CAT Shield support 2400 4300-3x5330-2050 Operating Manual - PDF DOWNLOAD

Translation of the original operating manual

Operating manual Shield support 2400/4300-3x5330-2050 Doc. No.: 7420 245 000 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

Table of content

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

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

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

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

1.3 1.3 1.4 1.4

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

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

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

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

E

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Staple clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3 3.3 3.4

3.5 3.5 3.5

3.8 3.8 3.9 3.10 3.11

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

4.3

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

4.3

Pressure equalization of the electronic control system . . .

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

Establishing a connection between the shields . . . . . . . . .

Requirements for the face hydraulic system . . . . .

4.10

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

4.11

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

4.12

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

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

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

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4.5 4.6 4.9

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4.12 4.14 4.14

Table of content 5. Operation 5.3 5.3 5.6

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

5.9

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

5.15

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

5.16

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

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

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

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

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

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

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

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

Intershield manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Base lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CV, hydraulically piloted . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear side of shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving canopy cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16

5.18 5.18 5.20

5.21 5.21 5.23 5.44 5.46 5.47 5.50 5.51 5.52 5.53 5.54 5.55 5.56 5.56 5.57 5.58 5.59 5.60 5.61 5.63 5.64 5.68

5.69 5.69 5.70 5.71 5.71 5.71

5.72 5.72 5.72 5.75 5.75 5.76 5.76 5.76

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

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

Table of content 6. Technical data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leg retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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Antitopple device “canopy/canopy” . . . . . . . . . . . . . . . . . . .

Anchoring device “canopy/canopy” . . . . . . . . . . . . . . . . . . .

Outrigger ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conveyor pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side plate extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Side seal cylinder (Z4a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side seal cylinder (Z4b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving canopy cylinder (Z5) . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper cylinder (Z7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base lifting cylinder (Z9) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side flap cylinder HG (Z10) . . . . . . . . . . . . . . . . . . . . . . . . . .

Side flap cylinder, TG (Z11) . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.5 6.7 6.8 6.14 6.16 6.18 6.20 6.21 6.22 6.27

6.29 6.29 6.37 6.42 6.44 6.46 6.52 6.54 6.56 6.58 6.60 6.61

6.63 6.63 6.65

6.67 6.67 6.69 6.69 6.70 6.70 6.71 6.71 6.72 6.72 6.73

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

6.75

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

6.77

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

6.78

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

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

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

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

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

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

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6.78 6.80 6.80 6.82

6.84 6.84

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

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

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

7.3

7.5 7.5 7.6

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

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

7.3

Shield support 2400/4300-3x5330-2050

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 2400/4300-3x5330-2050 * ID No.:

7420 245 000 00 01 7420 245 000 00 02

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.

*

Doc. No.: 7420 245 000 BA 00

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

VUSP / 01

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.

The 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

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Memorize the symbols and their meanings.

E

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

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

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

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

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

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

Observe the safety and accident prevention regulations of the following parties: 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 dealership service engineers or by specially trained personnel of the mining companies.

2.4

Shield support 2400/4300-3x5330-2050

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

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– 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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 catalogue. 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 2400/4300-3x5330-2050

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.

If the conveyor has to be pulled back during abnormal operation, it is preferable to use the functions of the electronic shield controlIf this is not possible, do as specified in the applicable work instructions of the mine.

Secure all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the lifting points intended for that purpose.

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

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

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

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

2.10

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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 catalogue 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.

2.12

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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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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. 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:

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Laying hydraulic line, slack

2.13

Safety instructions are not twisted, Fig. 4:

Laying hydraulic line, twist

Laying hydraulic line, bend

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 5:

E

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

1.5 x d

d

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.

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.

2.14

Shield support 2400/4300-3x5330-2050

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

Laying hydraulic line, connections to moving parts

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 7:

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2.15

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Safety instructions

2.16

Shield support 2400/4300-3x5330-2050

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

During 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 2400/4300-3x5330-2050

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

transport safety devices

Designation

Alignment

Complete shield unit

As for normal use

Note

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

Tab. 2: Transport safety devices Component

Transport safety device

Quantity

Face side

Transport safety device

1

Side seal, movable

Pin and securing device

4

Hydraulic system

Unused hydraulic connections are protected by protective caps or plugs

-

3.6

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Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

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

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

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Relay bar

Transport Fig. 8:

Transporting gate end shield as complete unit

HE

S1 Sy

X4

1905

So

X1

115

150

S2

94

150

3145 Sx

3526

S3

X5

X2

3422 L

10825

Caterpillar Global Mining Europe GmbH, Lünen 2013

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7270

W X3

W1

S1 transport hole in base, load capacity of 30 000 kg S2 load ring in base, load capacity of 30 000 kg S3 transport slote in base, load capacity of 30 000 kg X1 transport safety device for relay bar, face side X2 transport safety device for relay bar, gob side X3 transport safety device for movable side seal X4 transport safety device for flipper X5 transport safety device for flap So center of gravity

Tab. 3: Transport shield support 7420 245 000 00 01/02, dimensions and weights L in mm

W in mm

W1 in mm

HR in mm

7420 245 000 00 01

10 666

1950

1666

2400

2006/1448

68 500

7420 245 000 00 02

10 645

1950

1666

2400

2006/1448

68 500

Device number

Sx/Sy in mm

Weight in kg

Important!

For transporting, use the two lifting points S1 and S2 or S3.

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3.7

Transport safety device Transport safety device Relay bar assembly A transport safety device is to be attached to the relay bar assembly during face-side transportation.

Transport safety device, relay bar assembly, face side

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 9:

3

2

1

1 pin 2 locking clip

3.8

3 spring clip

Shield support 2400/4300-3x5330-2050

Transport safety device Flipper Fig. 10:

Transport safety device, flipper

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1

3

2

1 flipper 2 pin

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3 spring clip

3.9

Transport safety device Staple clip Fig. 11:

Securing the staples

3

4 2

1

1 staple clip DN 10 2 staple clip DN 12

3 staple clip DN 20 4 staple clip DN 25

Important!

All staples on the travel way and under the canopy are secured with staple clips.

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1

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

Transport safety device, side seal, principle

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 12:

10 10 pin 30/22x120

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20

10

20 20 locking clip 3.2

3.11

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Transport safety device

3.12

Shield support 2400/4300-3x5330-2050

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

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

Important!

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

identification for installation in the face

Doc. No.: 7420 245 000 BA 00

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

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4.3

Installation of the shield units shield number

Shield number, centered, face side

a

b

a shield number

b shield weight

Tab. 4: Shield support 0010 700 000 00 00, numbering Device no.

Quantity Use

Shield

Shield number

Special design Conveyor pulling device

7420 242 000 00 01

138

Face shield

8 to 143

SH001 to SH138

7420 243 000 00 01

1

Transition shield HG

5

TS001

Extension, right

7420 243 000 00 02

1

Transition shield TG

144

TS001

Extension, left

3

GS001

4

GS002

147 to 149

GS005 to GS007

145

GS003

146

GS004

1 to 2

BS001 to BS002

Gate end shield HG 7420 245 000 00 01

5 TG

7420 245 000 00 02

7420 244 000 00 01

4.4

2

2

Gate end shield TG

Segment shield HG

Side plate extension, right, side plate, right

Side plate extension, left side plate, left

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Fig. 13:

The shield number serves as an identification feature. All shields are numbered consecutively. The corresponding shield number is on the face side, on the left side of the base.

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. 14:

Example of a vent screw on an electronic control system b

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a

a vent screw

b electronic control system PMC®-R

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

Caution!

Take care to ensure that the vent screw is tightened by hand again after the control system pressure has been equalized. If this is not done, then dirt and moisture could penetrate the control unit and firedamp protection is no longer ensured.

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4.5

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

The shield functions must then be operated by means of an additional external PMC®-R control unit. An appropriate cable is used to connect it to the internal PMC®-R control unit.

Important!

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

Important!

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

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

Important!

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

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

Fig. 15:

Supply block with 5/3-way ball valve 1

HP DN 32

P

DN 50

W

DN 50

T

T

DN 63

DN 63

Lever position ON working position (pressure and return open) OFF depressurized (return open) PTO depressurized (pressure and return shut off) HP high-pressure line connection P pressure line connection T return line connection

4.6

W water line connection 1 5/3-way ball valve

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

The lever on the supply block (5/3-way ball valve) must be set to the PTO (power take off) position during installation by means of the auxiliary supply. Only in this position is the shield is depressurized and the return line is blocked. There is an information sign on the supply block, where the respective lever positions are explained.

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Lever position on the supply block

Installation of the shield units Connecting the auxiliary supply The auxiliary supply connections can be found on the left under the outer canopy, nearby the left side seal of the shield. An HP ball valve is in the pressure line of the auxiliary supply, which must remain open during the procedure.

Fig. 16:

Auxiliary supply, closed

29

23

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T

29 P 43 46 23 PRV, 80 bar 29 plug with pressure relief 43 through sleeve DN 20

connecting the auxiliary supply

46 HP ball valve DN 12 for auxiliary supply - open P connection for pressure line, auxiliary supply T connection for return line, auxiliary supply

. Check whether the lever on the supply block is in the PTO position.

. Open the HP ball valve, item 46. . Open the plug with pressure relief, item 29. . Remove the plugs from the connections P and T of the auxiliary supply.

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

. Secure the connections with staples.

The shield can now be moved by means of the external control units PMC®-R.

. Move the shield to the desired position.

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4.7

Installation of the shield units Fig. 17:

Auxiliary supply, open

43

23

T P 29

29 plug with pressure relief 43 through sleeve DN 20

sconnecting the auxiliary supply

46 HP ball valve DN 12 for auxiliary supply - open P connection for pressure line, auxiliary supply T connection for return line, auxiliary supply

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

. To relieve the pressure line, shut off the pressure supply line of the pump. Make sure the pump's return line remains open.

. Move the lever on the supply block to the OFF position. The pressure is released via the return line.

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

. Close the HP ball valve, item 46. . Close the plug with pressure relief, item 29.

Notice!

