Cat Shield support 1676/3581-2X5341-2056 Operating Manual - PDF DOWNLOAD

ID-Nr. BI628629 3 of 9 Febr. 2014

Operation and Maintenance Manual Roof Support Serial-N°.

LWF11466 – LWF11669 LWB00675 – LWB00680

Doc-No.:

7420 209 000 BA 05

SAFETY.CAT.COM SAFETY.CAT.COM

© 2003 CATERPILLAR ALL RIGHTS RESERVED

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

Operating Manual Shield support 1676/3581-2X5341-2056 Doc. no.: 7420 209 000 BA 05

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 laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar.

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2014E 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 . . . . . . . . . . . . . . . . . . . . .

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

1.3 1.3 1.4 1.4

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

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

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

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

E

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

2.3 2.3 2.4

2.5 2.5 2.5

2.6 2.6 2.7 2.8 2.9 2.11 2.12

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

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

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

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

Load units; dimensions and weights . . . . . . . . . . . . . . . . . .

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

Shield transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3 3.3 3.4

3.5 3.5 3.5 3.7 3.8

4. Installation Pre-assembly of the shield units . . . . . . . . . . . . . . .

4.3

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

4.3

Supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing a link between connections . . . . . . . . . . . . . . .

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4.5 4.9

Requirements for the face hydraulic system . . . . .

4.10

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

4.11

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Table of content Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To be observed prior to startup . . . . . . . . . . . . . . . . . . . . . . .

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

Corrosion protection of hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 4.12 4.14

4.14

5. Operation 5.3 5.3 5.6

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

5.9

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

5.15

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

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

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

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

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

Arrangement of hydraulic components on the support . . .

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

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

Supply block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check valve, hydraul. piloted, for shifting ram . . . . . . . . . .

Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrohydraulic control unit and water valve unit . . . . . . . .

Electrohydraulic control unit and twin CV . . . . . . . . . . . . . .

Twin CV for dozer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid driver module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic for lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Sliding canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.16

5.18 5.18 5.19

5.20 5.20 5.22 5.30 5.31 5.32 5.33 5.34 5.35 5.35 5.36 5.36 5.37 5.37 5.38 5.38 5.39 5.40

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

5.43

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

5.44

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

5.46

Shield variant functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functions of the water valve unit . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Regular, scheduled damage assessment . . . . . . . . . . . . . .

5.47 5.49

5.50 5.50 5.51 5.51 5.52 5.52

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

Table of content Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Internal by-pass in props . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Defective or blocked filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.53 5.53 5.53 5.56 5.56 5.57 5.57 5.57

6. Technical Data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Sliding canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Steering device “canopy - canopy” . . . . . . . . . . . . . . . . . . . .

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

End shield, device number 7420 209 000 00 05 . . . . . . . . .

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

Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic prop, two-stage . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Shifting ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Technical data, hydraulic cylinder . . . . . . . . . . . . . . . . . . . .

6.4 6.6 6.7 6.11 6.13 6.15 6.17

6.18 6.18

6.21 6.21

6.22 6.22 6.24

6.26 6.27 6.27 6.28 6.28 6.29

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

6.31

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

6.33

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

6.34

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

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

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

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

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

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6.3

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6.34 6.36 6.38

6.40 6.40

Table of content 7. For your information Standards and guidelines . . . . . . . . . . . . . . . . . . . . .

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

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

7.3

7.5 7.5 7.6

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

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

7.3

Shield support 1676/3581-2X5341-2056

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 provides you with information about the structure of the manual and the symbols used in it.

Before starting work applicable operating manual

shield type

Using an operating manual that is not written for the product type at hand can result in a safety hazard for yourself and others.

Ensure that the data on the shield agrees with the data given in the operating manual.

This operating manual belongs to the: Shield support 1676/3581-2X5341-2056 * ID number 7420 209 000 00 05 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 product available at the place of operation. new operating manual

Send for a new operating manual immediately if the present 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, prepare the rise heading, perform assembly/disassembly work, operate the shields, correct malfunctions, perform daily routine work on the face, monitor/look after for the hydraulic system, perform maintenance work, perform repair work. supervisory personnel who: Supervisory personnel who: initiate the activities named above and/or supervise the activities named above.

* 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 operating manual

This operating manual contains general information on the safe and efficient handling of shield supports and provides you with important instructions on the work performed directly on or with the shield support.

Therefore, read this operating manual completely and at leisure.

Pay special attention to the safety instructions.

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

Try to memorize the symbols and their meanings.

Danger!

Points in the text marked with this symbol alert you to an imminent danger. Possible consequences are very serious injury or even death.

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

Notice!

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

Important!

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

Items in lists are marked with bullets.

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

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

1.4

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

E

Characters and symbols used

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

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 be exposed to dangerous situations, e.g., as a result of environmental influences, machine damage or operator errors.

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

Use only original spare parts from Caterpillar. Note that use of parts from other manufacturers will void the guarantee.

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

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

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

Personnel Operation The shield support may be operated only by trained personnel. 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 of the operating manual, especially the chapter on safety, must constitute a part of this training.

They must possess and furnish proof of adequate familiarity with the mechanical system, hydraulic system, and control technology.

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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 trained adequately for these particular requirements.

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

Caterpillar Global Mining Europe GmbH, Lünen 2014

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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 1676/3581-2X5341-2056

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

Use the shield only as intended.

Intended uses are: propping the roof 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 2014

– 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 All uses which are not expressly included in the list of “intended uses” are considered to be unauthorized uses and are not permissible with the shield.

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

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

Caterpillar does not accept any liability for damage resulting from any such unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and protective devices in a functional condition.

Observe the acoustic and visual startup warnings. Pay special attention to the startup warnings for the conveyor and for the mining equipment.

EMERGENCY STOP

support lockout switch

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

- Only applies for version with the electrohydraulic shield control system: Actuate the support lockout 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 longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep 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 sent by the control unit in the shield unit currently operated.

Shield support 1676/3581-2X5341-2056

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signaling systems and safety equipment

Maintain the lighting systems in a functional condition.

Caterpillar Global Mining Europe GmbH, Lünen 2014

lighting system

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

Never stand under unsecured or suspended loads.

Observe the specified 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 the transport. transport safety device

side seals,

E Caterpillar Global Mining Europe GmbH, Lünen 2014

Ensure that the transport safety devices have been correctly installed. In particular, ensure that the following are secured for transport: flippers, relay bars (both face side and gob side).

transporting

Connect the hoisting gear only at 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 replacement part drawings which are included in the replacement parts catalog. Nonstandard transport assemblies are shown in special figures which are added in 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 floor conveying devices. The center of gravity must be as low as possible, in order to prevent tipping of the transport unit.

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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 wedgesbetween the lemniscatic links stabilize the position of the caving shield

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Fig. 1:

transport safety device

If the shield is provided with movable side seals these are pretensioned 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 such that the locking pins either drop down or can be pulled out without the use of excessive force.

When removing the transport safety device of the flipper ensure that nobody is present in the swiveling area of the latter as the flipper may swing downward.

travel way

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

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

2.8

Shield support 1676/3581-2X5341-2056

Safety instructions Operation shield control

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep 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 capable of functioning, see also chapter 6 “Technical data”.

You may only operate the shield control system if you have extensive 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 2014

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. Ensure 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. This way you will be able to extend the relay bar assembly without obstacles and to advance the conveyor without problems.

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

On an inclined face, the conveyor must be anchored neighboring to the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. And it reduces the risk of the relay bar assembly jamming between the skids.

Hydraulic anchorages must always be charged to 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 with respect to the conveyor and parallel with respect to each other. Use the aligning devices or the side seals for aligning the shields.

Align the shields as early as possible. Use the aligning devices or the side seals for aligning the shields.

Early alignment prevents: getting under the canopy of the neighboring shield, canting 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 will be loaded excessively in the longitudinal direction, as this may cause damage due to excessive stress and strain on the components.

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

residual stroke

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

retracting the conveyor

If possible, pull the conveyor back by operating the respective 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.

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

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

raising the conveyor

Secure your working area against falling rock. This measure is especially important if the conveyor must be lifted on the coal face side.

Only use the points of attachment intended for that purpose.

Never attach loads to hydraulic cylinders or to 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 the entire length.

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

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Shield support 1676/3581-2X5341-2056

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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 points of attachment are undamaged before attaching a load. lifting tackle of adequate load-carrying capacity.

Maintenance Make sure that all safety and safety equipment of the shield units are complete and functional. 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.

Secure your working area over a wide range, in order to avoid endangering other persons.

Immediately replace damaged components affecting safety. Stop and lockout the respective 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 foreman without delay.

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

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

Do not make modifications or carry out conversions which might impair the safety of the shield. Caterpillar must be informed of all conversions 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, isolate 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 the continuation of the mining work does not affect the safe performance of the repair work.

Before disconnecting the shield from the conveyor, you must: arrange that the mining operation is either stopped completely or is done outside the required safety area, 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 contact between your skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids pose a very serious danger to 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. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repair

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

pressure relief valves

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

Carry out a visual inspection of all the hydraulic components at regular intervals. Check, in particular, that: the hoses are not pinched, the hoses have no bubbles or blisters, the hoses or the outer sheaths of the hoses are not abnormallyrigid or hard,

2.12

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

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

Safety instructions the outer sheathing of the hose is not damaged, the connectors are securely inserted into the coupling sockets, the connections are leak-tight.

Make sure no dirt enters the hydraulics system during repair work.

Dirt in the hydraulic system can cause serious damage to the whole system. Flush the hydraulic lines thoroughly before installing them.

Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the coupling socket to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Make sure the line is depressurized.

Secure the plug connectors of the hydraulic elements with the proper staples only. Always fasten the staples completely with both sides.

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

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

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permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

Replace hydraulic hoses only 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 have no visible signs of damage.

Fig. 2:

Example: hose line, identification

1 1 manufacturer 2 calendar week

2

3

4 3 year 4 max. working pressure

Never try to hold a hydraulic hose line that is thrashing about. Immediately depressurize the section in concern.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hose lines at the first suspicion of damage.

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2.13

Safety instructions installing hydraulic hose lines

Fit the hydraulic hose lines properly behind the brackets and clips provided for them.

Always install hydraulic hose lines so that they: always have a little slack, Fig. 3:

Installing hydraulic hose line, slack

are not twisted, Installing a hydraulic hose line, twisted

are not bent directly behind the connections (distance min.

1.5 x nominal diameter), Fig. 5:

Installing hydraulic hose line, bending

1,5 x d

d

2.14

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Fig. 4:

Safety instructions cannot chafe, Fig. 6:

Installing hydraulic hose line, crossing

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

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

When installing the hydraulic hose lines, make sure they cannot be: torn out, kinked, crushed, driven over or twisted by the movement of the equipment (Fig.: 7).

