CAT Shield support 2100/4500-5x5330-Steel structure, hydr. components from CAT Operating Manual

Operating manual Shield support 2100/4500-5x5330 - Steel structure, hydr. components from CAT Doc. No.: 7420 246 000 BA 00

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

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

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

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

We reserve the right to introduce modifications due to technical development without previous notice.

Caterpillar Global Mining Europe GmbH, Lünen 2013E A Caterpillar Inc. Company

Contents

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

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

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

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

1.3 1.3 1.4 1.4

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

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

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

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

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

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

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

2.3 2.3 2.4

2.5 2.5 2.5

2.6

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

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

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

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

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

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

3.3 3.3 3.4

3.5 3.5 3.5

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

4.3

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

4.3

Pressure equalization of the electronic control system . . .

Requirements for the face hydraulic system . . . . .

4.5

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

4.6

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

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

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

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4.6 4.8 4.8

Contents 5. Operation 5.3 5.3 5.6

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

5.9

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

5.12

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

5.13

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

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

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

3/2-way ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Measuring coupling for pressure relief . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

Internal bypass inside the leg . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5.13

5.15 5.15 5.15

5.16 5.16 5.20 5.20 5.21 5.22 5.23

5.26 5.26 5.27 5.28 5.28 5.28

5.29 5.29 5.29 5.32 5.32 5.33 5.33 5.33

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

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

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

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

Lemniscatic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Leg retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.3 6.4 6.6 6.7 6.8 6.9 6.10 6.11 6.12

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

Contents Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic leg, two-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting ram (Z2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy cylinder (Z3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinders . . . . . . . . . . . . . . . . . . .

6.13 6.13 6.14

6.16 6.16 6.18 6.18 6.19

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

6.20

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

6.22

Permissible hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of the hydraulic fluid . . . . . . . . . . . . . . . . . . . .

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

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

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

6.28 6.28

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

6.22 6.24 6.24 6.26

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

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

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

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

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7.3 7.3

7.5 7.5

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Contents

Shield support 2100/4500-5x5330

1

About this manual

Before starting work

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

Before starting work applicable operating manual

shield type

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

This operating manual belongs to the Shield support 2100/4500-5x5330 * ID no.:

7420 246 000 00 01

and is only permitted to be used for shields of this type.

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

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

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

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

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

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

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

*

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

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1.3

Before starting work Purpose of this operating manual efficiency

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

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

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

service

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

safety

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

Observe this information and follow the procedural instructions.

Signs and symbols used

Danger!

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

Warning!

This symbol indicates information on hazardous situations.

Possible consequences are: very serious injury or even death.

Caution!

This symbol draws your attention to hazardous situations.

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

Notice!

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

Important!

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

They do not warn about harmful or hazardous situations.

Items in lists are indicated by bullet points.

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

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

1.4

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Memorize the symbols and their meanings.

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

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

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

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

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

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

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

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

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

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

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

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

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2.3

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

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

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

2.4

Shield support 2100/4500-5x5330

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

Use the shield only as intended!

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

the following conveyor operations: Caterpillar Global Mining Europe GmbH, Lünen 2013

– advancing – retracting forming an anchor for: – the conveyor and mining equipment – conveyor antitopple devices – devices for raising the conveyor – conveyor steering cylinders.

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

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

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

Caterpillar assumes no liability for damage caused by unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective equipment.

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

prerequisite

Only use shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

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

EMERGENCY STOP

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

support lock-out switch

- Only applies to the version with the electrohydraulic shield control system: Actuate the support lock-out switch (repair switch) before: maintenance work inspection work repair work prolonged presence in the shield.

moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: bases and relay bar assemblies canopies lemniscatic links side seals front cantilevers hydraulic legs and cylinders antitopple devices.

automatic mode

2.6

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

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signaling systems and safety equipment

Maintain the lighting systems in working condition.

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lighting system

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

Never stand under unsecured or suspended loads.

Observe the prescribed storage periods and the storage instructions.

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

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

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

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

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

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

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

Do not damage the polished surfaces of the cylinders and the legs.

Damage of this kind necessitates elaborate and expensive repair work.

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

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

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

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

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2.7

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

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

Mechanically secure the caving shield against involuntary lowering during: installation of the legs 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-locking hardwood wedges between the lemniscatic links stabilize the position of the caving shield

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Fig. 1:

transport safety device

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

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

travel way

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

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

2.8

Shield support 2100/4500-5x5330

Safety instructions Operation shield control

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

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

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

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

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

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

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

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

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

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

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

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

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2.9

Safety instructions shield alignment

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

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

Early alignment prevents: the canopy from getting under the neighboring shield the shields from tilting the shields from slipping 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 canopy is loaded excessively in the longitudinal direction; as this may cause damage due to excessive stress and strain on the components.

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

retracting the conveyor

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

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

Secure all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the lifting points intended for that purpose.

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

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

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

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

2.10

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the stabilizing cylinder is fully out or fully in;

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the maximum admissible angle of inclination of the canopy is exceeded;

Safety instructions For raising the conveyor, use only the following: High-strength, undamaged chain slings.

The lifting points provided for the purpose.