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

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

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23 PRV, 80 bar

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46

Installation of the shield units Establishing a connection between the shields hydraulic system

The supply block for the supply of the shield hydraulics is positioned in the center under the canopy.

The connection to the supply block of the neighboring shield is established by means of five hose lines: one high-pressure line HP (DN 32 SSKV-HD) two return lines T (DN 63 SSKV-ND) one pressure line P (DN 50 SSKV-HD) one water line W (DN 50 SSKV-ND).

Proceed as follows to join the shields to one another:

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

. Install the connection lines on the connections HP, T, W, P on Caterpillar Global Mining Europe GmbH, Lünen 2013

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the supply block and connect them to the supply block of the neighboring shield.

Fig. 18:

Connection lines to the neighboring shield (schematic diagram)

control unit

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

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

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

additional equipment

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

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

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4.9

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

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Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

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.

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

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

minimum pressure

For the Shield support 2400/4300-3x5330-2050 ID No.: 7420 245 000 00 01 Shield support 2400/4300-3x5330-2050 ID no.: 7420 245 000 00 02 a minimum pressure of 30 bar applies to the water spraying system.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Warning!

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

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

4.11

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. . Check the plugs of the relay bar assembly.

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

. Make sure that the additional device is mounted and secured on the bases.

1) Maximum possible plugging

4.12

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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

E

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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

4.13

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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Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Warning!

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

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

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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.3

Requirements Fig. 19:

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.

5.4

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

A travel way (minimum dimension, country-specific)

E

H

Requirements repair work

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

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

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

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

Caterpillar Global Mining Europe GmbH, Lünen 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. water spraying system

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

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

conveyor 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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.5

Requirements Safety requirements automatic mode

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

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

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

operating the shield unit

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

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

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

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

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

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

The 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.

5.6

Shield support 2400/4300-3x5330-2050

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. 20:

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

Shield unit with plough

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 21:

Shield unit with shearer

Shield unit with plough

Shield unit with shearer

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

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

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

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.

5.8

Shield support 2400/4300-3x5330-2050

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 22:

A looking toward coal face B looking toward gob general

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

Well-trained operating personnel, knowledge 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.

shield canopy position

Doc. No.: 7420 245 000 BA 00

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.

VUSP / 01

5.9

Operation of the shield support Caution!

Never exceed the permissible angle of inclination of the canopy!

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

Fig. 23:

Shield support in normal position

α=0

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

Caution!

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

Stabilizing cylinders must always have sufficient residual stroke!

Indicative value: at least 20 mm!

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

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

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

5.10

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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M

Operation of the shield support Fig. 24:

Shield support with extremely inclined shield canopy

α1

s1

M

s2 α2 Caterpillar Global Mining Europe GmbH, Lünen 2013

E

M

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

Caution!

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

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

Caution!

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

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.11

Operation of the shield support Caution!

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield), which is specified in chapter 6, section “Technical data”, is exceeded, this could lead to damage to 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.

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

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

WRONG

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

Fig. 26:

R i g h t : fill out roof falls

RIGHT

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.

5.12

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 25:

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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. operating on inclines

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

Since, in operations where there are inclines, the shield unit advance usually begins in the lower-lying part of the face, it is important that the 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.

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

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

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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.13

Operation of the shield support 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.

5.14

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Important!

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

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

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

Warning!

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

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

Caution!

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

Observe the following safety regulations:

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

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

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

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the 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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.15

Shield components Shield components Main components Fig. 27:

Gate end shield

21

22

c

a

d e 53

41 51

View A

61

9

A

8

86

13

3

1

85

52

87 6

71 72

81, 82

9

5 11 12

b 8 31

41

7 7 8 1 base 3x5330 3 relay bar assembly 5 lemniscatic link, front 6 lemniscatic link, front 7 lemniscatic link, rear, right 8 lemniscatic link, rear, left 9 lemniscatic link, front 11 canopy 3x5330-1060-2050 12 caving canopy 13 flap 21 side seal, CLH

5.16

22 side seal, caving canopy 31 caving shield 41 leg 51 base lifting cylinder 52 shifting ram 53 caving canopy cylinder 61 hydraulic system 71 thrust piece 72 pin 65/53x191 76 cover, rear

81 hex. head screw M 12x100-A 4-80 82 hex. nut M 12 85 information sign 86 information sign 87 information sign a flipper cylinder b caving canopy cylinder c electrohydr. control units d water valve unit e PMC®-R

Shield support 2400/4300-3x5330-2050

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76

Shield components

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Tab. 5: Gate end shield 7420 245 000 00 01/02, subassemblies Item

Description

01 03

Var.

ID No.

Approx. weight in kg

Note

1

2

Base 3x5330

x

x

7420 245 300 00 01

12191 Length: 3 434 mm

Relay bar assembly

x

x

7420 245 330 00 01

1104 Length: 2 541 mm

05

Lemniscatic link, front

x

x

7420 233 303 00 00

587 Length: 1 643 mm

06

Lemniscatic link, front

x

x

7420 245 303 00 00

590 Length: 1 643 mm

07

Lemniscatic link, rear right

x

x

7420 233 305 00 00

643 Length: 1 836 mm

08

Lemniscatic link, rear left

x

x

7420 233 306 00 00

643 Length: 1 836 mm

09

Lemniscatic link, front

x

x

7420 245 304 00 00

590 Length: 1 643 mm

11

Canopy 3x5330-1060-2050

x

-

7420 245 400 00 01

25273

Length: 8 700 mm + flipper 1 291 mm

11

Canopy 3x5330-1060-2050

-

x

7420 245 400 00 02

24833

Length: 8 500 mm + flipper 1 291 mm

2/11

Flipper

x

x

7420 242 470 00 01

1200 Flipper cylinder

12

Caving canopy

x

-

7420 245 450 00 00

5007 Length: 3 119 mm

12

Caving canopy

-

x

7420 245 480 00 00

5309 Length: 3 319 mm

13

Flap

x

x

7420 245 460 00 00

1593 Length: 1 615 mm

21

Side seal, canopy

x

-

7420 245 710 00 00

2110

Length: 7 510 mm Side seal cyl. Ø 78

8241 352 000 00 00

7420 245 720 00 00

Length: 7 310 mm 1810 Side seal cyl. Ø 78

8241 352 000 00 00

7420 245 760 00 00

Length: 2 560 mm 742 Side seal cyl. Ø 78

8241 352 000 00 00 8241 352 000 00 00

21 22

Side seal, canopy Side seal, caving canopy

x

x -

22

Side seal, caving canopy

-

x

7420 245 770 00 00

Length: 2 760 mm 774 Side seal cyl. Ø 78

31

Caving shield

x

x

7420 245 800 00 01

5044 Length: 2 419 mm

41

Hydraulic leg

x

x

8250 210 000 00 00

1818

51

Base lifting cylinder

x

x

8241 487 000 00 00

124 ZE-165/100-310-CR

52

Shifting ram

x

x

8241 535 000 00 00

457 ZE-240/100-1080-CR

53

Caving canopy cylinder on canopy

x

x

8241 536 000 00 00

351 ZE-225/140-530-BN

61

Hydraulic 3-legged shield

x

-

8241 521 000 00 00

SD-5300-380-1465/3285-BN PRV 520 bar

8112 377 000 00 00

Electrohydraulic control unit, 12-function Electrohydraulic control unit, 6-function Water valve unit Intershield manifold Lines Water spraying system Brackets Electrohydraulic control unit, 12-function Electrohydraulic control unit, 6-function Water valve unit Intershield manifold Lines Water spraying system Brackets

61

Hydraulic 3-legged shield

-

x

8112 378 000 00 00

71

Thrust piece

x

x

7420 233 328 00 00

72

Pin 65/53x191

x

x

7420 233 300 06 00

4

76

Cover, rear

x

x

7420 233 380 00 00

10.9

81

Hex. head screw M 12x100-A

x

x

0000 000 201 03 15

0.1

82

Hex. nut M 12

x

x

0000 000 235 00 26

0.01

85

Information sign

x

x

7420 245 000 01 00

0.01 1 set no. 1 to 7

86

Information sign

x

x

7420 245 000 02 00

0.01 Shield number

87

Information sign

x

x

7420 245 000 03 00

0.01 Weight

8154 182 000 00 00 8154 180 000 00 00 8401 008 500 00 00 8401 009 050 00 00 8112 377 010 00 00 8112 377 020 00 00 8112 377 030 00 00 8154 182 000 00 00 8154 180 000 00 00 8401 008 500 00 00 8401 009 050 00 00 8112 378 010 00 00 8112 377 020 00 00 8112 377 030 00 00

162

Important!

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.17

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

Ensure that the ball valve is engaged at all times.

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

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

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

Fig. 28:

2-way ball valve, open and closed

open

Flow for medium enabled

5.18

Flow for medium stopped

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

closed

Overview of shield hydraulics 5/3-way ball valve The 5/3-way ball valve has three switching or lever positions.

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

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

Fig. 29:

5/3-way ball valve, with three lever positions

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

ON

2

PTO

1

(Power Take Off)

OFF PTO depressurized (pressure and pressure relief shut off) medium flow stopped

OFF depressurized (pressure relief for output side to the tank) medium flow stopped 1 lever

ON working position (pressure open) medium flow open 2 engagement pin

. Change the lever position by 1. pulling the engagement pin (2), 2. turning the hand lever (1) in the respective position until the lever engages.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.19

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

The following ball valves are open during normal operation: 44, 45a, 45b, 45c, 47a, 47b, 48 The following ball valves are closed during normal operation: 46 Tab. 6: HP ball valves Designation

44

blue

HP ball valve DN 10

45a

red

HP ball valve DN 10

45b

red

HP ball valve DN 10

45c

red

HP ball valve DN 10

46

red

HP ball valve DN 12

47a

red

47b

red

48

blue

HP ball valve DN 20 with safety locking handle HP ball valve DN 20 with safety locking handle HP ball valve DN 20

Function For shutting off the side seal spraying system For shutting off the two front and the rear legs. Leg is not retracted when lowering.

For shutting off the piston space of the base lifting cylinder. Base lifting cylinder is not retracted when setting the leg.