Fig. 7:

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Installing hydraulic hose line, connections on moving parts

2.15

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Safety instructions

2.16

Shield support 1676/3581-2X5341-2056

3

Storage and transport

Storage

Storage and transport This chapter contains important information on 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 the points in this chapter will also help you to simplify your day-to-day work.

Storage

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Storage of the equipment corrosion protection

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

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

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

moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, for example with tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs.

short-term storage

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

long-term storage

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

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

This inspection can be carried out by Caterpillar upon request.

natural aging

Even with proper storage, seals and hoses 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 analogously for the storage of hydraulic components that have already been in use. corrosion protection

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

If this is not done, then the hydraulics 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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Water-bearing parts, such as the parts for the water spraying system of a shield, must be completely emptied, and possibly also filled with an antifreeze fluid if required.

3.4

Shield support 1676/3581-2X5341-2056

Transport Transport Load units; dimensions and weights It is imperative that you observe the transport sheets. 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!

Use only load handling devices which comply with the technical and legal regulations for transporting loads.

Falling components can cause serious injury and death.

Use only suitable load handling devices.

Before transport freezing temperature

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with by emulsion (HFAE and HFAS) must be completely drained and filled with a corrosion inhibitor (e.g. MinetechTM Protection Fluid).

The transport of equipment at temperatures of -21C to -40C is only safe if certain requirements for these conditions have been taken into account in the design and production of the equipment.

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor conveying devices 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 poor roads, the transport vehicle speed must therefore be limited to maximum 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 or outdoor storage of the equipment during winter.

Unless these components or the complete equipment is protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully against transport damage and the connectors must be protected against 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 upon in close cooperation with the customer.

Tab. 1: Transport units

transport safety devices

Designation

Transport position

Complete shield unit

As for normal use

Remarks

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 listed transport safety device are provided on the transport units.

Tab. 2: Transport safety devices Component

Transport safety device

Canopy/skid

Chain

2

Face side

Chain

1

Gob side

Chain

1

Unused hydraulic connections are protected by protective caps or plugs

-

Quantity

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 in 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.

Caution!

If the lifting points on the caving shield and on the canopy are to be used to transport the assembled head drive, the canopy and skid must first be mechanically connected to each other using an additional transport safety device so that they cannot move apart.

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Hydraulic system

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Relay bar

Transport Shield transport Fig. 8:

Transportation of the end shields as complete unit

X3, X4 Sy

HE

S3

S1

Sx L

S2

X1

X2 S4 D

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S4 B

S1 bore hole, 2x on the face side on the skid, capacity: 15 000 kg S2 bore hole, 2x on the gobside of the skid, capacity: 15 000 kg S6

S6

S5

420 1040 1905

S5

S3 slot, 2x at the front of the canopy, capacity: 15 000 kg S4 load ring, 2x on the caving shield, capacity: 30 000 kg S5 slot, 2x at the front of the skid, capacity: 15 000 kg S6 load ring, 2x on the skid, capacity: 15 000 kg X1, X2 transport safety device for relay bar, face side and gobside X3, X4 transport safety device canopy/skid So center of gravity

Important!

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

Tab. 3: Shield support 7420 209 000 00 05, Dimensions and weight

Doc. no.: 7420 209 000 BA 05

Device number

L mm

W mm

H mm

S0 = Sx/Sy mm

Weight kg

7420 209 000 00 05

9 111

2 000

1 676

1 369 / 975

42 232

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3.7

Transport Transport safety device Transport position, shield, face side

Fig. 10:

Transport position, shield, on the side

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Fig. 9:

126

3.8

Shield support 1676/3581-2X5341-2056

Transport Fig. 11:

Transport safety device X3:Canopy/skid, X4:canopy/relay bar assembly, face side

126 X1 X3

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127

X4

126 chain 10x65 127 shackle A 0.6

x1 transport safety device canopy/relay bar assembly x3, x4 transport safety device canopy/skid

When the shield unit is supplied, the connections for the supply lines are bypassed using the hose lines. These are then later used for connecting to the neighboring shield.

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3.9

Transport Fig. 12:

Transport safety device, X2: Relay bar assembly, (gobside)

126 127

126 chain 10x65 127 shackle A 0.6

a caving flap

Pin assembly for relay bar assembly are sent separately in boxes.

Fig. 13:

Pin assembly

2,3

5 1

1 pin 85/60x355 2 ring

3.10

3 cover 5 locking clips 11x50

Shield support 1676/3581-2X5341-2056

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a

Transport Fig. 14:

Transport safety device, sliding canopy

a

126 127

Caterpillar Global Mining Europe GmbH, Lünen 2014

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126 chain 10x65 127 shackle A 0.6

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a sliding canopy

3.11

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Transport

3.12

Shield support 1676/3581-2X5341-2056

4

Installation

Pre-assembly of the shield units

Installation In this chapter, you will get 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 “Lubricating greases and pastes”.

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Caution!

Before putting the transport units of the steel structure together, all slide surfaces must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See Chapter 6, Section “Lubricating greases and pastes”.

Pre-assembly of the shield units The shield units are delivered completely preassembled. Accordingly, no further pre-assembly is required on the mechanics and hydraulics 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”.

Further information about this can be found in chapter 3 “Transport”. Failure to comply can lead to personal injury and property damage. 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 provided with different functions, their setup on the longwall 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 in the face, they should be labeled with a sequential number. They 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

Shield number on the skid, example

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Fig. 15:

The shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the left-hand skid on the shield.

Tab. 4: Allocation of the shield numbers

4.4

Use

Shield number

Device number

VG2 to VG4

7420 209 000 00 05 End shield

Shield support 1676/3581-2X5341-2056

Installation of the shield units Supply connections During installation, pressure can be applied to the individual shield using the so-called auxiliary supply and operated. The auxiliary supply must be connected to connections a and b (Fig. 17).

Fig. 16:

View of the control units

19

b

P a

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W R 1 2

1 electrohydr. control unit 2 water valve unit 19 supply block P pressure line, DN 40SS

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R return line, DN 50 W water line, DN 50 a PMC®-R b bracket

4.5

Installation of the shield units Fig. 17:

View of the auxiliary connections to the supply block (supply lines short-circuited for transport) 10 12c a

b 11a

29 P

c

W

R

10 HP ball valve DN 25, in the pressure supply line 11a HP ball valve DN 12, for auxiliary supply 12c HD-Kugelhahn DN 10, für Bedüsung 19 supply block

29 HP ball valve DN 10 P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a pressure line auxiliary supply b return line auxiliary supply c plug for auxiliary supply

Notice!

The auxiliary supplies a and b must be sealed with plugs c during normal operation.

For operating the shield with the help of the auxiliary supply, the shield functions must be activated via an additional external PMC®-R control unit. This is connected to the internal PMC®-R control unit via a corresponding cable (see separate operating manual for the PMC®-R control unit).

The connections for the auxiliary supply are on the right next to the supply block (see Fig. 17 and in Chapter 5, the hydraulic diagram, Fig. 33).

For utilization of the auxiliary supply, the connections P, R and W (see Fig. 17) on the supply block must with blocked with the hoses that will later be responsible for the connection with the neighboring shield (this corresponds as a rule to the status at the time of delivery). If the supply hoses cannot be connected up in this way, then the connections must be sealed with corresponding plugs.

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19

Installation of the shield units Proceed as follows to join the shields to one another:

. Close the HP ball valves, Item 11a and Item 10 (see Fig. 17). . Remove the plugs c from connections a and b (see Fig. 17) of the auxiliary supply.

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

. Then open the HP ball valve, Item 11a, again.

Make sure that the HP ball valves, Item 9 (see Chapter 5, Fig. 42 and 43), are also open on the prop control valves.

The shield is now movable via the external control units.

. Move the shield to the desired position.

In order to relieve the pressure hose,

. bypass the HP ball valve, Item 11a, and activate the function Caterpillar Global Mining Europe GmbH, Lünen 2014

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“Advance conveyor” briefly until the pressure hose is relieved (support is not yet connected to the conveyor).

Warning!

Pressure may build up in the return line due to incorrect operation. This must be relieved via the relief valve (Item 23a, see Fig. 18) by screwing in the vented cap screw. After relieving the pressure, this screw must be screwed all the way out again.

Make sure that all hose lines are depressurized before you release the connection lines on the distributor block.

Fig. 18:

Plug cap on supply block, at rear 13

6 a

23a

19

6 RV, NW 25, in the return line 13 PRV, 80 bar 19 supply block

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23a plug DN 10 with pressure relief a vented cap screw

4.7

Installation of the shield units . Relieve the connections of the auxiliary supply. . Disconnect the connection lines of the auxiliary supply and seal the connections with the plugs.

. Release the three connection lines P, R and W on the distributor block and connect them to the neighboring shield.

Establishing a link between connections The hydraulic connections to the shield units are designed as plugtype connections in accordance with DIN 20043.

additional equipment

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

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

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

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.

4.8

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control unit

The supply block for supplying the shield hydraulics is located in the middle under the canopy between the two props. The connection to the supply block of the neighboring support is made using three hose lines: one pressure line (DN 40SS), one return line (DN 50) and one water line (DN 50), see also Fig. 16, and the hydraulic circuit diagrams in Chapter 6 of this manual.

Caterpillar Global Mining Europe GmbH, Lünen 2014

hydraulic system

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

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

Contamination Class 18/14 pursuant to ISO 4406.

pressure, permissible

Nominal pressure . . . . . . . . . . . . 320 bar Admissible tolerance . . . . . . . . . ¦ 10% of nominal pressure If the face hydraulic system is designed such 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.

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Caution!

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

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

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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 occur.

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 1676/3581-2X5341-2056 ID No.:

7420 209 000 00 05

a minimum pressure of 30 bar holds for the water spraying system.

The minimum pressure holds for all shields.

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Warning!

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

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

4.10

Shield support 1676/3581-2X5341-2056

Commissioning Commissioning Warning!

The initial startup 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 startup Commissioning may only be carried out by trained and qualified personnel. If the support is being used for the first time, it is absolutely imperative that the commissioning be carried out under the direction of the Caterpillar installation service.

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Please observe the following items: Caterpillar Global Mining Europe GmbH, Lünen 2014

Mechanical:

. 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 brackets of the electrohydraulic control unit so that the symbols are clearly legible.

. Check all mechanical connections on the shield units.

Notice!

Check the plugs of the relay bar assembly.

When 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.

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

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 support.

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

. Check the hydraulic supply pressure.