Check that the lifting points are undamaged before attaching the load.

Lifting gear of adequate load-carrying capacity.

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

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

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

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

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

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

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

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

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

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

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

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2.11

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

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

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

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

Hydraulic system Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

protective devices - hydraulic system

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

maintenance, repairs

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

pressure relief valves

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

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

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

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Caterpillar Global Mining Europe GmbH, Lünen 2013

On inclined faces secure the components to be replaced against slipping using chains or lifting gear, 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 Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the connector to check whether the line is still pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the hydraulic line.

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

Never use nails, wire or similar materials.

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

Only use hydraulic hoses approved for the prevailing pressures.

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

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

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

Fig. 2:

Example of a hose line, marking

1 1 manufacturer 2 calendar week

2

3

4 3 year 4 max. working pressure

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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2.13

Safety instructions installing hydraulic lines

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

Lay hydraulic lines so that they: are always slightly slack; Fig. 3:

Laying hydraulic line, slack

are not twisted; Laying hydraulic line, twist

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

Laying hydraulic line, bend

1.5 x d

d

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Fig. 4:

Safety instructions cannot chafe; Fig. 6:

Laying hydraulic 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 lines into the connector sockets by hand.

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

When laying hydraulic lines, ensure that they cannot be: torn out kinked pinched driven over twisted as a result of moving equipment (Fig.: 7).

Fig. 7:

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Laying hydraulic line, connections to moving parts

2.15

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Safety instructions

2.16

Shield support 2100/4500-5x5330

3

Storage and transport

Storage

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

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

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

Storage Storing the equipment

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anticorrosion protection

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

no direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

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

dirt and moisture

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

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

short-term storage

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

long-term storage

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

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

This inspection can be carried out by Caterpillar upon request.

natural aging

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

Important!

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

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3.3

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

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

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

*

3.4

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

Shield support 2100/4500-5x5330

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

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

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Warning!

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

Falling components can cause serious injury and death.

Only use suitable load handling devices.

Before transport temperatures below freezing

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

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

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

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

electrical and electronic components

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

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

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3.5

Transport transport units

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

Tab. 1: Transport units Alignment

Complete shield unit

As for normal use

Note

Caution!

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

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

Fig. 8:

Transport units

b

a a transport unit 1

3.6

b transport unit 2

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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.

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transport safety devices

Designation

Transport Fig. 9:

Transport unit 1

H

So

L

D2

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D1

B

3,4

1 cross strut 3 hex. head screw M 30x80-8.8

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1

4 hex. nut M 30-8

3.7

Transport Fig. 10:

Transport unit 2

2100

So

657

2382

765

5100

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5138

2

2 rod Tab. 2: Transport shield support 7420 244 000 00 01, dimensions and weights L in mm

W in mm

D1 in mm

D1 in mm

HR in mm

in mm

transport unit 1

7 974

3 305

8 476

7 650

2 100

/

????

transport unit 2

5 100

765

5 138

-

2 100

/

????

Transport unit

3.8

Sx/Sy

Weight in kg

Shield support 2100/4500-5x5330

4

Installation

Preassembly of the shield units

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

Warning!

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

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

Caution!

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

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Caution!

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

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

Installation of the shield units Caution!

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

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

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

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

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4.3

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

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

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

Pressure equalization is indicated by an audible hissing.

Caution!

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

Fig. 11:

Example of a vent screw on an electronic control system b

a vent screw

b electronic control system PMC®-R

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

Caution!

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

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

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a

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

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

permissible pressure

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

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

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

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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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4.5

Commissioning Commissioning Warning!

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

Notice!

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

See chapter 3, section “Transport”.

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

Mechanical system:

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

. Remove all plugs from the hydraulic connections of the legs and/or hydraulic cylinders. Install the legs 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 legs have been removed.

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

. Check all mechanical connections on the shield units.

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Please observe the following:

Commissioning Hydraulic system:

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

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

Danger!

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

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

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

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

. Check the hydraulic supply pressure. . Check the load-carrying function of the legs. The current presCaterpillar Global Mining Europe GmbH, Lünen 2013

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

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

Signaling and lighting systems, information signs: Important!

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

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

EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems are working properly.

Mining and conveying:

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

Warning!

Bent support canopies must not project into the mining area.

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4.7

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

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

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

face.

. Check all functions of the shield control unit.

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

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

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

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

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Warning!

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

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

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 an addition to hands-on training. It is recommended that you read this chapter as a supplement to the training, but this in no way releases the operator from participating in the training.

Danger!

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

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Warning!

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

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

Requirements Operating conditions face crew

face equipment

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

The face must be sufficiently illuminated.

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

travel way

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

Notice!

Make sure you observe the corresponding national regulations.

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

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

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

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5.3

Requirements Fig. 12:

Minimum dimension for the travel way, schematic diagram

W

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

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

work in the mining area

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

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

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

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

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

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

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

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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 the safety zone required for safely carrying out repair work.