For shutting off the annular spaces of the side seal cylinders

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

For shutting off the two front and the rear legs

Use Function of the water spraying system is deactivated.

During maintenance work and repairs on the leg and any removal During maintenance and repair work E

Color

Closed during transport, to prevent the side seal from extending and to allow the mechanical lock to be installed, for maintenance and repair work For moving the shield during commissioning and for connecting hydraulically operated auxiliary devices Interrupts the main pressure line to the shield during maintenance and repair work.

For shutting off the pressure supply to the flipper cylinder For shutting off the water spraying system

Function of the water spraying system is deactivated.

* Only for transition shield

5.20

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

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 gate end shields are specified in the following table.

Tab. 7: Hydraulic components

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Item Quantity Designation Electrohydraulic control unit, 01 1 12-function Electrohydraulic control unit, 02 1 6-function

Arrangement

Remark

In the middle beneath the canopy

On a bracket

On the left beneath the canopy

On a bracket

03

1

Leg CV, NG 20

3x1 each on the leg (Z1)

With shuttle valve, without compensating valve

06

1

Water valve unit, 4 function

1x centered under the canopy, behind the electrohydraulic control unit (2)

On a bracket

07

1

In the middle beneath the canopy

On a bracket

08

2

Intershield manifold SSKV 50; 32; DN 63; DN 50 Accumulator cartridge DN 20-SS

10

1

Double filter

11

1

Emulsion filter DN 12, 420 bar

12

1

Emulsion filter DN 20-40

15

2

Dual CV DN 10

17

3

CV, hydr. piloted DN 10

18

1

CV, hydr. piloted DN 12

20

1

Shuttle CV DN 20-SSO

21 22

3 4

CV DN 10 CV, NW 25

23

1

PRV DN 10, 80 bar

24

7

PRV DN 10, 380 bar

25 26

3 1

27

3

28

3

PRV, 450 bar PRV DN 10, 180 bar Rock burst valve DN 20/350-399 bar Setting pressure 380 bar PRV DN 20/25 SS 480 bar

29

2

Plug DN 10 with pressure relief

30

3

Pressure gauge port

1x each on electrohydraulic control unit (1+2) In the middle under canopy in front of electrohydraulic control unit (1) 1x behind the right leg on the caving shield next to the CV (18) 1x behind the left leg on the caving shield next to the HP ball valve (48) 2x1 each on flipper cylinder (Z7) 3x1 each on the caving canopy cylinder (Z5) 1x on the manifold (11) behind the right leg on the caving shield 1x on the shifting ram (Z2) behind the base lifting cylinder (Z9) 3x1 each on the leg (Z1) 4x on the intershield manifold (7) Left, under the canopy, next to the HP ball valve (46) a) 1x on the shifting ram (Z2) b) 1x on the manifold (35) on the base lifting cylinder (Z9) c) 1x on the manifold (42) d) 2x2 on the flipper cyl. (Z7) 3x1 each on the leg (Z1) 1x on shuttle CV (20)

For water valve unit (6) For flipper cylinders (Z7)

In the return line of the legs (Z1) In the return line a) For shifting ram (Z2) b) For base lifting cylinder (Z9) c) For side seal cylinder (Z4) d) For flipper cyl. (Z7) In the piston space of the legs

3x1 each on the caving flap cylinder 3x1 each on the leg (Z1) 2x left, under the canopy on PRV, 80 bar (23) 3x1 each on the leg (Z1)

With pressure relief valve

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.21

Operation of the shield hydraulics

31

14

32

1

33

1

Glycerine pressure gauge NG 50

Fan plug Screw-in socket DN 10 with throttle 4.0

34

13

Measuring coupling SMK20

35

1

36

1

Hydraulic manifold, 7-function, DN 10 Manifold DN 12/3xDN 10; DN 12/3xDN 10

37

1

Manifold (20SS/2x10; 12/2x10)

38

1

Manifold DN 12; DN 10

39

1

Manifold, 5-function

40 41 42

4 2 2

Swivel DN 63 SO/SSKV ND Swivel DN 51 SO/SSKV ND Manifold 10 x DN 10

43

1

Through sleeve DN 20/DN 12

44

1

HP ball valve DN 10, blue handle

45

5

HP ball valve DN 10, red handle

46

1

HP ball valve, DN 12 red handle

47

4

HP ball valve DN 20-SS, with safety locking handle

48

1

HP ball valve DN 20, blue handle

49

1

Diffuser

50

1

51

1

52 Z1 Z2 Z4a Z4b Z5 Z7 Z9 S1

1 3 1 3 2 2 2 1 3

Hose lines Water spraying system accessories Brackets and accessories Leg Shifting ram Side seal cylinder Side seal cylinder Caving canopy cylinder Flipper cylinder Base lifting cylinder Pressure sensor

5.22

Arrangement Remark a) 3x each on the leg CV (3) a) For leg (Z1) b) b) 2x1 on the emulsion filter (11) c c) 1x on the shuttle CV (20) d) d) 2x1 on the double filter (10) e) e) 1x on electrohydraulic control unit (1) f) f) 1x on electrohydraulic control unit (2) g) 2x1 each on the manifold (38, 35) g) h) For water valve unit (6) h) 1x on the emulsion filter (12) k) For intershield manifold (7) k) 1x between emulsion filter (12) and ball valve (48) 1x on water valve unit (6) On shuttle CV DN 20-SSO (20) a) 1x on manifold (35) on the base lifting cylinder (Z9) b) 1x on shifting ram (Z2) c) 1x on manifold (38) d) 2x2 each on the flipper cylinder (Z7) e) 3x1 each on the caving flap cylinder (Z5) f) 1x on the double filter (10) g) 1x on the manifold (42) h) 1x on the CV (18)

For the connection of measurement devices

E

Quantity Designation

On the base lifting cylinder (Z9) 1x on the caving canopy cylinder (Z5) Under canopy, centered at front, behind flipper cylinder (Z7) Behind base lifting cylinder (Z9) In the middle beneath the canopy, behind the double filter (10) On intershield manifold (7) On intershield manifold (7) 2x on the right under the canopy Left, under the canopy, next to the HP ball valve (46) 1x on water valve unit (6) via electrohydr. control unit (1) a) 3x1 each on the leg (Z1) via electrohydraulic control unit (1) b) 1x on the base lifting cylinder (Z9) c) 1x under the canopy 1x left under the canopy on the through sleeve (43) a) 3x1 each on the leg (Z1) b) 1x on the double filter (10) 1x on the emulsion filter (12) behind the left leg on the caving shield 1x right on the caving shield behind the rear leg (Z1)

For caving canopy cylinder For flipper and caving canopy cyl.

For side seal cylinder (Z4) For shutting off the water spraying For shutting off the water spraying a) Pressure relief of piston space of the leg b) For shutting off the piston space of the base lifting cylinder. c) For side seal cylinder (Z4) For auxiliary supply a) Interrupts the main pressure line to the shield b) For shutting off the pressure supply to the flipper cylinder For shutting off the water spraying Subassembly Subassembly Subassembly

2x front, 1x rear Centered in the base 3x for canopy 2x for caving shield On caving flap Canopy-flipper Base (relay bar assembly) On each leg (Z1)

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

Operation of the shield hydraulics Shield hydraulics Fig. 30:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7

View C 29 A

43

51 37 46

23

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

B

View D C

34g 42

24

36 D

27 34e

17

For A and B views, see Fig. 31

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.23

Operation of the shield hydraulics Fig. 31:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7 View A

34d

34d

15 View B

31d

10

47b

50

34f 39

45b

5.24

44

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

24d

Operation of the shield hydraulics Fig. 32:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7 B

C

View A

31a

27

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

A

3 30

45a

31a 3

45a 47a 21

47a

25

45b

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.25

Operation of the shield hydraulics Fig. 33:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7 View B 1

44

45c 8 6, 32 8 2

View C 31h

5.26

12

48

7

22

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

47b

Operation of the shield hydraulics Fig. 34:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7

View A 31a

28

45a

B

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

28

49

25 21

47a

A

View B

31g

33

38

26

34a 34c

24b 31g 20

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.27

Operation of the shield hydraulics Fig. 35:

Shield hydraulics, arrangement for both gate end shields Image caption: see table 7 View A B

35

31g

45b

24b

34a A

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

52

View B 31b

34h

31b

11 18

7

41 22

5.28

40

Shield support 2400/4300-3x5330-2050

Operation of the shield hydraulics Functions of the electrohydraulic control unit, 12-function, symbol plate

SP

Fig. 36:

8

1

T P

2

2

3

X2 1

X1

4

2 X2

5

3

X3

6

4 X4 5

X5

6

7 X6

Caterpillar Global Mining Europe GmbH, Lünen 2013

7

X7

E

8

8 X8

9

9

X9 10 10

X10

11

X11

11

12 X12

12

12-functions

1

3

5

7

9

11

2

4

6

8

10

12

Tab. 8: Electrohydraulic control unit with 12-functions, assignment of functions Function, designation

Doc. No.: 7420 245 000 BA 00

Function no.

Set rear leg

1

Set front leg

2

Advance shield

3

Push conveyor

4

---------

5

Set high pressure

6

Extend side seal cylinder

7

Retract side seal cylinder

8

Pull up rear conveyor

9

Extend base lifting cylinder

10

Retract rear leg

11

Retract front leg

12

VUSP / 01

5.29

Operation of the shield hydraulics Fig. 37:

Functions of the electrohydraulic control unit, 6-function, symbol plate 8

SP

1

T P

2

3 1 4

X1 2 X2 3

5 X3

4

E

X4 5 X5 6 X6

6-functions

1

3

5

2

4

6

W1

W3

W2

W4

Tab. 9: Electrohydraulic control unit with 6-functions, assignment of functions

5.30

Function, designation

Function no.

Extend flipper cylinder

7

Retract flipper cylinder

1

Extending the caving flap cylinder

3

Retracting the caving flap cylinder

4

---------

5

---------

6

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

6

Operation of the shield hydraulics Fig. 38:

Functions of the water valve unit, 4-function, symbol plate 4-function

W1

W2

W3

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

W4

breather

4-functions

1

3

5

W1

W3

2

4

6

W2

W4

Tab. 10: Water valve unit with 4-functions, allocation of functions

Doc. No.: 7420 245 000 BA 00

Function, designation

Function no.