. Check all operation elements to make sure they are working properly. Test whether the function is correctly executed when the corresponding operating element is activated. signaling and lighting systems, information plates Important!

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

. Check all signaling systems. . 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 function 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 together perfectly.

Warning!

Bent support canopies may not project into the mining area.

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Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

pressure under the piston of a prop can be queried on the PMC®-R control device. 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

Corrosion protection of hydraulic 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 for completeness and correctness, especially all supply lines of the shield hydraulics.

Caterpillar Global Mining Europe GmbH, Lünen 2014

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Warning!

Shutoff valves must not be installed into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in persons being seriously injured or even killed.

. 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.

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

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

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4.13

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Corrosion protection of hydraulic

4.14

Shield support 1676/3581-2X5341-2056

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 had instruction on the actual control 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 2014

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Warning!

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

The regulations concerning the safe operation of your mine must be strictly followed. 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.

To warn the face crew and for crew communication, intercommunication systems must be provided.

travel way

The minimum dimensions for the travel way specified must be maintained 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 for low seam heights.

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

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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 travel way must be marked at the ends of a longwall by a sign. roof support work

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

work in the mining area

Work in the mining area must not be carried out unless the mining equipment and the face conveyor have first been locked-out and secured to prevent restarting. 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 shield units are not equipped with flippers, some other kind of protection must be applied for sufficient shielding of 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 barricades, 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.

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Caterpillar Global Mining Europe GmbH, Lünen 2014

A travel way (minimum dimension, country-specific)

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H

Requirements repair work

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

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

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

If in exceptional cases, the 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 2014

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Safety equipment increases security 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 “Requirements for the water spraying system”).

Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily, depending on the operating state of the system, for example, when pushing 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 an inclined face, the conveyor must be anchored neighboring to the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. This allows you to reduce 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 bracing 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.

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5.5

Requirements Safety requirements automatic mode

Exercise special care and caution when traveling 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 system of the currently controlled shield.

Press the "Support lockout" 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 must not lower or advance a shield unit if there are persons 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 in the lower section in the case of inclined faces. The neighboring control offers the operator in the above-lying shield unit 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 abutments for conveyor steering devices.

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

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Caterpillar Global Mining Europe GmbH, Lünen 2014

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 body parts 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 plough

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

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Fig. 21:

Shield unit with shearer

Shield unit with plough

Shield unit with shearer

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

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

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

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5.7

Requirements control system, hydraulics

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 remain free to move. They may not be squeezed or overstretched. Make sure the hose lines are bundled properly.

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

The shield canopy and caving shield must be mechanically secured against falling when 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 are to be replaced. Analogously, this also applies for work on the hinges of the shield unit.

damage, spare parts

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

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

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Caterpillar Global Mining Europe GmbH, Lünen 2014

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

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Shutoff valves may not be installed in the return lines.

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

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

Definition of viewing direction, schematic diagram

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Fig. 22:

A looking toward coal face B looking toward gob general

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

Well-trained operating personnel, knowledge 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 control unit, it is imperative that the operator be 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 abutments for anchoring devices.

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

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

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5.9

Operation of the shield support shield canopy position

The shield units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible. Within the framework 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 especially applies for stabilizing cylinders, their mounting elements and fulcrum points on the shield canopy and caving shield.

Fig. 23:

Shield support in normal position

Caterpillar Global Mining Europe GmbH, Lünen 2014

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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!

Guide 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.

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Shield support 1676/3581-2X5341-2056

Operation of the shield support Fig. 24:

Shield support with extremely inclined shield canopy.

1

s1

M

s 

2

2

Caterpillar Global Mining Europe GmbH, Lünen 2014

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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 toward 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 inclination toward roof falls, the automatic positive setting function could lead to the stabilizing cylinders not having enough residual stroke or that they even are completely extended.

For this reason, in such or similar cases, move the support without the automatic positive setting.

Caution!

Keep the canopy from being excessively inclined by filling out the roof falls, for example, or by underpinning smaller roof falls with a horizontally positioned shield.

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

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5.11

Operation of the shield support Caution!

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

Since angle changes in 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 floor and roof, or fill breakouts in the roof.

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.

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Fig. 25:

WRONG

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

Fig. 26:

R i g h t : fill out roof falls

RIGHT

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Shield support 1676/3581-2X5341-2056

Operation of the shield support When underpinning a step in the roof, ensure that a shield canopy angled downward does not 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. support range of adjustment/ changing face thickness

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

The support must be operated so that there is always sufficient residual stroke remaining for lowering the shield unit. Otherwise, the shield unit can get stuck between the roof and floor and be seriously damaged by suddenly occurring load surges, caused by a rock burst, for example. Load surges 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 withdrawing the shield unit can be maintained by:

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keeping the longwall opening sufficiently large using the mining equipment, avoiding the accumulation of debris and fine coal on the floor, removing accumulated piles 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 done without obstacles and the subsequent return operation is not hindered for the conveyor. Also, aligning operations can be carried out more easily.

If the seam height increases considerably and the hydraulic stroke is not sufficient, the props must be extended in time or replaced by props with greater stroke. Here, only approved parts can be used.

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 by using side seals and aligning devices. This prevents a shield canopy from underpinning its neighboring unit, often causing considerable damage.

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

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

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

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5.13

Operation of the shield support On an inclined face, the conveyor must be anchored against the support. This way, you can prevent the conveyor from shifting to the side with respect to the support. This way you lessen the danger of jamming the relay bar assembly in the base frame, which would hinder the shield advancing.

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.

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

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

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

Warning!

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

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

Caution!

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

Observe the following safety regulations:

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

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

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

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the 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.

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5.15

Work safety Shield components Main components Fig. 27:

Shield, lateral view b

c

a 51

12 12a

f d

g

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41 Caterpillar Global Mining Europe GmbH, Lünen 2014

61 e 2

31

2 skid 12 canopy 12a sliding canopy 31 caving shield 41 prop 51 stabilizing cylinder 61 hydraulic system Fig. 28:

a PMC®-R control unit b electrohydraulic control unit c water valve unit d supply block e lifting cylinder f bracket g rubber sealing

Shield variants, rear view

1

6 3

2

1 caving shield 2 caving flap

5.16

3 holding eyelet 6 load ring RBS-30

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Work safety Tab. 5: Shield support 7420 209 000 00 05 subassemblies used

Item

Designation

ID No.

Approximate weight in kg

Remarks

0002

Skid

7420 209 300 00 02

Shifting ram 15 100 Lifting cylinder Relay bar assembly

0012

Canopy

7420 209 400 00 02

11 700

0031

Caving shield

7420 209 800 00 01

6 300

0041

Hydraulic prop

8250 169 000 00 00

1 850

0051

Stabilizing cylinder

8241 348 000 00 00

223

0061

Shield control system - 10 functions -

8112 412 000 00 00

Electrohydr. control unit Water valve unit 379 Lines Water spraying system Brackets

Caving flap

7420 209 891 00 00

134 on caving shield

holding eyelet

7420 209 801 02 00

2 054 on caving shield

Sliding canopy Dozer cylinder

8241 350 000 00 00 8241 351 000 00 00 7420 209 380 00 01 7420 209 441 00 00 8241 584 000 00 00

8154 118 000 00 00 8401 007 250 00 00 8112 412 010 00 00 8112 412 020 00 00 8112 412 030 00 00

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Important!

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

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5.17

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

Ensure that the ball valve is engaged at all times.

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

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

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

Fig. 29:

2-way ball valve, open and closed

open

Flow for medium enabled

5.18

Flow for medium stopped

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closed

Overview of shield hydraulics Functions of the HP ball valves 2-way ball valve The following ball valves are open during normal operation: 9, 10, 12a, 12b, 30 The following ball valves are closed during normal operation: 11a, 11b 12c, 29

Tab. 6: HP ball valves Color

Designation

9

Red

HP ball valve, DN 20

10

Red

HP ball valve, DN 25

11a

Red

HP ball valve, DN 12

11b

Red

HP ball valve, DN 12

12a

Red

HP ball valve, DN 10

12b

Red

HP ball valve, DN 10

12c

Red

HP ball valve, DN 10

29

Blue

HP ball valve, DN 10

30

Blue

HP ball valve, DN 20

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Item

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Function Is used for blocking the pressure supply to the prop piston space

Use During maintenance work on the prop and any prop disassembly Is used for blocking the pressure During maintenance and repair supply line to the shield work on the shield For moving the shield during Pressure supply during startup and startup and for connecting hydraulically operated auxiliary for auxiliary devices devices Used for shutting-off the water For spraying when backflushing supply for filter the filter Interrupts the stabilizing cylinder/ To deactivate the compensating compensating valve connection function of the stabilizing cylinder Used for shutting-off the pressure Used for holding the baselift cysupply to the baselift (lifting) cylinder in a certain position and linder for deactivating the lift function Used for blocking the water supply In order to deactivate the water and for the water spraying system spraying function Used for shutting-off the water For cleaning soiled components supply Used for shutting-off the water In order to deactivate the funcsupply tion of the water spraying system

5.19

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

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

Arrangement of hydraulic components on the support The following table indicates the hydraulic components for the support.

