nominal pressure: . . . . . . . . . . . 320 bar Tolerance range: . . . . . . . . . . . . . ± 10 % of nominal pressure If the face hydraulic system is designed in such a way that it is unstable or too weak, there could be a temporary pressure drop during operation.

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

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

Caution!

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

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

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4.9

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

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

For the Shield support 1295/3048-2x4083-1750 ID no.: 7420 248 000 00 01 a minimum pressure of 30 bar applies to the water spraying system!

4.10

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

Warning!

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

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

E

The minimum pressure applies to all shields.

Commissioning Commissioning Warning!

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

Notice!

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

See chapter 3, section “Transport”.

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Please observe the following: Mechanical system:

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

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

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

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

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

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

1) Maximum possible plugging

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4.11

Commissioning Hydraulic system:

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

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

Danger!

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

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

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

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

. Check the hydraulic supply pressure.

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

Signaling and lighting systems, information signs: Important!

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

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

EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems are working properly.

Mining and conveying:

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

Warning!

Bent support canopies must not project into the mining area.

4.12

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Caterpillar Global Mining Europe GmbH, Lünen 2012

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

E

. Check the load-carrying function of the props. The current

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

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

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

E

Warning!

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

. Check all functions of the shield control unit.

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

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

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

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4.13

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Commissioning

4.14

Shield support 1295/3048-2x4083-1750

5

Operation

Requirements

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

Danger!

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Warning!

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

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

Requirements Operating conditions face crew

face equipment

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

The face must be sufficiently illuminated.

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

travel way

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

Notice!

Make sure you observe the corresponding national regulations.

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

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.3

Requirements Fig. 19:

Minimum dimension for the travel way, schematic diagram

B

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

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

work in the mining area

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

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

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

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

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

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

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

5.4

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

A travel way (minimum dimension, country-specific)

E

H

Requirements repair work

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

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

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

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

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

conveyor 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.

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.5

Requirements Safety requirements automatic mode

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

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

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

operating the shield unit

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

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

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

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

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

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

The props 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.

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

5.6

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

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.

E

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!

Requirements Fig. 20:

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

Shield unit with plow

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Fig. 21:

Shield unit with shearer

Shield unit with plow

Shield unit with shearer

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

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

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

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

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.7

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

The shield canopy and caving shield must be mechanically secured against falling when replacing hose lines between piloted check valves and props or other hydraulic props 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.

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 provided by Caterpillar). If the layout was provided by the operator, we recommend that safety valves are installed at 50 m intervals in the return line. The valves should be set to 25 bar and spray into the atmosphere.

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

E

damage, spare parts

5.8

Shield support 1295/3048-2x4083-1750

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

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

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

Definition of viewing direction, schematic diagram

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Fig. 22:

A looking toward coal face B looking toward gob

1 right side, face side 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 system.

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.9

Operation of the shield support shield canopy position

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

Caution!

Never exceed the permissible angle of inclination of the canopy!

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

Fig. 23:

Shield support in normal position

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

0 M

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

Caution!

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

Stabilizing cylinders must always have sufficient residual stroke!

Indicative value: at least 20 mm!

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

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

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

5.10

Shield support 1295/3048-2x4083-1750

Operation of the shield support Fig. 24:

Shield support with extremely inclined shield canopy

1

s1

M

s2 2 Caterpillar Global Mining Europe GmbH, Lünen 2012

E

M

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

Caution!

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

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

Caution!

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.11

Operation of the shield support Caution!

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Fig. 25:

WRONG

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

Fig. 26:

R i g h t : fill out roof falls

RIGHT

5.12

Shield support 1295/3048-2x4083-1750

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

Accumulation on the shield canopy can be avoided by 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. adjustment range of support/ changing face thickness

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

keeping the face opening sufficiently large using the mining equipment, avoiding the accumulation of debris and fine coal on the floor, removing accumulations of rock on the shield canopies.

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

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

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

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

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

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.13

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

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor 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 mine floor conditions

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

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

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

Important!

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

5.14

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

Individual skids on two-prop shields can usually be lifted hydraulically by actively lowering a prop.

E

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

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

Warning!

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

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

Caution!

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

Observe the following safety regulations:

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

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

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

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: malfunction of the electronic control system, external jamming: – shield is wedged in between the neighboring shields.

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the skid.

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.15

Overview of the shield components Overview of the shield components Arrangement of the shield components Fig. 27:

Arrangement of the shield components, end shield 21

51 26

61

55

53

5 1

11

8

31

41

71

5.16

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

7

E

3

Overview of the shield components Tab. 5: Shield 7420 247 000 00 01, main subassemblies Weight approx. in kg

Item

Description

ID No.

01

Skid

7420 248 300 00 01

7272

03

Relay bar assembly

7420 248 330 00 01

982 Shifting ram

05

Lemniscatic link, front right

7420 248 303 00 00

463

07

Lemniscatic link, front left

7420 248 305 00 00

466

08

Lemniscatic link, rear right

7420 248 306 00 00

466

11

Canopy

7420 248 400 00 01

9047

21

Side seal, canopy

7420 248 710 00 01

867

26

Side seal, caving shield

7420 248 760 00 01

544

31

Caving shield

7420 248 800 00 01

4074

41

Hydraulic prop

8250 209 000 00 00

1429

51

Stabilizing cylinder

8241 545 000 00 00

206

53

Shifting ram

8241 534 000 00 00

414

55

Lifting cylinder

8241 530 000 00 00

72

61

Hydraulic system

8112 382 000 00 00

71

Caving flap

7420 248 328 00 00

8241 529 000 00 00

For more information, refer to tab. 7 Electrohydr. control unit 8154 183 000 00 00 Hose lines 8112 382 010 00 00 Water spraying system 8112 382 020 00 00 Brackets 8112 382 030 00 00 Water valve unit 8401 008 500 00 00

E Caterpillar Global Mining Europe GmbH, Lünen 2012

Note

98

Important!