Base spraying system

W1

Canopy tip spraying system

W2

Water spray canopy

W3

---------

W4

VUSP / 01

5.31

Operation of the shield hydraulics Shield hydraulics, for both gate end shields Image caption: see table 7

canopy tip spray

380 bar

15

Z7

water curtain

380 bar

37 29 80 bar

39

pontoon wash spray

x

5/3 way P

HP

7

11 backflush-filter

49

SP

1

2

X1

3

X5

4

X7

X3

7

5

8

X9

6

9

10

11

12

SP

12

10

22

W1

W2

1

2

3

4

5

6

W3

W4

breather

50

48

41

E

8

Z4a X11

2

x

T P

2 1 2

3 4 5 6 7 8 9 10 11 12

T P

1 2

3 4 5 6

xx

X2

X2

X4

X6

X8

X10

X12

X2

X4

X6

1

42 45

380 bar

Z4b

380 bar

A A AR PA PB A

18

26 PXPA 4mm

P/R

20

520 bar

A

180 bar

A

i s

28

A A AR PA PBAA

3

D.A.ram cyl.

A

21

380 bar

Z2

21

47 45 25

30

Z9

i p

i p

3

38

45

35

lift cyl.

30 47 45

25

Z1

leg

Z4a

Z4b

X1

X3

X5

Z4a

28

520 bar

33

520 bar

Z1

Z1 A 21

3 A PB PA RA A A

p i

Z5

27

17

rear adv. cyl.

380 bar

canopy cyl.

canopy cyl.

5.32

27

17

380 bar

si

Z5

36

45

i s

380 bar

47

i s

17

i s

si

rear adv. cyl.

30

canopy cyl.

25

caving shield spray

28

caving shield spray

27

Z5

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

6

23 HP = DN 32 SSKV-HD W = DN 50 SSKV-ND R = DN 63 SSKV-ND R = DN 63 SSKV-ND P = DN 50 SSKV-HD 40

8

32 44

380 bar

x x

PTO

46

51

si

47 43

si

flipper cyl.

Z7

flipper cyl.

Fig. 39:

Operation of the shield hydraulics Hydraulic line diagram, for both gate end shields Image caption: see table 7 34d 24d

24d 37

DN10 DN10

DN10

R

K

34c 31g

Z9 DN10 NIRO

SENSOR

DN10

DN12

DN25SS DN12

DN10 DN12 DN10 DN10 R

DN12

31f

Z4a

SP

K

DN25

8 2

7

41

41 40

22 22

DN10 NIRO

SENSOR

45a 25

Z4a

21

K

30 47a

42 R

DN25

49 31a

3

R

DN10 NIRO

DN10 DN10

22

40

DN10

48

31b

DN10

2*

K

31k

31b 11

DN10

DN10 NIRO

DN63 SSKV-ND DN63 SSKV-ND DN50SSKV-ND NIRO DN50 SSKV-HD DN32 SSKV

31a

18

31e

32 6

3

30

8

1

44

25 21 45a

DN10 DN10

DN12 DN10

DN20 NIRO DN20 NIRO

31h

DN25 DN20

12

45c

SP

DN10 NIRO DN10 NIRO DN10 NIRO

DN10

39

DN10 DN10 DN20SS DN12

DN20SS DN10 NIRO DN10 NIRO

46

47a

K

E

29

DN10

Z2

W4 W3 W W1 P

3

31a

Z4a

24a

DN10 NIRO

DN10 NIRO

DN20SS DN10 DN25

30

28 - x K

26 33 20

a 25 43 45a 23

Z1 DN10

34b

DN25 DN12 DN20SS DN12 DN10 DN12 DN10 DN10 DN25SS DN25SS DN25SS

DN10

21 47a

24c DN10 DN10 DN10 DN10

Z1

Z4b

K

1*

R

28 - x

27 34e

17

17

Doc. No.: 7420 245 000 BA 00

VUSP / 01

34e

17

Z5

1* hose lines 2* plug-in parts a whip chek x rear side, leg

DN10 DN10

27

Z4b

R

34e

DN10 DN10

27

Z5

K

36

DN10 DN10

Z5 DN10 DN10

Caterpillar Global Mining Europe GmbH, Lünen 2013

38

31e SENSOR

28 - x

34a

DN10

Z1

DN10 NIRO

24b 35 31g

DN10

31d 45b

DN20SS

DN12

47b

a

10

34f

R

31d

DN20 DN25

DN10 NIRO DN10 NIRO

DN10

Z7

15

DN10 DN10 DN20SS

15

34d 24d

R

Z7

DN10 NIRO

24d

DN12

Fig. 40:

5.33

5.34

K

R

R

R

105 40

DN10x1400 NIRO GW

93 93

Z5 65 K

107 63 95

7

Z5 62 35

DN10x600

1

7 DN12x3400 DN10x1000

5

34

75

7

Z5 6

61

40

DN25x900 BU

19

9

E

SENSOR

DN10x600

73 21

DN10x1400 DN10x1100

28

16

64

Z4a

18 20 14

DN10x1400 NIRO GW

Z4a

51 52 53

Z1

34 5 11

DN10x1000 DN10x1500

DN10x1000 DN10x1500

11 5

Z4b

13

a whip chek Z4b Items and lines shown in blue have different lengths in the variants. See tab. 11

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

29

K

R

26

DN10x2800 DN10x2800

50

R

32

X1

K

96

DN10x5200

94

DN10x1200 RY-TR

26

DN10x4900

10

3

DN25x2500 BU

Z2 8

DN20SSx4000

33

DN12x700 RY-TR

15

DN12x3200 RY-TR

70

DN25SSx1600 RD

DN10x900 NIRO GW

a

DN20x2300 BU

SP

R

DN10x800

DN10x1100

DN10x3900 DN12x4000 DN10x1300 DN10x1300

DN10x1600 DN10x1600

K

92

R

X3 97

12

K

106 17 31 R

DN10x1600 DN10x1600

DN12x5100 27 DN20SSx5000 DN12x4200 DN10x2800 RY-TR DN12x4200 DN10x5300 DN10x4000 DN25SSx2550 RD DN25SSx2000 RD DN25SSx1750 RD

108 DN12x1100

DN12x3500 RD

K

K

99

12

DN25x1200 BU

90

71 30

DN10x1200 DN10x1200

4 SP

2 DN10x1400 RD DN10x4800 DN20SSx1200 DN12x1200

Hose lines, for both gate end shields Z7

SENSOR

X2

W4W3 W1 P

72

W

DN10x900 NIRO GW

91

DN25x3700 BU

DN63x2800 SSKV-ND BU DN63x2800 SSKV-ND BU DN50x2800 SSKV-ND NIRO GW DN50x2800 SSKV-HD RD-TR DN32x2800 SSKV RY-TR

93

DN20SSx1700 DN10x1400 NIRO GW DN10x3000 NIRO GW DN10x1500 NIRO GW

36

DN10x2600 NIRO GW

60

DN10x150 NIRO GW DN10x1200 NIRO GW DN10x1200 NIRO GW

74 a

DN20x2300 BU

DN10x600

DN25x2200 BU

Z1 DN20SSx4100 DN10x700 DN25x500 BU

DN10x1200 RY-TR

1 SENSOR

Fig. 41:

DN10x1200 DN10x1200

DN10x1200 DN10x1200

DN10x900

Operation of the shield hydraulics

Z7

91

6 98

Z9 1

Z4a

Z1 21

Operation of the shield hydraulics Tab. 11: Differences in the lengths of the hose lines of variants 01, 02 Variable

X1

E

X2

Caterpillar Global Mining Europe GmbH, Lünen 2013

X3

Doc. No.: 7420 245 000 BA 00

VUSP / 01

Item Var. 01

02

Dimensions

13

-

2x SHL-LTG 4SP-DN10x2400-ST/ST-VERZ-TX

-

13

2x SHL-LTG 4SP-DN10x2500-ST/ST-VERZ-TX

21

-

2x SHL-LTG 4SP-DN10x6600-ST/ST-VERZ-TX

-

21

2x SHL-LTG 4SP-DN10x6400-ST/ST-VERZ-TX

32

-

1x SHL-LTG 4SP-DN12x3400-ST/ST-VERZ-TX

-

37

1x SHL-LTG 4SP-DN12x3200-ST/ST-VERZ-TX

71

-

1x SHL-LTG 4SP-DN20x1500-S/SO-VERZ-TX

-

71

1x SHL-LTG 4SP-DN20x1300-S/SO-VERZ-TX

96

-

1x SHL-LTG 4SP-DN10x2700-ST/ST-NIRO-GW-TX

-

96

1x SHL-LTG 4SP-DN10x2500-ST/ST-NIRO-GW-TX

97

-

1x SHL-LTG 4SP-DN10x3000-ST/ST-NIRO-GW-TX

-

100

1x SHL-LTG 4SP-DN10x2800-ST/ST-NIRO-GW-TX

98

-

1x SHL-LTG 4SP-DN10x4000-ST/ST-NIRO-GW-TX

-

98

1x SHL-LTG 4SP-DN10x3700-ST/ST-NIRO-GW-TX

99

-

1x SHL-LTG 4SP-DN10x4200-ST/ST-NIRO-GW-TX

-

99

1x SHL-LTG 4SP-DN10x3900-ST/ST-NIRO-GW-TX

100

-

2x SHL-LTG 4SP-DN20x1000-ST/ST-NIRO-GW-TX

-

101

2x SHL-LTG 4SP-DN20x1000-ST/ST-NIRO-GW-TX

5.35

Operation of the shield hydraulics Water spraying system accessories, for both gate end shields Z7 Z7 6*, 10*

a

8*, 10*

DN10 NIRO

R

DN10

DN12

4*, 10* DN10 NIRO

5*, 10*

K

a

SENSOR

DN10

DN10

SP

DN12

K

R

DN25

SP

W4 W3 W W1 P

DN10 DN10

DN10

DN10

DN25 DN12 DN20SS DN12 DN10 DN12 DN10 DN10 DN25SS DN25SS DN25SS

DN10 NIRO

DN20 DN25

Z4a

R

3* 11* (2x) K

3* 11* (2x)

SENSOR

DN25

K

Z4a

R

DN10 NIRO

DN10

DN10 DN10 DN10 DN10

K

R

Z1

Z5

5.36

Z5

Z5

DN10 DN10 R

1*,4* spray manifold 3* nozzle head 5*,6* spray manifold 8* spray manifold 90° 10* nozzle, cpl.