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

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

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

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

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5.5

Requirements Safety requirements automatic mode

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

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

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

operating the shield unit

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

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

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

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

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

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

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

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

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Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

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

Requirements Fig. 13:

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

Shield unit with plow

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 14:

Shield unit with shearer

Shield unit with plow

Shield unit with shearer

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

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

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

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5.7

Requirements control, hydraulic system

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

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

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

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

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

damage, spare parts

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

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

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Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Shut-off 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. 15:

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

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

The shield units must always be set until the setting pressure has been reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as an anchor 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. In the context of the maximum inclination and swivel angles specified on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

Caution!

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

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

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

Accumulation on the shield canopy can be avoided by using contact advance while advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy. adjustment range of support/ changing face thickness

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

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

The minimum residual stroke required for lowering the shield unit can be maintained by: keeping the longwall opening at a sufficient height using the mining equipment

5.10

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

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

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

E

Caution!

Never exceed the permissible angle of inclination of the canopy!

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

Operation of the shield support avoiding the accumulation of debris and fine coal on the floor removing accumulations of rock on the shield canopies.

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

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

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

E

operating on inclines

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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 gate end shields are well-aligned. Usually, hydraulic end supports, as well as aligning devices are used on the shield canopies and base frames or between the base frames and shield canopies for this.

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

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

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

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.

Doc. No.: 7420 246 000 BA 00

VTSP / 01

5.11

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

Warning!

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

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

Caution!

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

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 base.

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.

5.12

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

Observe the following safety regulations:

Shield components Shield components Main components Fig. 16:

Road shield 1

RW 001

14

2

3

RW 002

4 5 15 6

15 16

16

16

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

16 16 17

13

12

10

9

1 canopy I compl.

2 canopy II compl.

3 canopy III compl.

4 caving shield right 5 caving shield left 6 lemniscatic link front 7 lemniscatic link rear 8 base front right compl.

9 base front left compl.

10 base connecting piece

Doc. No.: 7420 246 000 BA 00

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7

11

10

18

8

17

11 base rear right compl.

12 base middle leftcompl.

13 base rear left compl.

14 stripper 15 canopy cylinder ZE-80/50-700-CR 16 Hydraulic leg SD-5100-380-1630/4000-BN 17 Shifting ram ZE-225/140-1080-CR 18 universal joint

5.13

Shield components Fig. 17:

Road shield, universal joint RW 002

RW 001

Caterpillar Global Mining Europe GmbH, Lünen 2013

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A

1 View A

View B

17

14 10

B

15 Z3

18

16 11

12 13

1 Road shield 2100/4500 10 pin 11 clevis 12 pin 49,8x121 13 pin 55/40x125

14 pin 13x152 15 roll pin 14x100 16 roll pin 8x100 17 looking clip 2,5 18 looking clip 4

Important!

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

5.14

Shield support 2100/4500-5x5330

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. 18:

2-way ball valve, open and closed

open

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

closed

Flow for medium enabled

Flow for medium stopped

3/2-way ball valve The 3/2-way ball valve is for shutting off the pressure supply line during maintenance work or repairs. Shutting off the pressure supply line connects the downstream hydraulic system with the tank at the same time. This releases the residual pressure in the hydraulic system.

Fig. 19:

Mode of operation, 3/2-way ball valve

direction of flow downward

T

direction of flow to the left

P

T

T tank P pressure

A consumer

A

Doc. No.: 7420 246 000 BA 00

VTSP / 01

P

A

5.15

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 unit's separate operating manual.

Arrangement of the hydraulic components The hydraulic components of the road shield are specified in the following table.

Tab. 3: Hydraulic components

02 03

Arrangement a) left b) right 1x1 each on electrohydraulic control unit (left+right)

On a bracket

5x1 each on the front leg (Z1)

04

1

Dual CV

05

1

PRV DN 10, 80 bar

06

2

PRV DN 10, 380 bar

07

5

PRV, 450 bar

on electrohydraulic control unit (1b) and canopy cylinder (Z3) beside electrohydraulic control unit (1b) on electrohydraulic control unit (1b) and canopy cylinder (Z3) 5x1 each on the leg (Z1)

08

5

PRV, 480 bar DN 20/25 SS

5x1 each on the leg (Z1)

09

5

Pressure gauge port

10

1

CV, NW 25

11

3

Measuring coupling SMK20

12

9

Glycerine pressure gauge NG 50

5x1 each on the leg (Z1) beside electrohydraulic control unit (1b) a) 1x1 beside electrohydraulic control unit (1b) b) 2x1 on canopy cylinder (Z3) between middle left and rear right leg (Z1) a) 2x1 each on electrohydraulic control unit (1b) b) 2x1 beside emulsion filter (15) c) 5x1 each on the leg (Z1)

14

1

15

1

16

5

17

1

3/2-way ball valve

18

1

symbol plate

19

5

screw-in socket M 20×1.5

20

1

symbol plate

Z1 Z2 Z3

5 2 2

Leg Shifting ram canopy cylinder

Einsteckmuffe DN 10 mit Drossel 2,0 Emulsion filter DN 12, 420 bar HP ball valve DN 20-SS, with safety locking handle

Remarks

1x on the dual CV (4)

For canopy cylinder (Z3) In the return line For canopy cylinder (Z3) In the piston space of the legs In the annular space of the legs In the return line