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.17

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

The following ball valves are open during normal operation: 9a, 9b, 11b, 12a, 12b, 12d, 12e, 30, 31, 3/2-way The following ball valves are closed during normal operation: 11a, 12c, 29a, 32 Fig. 28:

Position of the HP ball valves 12c

12d

3/2-way 29a 12a 31 11a

9a

32

12b 9b

11b

5.18

12e

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

30

Overview of shield hydraulics

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Tab. 6: HP ball valves Item

Color

Designation

9a

red

HP ball valve

9b

red

HP ball valve

11a

red

HP ball valve

11b

red

HP ball valve

12a

red

HP ball valve

12b

red

HP ball valve

12c

12d

red

red

HP ball valve

HP ball valve

12e

red

HP ball valve

29a

blue

HP ball valve

30

blue

HP ball valve

31

red

Compact ball valve

32 3/2-way

Block ball valve HP ball valve

Doc. No.: 7420 248 000 BA 00

SSSU / 01

Function For shutting off the pressure supply to the piston space of the left prop.

For shutting off the pressure supply to the piston space of the right prop.

For shutting off the pressure supply for the auxiliary supply.

Closed during normal operation!

For shutting off the return line from the double filter.

Open during normal operation!

For shutting off the right prop. The prop is not retracted during lowering.

For shutting off the left prop. The prop is not retracted during lowering.

For cleaning the nozzles of the water spray canopy.

Closed during normal operation!

For shutting off the piston space of the lifting cylinder.

Lifting cylinders are not retracted while setting props.

For shutting off the annular spaces of the seal cylinder.

Side seal cannot be retracted and extended.

For shutting off the water supply for the water hose.

For shutting off the water supply.

For switching off the stabilizing cylinder's automatic function. While the props 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.

For shutting off the water hose.

For shutting off the main pressure line to the shield.

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

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

For moving the shield during commissioning.

In the event of any leakage.

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

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

In the event of contaminated or clogged nozzles, flushing is performed at high pressure.

During maintenance and repair work.

Closed during transport, so that the side seal does not extend and the mechanical lock is mountable.

During maintenance and repair work.

Function of the water spraying system is deactivated.

The canopy remains inclined towards the roof for any maintenance work.

During maintenance and repair work.

Spraying or cleaning of soiled components.

During maintenance and repair work.

5.19

Overview of shield hydraulics HP ball valve versions Caution!

Ensure that the ball valve is engaged at all times.

A ball valve that is not engaged prevents an optimum throughflow. This can damage the ball valve.

2-way ball valve The 2-way ball valve is for shutting off the pressure supply line during maintenance work or repairs. Blue 2-way ball valves installed are for shutting off lines conveying water, such as the water supply.

Fig. 29:

2-way ball valve, open and closed

open

Flow for medium enabled

Flow for medium stopped

3/2-way ball valve The 3/2-way ball valve has two switching or lever positions. The 3/2-way ball valve is installed on the compact distributor and is for shutting off the pressure supply line during maintenance work or repairs.

Fig. 30: 3/2-way ball valve, with two lever positions open

OPEN working position (pressure open)

5.20

closed

CLOSED depressurized (pressure relief for output side for return line)

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

closed

Overview of shield hydraulics Arrangement of the hydraulic components on the end shield Warning!

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

Tab. 7: Hydraulic components on the end shield 7420 248 000 00 01 / hydraulic system no. 8112 382 000 00 00

01 02 03 04 05 06 07 08 09 10 11 12 13 14

Quantity 1 1 1 1 1 2 1 1 2 1 2 5 1 4

15

3

PRV, 380 bar DN 10

16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 32 35 36 37 38 39 40 S1 Z1 Z2 Z3 Z4 Z5

2 1 1 1 1 1 1 1 1 1 6 2 1 1 1 1 3 1 2 1 1 1 2 2 1 1 1 3

PRV F-420 bar CV, DN 10 CV, DN 10 Compact distributor Hose lines Water spraying system accessories Bracket and accessories Through sleeve DN 20/DN 12 Prop CV, DN 20 Prop CV, DN 20 Plug DN 10 with pressure relief Pressure gauge port HP ball valve HP ball valve Compact ball valve Block ball valve Glycerine pressure gauge NG 50 Distributor 2x DN 20;DN 25 Distributor Distributor, 5-way Distributor Plug DN 10 Pressure sensor Prop Lifting cylinder Stabilizing cylinder Shifting ram Seal cylinder

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Item

Designation

Note

Electrohydraulic control unit, 10 functions Water valve unit Accumulator cartridge DN 20 SS Replaceable CV DN 20-SSO Dual CV CV, NW 25 Water filter DN 20-100 MY Double filter DN 25 SS Automatic HP ball valve DN 20-SS Dual 3/2-way valve HP ball valve HP ball valve PRV, 80 bar DN 10 PRV, 380 bar

see separate operating manual see separate operating manual

Doc. No.: 7420 248 000 BA 00

SSSU / 01

for shifting rams for stabilizing cylinders in the return line see separate operating manual see page 5.19 see page 5.19 see page 5.19 in the return line of the auxiliary supply - in the piston space of the props - for piston space side and annular space side of the stabilizing cylinder - for lifting cylinders - for shifting ram - seal cylinder for props, setting pressure 420 bar in the water spray canopy in the water spray canopy subassembly subassembly subassembly

for pressure relief see page 5.19 see page 5.19 see page 5.19 see page 5.19

5.21

Overview of shield hydraulics Fig. 31:

Shield hydraulics, arrangement on end shield image caption: see table 7

22

16

Z 20

12b

9b

9a

31

12a

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

32

25

14 14

35

35 28

24 28

35

Z

23

13

29a

5.22

11a

27

Shield support 1295/3048-2x4083-1750

Overview of shield hydraulics Fig. 32:

Shield hydraulics, arrangement on end shield image caption: see table 7

18

38 30 17 7

E

12c

Caterpillar Global Mining Europe GmbH, Lünen 2012

2 19

12d

6 3 1

36

12e 8

4

10 A

40 11b

15 27

37 15

14

27

5

21

27

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.23

5.24

Z1

16

14

14

Z3

27 360 bar

Z4

27 15

4 PB T PA A

PB T PA A

R

35

Z1 28

16 9b

12b

Z5 E

11

12 P T

Z5 WWTT P

WWTT P T W W

X1

X3

X5

X7

X9

30

2

39 15 21

24

W T P

1

2

3

4

5

6

7

8

9

P

6

80 bar

23

T 3/2-WAY open

SP

coal

PTO

P

T 3/2-WAY to return

27 35

36

20

38

17

Caterpillar Global Mining Europe GmbH, Lünen 2012

27

LK

W1 W2 W3 W4

Z5 6

W2 W3 W4

Z2 WP

8 X12

X2

X2

X4

X6

X8

X10

10

19

W1

12e 25 mm P X11

T

2 P

2 1

4 3

6 5

8 7

10 9

40 10

water spray canopy

14 pi A

A A

380 bar

12d

420 bar

PB

28

leg

12a

PA

A A

9a s i

pi A

25

D.A.ram

PB T PA A

1

380 bar

31 35

420 bar

14 37

link cyl.