11* full cone spray Z4b nozzle a whip chek

K

DN10 DN10

DN10 DN10

DN10 DN10

Z4b

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

DN20SS

DN12

DN25SS DN12

K

DN10 DN10

DN12 DN10

DN10 NIRO

DN25 DN20

Z1

R

DN10 NIRO DN10 NIRO DN10 NIRO DN10 NIRO

DN10

DN20 NIRO DN20 NIRO

DN63 SSKV-ND DN63 SSKV-ND DN50SSKV-ND NIRO DN50 SSKV-HD DN32 SSKV

Z4a

Z2 DN10 DN12 DN10 DN10

DN10 DN10 DN20SS DN12

DN10 NIRO

DN20SS DN10 DN25

DN20SS DN10 NIRO DN10 NIRO

DN10

SENSOR

DN10

Z1

R

DN10

DN10

4*, 10*

DN10 DN10

K

DN10

DN10 NIRO DN10 NIRO

8*, 10*

DN10 DN10 DN20SS

DN10 NIRO

1*, 10*

6*, 10*

DN12

Fig. 42:

Operation of the shield hydraulics Fig. 43:

Shield hydraulics, brackets and accessories, for both gate end shields

35

35

40

40

37

31

18 36 39

41

E Caterpillar Global Mining Europe GmbH, Lünen 2013

15

21 16 1 20

14

34

15 33

8 4

12

Doc. No.: 7420 245 000 BA 00

1 bracket, electrohydraulic control units 4 bracket for manifold 8 bracket for manifold, 10-function 12 hose guide 14 hose guide 15 bracket, visual lamp, front 16 bracket for solenoid driver module 20 hose cover, PTO 21 bracket, PTO

VUSP / 01

31 spray manifold fastener 33 bracket for nozzle head 34 fastener, leg valve NG 20 35 support for water spraying block KS 36 bracket, backflush filter 37 bracket for manifold 39 cover, filter 40 staple clip, flipper cylinder 41 anti-twist device for socket with retaining bolt

5.37

Operation of the shield hydraulics Fig. 44:

Shield hydraulics, brackets and accessories, for both gate end shields B

5

A

6 9

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

View A

View B 30

38 2 3

17 2 bracket, intershield manifold 3 bracket for PMC®-R, long 5 cover, left 6 cover, right 9 bracket for manifold, 7-function

5.38

13

13 hose holder 17 cable bracket 30 bracket for lamp 38 bracket

Shield support 2400/4300-3x5330-2050

Operation of the shield hydraulics Fig. 45:

Shield hydraulics, brackets and accessories, for both gate end shields

A

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

7 45 View A 32

19 22

7 cover 19 bracket for manifold 22 bracket, shifting ram

Doc. No.: 7420 245 000 BA 00

VUSP / 01

32 hose guide 45 bracket for nozzle head

5.39

Operation of the shield hydraulics Bracket for control units and water valve The two electrohydraulic control units and the water valve unit are fastened in a bracket below the canopy.

Fig. 46:

Bracket for control units, dimensions

Bracket for control units, items 20 21

6

5

8

22, 30 a 1

19

9

10 25 2, 15

4 b 24

1 bracket 2 holding plate, symbol plate, 12-function 3 holding plate, symbol plate, 6-function + water spraying system 4 staple securing device 5 strain relief (UV), 6-function 6 staple securing device 8 staple securing device

5.40

3, 16 c 9 staple securing device 10 strain relief (UV), 5-function 15 symbol plate, 12-function 16 symbol plate, 6-function + water spraying system 19 hex. head screw M 10x16-A 2-70 20 hex. head screw M 10x20-A 2-70 21 hex. head screw M 6x20-A 2-70 22 hex. head screw M 16x45-A 4-80 23 hex. head screw M 10x25-A 2-70

23, 31 24 cyl. head screw M 6x8-A 2-70 25 hex. head screw M 6x16-A 2-70 30 hex. nut M 16-A 2-70 31 hex. nut M 10-A 2-70 a electrohydr. control unit, 12-function b electrohydr. control unit, 6-function c water valve unit * not visible

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 47:

E

(471)

(387)

(544)

Operation of the shield hydraulics Bracket for PMC®R The PMC®R is fastened on a bracket.

Bracket for PMC®R, dimensions

541

Fig. 48:

(453)

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

510

Fig. 49:

Bracket for PMC®R, items 1 2

9, 11

10, 11 4

8, 11

5

3 6 1 support I a 2 support II 3 support III 4 support IV 5 plate 6 tube 25x5 32 lg.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

8 hex. head screw M 12x30-A 2-70 9 hex. head screw M 12x35-A 2-70 10 cyl. head screw M 12x110-A 2-70 11 hex. nut M 12-A 4-80 a PMC®R

5.41

Operation of the shield hydraulics Bracket for solenoid driver module The solenoid driver module is fastened in a bracket below the canopy.

Fig. 50:

Bracket for solenoid driver module, dimensions (770)

Fig. 51:

Bracket for solenoid driver module, items 7, 8

1

5, 6 c

a, b

3

1 bracket for solenoid driver module, 2-function 2 retainer clip 3 fastener, solenoid driver module 5 hex. head screw M 12x25-A 2-70 6 hex. nut M 12-A 4-80 7 hex. head screw M 10x20-A 2-70

5.42

9, 10

2

8 hex. nut M 10-A 2-70 9 hex. head screw M 6x45-A 2-70 10 hex. nut M 6-A 4-80 a stud bolt M 10 b hex. nut M 10-A 2-70 c locking clip 2.5

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

(150)

(218,5)

(720) (540) (329)

Operation of the shield hydraulics Connecting the brackets The bracket for the two electrohydraulic control units and the water valve connected with each other below the canopy.

The bracket of the PMC®R is located below the bracket for the control units and is fastened to this with screws and nuts.

The bracket of the solenoid driver module is located above the bracket for the control units and is directly connected to the canopy.

Fig. 52:

Overview of the brackets for the control units, PMC®R and the solenoid driver module 3

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

d

a b c

2

d

1 bracket of the two electrohydraulic control units 2 bracket for the PMC®R, long 3 bracket for solenoid driver module

a electrohydr. control unit 12-function b electrohydr. control unit 6-function c water valve unit d PMC®R e fastening, solenoid driver module

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.43

Operation of the shield hydraulics Control units The two shield variants are equipped with the following control units: intershield manifold, electrohydraulic control unit, 12-function, electrohydraulic control unit, 6-function, water valve unit, 4-function, PMC®-R control unit.

Fig. 53:

Control units on the shield

1

6 2 7

a

1 electrohydr. control unit, 12-function 2 electrohydr. control unit, 6-function 6 water valve unit, 4-function

5.44

7 intershield manifold SSKV 10 double filter a PMC®-R control unit

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

10

Operation of the shield hydraulics Fig. 54:

Control units on the shield

44

a

45c

31e

E

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

6 31f 2

7 1 electrohydr. control unit, 12-function 2 electrohydr. control unit, 6-function 6 water valve unit, 4-function 7 intershield manifold SSKV 31e pressure gauge

Doc. No.: 7420 245 000 BA 00

VUSP / 01

31f pressure gauge 44 HP ball valve DN 10, blue 45c HP ball valve DN 10, red a solenoid driver module

5.45

Operation of the shield hydraulics Intershield manifold Fig. 55:

View of the intershield manifold, front

7

7 intershield manifold SSKV

Fig. 56:

a 5/3-way ball valve DN25-PN350/DN10-PN500

View of the intershield manifold, left

22

b

a

7

7 intershield manifold SSKV 22 CV NW 25

5.46

a 5/3-way ball valve DN25-PN350/DN10-PN500 b reducing L socket DN25/20

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

Operation of the shield hydraulics Fig. 57:

View above the intershield manifold

12

31h 31h

48

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

7 7 intershield manifold SSKV 12 emulsion filter DN 20

31h pressure gauge NG 50 48 HP ball valve DN 20

PMC®-R control unit PMC®-R control unit

Fig. 58:

d

b

c

a

a PMC®-R control unit b EMERGENCY STOP switch

Doc. No.: 7420 245 000 BA 00

VUSP / 01

c support lock-out switch d bracket

5.47

Operation of the shield hydraulics Electrohydraulic control units and water valve Fig. 59:

Electrohydraulic control units and water valve, front

b

45c

31e 1

31f

6

2

1 electrohydraul. control unit 12-function 2 electrohydraul. control unit 6-function 6 water valve unit, 4-function Fig. 60:

31e pressure gauge 31f pressure gauge 45c HP ball valve DN 10 a symbol bar b solenoid driver module

Electrohydraulic control units and water valve, lateral b

45c

31e

44 1 a

31f 6 2

1 electrohydraul. control unit 12-function 2 electrohydraul. control unit 6-function 6 water valve unit, 4-function 31e pressure gauge

5.48

31f pressure gauge 44 HP ball valve DN 10 45c HP ball valve DN 10 a symbol bar b solenoid driver module

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

Operation of the shield hydraulics Fig. 61:

Electrohydraulic control unit, 6-function, and water valve

8

6 2

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

2 electrohydraul. control unit, 6-function 6 water valve unit, 4-function Fig. 62:

8 accumulator cartridge DN 20-SS a symbol bar

Electrohydraulic control units and water valve with brackets

b

45c

31e 1 6 a

31f 2

1 electrohydraul. control unit, 12-function 2 electrohydraul. control unit, 6-function 6 water valve unit, 4-function 31e pressure gauge

Doc. No.: 7420 245 000 BA 00

VUSP / 01

c

31f pressure gauge 45c HP ball valve DN 10 a symbol bar b solenoid driver module c brackets