Tab. 7: Hydraulic components

02 03

1

04

1

05

1

06

1

07

1

08

1

09

2

10

1

11

2

12

2

Arrangement 1x between the props under the canopy 1x left next to the control unit 1x on the electrohydraulic control Accumulator cartridge unit (1) 1x under the canopy behind the CV DN 13, hydraulically piloted right prop Twin CV, NG 4 1x on the stabilizing cylinder (Z3) 1x on the supply block (19) next to CV, NW 25 the water filter (7) Water filter DN 20 1x near the supply block (19) Double filter, can be back1x in front of the right prop under flushed the canopy HP ball valve, DN 20 2x1 on prop respectively, face side red handle HP ball valve, DN 25 1x on the supply block (19) red handle a) 1x on the supply block (19) HP ball valve, DN 12 b) 1x next to the double filter (8) red handle

HP ball valve, DN 10 red handle

13

1

PRV, 80 bar

14

4

PRV, 420 bar

15

4

PRV, 380 bar

16 18

1 1

Twin CV, DN 10 CV, NW 20

19

1

Supply block

20

1

21

1

22

1

Hose lines Water spraying system accessories Brackets and accessories

a) 1x on the right prop on the compensating valve for the stabilizing cylinder b) 1x next to PRV (15b) to the left under the canopy c) 1x at the right on the supply block (19) 1x behind the supply block (19) a) 2x1 on each prop, gobside b) 2x on the stabilizing cylinder (Z3)

Remarks On a bracket

For shifting rams For stabilizing cylinder (Z3) In the return line In the water feed line Manually actuated In the pressure supply line In the pressure supply line a) In the auxiliary supply b) For spraying when backflushing the filter a) for stabilizing cylinders b) for lifting cylinders

c) for water spraying system,

In the return line a) in the piston space, high flow rate b) for the piston and annular space side a) 1x on the CV, piloted (4) a) for shifting ram (Z2) b) 1x under the canopy, next to HP b) for lifting cylinder (Z4) ball valve (12b) c) 2x on the dozer cylinder (Z5) c) for dozer cylinder (Z5) 1x on the dozer cylinder (Z5) for dozer cylinder (Z5) 1x behind the water valve unit (2) In the water feed 1x centered under the canopy in On a bracket front of the two props Subassembly group Subassembly, for face and transition shield only Subassembly group

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

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01

Quantity Designation Electrohydraulic control unit, 1 10 functions 1 Water valve unit

Caterpillar Global Mining Europe GmbH, Lünen 2014

Item

Operation of the shield hydraulics

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Item

Quantity Designation

23

5

24

1

25

1

28

2

29

1

30

1

35

3

36

2

37

2

S1

1

Z1 Z2 Z3 Z4 Z5

2 1 1 1 1

Arrangement a) 1x on the supply block (19) b) 2x on the twin CV (5) on the Plug DN 10 with pressure relief stabilizing cylinder (Z3) c) 2x on PRV (15c) Prop CV, NG 20 compact 1x on the left prop, face side 1x on the right-hand prop, face Prop CV, NG 20 compact side Pressure gauge port 2x1 on prop respectively, face side HP ball valve DN 10, 1x next to the supply block (19) unblue handle derneath the canopy, at PMC®-R 1x on the right next to the supply HP ball valve DN 20, block (19) in front of the water blue handle filter (7) a) on each prop CV (24, 25), face side Glycerine pressure gauge b) 1x on the supply block (19) On the twin valve (5) on the stabilNipple izing cylinder (Z3) On each prop on the PRV (14), Socket DN 20 gobside On the prop CV, only on the right Pressure sensor prop Prop Shifting ram Stabilizing cylinder Baselift cylinder (lifting) dozer cylinder

Remarks a) In the return line b) In the piston and annular space c) for dozer cylinder (Z5) Without compensating valve With compensating valve

In the spray line In the water circuit

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

Doc. no.: 7420 209 000 BA 05

VSSE / 01

5.21

Operation of the shield hydraulics Shield hydraulics Fig. 30:

Shield hydraulics, arrangement (1) Image caption: see Table 7 Z

View V

V 8

W

3

29 View W

2

1

15b

X

View Y rotated

12b

View X rotated

9

35a

9

28

35a 12a 28

25 View Z

24

10

35b 12c

22 11a

30

5.22

19

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Y

Operation of the shield hydraulics Fig. 31:

Shield hydraulics, end shield, arrangement (2) Image caption: see Table 7

21

23c 13 14b, 37 7

23a

11b

6

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

a

15c

15c 16

4 18 15a 14b 5, 36

23b

a PRV 520 bar

Doc. no.: 7420 209 000 BA 05

VSSE / 01

5.23

Operation of the shield hydraulics Fig. 32:

Electrohydraulic control unit functions, symbol plates

10 X10

9

10

X9 8

9 X8 8

7

X7

7 X6

6

6

X5

5

5

X4 4

X3

3

4

X2 3

2

X1

1 X2

1

T SP

Electrohydraulic control units with 10 functions, 2 functions for water valve unit 1

2

3 5 4 6

7

8

9 11 10

12

Tab. 8: Electrohydraulic control units, allocation of functions Function, designation

Function No. for

Advance shield

1

Extend prop

2

Slide conveyor

3

Extend baselift cylinder

4

Extend stabilizing cylinder

5

Retract stabilizing cylinder

6

Extend sliding cylinder

7

Retract sliding cylinder

8

Conveyor pullback

9

Retract prop

10

Water valve unit

5.24

Roof timbering sprinkling system

11

Water spraying system, face side

12

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

2

2 P

Z5

Z5

15c

15c 23c

23c

16

PTO

Shield hydraulics Image caption: see Table 7

sliding cyl.

Fig. 33:

sliding cyl.

Operation of the shield hydraulics

11a

12c 35b 19

29

3

DN 40-SS P DN 50 W DN 50 R

W1

23a

W

P

25 mm

11b

7 30

18

a

10 9 8 7 6 5 4 3 2 1 2 P T

6

8

W1

W2

P

X2

X2

X4

X6

X8

X10

E Caterpillar Global Mining Europe GmbH, Lünen 2014

R

P

workingpressure 320 bar.

13

X1

X3

X5

X7

X9

W2

10

W

1

2

3

4

5

6

7

8

9

10

SP

1

2

21 lifting cyl.

Z4

watercurtain 15b 12b

s i

20

28

4

12a

25

leg

24

14a

23b

37

36

Doc. no.: 7420 209 000 BA 05

14a 37

Z3 Z1

link cyl.

Z1 5 23b

VSSE / 01

35a 9 S1

leg

15a

waterspray canopy

pi

35a 9 28

D.A.ram cyl.

Z2

36

a leakage 14b

5.25

Operation of the shield hydraulics Fig. 34:

Hydraulic lines (1), overview Image caption: see Table 7 13* DN10 30x5, 2200lg 23b

12*

2x 36

Z3 14b

Z2

10*

7*

DN10

DN10 - 4SP

DN10

17*

DN12

11*

DN10

DN10

18

2 SP

DN10

E

DN10 DN10

3 13 23a

6

18* 29

11b

DN10

19

DN10

30

DN50 DN50 DN40SS

DN10

7

50x5, 1300lg DN25

DN20 DN20

DN10

40x5, 1400lg

DN20 DN10

11b

14*

DN25

1 DN12 DN10

DN10

2*

DN12

12b

11*

1*

8

DN10

35a 15b

DN20

9*

28

10

DN10 35b 12c

Z5

DN10

DN10

DN10

DN10

DN10

DN10

DN10 DN10

Z5

16

DN10

DN10

15c 15c 23c 23c

1* hose lines 2* plug-in parts 7*-19* protective hose

5.26

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

17*

24

40x5, 2600lg

DN20

DN10

19*

DN10 DN10

Z1

9

35a

Z4

25x3, 2800lg

28

9

25

25x3, 2800lg

50x5, 2400lg

DN25

12a

40x5, 2600lg

Z1

DN10 25x3, 2400lg

25x3, 2600lg

14a 37

DN10 25x3, 700lg

DN20

37 14a

25x3, 2600lg

10* DN10 DN20 DN12

25x3, 1000lg

DN20

DN10

14b

DN10

4

15* DN12

30x5, 600lg

DN10 DN10

DN12

15a

8*

23b

5

40x5, 2300lg

Operation of the shield hydraulics Fig. 35:

Water spraying system accessories, overview Image caption: see Table 7

7*

7* DN10

6*

6*

30x5, 2200lg 23b

5

23b

40x5, 2300lg 2x 36

DN10 DN10

Z1 24

40x5, 2600lg

DN20

25x3, 2800lg DN10

2

DN10 DN10 DN10

13 23a

6

DN20

DN50 DN50 DN40SS

11b

29

DN10

19

DN10

30

DN10

DN10

50x5, 1300lg DN25

1 DN12 DN10

DN20 40x5, 1400lg

DN20 DN10 DN25

7

18

SP

3

10

8* ,1*

8* ,1*

DN10 35b 12c

Z5

DN10

DN10

DN10

DN10

DN10

DN10

DN10 DN10

Z5

8* ,1*

3*, 7*

DN10

DN10

15c 15c 23c 23c

1* water spraying fitting DN10 3* spray distributor 6* spray distributor

VSSE / 01

8* ,1*

16

3*, 7*

Doc. no.: 7420 209 000 BA 05

12b

DN10

11b 8

DN12

DN10

DN12 DN10

28 35a 15b

DN20

DN10

DN10

40x5, 2600lg

Z4

9

35a

25x3, 2800lg

50x5, 2400lg

DN25

E Caterpillar Global Mining Europe GmbH, Lünen 2014

28

25

9

12a

DN10 25x3, 2400lg

25x3, 2600lg

Z1

DN10

DN10

14a 37

DN10 25x3, 700lg

37 14a

Z3 14b

Z2

DN20

DN10 DN20 DN12

25x3, 1000lg

DN10 - 4SP

8*

DN20

DN10

DN10 DN10

4

14b

25x3, 2600lg

30x5, 600lg

DN12

DN12

15a

7* nozzle, complete 8* solid steel nozzle

5.27

Operation of the shield hydraulics Fig. 36:

36, 42

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

36, 42

Bracket and accessories (1), overview

3 31, 41

10

38, 43

2

4 40

16 18, 45 1 12 13 32, 41

35, 42

35, 42

29

5.28

1 bracket for the control unit 2 bracket for the double backflush filter 3 bracket on the supply block 4 bracket for the PMC®-R 10 bracket 12 support 13 support 16 attachment tein check valve 18 stud bolt M 10x57 29 cyl. head screw M 10x50-1.4401 31 hex. head screw M 10x25-A 2-70 32 hex. head screw M 10x75-A 2-70 35 hex. head screw M 12x55-A 2-70 36 hex. head screw M 12x50-A 2-70 38 hex. head screw M 16x160-A 2-70 40 hex. nut M 10-A 2-70 41 hex. nut M 10-A 4-80 42 hex. nut M 12-1.4471 43 hex. nut M 16-A 2-70 45 spring clip 2.5

Shield support 1676/3581-2X5341-2056

Operation of the shield hydraulics Bracket and accessories (2), overview

8

9

6

7

15

14

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 37:

30

30 6 protection cover for prop valve, right 7 protection cover for prop valve, left 8 support

Doc. no.: 7420 209 000 BA 05

VSSE / 01

9 support 14 bracket, left 15 bracket, right 30 cyl. head screw M 10x55-A 2-70

5.29

Operation of the 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. electrohydraulic control unit 10 functions, electrohydraulic water valve unit, 2 functions, PMC®-R control unit.

Important!