360 bar 360 bar

leg

380 bar

37

200 bar 360 bar 100 bar PB T PA A A A

canopy

11b

water spray lemniscate

15 3

40 bar

For details, see Fig. 34

DN50 DN50 DN40SS

Fig. 33:

DN50 DN50 DN40SS

caving shield

Overview of shield hydraulics Shield hydraulics, end shield image caption: see table 7 11a 27

13

29a 32

7

For details, see Fig. 36

18

12c

27

5

Shield support 1295/3048-2x4083-1750

Overview of shield hydraulics Electrohydraulic control unit, 8 functions

Fig. 35:

1

2

3

X2

X1

4 X2

X4

X3

5

6 X6

X5

7 X7

8

T

P

2

1

2

3

4

5

6

7

8

9

10

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

X8

X10

X9

9

10

SP

Fig. 34:

Symbol plate on the electrohydraulic control unit, 10 functions 1

3

5

2

4

6

7 8

9 10

Tab. 8: Electrohydraulic control unit with 10 functions, assignment of functions Function, designation

Doc. No.: 7420 248 000 BA 00

Function no.

Advance shield

1

Set prop

2

Push conveyor

3

Extend lifting cylinder

4

Extend stabilizing cylinder

5

Retract stabilizing cylinder

6

Flush water spraying system nozzles

7

Extend side seal

8

Retract side seal

9

Lower prop

10

Filter backflushing

on the double filter

Filter backflushing

on the double filter

SSSU / 01

5.25

Overview of shield hydraulics Fig. 36:

Water valve, 4 functions W

P

W2 W2

W1 W1 W4 W4

W3 W3

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

LK

W (input) = DN 20 P, W1, W2, W3, W4 and leakage = DN 10 Fig. 37:

Symbol plate on the water valve unit, 1 function

W1

W3

W2

W4

Tab. 9: Water valve unit with 1 function, assignment of functions Function, designation

Function no.

Water spraying system for canopy / lemniscatic link

5.26

W1

Shield support 1295/3048-2x4083-1750

A

DN6

7

DN20

DN12

DN20SS

DN10 4

4

9 10

DN10 NIRO DN20 NIRO

DN20 NIRO

AT REAR SIDE / AN RUECKSEITE DN10 NIRO

DN10 DN25

AT REAR SIDE / AN RUECKSEITE

DN10 NIRO

DN25

8

DN25SS

DN10

DN10

DN20SS

AN RUECKSEITE

AT REAR SIDE / AN RUECKSEITE

DN10

DN20

DN10

DN10

11 DN10

DN25

DN20SS DN20SS

AT REAR SIDE /

DN20SS DN10 DN10 DN10

DN20

5

DN10 DN10 NIRO

DN12

6

K

DN10

R

DN10 NIRO DN10 NIRO

DN20SS

DN10 NIRO DN10 NIRO DN10 NIRO

DN20SS DN10

DN10 NIRO

DN10 NIRO

DN20 DN10

DN10

DN10

DN20 DN12

2

DN10

K R

3

5.27

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Doc. No.: 7420 248 000 BA 00

DN10

1

DN10 NIRO DN10 DN10

DN25SS

DN10

E

Hydraulic lines Fig. 38:

DN50 DN50 DN40SS

Caterpillar Global Mining Europe GmbH, Lünen 2012

Overview of shield hydraulics

For items: refer to spare part lists

DN12

Overview of shield hydraulics Fig. 39:

Shield hydraulics, brackets and accessories

For items: refer to spare part lists

13

14

A A

A

Caterpillar Global Mining Europe GmbH, Lünen 2012

AA

E

1

A

5

4 16

3 7

8

15

2

12

6

21

A A

A A

11

5.28

9

17

20

21

Shield support 1295/3048-2x4083-1750

Overview of shield hydraulics Control units The following control units are installed in the supports. Operation of the control units is not described here, but in a separate operating manual for the control unit.

PMC®-R control unit Electrohydraulic control unit Water valve unit Important!

More information on the corresponding control unit is available in the separate operating manual.

PMC®-R control unit normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

Fig. 40:

PMC®-R control unit a

Caterpillar Global Mining Europe GmbH, Lünen 2012

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b

c a PMC®-R control unit b EMERGENCY STOP switch

Doc. No.: 7420 248 000 BA 00

SSSU / 01

c support lock-out switch

5.29

Overview of shield hydraulics Electrohydraulic control unit different versions

The electrohydraulic control unit of the end shield has 10 functions.

Fig. 41:

Electrohydraulic control unit, 10 functions

a connecting sockets on the rear side b distributor block c pilot valve

d

e

f

d pushbuttons e connecting sockets for control unit f filter cartridge

Water valve unit Fig. 42:

Water valve unit, 4 functions g d e

f

e

b

a c a connection plate b pilot valve c valve cartridge d filter cartridge

5.30

e push-button f connecting sockets for control unit g connecting sockets on the rear side

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

c

b

E

a

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

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

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

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.

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Warning!

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

Warning!

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

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

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

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

Important!

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

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.

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.31

Overview of shield hydraulics The function stops as soon as you release the button.

Danger!

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

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

Warning!

Manual actuation of a button on one of the pilot valves initiates the direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the “advance shield” function can be activated without previously activating the “retract side seal” and “actively lower support” functions. This can cause dangerous situations which can result in very serious injuries.

Shield functions Symbol plate on the electrohydraulic control unit, 10 functions

1

1

3

5

2

4

6

7 8

9 10

Advance shield The “Lower prop” function must have been executed before this function can be executed.

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.

2

Set prop Before this function is actuated, the shield canopy must be correctly aligned. The baselift cylinder retracts automatically. 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 props 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.

3

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

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

4

Extend lifting cylinder 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.