For the connection of measurement devices a) for accumulator cartridge (2) b) In the pressur line c) For leg (Z1*) With shuttle valve and compensating valve

1x between pressure gauge (12b) 5x1 each on the leg (Z1) 1x beside electrohydraulic control unit (1b) 1x beside electrohydraulic control unit (1a) 5x1 each on the leg (Z1) 1x beside electrohydraulic control unit (1b)

Interrupts the main pressure line to the shield In the pressur line

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

5.16

Shield support 2100/4500-5x5330

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01

Quantity Designation Electrohydraulic control unit, 2 8-function Accumulator cartridge 2 DN 20-SS Leg CV, Dn 20SSO with 1 distance plate

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

Operation of the shield hydraulics Fig. 20:

Shield hydraulics, arrangement Image caption: see table 3

16

9

pi A PB PB PA A A A

7

xx

12c

x

3 leg

8 Z1

4

6 14 2mm 11b 16

rear canopy cyl.

11b

x

12c 3

3

12c

leg

leg

8 8

Z1

Z1

SP T

12c SP

9

X5 X7

X2 X4 X6 X8

X1 X3 X5 X7

X2 X4 X6 X8

8 leg

leg

X3

x

3 8

2 3 4 5 6x7 8

xx

12c

2a

P 1

pi A PB PB PA A A A

7

x

3

xx

pi A PB PB PA

A A

12c

T

16 front canopy cyl.

X1

Z3

16

9 7

1b, 20

19

19

8 7 6 5 4 3 2 1

2 3 4 5 6x7 8

8 7 6 5 4 3 2 1

2b

P 1

Z1

Z1 1a, 18 19

Z2

VTSP / 01

Z2

si

si

Doc. No.: 7420 246 000 BA 00

advancing cyl.

19 advancing cyl.

Caterpillar Global Mining Europe GmbH, Lünen 2013

16

x

7 12c

7

xx

5

15 12b 12b

Z3

9

pi A PB PB PA A A A

17

xx

11a P R 10

pi A PB PB PA A A A

E

9

19

6

5.17

Operation of the shield hydraulics Functions of the electrohydraulic control unit, 8-function

X8

8

Fig. 21:

8

X7 6x 7

7 X6

1

4 5

X5

6 X4

5

2 3

X3 4

X2 X1

1

3 2

P

2

Fig. 22:

symbol plate - control unit right

1

2

3

5

4

6

7 8

Tab. 4: Electrohydraulic control unit with 8 functions, assignment of functions Funktion, Bezeichnung

5.18

Funktions-Nr.

Extend right legs

1

Retract rear right legs

2

Advance shield

3

Push conveyor

4

Retract front right legs

5

---------

6

Retract canopy cylinder

7

Retract canopy cylinder

8

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

SP

E

T

1

Operation of the shield hydraulics Fig. 23:

symbol plate - control unit left

1

2

3

5

4

6

7 8

Tab. 5: Electrohydraulic control unit with 8 functions, assignment of functions

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Funktion, Bezeichnung

Doc. No.: 7420 246 000 BA 00

Funktions-Nr.

Extend front left legs

1

Retract middle left legs

2

Push conveyor

3

Advance shield

4

Retract front left legs

5

---------

6

Extend rear left legs

7

Retract rear left legs

8

VTSP / 01

5.19

Operation of the shield hydraulics Control units The road shield is equipped with the following control units: intershield manifold electrohydraulic control unit, 8-function PMC®-R control unit.

Measuring coupling for pressure relief The measuring coupling (SMK20) is used to monitor and check the pressure in the system. The measuring couplings are, for example, installed on cylinders and legs.

The pressure can be read and the system relieved of pressure by connecting measurement and test devices.

Fig. 24:

Measuring coupling for pressure relief 3

1 1 leg or cylinder connection 2 measurement device connection for pressure relief

3 protective cap

The shield is equipped with three measuring coupling.

5.20

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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2

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

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

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Warning!

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

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

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

The 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.

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

Doc. No.: 7420 246 000 BA 00

VTSP / 01

5.21

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

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 therefore 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.

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

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.

5.22

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

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

Operation of the shield hydraulics Shield functions Functions of the control unit 8-function right Fig. 25:

Symbol plate for electrohydraulic control unit right

1

3

2

4

1

5

6

7

8

Extend right legs Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

2

Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

E Caterpillar Global Mining Europe GmbH, Lünen 2013

Retract rear right leg

Advance shield 3

Function “Retract leg” needs to have been performed before this function can be performed.

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.

Push conveyer

4

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

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

5

Retract front right leg Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

6

Doc. No.: 7420 246 000 BA 00

----------

VTSP / 01

5.23

Operation of the shield hydraulics Extend canopy cylinder

7

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 legs must be reset.

Retract canopy cylinder

8

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 legs must be reset.

Functions of the control unit 8-function left

1

3

5

7

2

4

6

8

1

Extend front left legs Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

2

Retract middle left leg Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Advance shield

3

Function “Retract leg” needs to have been performed before this function can be performed.

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.