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

View of the control units

19

b

P a W R 1 2

1 electrohydr. control unit 2 water valve unit 19 supply block P pressure line, DN 40SS

5.30

R return line, DN 50 W water line, DN 50 a PMC®-R b bracket

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 38:

Operation of the shield hydraulics Supply block Fig. 39:

View of the supply block 10 12c a

b 11a

29 P

c

W

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

R

19

10 HP ball valve DN 25, in the pressure supply line 11a HP ball valve DN 12, for auxiliary supply 12c HD-Kugelhahn DN 10, für Bedüsung 19 supply block

Doc. no.: 7420 209 000 BA 05

VSSE / 01

29 HP ball valve DN 10 P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a pressure line auxiliary supply b return line auxiliary supply c plug for auxiliary supply

5.31

Operation of the shield hydraulics Fig. 40:

View from under the supply block 30 7

13 10 11a 23c 23a

19

R

W P

6 RV, NW 25, in the return line 7 water filter in the water supply 10 HP ball valve DN 25, in the pressure supply line 11a HP ball valve DN 12,

for auxiliary supply 13 PRV 80 bar, in the return line 19 supply block 23a plug DN 10 with pressure relief 23c plug DN 10 with pressure relief

30 HP ball valve DN 20, blue, in the water circuit P pressure line, DN 40SS R return line, DN 50 W water line, DN 50

Check valve, hydraul. piloted, for shifting ram Fig. 41:

View under the canopy behind the right prop on the piloted CV

4

15a

4 CV, hydraul. piloted, for shifting ram

5.32

15a PRV 380 bar, for shifting rams

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

a

E

6

Operation of the shield hydraulics Prop Fig. 42:

Left prop, with and without cover, view from the face side 35a 9 28

a

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

24

9 HP ball valve DN 20, in the pressure supply line to the prop 24 prop control valve Fig. 43:

28 pressure gauge port 35a pressure gauge a cover

Right prop, view from the end side, with and without cover

b 28

S1 12a

35a

9

a

25

9 HP ball valve DN 20, in the pressure supply line to the prop 12a HP ball valve DN 20, on the compensating valve for stabilizing cylinder 25 prop control valve

Doc. no.: 7420 209 000 BA 05

VSSE / 01

28 pressure gauge port 35a pressure gauge S1 pressure sensor a compensating valve b cover

5.33

Operation of the shield hydraulics Fig. 44:

Prop, view from the gobside

a 14a

Electrohydraulic control unit and water valve unit Fig. 45:

View of the electrohydr. control unit and water valve unit

1 2 3

a 1 electrohydr. control unit 2 water valve unit

5.34

3 accumulator cartridge

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

14a PRV 420 bar, piston space a PRV 520 bar, annular space

Operation of the shield hydraulics Electrohydraulic control unit and twin CV Fig. 46:

View of the electrohydr. control unit and twin CV

16 2

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

1

1 electrohydr. control unit 2 water valve unit

16 twin CV DN 10

Twin CV for dozer cylinder Fig. 47:

View of the twin CV

23c

23c

15c

15c

16

1 electrohydr. control unit 2 water valve unit 15c PRV 380 bar

Doc. no.: 7420 209 000 BA 05

VSSE / 01

16 twin CV DN 10 23c plug DN 10 with pressure relief

5.35

Operation of the shield hydraulics PMC®-R Fig. 48:

Bracket for PMC®-R

b

3

c d

a 5

1

4

E

a PMC®-R b emergency stop switch c support lockout switch d solenoid driver module

Caterpillar Global Mining Europe GmbH, Lünen 2014

1 bracket 3 cyl. screw M12x55-A 2-70 4 hex. head screw M12x30-A 4-80 5 hex. nut M 12-A 4-80

Solenoid driver module Fig. 49:

Solenoid driver module b

c

29

a

29 HP ball valve DN 10, in the spray line

5.36

a PMC®-R b solenoid driver module c PMC®-R bracket

Shield support 1676/3581-2X5341-2056

Operation of the shield hydraulics Double filter Fig. 50:

End shield - View under the canopy, to the right behind the prop on the double filter

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

8

8 double filter, can be backflushed

Hydraulic for lifting cylinder Fig. 51:

Hydraulic for lifting cylinder

12b

15b

12b HP ball valve, DN 10, for baselift cylinder 15b PRV 380 bar, ffor baselift cylinder

Doc. no.: 7420 209 000 BA 05

VSSE / 01

5.37

Operation of the shield hydraulics Stabilizing cylinder Fig. 52:

Stabilizing cylinder

a

23b

14b

14b 23b

Z3 Stabilizing cylinder a spray distributor

Caterpillar Global Mining Europe GmbH, Lünen 2014

5 twin CV, NG 4 14b PRV 420 bar 23b Plug DN 10 with pressure relief

E

5

Z3

Dozer cylinder Fig. 53:

View of the dozer cylinder

a

Z5 Z5

b Z5 docer cylinder a spray distributor

5.38

b sliding canopy

Shield support 1676/3581-2X5341-2056

Operation of the shield hydraulics Sliding canopy Fig. 54:

Sliding canopy

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

a

Z5 Z5 dozer cylinder

Doc. no.: 7420 209 000 BA 05

VSSE / 01

a Sliding canopy

5.39

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

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

Fig. 55:

Plug DN 10 with pressure relief

Open pressure relief: screw in screw

Close pressure relief: screw out screw

b

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

b O-ring

Important!

Check the porosity of the sealing ring (b) regularly. Just to make sure, you can cover the ring with a rag to prevent hydraulic fluid from spraying out.

The shield has five plugs DN 10 with pressure relief: on the supply block (19), 2x on the twin check valve (5) on the stabilizing cylinder (Z3), 2x on the twin check valve (16) on the dozer cylinder (Z5).

5.40

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

a

Operation of the shield hydraulics The plug with pressure relief on the supply block is for reducing any pressure in the return line. This can be necessary for instance when the supply line connections have been bypassed for transport and increased pressure has built up in the return line during installation.

Fig. 56:

Plug cap on supply block, at rear

13

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

6

23a

19 6 RV, NW 25, in the return line 13 PRV, 80 bar 19 supply block Fig. 57:

23a plug DN 10 with pressure relief a pressure relief

Plug (lateral) on the stabilizing cylinder

23b

Z3

5 5 twin CV 23b plug with pressure relief

Doc. no.: 7420 209 000 BA 05

VSSE / 01

Z3 stabilizing cylinder

5.41

Operation of the shield hydraulics Fig. 58:

Plug (lateral) on the stabilizing cylinder

5 23b

23b

5 twin CV 23b plug with pressure relief Fig. 59:

Z3 stabilizing cylinder

Plug (lateral) for the sliding cylinder

23c

23c

15c

15c 16

15c PRV 380 bar 16 twin CV

5.42

23c plug with pressure relief

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Z3

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

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

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

backflushing

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid) the frequency of backflushing cannot be predetermined. We recommend backflushing both filters routinely once per shift.

Warning!

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

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

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

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

Fig. 60:

View of the double filter

8

B

A

B

A

8 double filter, can be backflushed A normal operation: both levers in position “A” B backflushing: one of the levers in position “B”

Doc. no.: 7420 209 000 BA 05

VSSE / 01

5.43

Repair and emergency operation 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 shutoff 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 instead.

Caution!

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

The drawings Fig. 61 and 62 show the position of the PMC®-R control unit and the electrohydraulic control unit on the support.

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

5.44

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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 work instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury.

E

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

Repair and emergency operation Fig. 61:

Front view of control units (supply lines short-circuited for transport)

19

b

P a W R 1

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

2

R return line, DN 50 W water line, DN 50 a PMC®-R b bracket

1 electrohydr. control unit 2 water valve unit 19 supply block P pressure line, DN 40SS Fig. 62:

View of the electrohydr. control unit and the water valve unit

1 2 3

a 1 electrohydr. control unit 2 water valve unit

Doc. no.: 7420 209 000 BA 05

VSSE / 01

3 accumulator cartridge

5.45

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

The meaning of the symbols and functions are described below.

Fig. 63:

Functions of the electrohydraulic control unit, symbol plates

8 functions + 2 water valve unit functions 1

3

5

7

9 11

2

4

6

8

10

12

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 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.

Controlling the shields during repair operation is especially dangerous because you are then operating the shield directly and immediately under where you are standing. It is therefore extremely important that you know and understand the interrelationships 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.

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.

5.46

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

E

Operation and functions of the electrohydraulic control unit

Operation and functions of the electrohydraulic control unit 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 function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”. This can cause dangerous situations which can result in very serious injuries.

Shield variant functions (10 functions) 1

Before executing this function, “Lower prop” must have been executed for both props.

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

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

E Caterpillar Global Mining Europe GmbH, Lünen 2014

Advance shield

2

Set props 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 function of the compensating valve for the stabilizing cylinder is not blocked.

Compensating valve The compensating valve a (see Fig. 43) and the associated shutoff valve (Fig. 43, Pos. 12a) are on the right prop when looking at the coal face. When the shutoff valve is open (lever in the direction of flow), the compensating valve is activated. When the shutoff valve is closed (lever perpendicular to direction of flow), the compensating valve has no function.

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

3

Advancing the conveyor Before initiating 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.

Doc. no.: 7420 209 000 BA 05

VSSE / 01

5.47

Operation and functions of the electrohydraulic control unit 4

Extend baselift 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

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!

Observe the value for minimum residual stroke.

Before initiating 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.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

7

Extending the dozer cylinder Before this function is executed, the canopy must be detached from the roof to such an extent that it can be moved freely. Afterwards, the cantilever must also be realigned if required and the shield must be reset.

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

8

Retracting the dozer cylinder Before this function is executed, the canopy must be detached from the roof to such an extent that it can be moved freely. Afterwards, the cantilever must also be realigned if required and the shield must be reset.

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

9

Conveyor pullback Before initiating 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.

5.48

Shield support 1676/3581-2X5341-2056

E

Retracting stabilizing cylinder

Caterpillar Global Mining Europe GmbH, Lünen 2014

6

Operation and functions of the electrohydraulic control unit 10

Lower props Before initiating 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.

Functions of the water valve unit 11

Roof timbering sprinkling system The function is executed as long as the button remains pressed.

12

Water spraying system, face side

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

Doc. no.: 7420 209 000 BA 05

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5.49

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

hydraulic control

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

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 against damage caused by contaminants in the hydraulic medium. These 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 in the preparation of the hydraulic medium, there will be an increased risk of failures due to clogged filters.

replacing filters

The time intervals between mandatory filter replacements depends on the degree of contamination in the water and/or of the emulsion (HFA fluid) used and must therefore be determined on a case-bycase 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 double filter, can be backflushed

piston rods

5.50

Replace water filter directly. backflush double filters (both filters) regularly once per shift.

The piston rods of cylinders, which 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 corrosion inhibitor on all shields which are equipped with a water spraying system.

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

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.

Pressure relief valves which are pretensioned with gas pressure must be additionally spot checked at regular intervals to ensure their correct function. We recommend such spot checks 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 correct function of the system. I

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid at the following points: – hose lines, – electrohydr. control unit, – valves,

Caterpillar Global Mining Europe GmbH, Lünen 2014

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– props, – shifting rams and lifting cylinders, – link, steering 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 instance: – on the relay bar assembly, – on pin connections and retaining devices, – on the side seal, – on brackets, etc.