5.49

Operation of the shield hydraulics Double filter Fig. 63:

Double filter

31d

10

1

31d

1 electrohydr. control unit 10 double filter Fig. 64:

31d pressure gauge 47b HP ball valve DN 20

Double filter with cover

10

10 double filter

5.50

a

a cover

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

47b

Operation of the shield hydraulics Base lifting cylinder Fig. 65:

In front of the base lifting cylinder

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z9

35

45b 31g

34a

24b

24b PRV DN 10 380 bar 31g pressure gauge 34a measuring coupling SMK20

Doc. No.: 7420 245 000 BA 00

VUSP / 01

35 hydraulic manifold, 7-function DN 10 45b HP ball valve DN 10 Z9 base lifting cylinder

5.51

Operation of the shield hydraulics Fig. 66:

Base lifting cylinder, covered

a cover

CV, hydraulically piloted Fig. 67:

Piloted check valve

31b 31b

11 18

11 emulsion filter DN 12, 420 bar 18 CV, hydraulically piloted

5.52

31b pressure gauge

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

Operation of the shield hydraulics Flipper Fig. 68:

Flipper, extended a b

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z7

Z7

Z7 flipper cylinder

Fig. 69:

a canopy b flipper

Flipper, retracted a

b a canopy

Doc. No.: 7420 245 000 BA 00

VUSP / 01

b flipper

5.53

Operation of the shield hydraulics Flipper cylinder Fig. 70:

Flipper cylinder

b

Z7

a

24d

34d

34d

24d

15

15 dual CV DN 10 24d PRV 380 bar 34d measuring coupling SMK20

5.54

Z7 flipper cylinder a canopy b flipper

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z7

Operation of the shield hydraulics Leg The hydraulic components of the three legs - left, right and rear are the same.

Fig. 71:

Leg 31a

3

a

30

45a

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

47a

b 3 leg CV DN 20 21 CV DN 10 25 PRV, 450 bar 30 pressure gauge port 31a pressure gauge Fig. 72:

25

21 45a HP ball valve DN 10 47a HP ball valve DN 20-SS a PRV, 520 bar b sensor

Leg

28 a

28 PRV DN 20/25SS, 480 bar

Doc. No.: 7420 245 000 BA 00

VUSP / 01

a cover

5.55

Operation of the shield hydraulics Rear side of shield Fig. 73:

Rear side of gate end shield

a

c

Z5

Z5

Z5

Z1

a caving canopy b caving shield c side seal

Z1 leg, rear Z5 caving canopy cylinder

Caving canopy Fig. 74:

Caving canopy

Z5 Z5

Z5

Z1

Z1 leg, rear

5.56

Z5 caving canopy cylinder

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

b

Operation of the shield hydraulics Caving canopy cylinder Fig. 75:

Caving canopy cylinder

Z5

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

27

34e

17

Z5 caving canopy cylinder 17 CV, hydraul. piloted, DN 10

Doc. No.: 7420 245 000 BA 00

VUSP / 01

27 rock burst valvel DN 20 34e measuring coupling SMK20

5.57

Operation of the shield hydraulics Side seal Fig. 76:

Side seal, gate end shield - left, extendable

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

a side seal

5.58

Shield support 2400/4300-3x5330-2050

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

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

Fig. 77:

Plug DN 10 with pressure relief

To open pressure relief: Screw in screw.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a

To close pressure relief: Screw out screw.

b

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

b sealing ring

Important!

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

The shield is equipped with two plugs DN 10 with vented cap screw.

The plugs (29) positioned on a through sleeve with pressure relief are used to relieve any potential pressure in the return line. This can be necessary, e.g. when the supply line connections have been closed off for transport and increased pressure has built up in the return line during installation.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.59

Operation of the shield hydraulics Fig. 78:

View of the through sleeve 23

29

29

50 46

E

29 plug DN 10 with pressure relief 50 through sleeve

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. 79:

Measuring coupling for pressure relief

2 3

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

5.60

3 protective cap

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

23 PRV, 80 bar 46 HP ball valve DN 12

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.

Fig. 80 shows the arrangement of the PMC®-R control unit and the electrohydraulic control unit on the support.

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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.61

Operation of the shield hydraulics 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.

Fig. 80:

Control units on the shield

1

6 2

a

1 electrohydr. control unit, 12-function 2 electrohydr. control unit, 6-function 6 water valve unit, 4-function

7 intershield manifold SSKV 10 double filter a PMC®-R control unit

Important!

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

5.62

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

7

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.

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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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

There are two pushbuttons on the cover of each individual pilot valve. When you press a button, the corresponding 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. For example, the “advance shield” function can be activated without previously activating the “retract side seal” and “actively lower support” functions. This can cause dangerous situations which can result in very serious injuries.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.63

Operation of the shield hydraulics Shield functions Functions of the control units, face shield Fig. 81:

Symbol plate for electrohydraulic control unit, 12-function 1

3

5

7

9

11

2

4

6

8

10

12

1

Set rear 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.

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.

3

Advance shield Before this function is performed, the functions 11 “Retract rear leg” and 12 “Retract front leg” must have been executed.

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

4

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

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

5

6

----------

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

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

5.64

Shield support 2400/4300-3x5330-2050

E

Set front leg Caterpillar Global Mining Europe GmbH, Lünen 2013

2

Operation of the shield hydraulics Extend side seal cylinder

7

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

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

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

Retract side seal cylinder

8

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

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

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

9

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

Pull up rear conveyor

10

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

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

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

11

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

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

12

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

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.65

Operation of the shield hydraulics Fig. 82:

Symbol plate for electrohydraulic control unit, 6-function

1

3

5

2

4

6

1

W1

W3

W2

W4

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

2

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

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

4

Retracting the caving flap cylinder The function is executed as long as the button is pressed or until the end position is reached.

5.66

5

----------

6

----------

Shield support 2400/4300-3x5330-2050

E

Extending the caving flap cylinder Caterpillar Global Mining Europe GmbH, Lünen 2013

3

Operation of the shield hydraulics Functions of the water valve unit, face shield Fig. 83:

Symbol plate for water valve unit

1

3

5

W1

W3

2

4

6

W2

W4

W1

Base spraying system Pressing the button causes the spraying valve on the base to open.

It is locked in idle status.

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

W2

Canopy tip spraying system

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

The spraying valve on the canopy tip is opened by pressing the button. It is locked in idle status.

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

W3

Water spray canopy Pressing the button causes the spraying valve on the canopies to open. It is locked in idle status.

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

W4

Doc. No.: 7420 245 000 BA 00

----------

VUSP / 01

5.67

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

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

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

backflushing

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

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

Fig. 84: Operating the double filter

A normal operation: both levers in position “A”

5.68

B backflushing: one of the levers in position “B”

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Warning!

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

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 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).

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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

The filter cartridges on the 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.

We recommend:

emulsion filters piston rods

Doc. No.: 7420 245 000 BA 00

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 about every 6 months and then treated with a suitable preservative.

VUSP / 01

5.69

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 two years of operation for safety reasons and to ensure the correct function of the system.

double filter, can be backflushed

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

. Check all shields by visually inspecting them for escaping hydraulic fluid at:

– hose lines – electrohydr. 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.

5.70

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

hydraulic system

E

Daily maintenance

Maintenance Weekly maintenance control

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

. Clean the control systems, especially the control panel.

Notice!

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

Every six months

. Apply a preservative to the piston rods of the hydraulic cylin-

ders. Further details are contained in this chapter in the “Special measures” section.

hydraulic leg

. Lubricate the wiper seals of both telescope stages via the lubric-

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

ating nipples. Use the grease A2 in accordance with EWN 7068, see chapter 6, section “Greases and lubricating pastes”.

Fig. 85:

Lubricating nipples on the hydraulic legs

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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.71

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 catalogue.

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.

Fault localization support cannot be lowered

5.72

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.

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

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

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 between the neighboring supports. neighboring 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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The pressure of the hydraulic supply is too low.

support cannot be advanced

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.73

canopy cannot be positioned

canopy cannot be lowered

5.74

Possible cause

Measure required

Leg control valve is defective.

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

Legs are damaged.

Check legs for damage and replace, if necessary.

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

Pressure relief valve defective

Monitor pressure drop on the pressure gauge.

Is pressurized fluid leaking from the pressure relief valve? 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.

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Troubleshooting

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.

internal leakage

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.

E Caterpillar Global Mining Europe GmbH, Lünen 2013

. Locate the faulty valve by actuating the functions individually in

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.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

5.75

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.

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 catalogue.

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.

5.76

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

Pressure relief valve defective

6

Technical data

Description

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

Description Model 2400/4300-3x5330-2050 The three-legged shield mainly consists of the following main subassemblies: base frame with lemniscatic links and relay bar assembly, canopy with flipper, caving canopy and flap, side seals, caving shield, Caterpillar Global Mining Europe GmbH, Lünen 2013

E

hydraulic legs, hydraulic equipment with hose lines and control.

Tab. 12: Shield support variants, dimensions and weight Dimensions, L x H x W max. / min. in mm

Approxim. weight in kg

Use

Device number

Gate end shield

7420 245 000 00 01

13 202 x 4 300 x 1 950 10 666 x 2 400 x 1 950

68 500

Gate end shield

7420 245 000 00 02

13 202 x 4 300 x 1 950 10 636 x 2 400 x 1 950

68 500

Tab. 13: Shield support, numbering Device number

Shield number 003 to 004 GS001 to GS002

Special design Antitopple device 1 canopy/canopy Dr. no. 7427 115 000 00 00 Antitopple device 2 canopy/canopy Dr. no. 7427 116 000 00 00

7420 245 000 00 01

147 to 149 GS005 to GS007

7420 245 000 00 02

Doc. No.: 7420 245 000 BA 00

VUSP / 01

Anchoring device, canopy/canopy Dr. no. 7427 111 000 00 00 End shield steering device Dr. no. 7427 113 000 00 00

145 GS003 146 GS004

Anchoring device, canopy/canopy Dr. no. 7427 111 000 00 00

6.3

Description base frame

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

caving shield

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

canopy

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

hydraulic system

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

6.4

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

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.