Push conveyer

4

5.24

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

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

Shield support 2100/4500-5x5330

E

Symbol plate for electrohydraulic control unit left

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 26:

Operation of the shield hydraulics 5

Retract front left leg 6

----------

Extend rear left leg

7

Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Retract rear left leg 8

Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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8

Doc. No.: 7420 246 000 BA 00

VTSP / 01

5.25

Maintenance Maintenance Warning!

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

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

hydraulic control system

Special measures

filter cartridges

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

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

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

replacing filters

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

Our recommendation:

emulsion filters piston rods

5.26

Replace the emulsion filters directly.

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

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Caution!

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

Maintenance pressure relief valves

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

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

high-pressure hydraulic hoses

All high-pressure hydraulic hose lines must be replaced irrespective of any visible damage at the latest after 2 years of operation for safety reasons and to ensure the correct function of the system.

double filter, can be backflushed

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Daily maintenance hydraulic system

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

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

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

Doc. No.: 7420 246 000 BA 00

VTSP / 01

5.27

Maintenance 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 control panel.

Notice!

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

Every six months

. Apply a preservative to the piston rods of the hydraulic cylinders. Further details are contained in this chapter in the “Special measures” section. lubricating nipples. Use the grease A2 in accordance with EWN 7068. See chapter 6, section “Greases and lubricating pastes”.

Fig. 27:

Lubricating nipples on the hydraulic leg

b

a

a lubricating nipples on the guide bushing

b grease escaping at wiper seal

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

5.28

Shield support 2100/4500-5x5330

E

. Lubricate the wiper seals of both telescope stages via the Caterpillar Global Mining Europe GmbH, Lünen 2013

hydraulic leg

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

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

These are normally audible to the operator.

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Warning!

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

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

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

Fault localization support cannot be lowered

Doc. No.: 7420 246 000 BA 00

Possible cause

Measure required

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

Open the shut-off valve.

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

The shield canopy is stuck between the neighboring supports.

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

Control piston on the leg control valve is not working.

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

The leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

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

Leg is defective.

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

VTSP / 01

5.29

Troubleshooting support cannot be set

Possible cause

Measure required

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

Open the shut-off valve.

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

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

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

Control piston on the leg control valve is not working.

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

The leg control valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

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

Leg is defective.

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

Possible cause

Measure required

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

Open the shut-off valve.

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

The support is stuck between the neighboring supports.

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

Step on roof or floor blocking the support.

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

The pressure of the hydraulic supply is too low.

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

Control piston on the piloted check valve is not working.

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

The leg control valve may be defective.

Damaged or trapped hose line.

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

Shifting ram is defective.

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

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

support cannot be advanced

5.30

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

The pressure of the hydraulic supply is too low.

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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canopy cannot be positioned

canopy cannot be lowered

Doc. No.: 7420 246 000 BA 00

Possible cause

Measure required

Leg control valve is defective.

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

Legs are damaged.

Check legs for damage and replace, if necessary.

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

Pressure relief valve is defective.

Monitor pressure drop on the pressure gauge.

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

Possible cause

Measure required

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

Open the shut-off valve.

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve is not working.

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

The check valve may be defective.

Damaged or trapped hose line.

Check for damaged or kinked leg hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Measure required

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

Open the shut-off valve.

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve is not working.

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

The check valve may be defective.

Damaged or trapped hose line.

Check hose lines for controlling the leg/ stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

VTSP / 01

5.31

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

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

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

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

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

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

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

valve replacement

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

. Then actuate the functions manually to depressurize the system.

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

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

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

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

. Check the valve and replace it, if defective.

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

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

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

5.32

Shield support 2100/4500-5x5330

E

. Locate the faulty valve by actuating the functions individually in

Caterpillar Global Mining Europe GmbH, Lünen 2013

internal leakage

Troubleshooting Internal bypass inside the leg If an internal bypass in the leg is suspected proceed as follows:

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

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

If there is an internal bypass in the leg, for example due to damaged piston packing, fluid will flow out of the leg's lowering connection. If this happens, the leg 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 2013

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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 pressurized fluid is already discharged at working pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

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

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

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

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

. Check the filters in the hydraulic system.

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

Doc. No.: 7420 246 000 BA 00

VTSP / 01

5.33

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Troubleshooting

5.34

Shield support 2100/4500-5x5330

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 2100/4500-5x5330 RW 001

RW 002

The road shield mainly consists of the following main subassemblies: base frame, canopy, caving shield, hydraulic legs - 3 left legs, 2 right legs, hydraulic equipment with hose lines and control.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Tab. 6: Road shield, dimensions and weight Use road shield RW 001 road shield RW 002

Device number

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

Approx. weight in kg

12 069 x 2 100 x 969 7420 246 000 00 01

63 403 7 041 x 2 100 x 969

Tab. 7: Shield support, numbering Device number 7420 246 000 00 01

base frame

Shield number

Special design

RW 001 RW 002

The shield is equipped with a one-piece base frame.

This consists of two bases which are tightly connected to each other.

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 canopy is a two-piece steel construction, which is fastened by two strippers connected with canopy cylinders. The connection to the caving shield is flexible by means of pin connections.

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 multi-stage hydraulic legs have the same load capacity at any stage and act on both sides.