Weekly maintenance control system

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

. Clean the control systems, especially the operating panel.

Notice!

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

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5.51

Maintenance Every six months

. Apply a corrosion inhibitor to the piston rods of the hydraulic cylinders. More detailed information is contained in this chapter in the “Special measures” section. hydraulic prop

. Lubricate the dirt strippers of both telescope stages via the lubricating nipples. Use the lubricating grease A2 in accordance with EWN 7068. See Chapter 6, section “Lubricating greases and pastes”.

Fig. 64:

Lubricating nipples on the hydraulic props

a

a lubricating nipples on the guide bushing

b grease escaping at dirt stripper

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

5.52

Shield support 1676/3581-2X5341-2056

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b

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

Functional errors can, in principle, occur in 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 2014

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Warning!

There is a heightened risk of accidents when performing troubleshooting work 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 209 000 BA 05

Possible cause

Measure required

The shutoff valve for the shield supply on the supply block is closed.

Open the shutoff valve.

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

The shutoff valve in the supply line to the prop piston chamber is closed.

Open the shutoff valve.

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find 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 lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage. Replace the prop, if necessary.

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5.53

Troubleshooting support cannot be set

Possible cause

Measure required

The shutoff valve for the shield supply on the supply block is closed.

Open the shutoff valve.

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

The shutoff valve in the supply line Open the shutoff valve. to the prop piston chamber is Lines to the piston and annular space of the closed. prop must be open.

Find 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 shutoff 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 lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage. Replace the prop, if necessary.

Possible cause

Measure required

The shutoff valve for the shield supply on the supply block is closed.

Open the shutoff valve.

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

The support is stuck between the neighboring supports.

Find 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 canopy sufficiently to clear the step or lift the skid.

The pressure of the hydraulic supply is too low.

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

The control piston on the piloted check valve does not work.

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 lines.

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

Shifting ram is defective.

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

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

support cannot be advanced

5.54

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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The shield canopy is stuck between the neighboring supports.

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

Caterpillar Global Mining Europe GmbH, Lünen 2014

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canopy cannot be positioned

canopy cannot be lowered

Doc. no.: 7420 209 000 BA 05

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 lower connection and check whether pressure 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 pressure fluid leaking from the pressure relief valve? If so: Replace the pressure relief valve and retest the function.

Possible cause

Measure required

The shutoff valve for the shield supply on the supply block is closed.

Open the shutoff valve.

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

The shield canopy is stuck between the neighboring supports.

Find 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 shutoff valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

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

The check valve may be defective.

Damaged or trapped hose lines.

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 shutoff valve for the shield supply on the supply block is closed.

Open the shutoff valve.

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

The shield canopy is stuck between the neighboring supports.

Find 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 shutoff 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 is about 80 bar.

The check valve may be defective.

Damaged or trapped hose lines.

Check hose lines for controlling the prop / stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

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5.55

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 work valves of the electrohydraulic control unit by an easily 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 can therefore be faulty. valve sticks

. Try to solve the problem by activating the function several times on the electrohydraulic control unit or electronic control system. one by one.

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

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

replace valve

. Close the main shutoff valve in the pressure feed line at the pipe distributor.

. Then operate 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 shown by a drop in pressure.

. Try to solve the problem by activating the function several times on the electrohydraulic control unit or electronic control system.

If the problem occurs once more, the valve may be defective.

. Check the valve and replace if defective Checking the check valves on the props To check the prop check valves please proceed as follows:

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

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

5.56

Shield support 1676/3581-2X5341-2056

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. Locate the faulty valve by activating the functions individually

Caterpillar Global Mining Europe GmbH, Lünen 2014

internal leakage

Troubleshooting Internal by-pass in props If an internal by-pass in the prop is suspected, this procedure should be followed:

. Set the prop until the setting pressure has been reached. . Depressurize the annular space side of the prop to be checked.

To do this, temporarily remove the hose line from the prop annular space connections (located on the prop pipe) and apply pressure to the control connection (extend prop) of the piloted check valve.

. Activate the “set props” function.

If there is an internal by-pass in the prop, for example due to damaged piston packing, fluid will flow out of the prop lower 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 2014

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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 models of pressure relief valves are used. For example, pressure relief valves with a high flow rate are used on the props. While the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow.

Pressure relief valves for different cylinders of 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 replacement parts catalog.

Defective or blocked 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.

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5.57

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Troubleshooting

5.58

Shield support 1676/3581-2X5341-2056

6

Technical data

Description

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

Description Type 1676/3581-2X5341-2056 Two-prop shields mainly consist of the following listed main subassemblies: base frame with lemniscatic links, relay bar assembly, lifting cylinder canopy with sliding canopy, caving shield with caving flap, hydraulic props,

Caterpillar Global Mining Europe GmbH, Lünen 2014

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hydraulic equipment with hose lines and control.

Tab. 9: Shield Application

Device number

Dimensions, LxWxH max./min. in mm

Approximate weight in kg

End shield

7420 209 000 00 05

9 082 x 2 000 x 1 676 x 2 000 x 3 581

42 232

base frame

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

caving shield

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

canopy

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

hydraulic system

Programmed methods of calculation ensure the best possible support. This ensures that the support resistance and range of vertical adjustment is coordinated in optimum fashion. The multistage 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 realizing an electrohydraulic neighboring control with the electronic PMC®-R control system.

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6.3

Description Main subassemblies Shield support Fig. 65:

Shield, lateral view b

c

a 51

12 12a

f d

g

E

41 Caterpillar Global Mining Europe GmbH, Lünen 2014

61 e 2

31

2 skid 12 canopy 12a sliding canopy 31 caving shield 41 prop 51 stabilizing cylinder 61 hydraulic system Fig. 66:

a PMC®-R control unit b electrohydraulic control unit c water valve unit d supply block e lifting cylinder f bracket g rubber sealing

Shield variants, rear view

1

6 3

2

1 caving shield 2 caving flap

6.4

3 holding eyelet 6 load ring RBS-30

Shield support 1676/3581-2X5341-2056

Description Tab. 10: Shield support 7420 209 000 00 05 subassemblies used Approximate weight in kg

Item

Designation

ID No.

Remarks

0002

Skid

7420 209 300 00 02

Shifting ram 15 100 Lifting cylinder Relay bar assembly

0012

Canopy

7420 209 400 00 02

11 700

0031

Caving shield

7420 209 800 00 01

6 300

0041

Hydraulic prop

8250 169 000 00 00

1 850

0051

Stabilizing cylinder

8241 348 000 00 00

223

0061

Shield control system - 10 functions -

8112 412 000 00 00

Electrohydr. control unit Water valve unit 379 Lines Water spraying system Brackets

Caving flap

7420 209 891 00 00

134 on caving shield

holding eyelet

7420 209 801 02 00

2 054 on caving shield

7420 209 441 00 00 8241 584 000 00 00

8154 118 000 00 00 8401 007 250 00 00 8112 412 010 00 00 8112 412 020 00 00 8112 412 030 00 00

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Sliding canopy Dozer cylinder

8241 350 000 00 00 8241 351 000 00 00 7420 209 380 00 01

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6.5

Description Main dimensions Fig. 67:

End shield, dimensions

L1

150

L2

HE

H

HA

L3

2085

600

740

1075 Caterpillar Global Mining Europe GmbH, Lünen 2014

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L M B

HA height, extended HE height, retracted L transport length B width M support center distance

B3 B2 B1 Tab. 11: Shield variants, dimensions

6.6

L

L1

L2

L3

M

H

HA

HE

B

B1

B2

B3

9 082

6 615

1 355

5 260

2 056

2 641

3 581

1 676

2 000

1 905

1 040

420

Shield support 1676/3581-2X5341-2056

Description Skid with lemniscatic links and relay bar assembly The one-piece base frame transmits the shield load of the hydraulic props into the floor. The props are in hinged position 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 placement of the relay bar assembly in the middle between the two skids. The relay bar assembly is reverse-mounted so the force of the piston surface area of the shifting ram is used to advance the shield. Correspondingly, the conveyor is advanced with the smaller force, which is generated via the annular surface.

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

Fig. 68:

Skid, dimensions

E

LL!

Caterpillar Global Mining Europe GmbH, Lünen 2014

LL2

245

330

H

0

L1

L2

L3

L

350 1905 Tab. 12: Skid, differences Shield

Skid Device number

L

L1

L2

L3

H

LL1

LL2

7420 209 000 00 05

7420 209 300 00 04

4 500

2 085

600

740

780

1 660

1 540

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Dimensions

6.7

Description Fig. 69:

Skid, positions 5

6

1 8 5

10

A

2 12

15, 21 E

15, 21 View A

26, 36

26, 25

3 23 4

a

17, 23

16

27

20, 19 13 1 shifting ram ZE-165/100-1130 2 lifting cylinder ZE-150/90-300 3 skid 4 relay bar assembly 5 lemniscatic link, front 7 lemniscatic link, rear 8 prop retainer, right 9 prop retainer, left 10 cylinder bearing

11 joint pin Ø189,3x667 12 joint pin Ø174,3x617 13 pin 60/50x141 14 pin 35/29x61 15 locking plate 16 pin Ø70x312 17 pin Ø16x117 19 hex. nut M 16-1.4301 20 hex. head screw M 16x120-A 4-80

21 spring clip 5,6 22 spring clip 4 23 staple DN 10 25 retainer 26 retainer 27 pin 30/20x191 a load ring load capacity 15 000 kg

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces. *) EWN = works standard

6.8

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

11

Description Relay bar assembly The relay bar assembly is located in the middle of the base frame.

It consists mainly of the relay bar, shifting ram, baselift 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 from the floor during pulling up.

The baselift cylinder is located in the center of the base frame. The force of the baselift cylinder acts on the floor via the relay bar.

Tab. 13: Relay bar assembly, difference Relay bar assembly, Device number

Shield

L

L1

H

H1

H2

4 558

4 282

440

295

242

Fig. 70:

Relay bar assembly, dimensions L

140

H2

H1 H

295

165

340

270

390

L1

115

Caterpillar Global Mining Europe GmbH, Lünen 2014

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7420 209 000 00 05 7420 209 380 00 04

Dimensions

10, 11

1

6

15, 16

a

7

5

2

1 relay bar 2 clevis assembly for conveyor 5 BG pin 6 shear pin 60/53x210 7 pin 75/68x193

10 hex. head screw M 16x120-A 4-80 11 hex. nut M 16-1.4301 15 hex. head screw M 16x140-A 4-80 16 hex. nut M 16-A 4-80 a load ring 3 000 kg

Notice!