Description Main subassemblies Fig. 86:

Gate end shield

21

22

53

41 51 61

View A

9

A

8

86

13

76

1

85

52

87

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

3

6 71 72

81, 82

9

5 11

12

8 31

41

7 8 1 base 3x5330 3 relay bar assembly 5 lemniscatic link, front 6 lemniscatic link, front 7 lemniscatic link, rear, right 8 lemniscatic link, rear, left 9 lemniscatic link, front 11 canopy 3x5330-1060-2050 12 caving canopy

Doc. No.: 7420 245 000 BA 00

13 flap 21 side seal, CLH 22 side seal, caving canopy 31 caving shield 41 leg 51 base lifting cylinder 52 shifting ram 53 caving canopy cylinder 61 hydraulic system

VUSP / 01

7 71 thrust piece 72 pin 65/53x191 76 cover, rear 81 hex. head screw M 12x100-A 4-80 82 hex. nut M 12 85 information sign 86 information sign 87 information sign

6.5

Description Tab. 14: Gate end shield 7420 245 000 00 01/02, subassemblies

01 03

Var.

ID No.

Approx. weight in kg

Note

1

2

Base 3x5330

x

x

7420 245 300 00 01

12191 Length: 3 434 mm

Relay bar assembly

x

x

7420 245 330 00 01

1 104 Length: 2 541 mm

05

Lemniscatic link, front

x

x

7420 233 303 00 00

587 Length: 1 643 mm

06

Lemniscatic link, front

x

x

7420 245 303 00 00

590 Length: 1 643 mm

07

Lemniscatic link, rear right

x

x

7420 233 305 00 00

643 Length: 1 836 mm

08

Lemniscatic link, rear left

x

x

7420 233 306 00 00

643 Length: 1 836 mm

09

Lemniscatic link, front

x

x

7420 245 304 00 00

590 Length: 1 643 mm

11

Canopy 3x5330-1060-2050

x

-

7420 245 400 00 01

25273

Length: 8 700 mm + Flipper 1 291 mm

11

Canopy 3x5330-1060-2050

-

x

7420 245 400 00 02

24833

Length: 8 500 mm + Flipper 1 291 mm

2/11

Flipper

x

x

7420 242 470 00 01

1200 Flipper cylinder

12

Caving canopy

x

-

7420 245 450 00 00

5007 Length: 3 119 mm

12

Caving canopy

-

x

7420 245 480 00 00

5309 Length: 3 319 mm

13

Flap

x

x

7420 245 460 00 00

1593 Length: 1 615 mm

21

Side seal, canopy

x

-

7420 245 710 00 00

2110

Length: 7 510 mm Side seal cyl. Ø 78

8241 352 000 00 00

21

Side seal, canopy

-

x

7420 245 720 00 00

1810

Length: 7 310 mm Side seal cyl. Ø 78

8241 352 000 00 00

7420 245 760 00 00

Length: 2 560 mm 742 Side seal cyl. Ø 78

8241 352 000 00 00 8241 352 000 00 00

22

x

-

22

Side seal, caving canopy

-

x

7420 245 770 00 00

Length: 2 760 mm 774 Side seal cyl. Ø 78

31

Caving shield

x

x

7420 245 800 00 01

5044 Length: 2 419 mm

41

Hydraulic leg

x

x

8250 210 000 00 00

1818

51

Base lifting cylinder

x

x

8241 487 000 00 00

124 ZE-165/100-310-CR

52

Shifting ram

x

x

8241 535 000 00 00

457 ZE-240/100-1080-CR

53

Caving canopy cylinder on canopy

x

x

8241 536 000 00 00

351 ZE-225/140-530-BN

61

6.6

Side seal, caving canopy

Hydraulic 3-legged shield

x

-

8241 521 000 00 00

SD-5300-380-1465/3285-BN PRV 520 bar

8112 377 000 00 00

Electrohydraulic control unit, 12-function Electrohydraulic control unit, 6-function Water valve unit Intershield manifold Lines Water spraying system Brackets Electrohydraulic control unit, 12-function Electrohydraulic control unit, 6-function Water valve unit Intershield manifold Lines Water spraying system Brackets

61

Hydraulic 3-legged shield

-

x

8112 378 000 00 00

71

Thrust piece

x

x

7420 233 328 00 00

72

Pin 65/53x191

x

x

7420 233 300 06 00

4

76

Cover, rear

x

x

7420 233 380 00 00

10.9

81

Hex. head screw M 12x100-A

x

x

0000 000 201 03 15

0.1

82

Hex. nut M 12

x

x

0000 000 235 00 26

0.01

85

Information sign

x

x

7420 245 000 01 00

0.01 1 set no. 1 to 7

86

Information sign

x

x

7420 245 000 02 00

0.01 Shield number

87

Information sign

x

x

7420 245 000 03 00

0.01 Weight

8154 182 000 00 00 8154 180 000 00 00 8401 008 500 00 00 8401 009 050 00 00 8112 377 010 00 00 8112 377 020 00 00 8112 377 030 00 00 8154 182 000 00 00 8154 180 000 00 00 8401 008 500 00 00 8401 009 050 00 00 8112 378 010 00 00 8112 377 020 00 00 8112 377 030 00 00

162

Shield support 2400/4300-3x5330-2050

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Description

Caterpillar Global Mining Europe GmbH, Lünen 2013

Item

Description Main dimensions Fig. 87:

Gate end shield, dimensions L L3

1291

L1

L2

3700

115

HR

2295

H

1500

HE

10

3553

3295

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

LT

M

W

HE height, extended

W3 W2 B1

W width M support center distance * not in var. 01

HR height, retracted LT transport length

Tab. 15: Shield variants, dimensions Var.

L

LT

L1

L2

L3

H

HE

HR

W

W1

W2

W3

W4

M

01

13202

10666

8700

5000

2800

3500

4300

2400

1950

1666

1060

440

410

2050

02

12202

10645

8500

4800

3000

3500

4300

2400

1950

1666

1060

440

410

2050

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.7

Description Base with lemniscatic links and relay bar assembly The one-piece base frame transmits the bearing strength of the hydraulic leg 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 three lemniscatic links are hinged to the base frame with a pin connection.

Characteristic for the base frame is the arrangement of the relay bar assembly in the middle between the two bases. The relay bar assembly is reverse-mounted. This means, the force applied to the piston surface of the shifting ram is used to advance the shield.

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

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

Base

Base, dimensions

1355

1432

Fig. 88:

3295 3434

1277

1060 1666 1870

1685

Notice!

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

*) EWN = works standard

6.8

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

The base is the same for both shield variants.

Description Fig. 89:

Base, items 46

40

2

21

29

A

B

4 18, 42 28 25 14 19 1 11

47

15

27, 37 b

16

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

View A

13 24, 38

32, 34 12

30, 33

7

17 26, 41 8

9 View B 3

10

22

a

23

6 31, 34

1 base 2 leg retainer, right rear 3 leg retainer, left rear 4 leg retainer, right front 5 leg retainer, left front 6 cylinder bearing 7 cylinder bearing 8 securing device 9 tie-bar 10 running board, center 11 running board, right 12 running board, left 13 running board 14 running board 15 cover plate

Doc. No.: 7420 245 000 BA 00

16 cover plate 17 plug 18 transport rod 19 cover 21 lemniscatic link pin 154.3x602 22 lemniscatic link pin 144.3x602 23 pin 60/50x136 24 pin 45/41x97 25 bolt 29/35x85 26 pin 20/25x90 27 locking plate 28 filler piece, front 29 filler piece, rear 30 hex. head screw M 24x90-A 4-80 31 hex. head screw M 12x100-A 4-80

VUSP / 01

45 32 hex. head screw M 12x70-8.8 33 hex. nut VM 24-8-A3A 34 hex. nut M 12-1.4571 37 locking clip 5.6 38 locking clip 4 40 spring cotter 6.3 41 spring cotter 5 42 spring clip Ø6 45 clevis assembly 46 running board, right 47 running board, left a load ring RBS-30 b load ring load capacity of 3000 kg

6.9

Description Relay bar assembly The relay bar assembly is used to push the conveyor and advance the shield. To do this, it is telescopically extended or retracted using the shifting ram. The shifting ram functions directly. This means that the greater force generated by the piston surface is used to advance the conveyor.

Relay bar assembly, dimensions

150

190

365

235

Fig. 90:

295

620

410 2541

E

60

Notice!

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

*) EWN = works standard

6.10

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

115

225

Description Fig. 91:

6

Relay bar assembly, items 2 8 14 1

7, 9 5, 20

a

21, 22

a

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1 relay bar 2 clevis assembly for conveyor 5 pin 25/16x138 6 pin 80/60x320 7 retaining ring 8 pin 70/60x240 9 pin 12/20x95

14 pin 80/70x193 20 locking clip 2.5 21 hex. head screw M 12x100-A 4-80 16 nut M 12-1.4571 a load ring load capacity 3000 kg

Functions of the relay bar assembly 1. Original position of the shield The shifting ram is retracted.

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

Warning!

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

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

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

4. Advancing the conveyor The shifting ram is retracted.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.11

Description Lemniscatic links The lemniscatic links of the gate end shield vary in: the length, the design.