5.32

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Fig. 43:

Overview of shield hydraulics 5

Extend stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

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

Caution!

Do not exceed the permissible inclination!

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

6

Retract stabilizing cylinder Before executing this function, it must be made sure that the neighboring shields are completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached. After the canopy has been correctly aligned, the props must be reset.

7

Before executing this function, ensure that HP ball valve 12c is open.

This function flushes contaminated or clogged nozzles of the water spray canopy.

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

E Caterpillar Global Mining Europe GmbH, Lünen 2012

Flush water spraying system nozzles

8

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

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

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

9

Retract seal cylinder The “Retract prop” function must have been executed with the side seal in place before this function can be executed.

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

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

10

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

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

Fig. 44:

Symbol plate on the water valve unit, 4 functions

W1 W2

Doc. No.: 7420 248 000 BA 00

SSSU / 01

W3

W4

5.33

Overview of shield hydraulics W1

Water spraying system for canopy / lemniscatic link The function is executed as long as the button is pressed.

No function

W3

No function

W4

No function

Caterpillar Global Mining Europe GmbH, Lünen 2012

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W2

5.34

Shield support 1295/3048-2x4083-1750

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

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

Fig. 45:

Plug DN 10 with pressure relief

Open pressure relief: screw in screw

Caterpillar Global Mining Europe GmbH, Lünen 2012

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a

Close pressure relief: screw out screw

b

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

b sealing ring

Important!

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.35

Maintenance Maintenance Warning!

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

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

hydraulic control system

Special measures

filter cartridges

The filter cartridges on the 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.

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

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

replacing filters

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

We recommend:

water filter piston rods

5.36

Replace the water filter directly.

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

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

E

Caution!

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

Maintenance pressure relief valves

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

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

high-pressure hydraulic hoses

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

double filter, can be backflushed

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Daily maintenance hydraulic system

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

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

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.37

Maintenance Weekly maintenance control

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

. Clean the control systems, especially the control panel.

Notice!

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

Every six months hydraulic prop

. Lubricate the dirt strippers of both telescope stages via the lubricating nipples. Use the grease A2 in accordance with EWN 7068, see chapter 6, section “Greases and lubricating pastes”.

E

Lubricating nipples on the hydraulic prop

b

a

a lubricating nipple on the guide bushing

b grease escaping at dirt stripper

. Apply a preservative to the piston rods of the hydraulic cylinders. Further details are contained in this chapter in the “Special measures” section.

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

5.38

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 46:

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

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

These are normally audible to the operator.

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

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Warning!

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

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

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

Fault localization support cannot be lowered

Doc. No.: 7420 248 000 BA 00

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 prop control valve is not working.

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

The prop control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leaks.

Replace the prop, if necessary.

SSSU / 01

5.39

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

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

Control piston on the prop control valve is not working.

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

The prop control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leaks.

Replace the prop, 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 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 skid one step.

The pressure of the hydraulic supply is too low.

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

Control piston on the piloted check valve is not working.

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

The prop control valve may be defective.

Damaged or trapped hose line.

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

Shifting ram is defective.

Check whether the - shifting ram is damaged, - the piloted check valve is working properly.

Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressurized fluid escapes, replace the shifting ram.

support cannot be advanced

5.40

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

The pressure of the hydraulic supply is too low.

Troubleshooting setting pressure is not reached / prop pressure drops again after setting

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

canopy cannot be positioned

canopy cannot be lowered

Doc. No.: 7420 248 000 BA 00

Possible cause

Measure required

Prop control valve is defective.

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

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lowering connection and check whether pressurized fluid is escaping even though the prop is no longer being extended. If applicable: piston packing defective, replace prop.

Pressure relief valve defective.

Monitor pressure drop on the pressure gauge.

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

Possible cause

Measure required

The shut-off valve for the shield supply on the 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 is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked prop 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 is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose line.

Check hose lines for controlling the prop / stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

SSSU / 01

5.41

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

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

Defective pilot valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, such as discharged fluid, for example.

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

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

If the noise stops while a function is actuated, that valve is faulty.

You may have to press the button for the faulty function for several seconds before the noise ceases.

valve replacement

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

. Then actuate the functions manually to depressurize the system.

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

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

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

If the problem occurs again, the valve may be defective.

. Check the valve and replace it if it is defective.

Checking the prop check valves To check the prop check valves please proceed as follows:

. Set the prop until the setting pressure has been reached. . Remove the “set prop” hose line on the piloted check valve.

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

5.42

Shield support 1295/3048-2x4083-1750

E

. Locate the faulty valve by actuating the functions individually in

Caterpillar Global Mining Europe GmbH, Lünen 2012

internal leakage

Troubleshooting Internal bypass inside the prop If an internal bypass in a prop is suspected, this procedure should be followed:

. Set the prop until the setting pressure has been reached. . Make sure that the annular space of the prop is depressurized. . Release the hose of the prop annular space connection at the prop.

. Actuate the “set prop” function from the neighboring support.

If there is an internal bypass in the prop, for example due to damaged piston packing, fluid will flow out of the prop's lowering connection. If this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

Pressure relief valve defective

Caterpillar Global Mining Europe GmbH, Lünen 2012

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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 props, whereas the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow rate.

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

Defective or clogged filter Operation of the shield is slow although the system pressure lies in the normal range.

It is also possible that the hydraulic system has been contaminated, for example during repair work on the hydraulic system.

. Check the filters in the hydraulic system.

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

Doc. No.: 7420 248 000 BA 00

SSSU / 01

5.43

Caterpillar Global Mining Europe GmbH, Lünen 2012

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Troubleshooting

5.44

Shield support 1295/3048-2x4083-1750

6

Technical data

Description

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

Description Model 1295/3048-2x4083-1750 The two-prop shield mainly consists of the following main subassemblies: base frame with lemniscatic links and relay bar assembly, canopy, caving shield, side seals, hydraulic props, Caterpillar Global Mining Europe GmbH, Lünen 2012

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hydraulic equipment with hose lines and control.