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

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

Doc. No.: 7420 246 000 BA 00

VTSP / 01

6.3

Description Main subassemblies Fig. 28:

Road shield 1

RW 001

14

2

3

RW 002

4 5 15 6

15 16

16

16

16 16 17

13

12

10

9

1 canopy I compl.

2 canopy II compl.

3 canopy III compl.

4 caving shield right 5 caving shield left 6 lemniscatic link front 7 lemniscatic link rear 8 base front right compl.

9 base front left compl.

10 base connecting piece

6.4

11

10

18

8

17

11 base rear right compl.

12 base middle leftcompl.

13 base rear left compl.

14 stripper 15 canopy cylinder ZE-80/50-700-CR 16 Hydraulic leg SD-5100-380-1630/4000-BN 17 Shifting ram ZE-225/140-1080-CR 18 universal joint

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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7

Description Fig. 29:

Road shield, universal joint RW 002

RW 001

Caterpillar Global Mining Europe GmbH, Lünen 2013

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A

1 View A

View B

17

14 10

B

15 Z3

18

16 11

12 13

1 Road shield 2100/4500 10 pin 11 clevis 12 pin 49,8x121 13 pin 55/40x125

Doc. No.: 7420 246 000 BA 00

VTSP / 01

14 pin 13x152 15 roll pin 14x100 16 roll pin 8x100 17 looking clip 2,5 18 looking clip 4

6.5

Description Main dimensions Fig. 30:

Road shield, dimensions

4950

3900 3820

HA

H

150

HE

24

2915

2139

LT 002

2520

Caterpillar Global Mining Europe GmbH, Lünen 2013

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LT 001

5030

W

W2

HE height, extended HR height, retracted

W1

LT transport length W width

Tab. 8: Road shield, dimensions

6.6

LT 001

LT 002

H

HA

HE

W

W1

W2

12 069

7 041

3 500

4 500

2 100

3 348

3 270

1 880

Shield support 2100/4500-5x5330

Description Base with lemniscatic links and relay bar assembly The two-piece base frame transmits the shield load of the hydraulic props to the floor. The legs are mounted on hinges in the ball sockets in the bases and are held on both sides by leg retainers.

The four lemniscatic links are hinged to the base frame with a pin connection.

Base The legs are stored in the base. Mounting devices for the shifting rams are fastened on the ends of the base.

Base

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Fig. 31:

RW 001 a RW 002 b

c

RW 001 base long RW 002 base short

1 cylinder seat 2 pin 3 pin

Notice!

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

Fig. 32:

Base with Shifting ram

*) EWN = works standard

Doc. No.: 7420 246 000 BA 00

VTSP / 01

6.7

Description Lemniscatic link The lemniscatic links of the road shield deviate in: the length.

The front lemniscatic links are longer than the rear lemniscatic links.

Fig. 33:

Lemniscatic link

b

a front lemniscatic links

6.8

b rear lemniscatic links

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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a

Description Canopy The canopy transfers the supporting force of the legs to the roof. It is hinged to the caving shield by means of pin connections.

The legs are fastened in the canopy. The mounting devices for the canopy cylinders are located on the strippers.

Fig. 34:

Kappe, Positionen 1

4

5, 6

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

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2

7

8 9

11 10 9 1 canopy RW 001 2 canopy RW 002 3 stripper 4 retainer 20x170 5 pin 6 locking clip 3,2

Doc. No.: 7420 246 000 BA 00

VTSP / 01

7 pin 8 load ring 9 screw connection complete 10 pin 11 pin

6.9

Description Fig. 35:

Canopy with cylinder 1

3

2

4 1 canopy RW 001 2 canopy RW 002

3 stripper 4 canopy cylinder

Fig. 36:

Fastening the leg head - rear leg 5

6 4

4 retainer 5 pin

6.10

6 spring clip 2.5

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

Important!

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

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

E

Leg retainers

Description Caving shield The caving shield is hinged to the canopy and to the base frame via the front and rear lemniscatic links.

Fig. 37:

Caving shield, items 3

Caterpillar Global Mining Europe GmbH, Lünen 2013

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1

2

1 caving shield RW 001 2 caving shield RW 002

3 load ring

Notice!

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

*) EWN = works standard

Doc. No.: 7420 246 000 BA 00

VTSP / 01

6.11

Description Technical data, steel structure Shield support, device number 7420 246 000 00 01 Height, retracted . . . . . . . . . . . . . . . . . . . . mm

2 100

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

4 500

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

2 400

Height adjustment by means of hydr. leg stroke . . . . . . . . . . . . . . . . . . . . . mm

2 400

mech. extension . . . . . . . . . . . . . . . . . . . . mm

---

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

1 000

Cylinder stroke . . . . . . . . . . . . . . . . . . . . . mm

1 080

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

---

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

3 970 / 9 000

6.12

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

8.3

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

50.4

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Caving shield inclination:

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

The shield 7420 246 000 01 is equipped with two electrohydraulic control units: Caterpillar Global Mining Europe GmbH, Lünen 2013

E

8154 176 000 00 00 has 8 functions.