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

*) EWN = works standard

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6.9

Description Pin assembly BG Bolzen

(

Fig. 71:

(284,5) (383) 1

2

1 pin 85/60x355 2 ring

3 cover 5 locking clips 11x50

Functional description 1. Original 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!

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

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

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

4. Advancing the conveyor The shifting ram is retracted.

6.10

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Caterpillar Global Mining Europe GmbH, Lünen 2014

5

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3

Description Canopy The canopy transfers the supporting force of the props to the roof.

It is articulated and is connected with 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 cylinder, 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. 72:

Canopy, dimensions

2000

(150)

6615

(230)

L 1000 HUB 1060

(240)

(1000)

(540)

Caterpillar Global Mining Europe GmbH, Lünen 2014

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(1040)

(L1)

Tab. 14: Shield canopy Shield

Canopy, Device No.

L

L1

7420 209 000 00 05

7420 209 400 00 02

6 835

1 355

Notice!

The lifting points in the canopy (see Fig. 73) are for fastening lifting tackle and may only be used when the shield is completely set.

Pay attention to the load limits.

The force of the hydraulic support may not be used for lifting.

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6.11

Description Fig. 73:

Canopy, positions b, 25

c 3

d

1

e

a

2

8

9 19

6, 7

16

14, 15 17, 18

5

10, 11

13

4 12

1 canopy 2 plug 5 peg 73x134 6 pin Ø20x160 7 locking clip 5x32 8 joint pin Ø138,5x618 9 retainer 10 pin Ø12x120 11 spring clip 2,5

12 pin 70/63x165 25 spring cotter 5 13 retaining ring a load ring load capacity 1 000 kg 14 hex. head screw M 10x90-A 2-70 15 hex. nut M 10-A 2-70 b load ring load capacity 3 000 kg 16 retainer c lifting point (clip) 17 hex. head screw M 16x170-A 2-70 load capacity 8 000 kg 18 hex. nut M 16-A 2-70 d springling mount 19 pin 65/58x163 20 hex. head screw M 10x75-A 2-70 e bracket

Notice!

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

*) EWN = works standard

6.12

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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15, 20

Description Sliding canopy sliding canopy, dimensions

(1760)

355

Fig. 74:

2020

Caterpillar Global Mining Europe GmbH, Lünen 2014

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(280) Fig. 75:

Sliding canopy, positions 3

18

1 22

30

2 13 24

1 front plate 2 top plate 3 intermediate plate 13 lug 18 intermediate belt

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22 specer plate 24 lug 30 name plate For parts not listed here, please refer to the spare parts list supplied.

6.13

Description Prop head with peg Important!

Before installing the prop head, put the pegs of the prop head fixture into the bore holes of the mounting device. Secure the pegs with the securing device (pins, locking clips) in the second groove.

After installing the prop head, push the pegs in the bore holes of the prop head. Secure the pegs in the first groove by using the securing devices.

Fig. 76: Prop head attachment 6

5

5 peg 73x134 6 pin 20x160

6.14

7 locking clip 5x32

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

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7

Description Caving shield The caving shield protects the face area toward the caving area. It is connected to the shield canopy and with 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 articulation.

Fig. 77:

Caving shield, dimensions 1950 410

L1 480

L

Caterpillar Global Mining Europe GmbH, Lünen 2014

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1125

310

460 1040 H

B Tab. 15: Caving shield Shield

Caving shield, Device No.

7420 209 000 00 05 7420 209 800 00 01

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L

L1

B

H

2 718

2 140

2 000

1 000

6.15

Description Fig. 78:

Caving shield, positions

4

1

S2

S2

5

S1 6

8, 9

12

14, 15

2

11

1 caving shield 2 plug 205 mm 4 lemniscatic link pin Ø189,3x632 5 lemniscatic link pin Ø174,3x632 6 securing device 8 pin 15/12x120 9 spring clip 2,5 11 pin 70/63x165

12 retaining ring 13 spring cotter5 14 hex. head screw M 10x90-A 2-70 15 hex. nut M 10-A 2-70 S1 lifting eye, load capacity: 3 000 kg S2 load ring RBS-30, load capacity: 30 000 kg

Notice!

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

*) EWN = works standard

6.16

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Caterpillar Global Mining Europe GmbH, Lünen 2014

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S1

Description Caving flap

Fig. 79:

Caving flap, dimensions 560

(40)

(52,5)

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

740

2

1

570 Fig. 80:

Caving flap, positions 2

1 1 caving plate

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2 round steel

6.17

Accessories Accessories Steering device “canopy - canopy” The steering device “canopy / canopy” as per Drawing Number 7424 122 000 00 00 is only for use with the shield 7420 209 000 00 05 Before aligning, the shield to be aligned should be lowered. The neighboring shield on to which the alignment cylinder is attached must be set.

By actuating (pushing or pulling) the lever “Z” (Fig. 85) the corresponding alignment cylinder is retracted and the shield is aligned.

It may be necessary to also use the corresponding side seal or pusher cylinder to align more precisely.

Steering device “canopy - canopy”

1067 web/Schritt

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 81:

2056

350

2056

1121

6.18

Shield support 1676/3581-2X5341-2056

Accessories Fig. 82:

Steering device “canopy - canopy”

Shield 1

Shield 2

Shield 3

a

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

a Steering device “canopy - canopy” Fig. 83: Steering device “canopy - canopy” positions 45

49, 56

1

View A 23, 62

73

72

22

A

70 71

10, 48, 63 15 1 hydraulic prop ZE 80/50-600 retracted: 910 mm extended: 1510 mm 5 chain joint 10 pin 55/40x125 15 universal joint 16 universal joint

Doc. no.: 7420 209 000 BA 05

5 16 21 21 pin 49.8x200 22 pin 23 pin 13x190 45 bracket 48 washer 41 49 hex. head screw M 24x90-8.8 56 hex. nut M 24-8

VSSE / 01

62 locking clip 2,5 63 locking clip 4 70 spring dowel pin 8x100 71 spring dowel pin 14x100 72 flat connecting chain link 26x92 73 chain

6.19

Accessories Warning!

Make sure that the offset between shield 1 and shield 2 does not exceed the maximum permissible amount.

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts. The offset may never exceed 400 mm!

Caution!

Serious damage can be caused to the shields by not following the correct sequence of steps when pulling up the shields.

Pull up the shields only in the sequence 2-1-3 or 2-3-1!

Hydraulic control system for steering device

a

b

a Steering device “canopy - canopy”

6.20

b hydraulic

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 84: Hydraulic control system for steering device “canopy - canopy”

Accessories By actuating (pushing or pulling) the lever Z on the control block (1) the corresponding alignment cylinder is retracted and the shield is aligned.

Fig. 85:

Hydraulic control system for steering device “canopy - canopy”

A

A

View X 9

10x1200

23 A-A

10x1000

22

11 14

B PTO

16

B-B

P

P

5 1

25 mm

R

Y 10

12x500

24

B

20x700

steering cyl.

W

17

R DN 50 W DN 50 P DN 40-SS

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

X

workingpressure 320 bar

25

2

View Y rotated

12

1

13

P T

1 hydraulic control unit, 2-way 5 bracket for control unit 9 plug-in elbow socket DN 10 10 plug-in elbow socket DN 20

Z 18

15

11 Fitting DN 25 12 plug-in reducing socket DN 12/10 13 plug-in reducing socket DN 20/12 14 plug-in reducing socket DN 25/12 15 plug-in reducing socket DN 25/20

Doc. no.: 7420 209 000 BA 05

VSSE / 01

2

2

1

1 N2

16 plug-in L-sleeve DN 20/10/20 17 plug-in L-sleeve DN 25/20/25 18 plug DN 12 22-25 hose 30 staple DN 10 31 staple DN 12 32 staple DN 20 33 staple DN 20 Z lever to actuate the steering device

6.21

Technical data, steel structure Technical data, steel structure End shield, device number 7420 209 000 00 05

6.22

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

1 676

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

3 581

Height adjustment of shield . . . . . . . . . . . mm

1 905

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

1 067

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

1 130

Distance of prop centers (inclination) . . mm

1 040

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

5 260

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

1 505

Canopy width . . . . . . . . . . . . . . . . . . . . . . mm

2 000

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

6 765

Caving shield inclination, support retracted . . . . . . . . . . . . . . . . . . . degrees

13

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

52,95

Caving shield width . . . . . . . . . . . . . . . . . mm

2 000

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

1 905

Total area of the base frame . . . . . . . . . . cm2

51 084

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

2 056

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

2 200

a) with 310 bar setting pressure . . . . . . . kN

7 186

b) with 425 bar nominal pressure . . . . . . kN

9 543

Support resistance per m2 roof surface for average seam of . . . . . . . . . . . . . . . . . mm

2200

a) at 310 bar setting pressure . . . . . . . . . kN/m2

514

b) for 425 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

590 / 682

Shield support 1676/3581-2X5341-2056

E

15

Caterpillar Global Mining Europe GmbH, Lünen 2014

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

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. Supplemental information can be found in the replacement parts catalog for the shield support or the hydraulic components listed in Chapter 5.

normal and exceptional operation

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

Shield control system Electrohydraulic control unit The electrohydraulic control unit has 10 functions.

The pilot valves of the electrohydraulic control unit are equipped with buttons which allow the shield functions to be actuated manually. A symbol plate shows the function/button allocation.

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 86: Electrohydraulic control unit, 10 functions

a

1

2

a connection (DN 20) for accumulator cartridge 1 distributor block

3

4

2 pilot valves with electromagnetic operation 3 button for manual operation 4 contact for electrical connection to the solenoid driver module

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Noncompliance can cause unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

The buttons on the pilot valves should only be used in special exceptional cases, for example for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations.

Doc. no.: 7420 209 000 BA 05

VSSE / 01

6.23

Hydraulic system Water valve unit The water valve unit has 2 functions.

Fig. 87:

Water valve unit, 2 functions 1 4

22

5

12, 13 1 Double 3/2-way magnetic pilot solenoid valve 3 Connection plate 4 Intermediate plate 5 Valve cartridge

12 Screw fitting M10x1-A 2-70 13 Sealing ring A 10x14 22 Cylinder head screw M6x30-A 4-80 Components not listed can be found in the spare parts catalog supplied.

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

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

6.24

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

3

Hydraulic system Hydraulic prop, two-stage The two-stage telescopic prop is double acting and is designed for equal load-bearing capacity on both stages. Equal load-bearing capacity of the two stages is ensured by a piloted check valve which is installed in the piston pipe.

The head is fastened using two pegs each that are inserted into the bore 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 bore 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”.