Tab. 10: Shield support variants, dimensions and weight Use

Device number

Dimensions, L x W x H max./min. in mm

Approx. weight in kg

End shield

7420 248 000 00 01

1295/3048-2x4083-1750

28400

Tab. 11: Shield support, numbering Use

Shield number

Special design

End shield

BG-01 to BG-16

Moving side seal

The two-prop shield is equipped with a two-part base frame. It consists of two individual skids that are connected on the gobside via the yoke of the relay bar assembly. The relay bar assembly is in the center between the skids. The shifting ram functions directly.

The caving shield is a one-piece steel construction, connected to the base frame by the lemniscatic links.

The shield canopy transmits the supporting force of the props to the roof. The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

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 props 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.

Doc. No.: 7420 248 000 BA 00

SSSU / 01

6.3

Description Main subassemblies Arrangement of the shield components on the end shield Fig. 47:

Arrangement of the shield components, end shield 21

51 26

61

55

53

5 1

11

8

31

41

71

6.4

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

7

E

3

Description Tab. 12: Shield 7420 247 000 00 01 , main subassemblies Weight approx. in kg

Item

Description

ID No.

01

Skid

7420 248 300 00 01

7272

03

Relay bar assembly

7420 248 330 00 01

982 Shifting ram

05

Lemniscatic link, front right

7420 248 303 00 00

463

07

Lemniscatic link, front left

7420 248 305 00 00

466

08

Lemniscatic link, rear right

7420 248 306 00 00

466

11

Canopy

7420 248 400 00 01

9047

21

Side seal, canopy

7420 248 710 00 01

867

26

Side seal, caving shield

7420 248 760 00 01

544

31

Caving shield

7420 248 800 00 01

4074

41

Hydraulic prop

8250 209 000 00 00

1429

51

Stabilizing cylinder

8241 545 000 00 00

206

53

Shifting ram

8241 534 000 00 00

414

55

Lifting cylinder

8241 530 000 00 00

72

61

Hydraulic system

8112 382 000 00 00

71

Caving flap

7420 248 328 00 00

SSSU / 01

Caterpillar Global Mining Europe GmbH, Lünen 2012

8241 529 000 00 00

For more information, refer to tab. 7 Electrohydr. control unit 8154 183 000 00 00 Hose lines 8112 382 010 00 00 Water spraying system 8112 382 020 00 00 Brackets 8112 382 030 00 00 Water valve unit 8401 008 500 00 00

E

Doc. No.: 7420 248 000 BA 00

Note

98

6.5

Description Main dimensions Fig. 48:

Dimensions 4550

1340

140

394

449

1142

1295

416

210

1067

273 683

1283

1600

1861

1067

2285 3048

438

1113

HE

HR

1885

252 4290

1142

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

8042 L

8014

M 1750 W 1700

340 930 1650

6.6

HE height, extended HR height, retracted L transport length

W width M support center distance

Shield support 1295/3048-2x4083-1750

Description Skid The one-piece base frame transfers the bearing strengths of the hydraulic props to the floor. The props are mounted on hinges in the ball sockets in the skids and are held on both sides by prop 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 reverse-mounted. This means, the force applied to the piston surface of the shifting ram is used to advance the shield.

Correspondingly, the conveyor is advanced with the smaller force generated via the annular surface.

The fork joint of the relay bar assembly establishes the connection to the conveyor.

With the help of the lifting cylinder, the shield can be lifted during shield advance.

E

Fig. 49:

Skid, dimensions

Caterpillar Global Mining Europe GmbH, Lünen 2012

L

H

W

L 4290 W 1650

Doc. No.: 7420 248 000 BA 00

SSSU / 01

H 620

6.7

Description Fig. 50:

Skid, dimensions 35

41, 58 3

36

4

5, 51, 53 2

1

38, 53

7, 50, 56 20 37, 57 42, 52, 53

1 skid 2 cylinder bearing 3 prop retainer, right 4 prop retainer, left 5 mounting link 7 safety segment 20 pin 90x285 35 lemniscatic link pin 168.5x587 36 lemniscatic link pin 148.5x577 37 pin 35/29x78

38 threaded bolt 30/18x148 41 pin 35/29x62 42 pin 60/50x116 50 hex. head screw M 30x50-A 4-50 51 hex. head screw M 16x80-A 4-80 52 hex. head screw M 16x120-A 4-80 53 hex. nut M 16 -A 2-70 56 washer 57 spring clip A 58 locking clip 4

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.8

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

7, 50, 56

Description 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 to pull up 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 lifting equipment, the base frame can be lifted off the floor when 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.

Fig. 51:

Relay bar assembly, dimensions

H

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

W

L

L 4437 W 280

H 385

Functional description 1. Initial position of the shield The shifting ram is retracted.

2. Advancing the shield While the shield is being advanced, the baselift cylinder presses on the relay bar, causing the skids to be lifted up off the floor.

Warning!

Parts of the body which get between moving parts of the relay bar assembly and support can be crushed.

For this reason, make sure that you are at a sufficient distance from shields which are being advanced or are to be advanced soon.

3. Setting the support When setting the shield, the baselift cylinder retracts again automatically.

4. Advancing the conveyor The shifting ram is retracted.

Doc. No.: 7420 248 000 BA 00

SSSU / 01

6.9

Description Fig. 52:

Relay bar assembly, items

1

10, 11 9 7, 8 2

6, 12

4 8, 14 1 relay bar 2 clevis assembly for conveyor 3 pin 80/60x275 4 retaining ring D85/61x40 6 pin 70/53x144 7 hex. head screw M 16x120-A2-70

8 hex. nut M 16-A4-80 9 pin 65/58x180 10 hex. head screw M 12x120-A2-70 11 hex. nut M 12-A4-80 12 hex. head screw M 16x25-A2-70 14 hex. head screw M 16x100-A4-80

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces.

*) EWN = works standard

6.10

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

3

Description Canopy The canopy transfers the supporting force of the props 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 props are fastened to the canopy and can be rotated.

Caution!

To avoid overloading the stabilizing cylinders, you must make sure that the setting angle of the shield canopy does not exceed the maximum permissible value, e.g. when the canopy is set in a roof fall.