Fig. 38:

Electrohydraulic control unit, 8-function

View A

9

6

10

5 1 3, 7 1 manifold block, 8-function 2 double 3/2-way magnetic pilot solenoid valve 3 control valve cartridge NG 20 4 control valve cartridge NG 13 5 check valve NG 2

2

4, 8

A

6 filter cartridge 7 screw fitting 8 screw fitting 9 plug M 16x1 10 plug M 18x1

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Non-compliance 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 246 000 BA 00

VTSP / 01

6.13

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

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

This allows the leg to be joined to the support via a rotatable fastening.

The head is fastened using two retainers each that are inserted into the holes in the retainer before the leg head is installed. The retainers are secured in the second groove by a pin and locking clip.

After the leg head is installed, the retainers are pushed into the holes of the leg head and secured in the first groove with a pin and locking clip.

Fig. 39: Double-telescopic leg, type SD-5100-380-1630/4000-BN, 6

21

5 e

2

d 1

a

c 1 leg base 2 major stage 5 PRV 520 bar 6 burst disc 21 piston rod

a piston space connection b annular space connection c safety cam d load ring 3000 kg e lubricating nipple

Tab. 9: Telescopic leg Length in mm ID no.

Telescopic leg 8250 203 000 00 00

6.14

Stroke in mm

retracted

extended

upper stage

lower stage

1625

3875

1126

1124

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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b

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

Warning!

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

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

set leg

Pressurized fluid is admitted under the major stage via the piston space connection. The major stage first extends, while the pressurized fluid in the annular space is discharged into the return line. If the piston of the major stage moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressurized fluid is supplied at the same time via the check valve in the bottom of the major stage.

load leg

a) Major stage extended only: The force is transferred mechanically from the shield canopy via the leg head to the piston rod and again via the bottom of the piston rod to the bottom of the major stage. Further transmission of the force takes place hydraulically via the pressurized fluid under the major stage in the leg base and from there, mechanically into the base frame (base).

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Function

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

The piston rod supports itself on the pressurized fluid, which is blocked by the check valve in the bottom of the major stage.

Further transmission of force up to the setting of the major stage is as described under a). lower leg

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

Both stages of the leg can be actively lowered. Only when the major stage is completely retracted is the check valve in the bottom of the major stage opened by the tappet and the piston rod can then retract.

A few millimeters before the major stage is “fully retracted”, the check valve is opened by a tappet, whereby the pressurized fluid underneath the major stage acts like a spring lifting the major stage to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

Doc. No.: 7420 246 000 BA 00

VTSP / 01

6.15

Hydraulic cylinder Hydraulic cylinder Setup 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. 40:

Hydraulic cylinder, typical example

Type a)

2 1

3

5

4

1

4

6

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

4 guide bushing 5 connection 6 connection

Notice!

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

Warning!

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

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

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

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

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

6.16

Shield support 2100/4500-5x5330

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Type b)

Hydraulic cylinder Fig. 41:

Items of the hydraulic leg canopy RW 002

canopy RW 001

Caving shield

Z3

Z2 Z2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Z1

Z1 base RW 002 base RW 001

Tab. 10: Leg and hydraulic cylinder, position ID

QuanName tity

Z1

5

Leg

Z2 Z3

2 2

Shifting ram Canopy cylinder

Doc. No.: 7420 246 000 BA 00

Location RW 001 3x RW 002 2x On the end of base canopy-canopy

VTSP / 01

Drawing no.

Type

8250 213 000 00 00 SD-5100-380-1630/4000-BN 8241 548 000 00 00 ZE-225/140-1080 8241 550 000 00 00 ZE-80/50-700-BN

6.17

Hydraulic cylinder Shifting ram (Z2) Fig. 42:

Hydraulic cylinder, type ZE-225/140-1080

72

72 L b 2 14

c

11

1 a

2 reed rod 11 piston rod 14 screw fitting 27 staple DN 20-D

E

a piston space connection b annular space connection c load ring 3 000 kg L retracted 1 560 extended 2 640 Stroke: 1080

Caterpillar Global Mining Europe GmbH, Lünen 2013

1 cylinder tube

Canopy cylinder (Z3) Fig. 43:

Hydraulic cylinder ZE-80/50-700

41,5

41,5 L

b

2 a 1 1 cylinder tube 2 piston rod a piston space connection

6.18

b annular space connection L retracted 985 extended 1525 Stroke: 540

Shield support 2100/4500-5x5330

Hydraulic cylinder Technical data, hydraulic cylinders

Caterpillar Global Mining Europe GmbH, Lünen 2013

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telescopic leg, double acting, 2-stage

shifting ram double acting, reverse mounted

canopy cylinder, double acting

Doc. No.: 7420 246 000 BA 00

Type SD-5100-380-1630/4000

Device no. 8250 213 000 00 00

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

1 630

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

4 000

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

2 370

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

380 / 270

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

350 / 250

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

1 134,1 / 573

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

172 / 82

Leg force at setting pressure, 350 bar . . kN

3 969

Setting pressure, 450 bar . . . . . . . . . . . . kN

5 103

Retracting force at 350 bar . . . . . . . . . . . kN

602

Type ZE-225/140-1080 version with reed rod

Device no. 8241 548 000 00 00

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

1 080

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

225

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

140

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

397,6

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

243,7

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

1 392 / ---

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

853 / ---

Type ZE-80/50-700

Device no. 8241 550 000 00 00

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

700

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

80

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

50

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

50.3

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

30.6

Thrust force at 320 / 350 bar . . . . . . . . . kN

161 / 176

Pulling force at 320 / 350 bar . . . . . . . . . kN

98 / 107

VTSP / 01

6.19

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as legs and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

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

Tab. 11: Pressure relief valves, use of the various types

For return line

Spring-loaded

80

8220 042 080 00 00

For cylinders

Spring-loaded

380

7337 486 380 00 00

For legs

Spring-loaded

450

7337 486 450 00 00

Caution!