Fig. 88:

Double-telescopic prop,

42 Caterpillar Global Mining Europe GmbH, Lünen 2014

E

21 2

a 4 1

c b

1 prop base 2 piston pipe 4 PRV, 520 bar 21 piston rod

42 lubricant a valve connection plate b valve port d load ring 3 000 kg

Tab. 16: Hydraulic prop Length in mm

Doc. no.: 7420 209 000 BA 05

Stroke in mm

ID No. Hydraulic prop

Retracted

Extended

Upper stage

Lower stage

8250 169 000 000 00

1 340

3 095

850

905

VSSE / 01

6.25

Hydraulic system Warning!

Risk of serious bodily injuries due to pressure 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 more than the set pressure.

Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the annular space is conducted away 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 pressure fluid is supplied at the same time via the check valve in the bottom of the piston pipe.

loading props

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 is hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the base frame.

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated check valve. If the pressure set on the pressure relief valve is exceeded, the pressure fluid flows out of the prop and the prop is pushed in under the nominal prop force. b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure 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 props

The pressure fluid is connected to the return under the piston pipe 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 pressure 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.

6.26

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

set props

E

Function

Hydraulic cylinder Hydraulic cylinder Design 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. 89:

Hydraulic cylinders, typical examples

Type a)

2 1

3

5

4

1

4

6

Caterpillar Global Mining Europe GmbH, Lünen 2014

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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 serious bodily injuries due to pressure 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, when extending the prop, a pressure can build up in the annular space which is several times more than the set pressure.

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 working loose using clamping screws or a spring pin connection.

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

Doc. no.: 7420 209 000 BA 05

VSSE / 01

6.27

Hydraulic cylinder Shifting ram Fig. 90:

Shifting ram type ZE-225/140-1130

72

72 L a

d

b c 14

2 11

1 cylinder tube 2 reed rod

b piston space connection

11 piston rod 14 screw fitting a annular space connection

d load ring 1 000 kg

c relay bar adaptor L retracted 1660 - extended 2790 stroke: 1130

Stabilizing cylinder Fig. 91:

Hydraulic cylinder ZE-200/125-500

65

65 L b

a

11

d c

1 1 cylinder tube 11 piston rod a valve connection plate b PRV connection, annular space

6.28

c PRV connection, piston space d load ring 3 000 kg L retracted 945 - extended 1445 stroke: 500

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

1

Hydraulic cylinder Lifting cylinder Fig. 92:

Hydraulic cylinder ZE-150/90-300

415

c

3

a b

1

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

L

2 1 cylinder tube 2 wearing bottom 3 piston rod a piston space connection

b annular space connection c load ring 1 000 kg L retracted 588 - extended 888 stroke: 300

Dozer cylinder Fig. 93:

Dozer cylinder ZE-125/90-1060

70

60 L d

a

c

b 7

2

4 1 1 cylinder tube 2 reed rod 4 piston rod 7 screw fitting a annular space connection

Doc. no.: 7420 209 000 BA 05

VSSE / 01

b piston space connection c load ring 1 000 kg d clamp L retracted 1 390 - extended 2 450 stroke: 1 060

6.29

Hydraulic cylinder Technical data, hydraulic cylinder

shifting ram double-acting,

stabilizing cylinder, double-acting

6.30

Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1 340

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

3 095

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

1 755

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

400 / 285

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

370 / 265

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

1 256.6 / 638

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

181.4 / 86.4

Prop force setting pressure, 310 bar . . . kN

3 895

Setting pressure, 425 bar . . . . . . . . . . . . kN

5 341

Retracting force at 310 bar . . . . . . . . . . . kN

562

Type ZE-225/140-1130, Gerätenr. 8241 350 000 00 00, Version with reed rod

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

1 130

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

225

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

140

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

154

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

243,6

Thrust at 310 bar . . . . . . . . . . . . . . . . . . . kN

478

Pulling force at 310 bar . . . . . . . . . . . . . . kN

756

Type ZE-200/125-500,

Device number 8241 348 000 00 00

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

500

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

200

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

125

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

314.2

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

191.4

Thrust at 310 / 425 bar . . . . . . . . . . . . . . kN

974 / 1 335

Pulling force at 310 / 425 bar . . . . . . . . . kN

593 / 813

Shield support 1676/3581-2X5341-2056

E

Type SD-5300-400-1340/3095-BN, Gerätenr. 8250 169 000 00 00 For the HI shield

Caterpillar Global Mining Europe GmbH, Lünen 2014

telescopic prop, double-acting, 2-stage

Hydraulic cylinder baselift cylinder, double-acting

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

dozer cylinder, double-acting

Doc. no.: 7420 209 000 BA 05

Type ZE-150/90-300

Device number 8241 351 000 00 00

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

300

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

150

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

90

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

176.7

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

113.1

Thrust at 310 bar . . . . . . . . . . . . . . . . . . . kN

547

Pulling force at 310 bar . . . . . . . . . . . . . . kN

350

Type ZE-150/90-1060

Device number 8241 584 000 00 00

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

1 060

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

150

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

90

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

122.7

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

59.1

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

393

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

189.1

VSSE / 01

6.31

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 diagram and spare parts catalog.

Tab. 17: Pressure relief valves, use of the various models Design

Setting pressure in bar

Device number

For return line

Spring-loaded

80

8220 042 080 00 00

For shifting rams and Spring-loaded lifting cylinders

380

7337 486 380 00 00

For stabilizing cylinder and proponly

Spring-loaded

420

8220 027 420 00 00

For securing the annular space

Spring-loaded

520

8220 061 520 00 00

Caution!

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

Noncompliance endangers 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 having the same properties. Always compare with the hydraulic system diagram. Noncompliance endangers 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.

Noncompliance can lead to leaks on the staple locks and compromise the operational safety of the hydraulic system.

Identification

Pressure relief valves are color-coded and letter-coded pursuant 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 last changes.

6.32

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Application

Pressure relief valves Tab. 18: Letter 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 located. The following Fig. 94 shows a pressure relief valve provided with a blue/white color code.

This color code corresponds to the pressure range of 350 to 399 bar.

Pressure relief valve, example

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 94:

b

a

a color code b protective cap

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

Tab. 19: Color codes for pressure relief valves, overview 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

1) Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar,

“42” equals 420 bar, “08” equals 80 bar

Doc. no.: 7420 209 000 BA 05

VSSE / 01

6.33

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. 95:

Angles  1 / 2

1 2

Tab. 20: Angles  1 / 2 at height M Inclination  at height M

Shield ID No.

7420 209 000 00 05

1 in °

 in °

M in mm

5

0

1 676 bis 1 810

10

5

1 810 bis 2 000

15

10

2 000 bis 3 231

0

15

3 231 bis 3 581

Caution!

Exceeding the specified permissible angles can lead to damage to the props and cylinders and their fastening elements, as well as to the component 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 positioned.

6.34

Shield support 1676/3581-2X5341-2056

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

M

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

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

In general, for operating hydraulic components from Caterpillar, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Caterpillar. Caterpillar will not accept any claims under warranty for components which have been or are operated using 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.

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

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, e.g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by Caterpillar on request.

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

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

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

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

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

Doc. no.: 7420 209 000 BA 05

VSSE / 01

6.35

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Caterpillar hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

Typical certificate

Caterpillar Global Mining Europe GmbH, Lünen 2014

E

Fig. 96:

6.36

Shield support 1676/3581-2X5341-2056

Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected, but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: pH – target value: 7.5 to 9.5 Caterpillar Global Mining Europe GmbH, Lünen 2014

E

concentrate ratio – target value: see certificate microbial load – target value:  105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55°C. During normal operation, however, an operating temperature of 45°C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water use for hydraulic fluids

The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limits shown in the table LEERER MERKER are maintained, it can be assumed that the water is basically suitable.

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

Furthermore, water treatment may also be necessary.

However, the customer shall in any case provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

Doc. no.: 7420 209 000 BA 05

VSSE / 01

6.37

Permissible media use as spraying water

limit values

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

Caution!

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

Limit value

Appearance, color, smell

No peculiarities permissible, e.g.turbidity, bad smell, 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 with 1.2 m filtration in accordance with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

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

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

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Test criterion

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Tab. 21: Properties of the process water, limit values

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

Important!

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

Greases grease A1

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

Tab. 22: Greases A1 Supplier

Type

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

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

Tab. 23: Grease A2 Supplier

Type

Base

Shell

Alvania E.P. grease 2

Lithium soap

NLGI class

Flashpoint in °C

2

205

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

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

Tab. 24: Grease A8 Supplier

Type

Base

Castrol

Molub-Alloy 3036/680-1

Lithium soap

NLGI class

Flashpoint in °C

1

210

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

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6.39

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. 25: Lubricating paste B3 Supplier

Type

Base

gleitmolybdän

gleitmo 805

Lithium soap

NLGI class

Flashpoint in °C

2

220

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

Tab. 26: Lubricant B6 Supplier

Type

Base

Chesterton

parting and lubricating material 785

Petroleum

Flashpoint in °C 132

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

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lubricant B6

Tightening torques Tightening torques Screws with ISO metric thread Tab. 27: Tightening torques at tot. = 0.14 Thread 1)

Pitch P

Tightening torque 4)

(mm)

MA (Nm)

Caterpillar Global Mining Europe GmbH, Lünen 2014

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(mm) d

Coarse thread

M8

Fine thread

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

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 stated in the spare parts lists must be observed during installation and maintenance work.

1) the dimensions listed in brackets are used in exceptional cases only.

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

3) only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

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

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Tightening torques

6.42

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7

For your information

Standards and guidelines

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

Standards and guidelines Referenced standards and guidelines Tab. 28: Standards and guidelines, extract

Caterpillar Global Mining Europe GmbH, Lünen 2014

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Designation

Date of issue

Title

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

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Standards and guidelines Date of issue

Designation

Title

EWN 6003 1)

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

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

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

1985-02

1) EWN = works standard

7.4

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Identification of the shield Identification of the shield Name plate The main subassemblies of the shields are identified by a type plate.

Name plate, example

Caterpillar Global Mining Europe GmbH, Lünen 2014

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Fig. 95:

1 manufacturer 2 SAP/order no.

3 date of manufacture

5 device number 6 number of props 7 prop force

4 serial component no.

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7.5

Identification of the shield Shield number The shields are numbered consecutively. Plates showing the shield number are on the base frame, face side at the left.

Shield number on the skid, example

Caterpillar Global Mining Europe GmbH, Lünen 2014

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Fig. 96:

Tab. 29: Allocation of the shield numbers Shield number VG2 to VG4

7.6

Device number

Use

7420 209 000 00 05 End shield

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