Fig. 53:

Canopy, dimensions

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

W

H L

L 6103 W 1680

Doc. No.: 7420 248 000 BA 00

SSSU / 01

H 935

6.11

Description Fig. 54:

Canopy, items 5

3

15, 16

6, 17

20*, 12*

7, 8

4

9 11, 17

3 pin retainer 4 joint pin Ø133.5x570 5 peg 68x142 6 pin 25/16x155 7 pin 70/58x171 8 retaining ring 9 plug 10 securing device

10 11 pin 15/12x120 12 pin 40/34x307 13 pin 15/34x257 15 hex. head screw M 10x90-A 2-70 16 hex. nut M 10-A 2-70 17 locking clip 2.5 20 staple * remove transport safety device at commissioning

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces. *) EWN = works standard

6.12

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

20*, 13*

Description Side seal The side seals seal neighboring shield units off from one another.

In addition, they can be used for aligning one shield unit relative to the neighboring shield units.

The side seals are arranged on the canopy and the caving shield and are designed to be movable on the left side. They are guided by guiding pins and are constantly pressed against the neighboring shield with compression springs. With the help of hydraulic cylinders, the side seals can be extended and retracted.

Warning!

Risk of injury due to the unexpected movement of the side seal! The moving side seal is under spring pressure!

Never remove the connection elements of the side seal before the side seal is pulled together and secured with clamp clips.

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Caution!

Before commissioning the shield unit, the transport safety devices of the side seal must be removed.

For transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured with staples.

Fig. 55: Transport safety device, side seal 13

side seal, canopy

12 24

side seal, caving shield 11

24 20

Canopy side seal 12 pin 40/34x307 13 pin 40/34x257 20 staples DN 25

Doc. No.: 7420 248 000 BA 00

SSSU / 01

11

20

Caving shield side seal 11 transport safety devices 22x128 24 staples DN 12

6.13

Description Side seal, canopy Fig. 56: Side seal, canopy, dimensions

z H

L

W

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces.

Fig. 57: Side seal, items

112, 19, 23

a

15 8 16 6 17, 20 11, 22 1 18, 21 1 seal cylinder ZE-63/50-215 3 side seal, canopy, left 6 guiding pin 103x1065 8 guiding pin 103x625 10 pin 30/25x175 11 pin 28x93 12 pin 15/12x120 15 plug 16 compression spring 12x79x560 17 cylinder liner 103x105

18 cover plate 19 securing device 20 screw pin M 10x12 21 hex. head screw M 12x20-A 4-80 22 split pin 6.3x40 23 locking clip 2.5 24 staples DN 12 a bore for pin of the transport safety device (see Fig. 55)

*) EWN = works standard

6.14

Shield support 1295/3048-2x4083-1750

E

H 935

Caterpillar Global Mining Europe GmbH, Lünen 2012

L 4352 W 1540

Description Side seal, caving shield Fig. 58: Side seal, caving shield, dimensions L W H

L 2140 W 1525

H 975

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces.

Fig. 59: Side seal, caving shield, items

11*, 24*

11*, 24*

3

10, 23

8

16 1 17, 20 6 12, 22 1 seal cylinder ZE-63/50-215 3 side seal, caving shield, left 6 guiding pin 90x1050 8 guiding pin 10 pin 22x177 11 transport safety device 22x128 (see Fig. 55) 12 pin 28x74 16 compression spring 12x64x621

18, 21

17 cylinder liner 92x105 18 cover plate 20 screw pin M 6x8-14 22 spring dowel pin 23 locking clip 24 staples DN 12 * remove transport safety device at commissioning

*) EWN = works standard

Doc. No.: 7420 248 000 BA 00

SSSU / 01

6.15

Description Caving shield The caving shield protects the face area toward the caving area.

It is connected to the shield canopy and to the base frame via the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the shield canopy to provide stability for the hinge.

Fig. 60:

Caving shield, dimensions

W H

Fig. 61:

H 975

Caving shield, items

11, 14 7, 8, 12, 13

5

15

6

10

5 lemniscatic link pin 168.5x587 6 lemniscatic link pin 148.5x577 7 pin 70/58x171 8 retaining ring 10 securing device

11 pin 15/12x120 12 hex. head screw M 10x90-A 2-70 13 hex. nut M 10-A 2-70 14 spring clip 2.5 15 spring cotter 5

Notice!

Apply lubricant B6 as per EWN 7068*) to all connecting points and slide surfaces. *) EWN = works standard

6.16

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

L 2310 W 1680

E

L

Description Technical data of steel structure, end shield Device number 7420 248 000 00 01

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Securing from tipping Permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

15

Height, retracted . . . . . . . . . . . . . . . . . . . . mm

1295

Height, extended . . . . . . . . . . . . . . . . . . . mm

3048

Height adjustment . . . . . . . . . . . . . . . . . . . mm

1753

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

1067

Shifting ram stroke . . . . . . . . . . . . . . . . . . mm

1130

Change in length of the support connection / PF . . . . . . . . mm

-

Prop clearance in inclines . . . . . . . . . . . mm

930

Forepole of canopy . . . . . . . . . . . . . . . . . . mm

4550

Rear projection of canopy . . . . . . . . . . . . mm

1480

Canopy width including side seal . . . . . . . . . . . . . . . . . . mm

1700

Canopy length . . . . . . . . . . . . . . . . . . . . . . mm

6030

Caving shield inclination:

Doc. No.: 7420 248 000 BA 00

Support retracted . . . . . . . . . . . . . . . . . . . degrees

6.01

Support extended . . . . . . . . . . . . . . . . . . . degrees

55.18

Caving shield width, with side seal . . . . mm

1700

Base frame width . . . . . . . . . . . . . . . . . . . mm

1650

Total surface area of the skids . . . . . . . . cm2

42312

Support center distance . . . . . . . . . . . . . . mm

1750

Supporting force of support for average seam thickness of . . . . . . . . . . . mm

2500

a) at 276 bar setting pressure . . . . . . . . . kN

5736

b) at 360 bar nominal pressure . . . . . . . . kN

7482

Support resistance for each m2 of roof surface with average seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm

2500

a) at 276 bar setting pressure . . . . . . . . . kN/m2

500

b) at 380 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

561 / 652

SSSU / 01

6.17

Hydraulic cylinder Hydraulic cylinder The following section provides an overview of the design and the technical data of the props / cylinders. Supplemental information can be found in the spare parts catalog for the shield support or the hydraulic components listed in chapter 5.