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

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

Caution!

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

Notice!

Always fit new seals when replacing a pressure relief valve.

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

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

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

6.20

Shield support 2100/4500-5x5330

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Device no.

Design

Caterpillar Global Mining Europe GmbH, Lünen 2013

Setting pressure in bar

Application

Pressure relief valves Tab. 12: Text code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

Color coding is with either one or two colors. It indicates the range within which its setting pressure lies. The following figure 44 shows a pressure relief valve provided with a blue and white color code.

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

Pressure relief valve, example

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 44:

b

a

a color code b protective cap

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

Tab. 13: Color codes for pressure relief valves, overview

1)

Doc. No.: 7420 246 000 BA 00

Color

Pressure range (bar)

black

0 - 49

black/white

50 - 99

brown

100 - 149

brown/white

150 - 199

green

200 - 249

green/white

250 - 299

blue

300 - 349

blue/white

350 - 399

red

400 - 449

red/white

450 - 499

yellow

500 - 549

yellow/white

550 - 599

orange

600 - 649

orange/white

650 - 699

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

VTSP / 01

6.21

Hydraulic fluids Hydraulic fluids Permissible hydraulic fluids Notice!

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

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

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

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

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

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

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

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If a mine only uses individual hydraulic components without using Caterpillar shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Caterpillar. The same applies for example to hydraulic chain tensioners, hydraulically tensionable drives etc. A corresponding certificate of exemption will be issued

by Caterpillar upon request.

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

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

The following figure shows a typical certificate.

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Fig. 45: Certificate, example

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Hydraulic fluids Maintenance of the hydraulic fluid Consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. Ideally, the most important properties of the hydraulic fluid are monitored automatically and documented continuously in order to directly counteract any harmful development.

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

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

If it is not possible to monitor the hydraulic fluid continuously, the properties listed below should be checked at least once every week: pH value – setpoint: 7.5 to 9.5 – setpoint: see certificate microbial load – setpoint:  105 col/ml In addition, the electrical conductivity, foaming and the working temperature of the hydraulic fluid should be monitored regularly.

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

Quality of the process water for use for hydraulic fluids

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

If the limit values shown in the table 14 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not complied with this should be taken into consideration when selecting a concentrate. Furthermore, water treatment may also be necessary.

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

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

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concentrate content

Hydraulic fluids for use as spraying water

limit values

Water used for this purpose may not contain aggressive components or dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter of at least 100 m.

In order to protect the components, the limit values listed in the table must not be exceeded.

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

Caution!

Using water that is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Only use water that complies with the specified limit values!

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Tab. 14: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, odor

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

Electrical conductivity

< 1800 S/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+ content

Not specified

Water hardness

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

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



1 mg/l

Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 m filtering 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 if the water is used exclusively as spraying water.

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Hydraulic fluids Greases and lubricating pastes Only the recommended lubricants or products certified as equivalent may be used.

Important!

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

Greases grease A1

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

Tab. 15: Grease A1 Supplier

Make

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

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

Application temperature range: . . . . . . . -40 to +120C grease A2

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

Tab. 16: Grease A2 Supplier

Make

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 Application temperature range: . . . . . . . -15 to +120C grease A8

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

Tab. 17: grease A8 Supplier

Make

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 of application: . . . . . . . . . . -20 to +120C

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

Hydraulic fluids 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. 18: Lubricating paste B3 Supplier

Make

Lubricant carrier

NLGI class

Flashpoint in °C

Gleitmolybdän

gleitmo 805

Lithium soap

2

220

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

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lubricant B6

Tab. 19: Lubricant B6 Supplier

Make

Lubricant carrier

Flashpoint in °C

Chesterton

Parting agent/lubricant 785

Paraffin base

132

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

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Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 20: Tightening torques at tot. = 0.14 Torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

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

1) The dimensions listed in brackets are applied in exceptional cases only.

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

3) Only for expansion bolts with a reduced shaft diameter of 24.2 mm.

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

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(mm)

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Thread 1)

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For your information

Standards and directives

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

Standards and directives Applied standards and directives Tab. 21: Standards and directives, excerpt

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Designation

Date of issue

Title

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

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Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA-fluids in mining

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

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

1985-02

1) EWN = works standard

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

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Fig. 46:

Name plate, example

Caterpillar Global Mining Europe GmbH, Lünen 2013

1 manufacturer 2 SAP/order no.

3 date of manufacture 4 serial component no.

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5 device number 6 number of legs 7 leg force

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Identification of the shield

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