Fig. 62:

Hydraulic cylinder Z5

Z3

Z2 Z1 Z2 Z3 Z4 Z5

Name Prop Lifting cylinder Stabilizing cylinder Shifting ram Seal cylinder

Dr. No. 8250 212 000 00 00 8241 530 000 00 00 8241 545 000 00 00 8241 529 000 00 00 8241 352 000 00 00

Z4

Type SD-4300-380-1040/2310 ZE-135/90-235 ZE-180/100-470 ZE-150/90-1130 ZE-63/50-215

Hydraulic prop, two-stage (Z1) The double-telescopic prop is double acting and designed for the same load-bearing capacity in all stages. Identical load capacity is ensured by a piloted check valve (floor valve) which is installed in the piston pipe.

The bottom and top of the prop are designed as a spherical joint.

This allows the prop to be joined to the support via a rotatable fastening. The head is fastened using two pegs each that are inserted into the holes in the retainer before the prop head is installed.

The pegs are secured in the second groove by a pin and locking clip. After the prop head is installed, the pegs are pushed into the holes of the prop head and secured in the first groove with a pin and locking clip.

The technical data can be found in the section “Technical data, hydraulic cylinders”.

6.18

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Z1

Hydraulic cylinder Fig. 63:

Double-telescopic prop, type SD-4080-380-1150/2640

21

e 2 4

b f

a

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

d

1

c 1 prop base 2 piston pipe 21 piston rod a piston space connection b annular space connection c safety cam (Z1) telescopic prop, double acting, 2-stage

Doc. No.: 7420 248 000 BA 00

d load ring 3000 kg e lubricating nipple f valve connection plate stroke upper stage 760 stroke lower stage 730

Type SD-4080-380-1150/2640 device no. 8250 209 000 00 00 Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1050

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2640

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1490

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

380 / 270

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

350 / 250

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

1134.1 / 573

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

172 / 82

Prop force at setting pressure, 276 bar . . . . . . . . . . . . . kN

3130

Prop force at setting pressure, 360 bar . . . . . . . . . . . . . kN

4083

Retracting force at 276 bar . . . . . . . . . . . kN

475

SSSU / 01

6.19

Hydraulic cylinder Warning!

Risk of injury due to pressurized fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never close the lowering connections on double acting props so that they are pressure-tight! Otherwise, pressure might build up in the annular space when extending the prop which is several times higher than the setting pressure.

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.

load prop

a) Piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop 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 prop 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 prop and the prop is pushed in by the nominal prop force. b) Piston pipe and piston rod extended: The force is transferred mechanically from the shield canopy via the prop 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 a).

lower prop

The pressurized fluid is connected to the return line under the middle prop via the control valve for the prop.

Both stages of the prop 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.

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.

6.20

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

set prop

E

Function

Hydraulic cylinder Design of hydraulic cylinders The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod.

Fig. 64:

Hydraulic cylinder, typical example

Type a)

2 1

3

5

4

1

4

6

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Type b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

4 guide bushing 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical data, hydraulic cylinders” section for the shield unit used.

Warning!

Risk of injury due to pressurized fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, pressure that is several times higher than the setting pressure can build up in the annular space when extending the cylinder!

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against loosening using clamping screws or a spring pin connection.

The operating fluid is fed through the connections either on the outer cylinder (type a) or on the piston rod (type b).

Doc. No.: 7420 248 000 BA 00

SSSU / 01

6.21

Hydraulic cylinder Lifting cylinder (Z2) Fig. 65:

Hydraulic cylinder, model ZE-135/90-235

L

a 2

1 1 cylinder tube 2 piston rod a annular space connection (Z2) lifting cylinder, double acting

6.22

b piston space connection L retracted 525 extended 760 stroke: 235

Type ZE-135/90-235, device number 8241 530 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

235

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

135

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

90

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

143.1

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

79.5

Thrust force at 276 / 350 bar . . . . . . . . . kN

395 / 544

Pulling force at 276 / 350 bar . . . . . . . . . kN

219 / 302

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

b

Hydraulic cylinder Stabilizing cylinder (Z3) Fig. 66:

Hydraulic cylinder ZE-180/100-470

60

60 L

2 1

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

a

1 cylinder tube 2 piston rod

L retracted 890 extended 1360 stroke: 470

a valve connection plate (Z3) stabilizing cylinder, double acting

Doc. No.: 7420 248 000 BA 00

Type ZE-180/100-470, device number 8241 545 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

470

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

180

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

100

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

254.5

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

175.9

Thrust force at 350 / 430 bar . . . . . . . . . kN

702 / 967

Pulling force at 276 / 380 bar . . . . . . . . . kN

485 / 668

SSSU / 01

6.23

Hydraulic cylinder Shifting ram (Z4) Fig. 67:

Hydraulic cylinder, type ZE-200/125-1130

62 L c 3 26

a

b

1

2 6

(Z4) shifting ram double acting, driven directly

6.24

a annular space connection b piston space connection d load ring 1000 kg L retracted: 1597 extended: 2727 stroke: 1130

Type ZE-200/125-1130, device number 8241 534 000 00 00 version with reed rod Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

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

200

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

125

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

314

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

191

Thrust force at 276 / 380 bar . . . . . . . . . kN

867 / 1193

Pulling force at 276 / 380 bar . . . . . . . . . kN

527 / 726

Shield support 1295/3048-2x4083-1750

Caterpillar Global Mining Europe GmbH, Lünen 2012

1 cylinder tube 2 reed rod 3 piston rod 6 screw fitting 26 plug-in elbow, Lumberg SKK24 (path measurement)

E

d

Hydraulic cylinder Seal cylinder (Z5) Fig. 68: Hydraulic cylinder, type ZE-63/50-215

30 L a 2

b

Caterpillar Global Mining Europe GmbH, Lünen 2012

E

1

1 cylinder tube 2 piston rod a piston space connection (Z5) seal cylinder, double acting

Doc. No.: 7420 248 000 BA 00

b annular space connection L retracted 440 extended 655 stroke: 215

Type ZE-63/50-215, device number 8241 352 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

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

63

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

50

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

31.2

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

11.5

Thrust force at 320 / 380 bar . . . . . . . . . kN

100 / 118.6

Pulling force at 320 / 380 bar . . . . . . . . . kN

37 / 43.7

SSSU / 01

6.25

Pressure relief valves 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 in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalog.

Tab. 13: Pressure relief valves, use of the various types Device no.

Spring-loaded

80

8220 042 080 00 00

Spring-loaded

360

8220 027 360 00 00

Spring-loaded

380

7337 486 380 00 00

Spring-loaded

420

7337 486 420 00 00

Caution!

The setting pressure of pressure relief valves must not be changed! Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance will endanger the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves with the same properties. Always compare with the hydraulic system diagram. Non-compliance will endanger the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Non-compliance can lead to leaks on the connector and endanger the operational safety of the hydraulic system. identification

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

The text code includes the following information: setting pressure, setpoint, the week the setting was made, the year the setting was made, person who made the last changes.

6.26

Shield support 1295/3048-2x4083-1750

E

Setting pressure in bar

Caterpillar Global Mining Europe GmbH, Lünen 2012

Design

Pressure relief valves Tab. 14: Text code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

Color coding is with either one or two colors. It indicates the range within which the setting pressure is. The following Fig. 69 shows a pressure relief valve marked with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

E

Fig. 69:

Pressure relief valve, example

Caterpillar Global Mining Europe GmbH, Lünen 2012

b

a

a color code b protective cap

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

Tab. 15: Color codes for pressure relief valves, overview

1)

Doc. No.: 7420 248 000 BA 00

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

Specification of the setting pressure in acc. with DIN 21557: 1/10 x nominal pressure in bar, “42” is equivalent to 420 bar, “08” is equivalent to 80 bar

SSSU / 01

6.27

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the mine floor level are at least 15 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

Fig. 70:

Angles  1 / 2

1 2

Tab. 16: Change angle  1 / 2 at height M Inclination  at height M

Shield ID no.

7420 247 000 00 01

1 in °

 in °

M in mm

6

0

1295 to 1700

15

15

>1700 to 3048

Caution!

Exceeding the permissible angles specified can lead to damage to the props and cylinders and their fastening elements as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the “canopy/caving shield” crosspoint moves correspondingly when the canopy is lowered or aligned/positioned.

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Only use hydraulic fluids for which you have a valid certificate issued by Caterpillar. Otherwise, there is a risk that the hydraulic system could be seriously damaged and result in the loss of warranty claims.

Only those hydraulic fluids for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption certificate from Caterpillar may be used for the operation of hydraulic components from Caterpillar. Caterpillar will not accept any warranty claims for any components which have been or are operated with a different hydraulic fluid.

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

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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 Caterpillar issues a certificate for a hydraulic fluid, the respective fluid must be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health, safety and environmental protection.

To perform the suitability test, original samples are required of the concentrate and the water that will be subsequently used when preparing the hydraulic fluid at the mine.

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

Furthermore, a chemical “fingerprint” of the concentrate is created in order to rule out or verify any possible changes in the composition of the concentrate if necessary.

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

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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 figure shows a typical certificate.

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Fig. 71: Certificate, example

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Permissible media 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 on a continual basis in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH value, concentrate content and microbial load.

The operator of the equipment must compile a hydraulic fluid maintenance plan for the specific application. The maintenance plan should be prepared in close cooperation with the manufacturer of the concentrate, and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed below should be checked at least once every week: pH value – setpoint: 7.5 to 9.5 Caterpillar Global Mining Europe GmbH, Lünen 2012

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concentrate content – setpoint: see certificate microbial load – setpoint:  105 col/ml In addition, the electrical conductivity, foaming and the working temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55C. During normal operation, however, an operating temperature of 45C should not be exceeded. A higher working temperature will reduce the stability of the emulsion and shorten the service life of the sealing material.

Quality of the process water for use for hydraulic fluids

The quality of the water used to create the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limit values shown in the table 17 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not complied with this should be taken into consideration when selecting a concentrate. Furthermore, water treatment may also be necessary.

However, the customer shall in any case provide a sample of the original water to permit the conduction of the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

for use as spraying water

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

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Permissible media limit values

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

Caution!

Using water that is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Only use water that complies with the specified limit values!

Limit value

Appearance, color, odor

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

Electrical conductivity

< 1800 S/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+ content

Not specified

Water hardness

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

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



1 mg/l

Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 m filtering according to DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

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

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

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Tab. 17: Properties of the process water, limit values

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

Important!

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

Greases grease A1

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

Tab. 18: Grease A1 Supplier

Make

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

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

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Behavior in the presence of water: . . . practically insoluble in water Application temperature range: . . . . . . -40 to +120C grease A2

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

Tab. 19: Grease A2 Supplier

Make

Base

NLGI class

Flashpoint in °C

Shell

Alvania E.P. grease 2

Lithium soap

2

205

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

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

Tab. 20: Grease A8 Supplier

Make

Base

NLGI class

Flashpoint in °C

Castrol

Molub-Alloy 3036/680-1

Lithium soap

1

210

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

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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. 21: Lubricating paste B3 Supplier

Make

Lubricant carrier

NLGI class

Flashpoint in °C

Gleitmolybdän

gleitmo 805

Lithium soap

2

220

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

Tab. 22: Lubricant B6 Supplier

Make

Lubricant carrier

Flashpoint in °C

Chesterton

Parting agent/lubricant 785

Paraffin base

132

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

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lubricant B6

Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 23: Tightening torques at tot. = 0.14 Thread 1)

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(mm)

Caterpillar Global Mining Europe GmbH, Lünen 2012

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

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

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

1) The dimensions listed in brackets are applied in exceptional cases only.

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

3) Only for expansion bolts with a reduced shaft diameter of 24.2 mm.

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

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Tightening torques

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For your information

Standards and directives

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

Standards and directives Applied standards and directives Tab. 24: Standards and directives, excerpt

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Designation

Date of issue

Title

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

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Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA-fluids in mining

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

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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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Identification of the shield Identification of the shield Name plate The main subassemblies of the shields are identified by a name plate.

Name plate, example

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Fig. 72:

1 manufacturer 2 SAP/order no.

3 date of manufacture 4 serial component no.

5 device number 6 number of props 7 prop force

Shield number shield number

The shield number serves as an identification feature. All shields are numbered consecutively. The shield numbers are on the skid, caving shield and canopy.

Fig. 73:

Example of shield number

BG-01

Tab. 25: Shield support, numbering

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Use

Shield number

Special design

End shield

BG-01 to BG-16

Moving side seal

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Identification of the shield

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