Lemniscatic links, dimensions L2 D1

D2

H

Fig. 92:

50

H2

H1

85

L1 L

Tab. 16: Shield support 7420 233 000 00 01 to 06, dimensions Item

Lemniscatic links

Drawing number

Quantity

L

L1

L2

D1

D2

H

H1

H2

5

at front

7420 233 303 00 00

2

1643

1283

300

155

155

360

190

160

2x load rings

6

at front

7420 245 303 00 00

1

1643

1283

300

155

155

360

190

160

2x load rings 1x stop

9

at front

7420 245 304 00 00

1

1643

1283

300

155

155

360

190

160

2x load rings 1x stop

7

rear right

7420 233 305 00 00

2

1836

-

710

145

145

360

190

160

1x load ring

8

rear left

7420 233 306 00 00

2

1836

-

710

145

145

360

190

160

1x load ring

E

Lemniscatic link, front - 7420 245 303 00 00 9 10

10

1

1 Lemniscatic link, front - 7420 245 304 00 00 9 9

9

5

5 1

9 10 Lemniscatic link, rear right 7420 233 305 00 00

10

10

9

6.12

Lemniscatic link, rear left 7420 233 306 00 00

1 1 lemniscatic link 5 clevis assembly

9

1 9 load ring load capacity 3000 kg 10 name plate

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 93: Lemniscatic links, overview Lemniscatic link, front - 7420 233 303 00 00 9

Note

Description Fig. 94:

Lemniscatic links on shield

Lemniscatic link, front

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

6

9 5

Lemniscatic link, rear

7

8

7

8 5 lemniscatic link, front 6 lemniscatic link, front 7 lemniscatic link, rear right

Doc. No.: 7420 245 000 BA 00

VUSP / 01

8 lemniscatic link, rear left 9 lemniscatic link, front

6.13

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 canopy is provided with a flipper for all shield variants. The canopy of shield variant 01 is 200 mm longer.

Fig. 95:

Canopy, dimensions

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1291

1500

1310

2985

L

20

1060 1930

955

Tab. 17: Canopy length of the shield variants

6.14

Canopy variants

L

7420 245 400 00 01

8700

* for shield variant 01

7420 245 400 00 02

8500

* for shield variant 02

Note

Shield support 2400/4300-3x5330-2050

Description Fig. 96:

Canopy, items

22, 28

g

h

10

29

A

1 b

k, o, 27

30 B

4

5 a c, m, 26

2

d, n, 26 21, 22

View B 11

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

25 16

3 23 18

14 View A 13

12

15, 17, 20

5 f 19, 24 e

32 31 1 canopy 2 flipper 3 cover plate 4 plug 5 plug 157 mm 10 joint pin Ø143.5x640 11 joint pin Ø143.5x570 12 peg 68x127 13 pin 75/69x218 14 securing device 15 retaining ring 16 pin 50/44x92 17 hex. head screw M 10x110-A 2-70

Doc. No.: 7420 245 000 BA 00

18 pin Ø 20x170 19 pin 15/12x120 20 hex. nut M 10-A 2-70 21 hex. head screw M 12x35-A 4-80 22 hex. nut M 12-A 4-80 23 locking clip 3.2 24 locking clip 2.5 25 staple DN 32-130 lg 26 spring cotter 5 27 spring cotter 8 28 hex. head screw M 12x50-A 4-80 29 holding plate, clevis assembly 30 clevis assembly 31 rubber seal

VUSP / 01

11

22, 28

32 strip a abutment plate b clip 8000 kg c load ring 3000 kg d load ring 5000 kg e load ring 15 000 kg f screw holder M12 g screw holder M10 h screw holder M8 k load ring m dowel 3000 kg n dowel 5000 kg o dowel 30 000 kg

6.15

Description Flipper The flipper is identical for all shield variants.

122 178 90 203

(1217) (327)

(1250)

Notice!

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

*) EWN = works standard

6.16

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

770

1140

Flipper, dimensions

(1500)

Fig. 97:

Description Fig. 98:

Flipper, items 20

b 5 8, 13, 14

3 20

21

6, 12, 14

22

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

9, 19, 14 24 23 a 2

4, 10, 11 15, 16

17

1

7, 13, 14 6 18, 25

8, 13, 14

1 flap 2 flange plate 3 fork control arm 4 securing device 5 fork control arm 6 pin 55/43.5x153 7 pin Ø 58.5x400 8 pin Ø 58.5x240 9 pin Ø 58.5x170 10 hex. head screw M 16x170-A 2-70 11 hex. nut M 16-A 2-70 12 hex. head screw M 10x60-A 2-70 13 hex. head screw M 10x75-A 2-70 14 hex. nut M 10-A 2-70

Doc. No.: 7420 245 000 BA 00

VUSP / 01

15 hex. head screw M 30x80-10.9 16 hex. nut M 30-10 17 flipper cylinder ZE-125/90-615 18 pin 45/38.5x165 19 hex. head screw M 10x70-A 2-70 20 damper 21 plate 22 washer 17 23 hex. nut VM 16-1.4571 24 cyl. head screw M 16x45-1.4301 25 spring cotter 7 a support (transparent) b load ring load capacity 3000 kg

6.17

Description Caving canopy The caving canopy

7420 245 450 00 01

is attached to the canopy on the gob side. 7420 245 400 00 01 The caving canopy

7420 245 480 00 01

is attached to the canopy

7420 245 400 00 02

on the gob side.

The caving canopies vary in length: the caving canopy of shield variant 01 is 200 mm shorter.

Caving canopy, dimensions

3119 Tab. 18: Caving canopy Gate end shield

Caving shield

L

7420 245 000 00 01

7420 245 450 00 01

3 119

7420 245 000 00 02

7420 245 480 00 01

3 319

Notice!

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

*) EWN = works standard

6.18

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

670 735

390

530

1930

530

E

390

20

Fig. 99:

Description Fig. 100: Caving canopy, items

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

5, 9

3

a c

b

11, 12 16

14

17

15 7, 10, 13

6

Doc. No.: 7420 245 000 BA 00

18, 19 1 canopy 3 cover plate 5 pin 40/34x100 6 pin 75/69x218 7 retaining ring 9 staple DN 25-105 lg 10 hex. head screw M 10x100-A 2-70 11 hex. head screw M 12x35-A 4-80 12 hex. nut M 12-A 4-80 13 hex. nut M 10-A 2-70

VUSP / 01

14 rubber seal 15 strip 16 rubber seal 17 strip 18 hex. head screw M 12x40-A 4-70 19 hex. nut M 12-A 4-80 a load ring 8000 kg b load ring 3000 kg c side seal, right

6.19

Description Flap The flap

7420 245 460 00 00

is attached on the gob side on the caving canopy for shield variant 01 and

7420 245 450 00 01

on the caving canopy for the shield variant 02.

7420 245 480 00 01

Fig. 101: Flap, dimensions

1900

60

Notice!

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

Fig. 102: Flap, dimensions 4, 6 3

1

a 1 flap 3 pin 80/70x110 4 pin 15/12x125

6 locking clip 3.2 a load ring 3000 kg

*) EWN = works standard

6.20

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1500

1615

70

100

Description Tab. 19: Overview of canopies of the variants Shield No.

7420 245 000 00 01

7420 245 000 00 02

Canopy No.

Note

7420 245 400 00 01

Canopy

7420 242 470 00 01

Flipper

7420 245 450 00 01

Caving canopy

7420 245 460 00 01

Flap

7420 245 400 00 02

Canopy

7420 242 470 00 01

Flipper

7420 245 480 00 01

Caving canopy

7420 245 460 00 01

Flap

Leg retainer

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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.

Fig. 103: Mounting the leg head

23

18

12 12 peg 69x127 18 pin Ø20x170

Doc. No.: 7420 245 000 BA 00

VUSP / 01

23 locking clip 3.2

6.21

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

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

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

Notice!

Remove the transport safety devices during commissioning!

Tab. 20: Side seal overview of variants Shield No. 7420 245 000 00 01 7420 245 000 00 02

6.22

Side seal No.

Note

7420 245 710 00 00

for canopy

7420 233 760 00 00

for caving canopy

7420 245 720 00 00

for canopy

7420 233 770 00 00

for caving canopy

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

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

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

E

Warning!

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

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

Description Side seal, canopy 7420 245 710 .... ... is included in: variant 01 - 7420 245 000 00 01 Side seal, canopy 7420 245 720 .... ... is included in: variant 02 - 7420 245 000 00 02 The side seals vary in length: the side seal of shield variant 01 is 200 mm longer.

3540

L

670

270

685 330

133

133

450

1295

310 20

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

900

200 20

Fig. 104: Side seal, canopy, dimensions

Side seal variant

L

Note

7420 245 710 00 00

7510

* for shield variant 01

7420 245 720 00 00

7310

* for shield variant 02

Notice!

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

*) EWN = works standard

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.23

Description Fig. 105: Side seal, canopy, items 3

7 6

14

1 13 15

11, 21 E

17 8

15

18

5

20 10

4 1 side seal cylinder ZE-63/50-215 3 side plate 4 plug 5 plug 157 mm 6 guiding pin Ø133x1355 7 guiding pin Ø133x765 8 pin 35/28x232 9 pin Ø28x93 10 pin 30/22x120

6.24

11 pin 15/12x120 13 cylinder liner 133x105 14 compression spring 12x79x560 15 securing device 17 screw pin M 10x12 18 staple DN 20-100 lg 19 split pin 6.3x40 20 locking clip 3.2 21 locking clip 2.5

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

11, 21

9, 19

Description Side seal, caving canopy 7420 245 760 .... ... is included in: variant 01 - 7420 245 000 00 01 Side seal, caving canopy 7420 245 770 .... ... is included in: variant 02 - 7420 245 000 00 02 The side seals vary in length: the side seal of shield variant 01 is 200 mm shorter.

Fig. 106: Side seal, caving canopy, dimensions

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

710

R235

220

135

L

205 15 20 103

330

1235

350

645

330

30

L1

455

103

Side seal variant

L

L1

7420 245 760 00 00

2560

2418

* for shield variant 01

Note

7420 245 770 00 00

2760

2618

* for shield variant 02

Notice!

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

*) EWN = works standard

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.25

Description Fig. 107: Side seal, caving canopy, items 3

8 14 11

6

19

20

18 16

6.26

9

12, 17

1 side seal cylinder ZE-63/50-215 3 side seal BK 6 guiding pin Ø103x1295

14 compression spring 12x79x560 16 locking clip 3.2 17 split pin 6.3x40

8 guiding pin Ø133x695 9 pin 30/25x175 11 pin 30/22x120 12 pin Ø28x93

18 staple DN 20-97 lg 19 cylinder liner 103x105 20 screw pin M 10x12

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

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

It is connected to the shield canopy and to the base frame via the front and rear lemniscatic links.

Fig. 108: Caving shield, dimensions 1030

154.3 144.3

400

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

4

2419

1937

145

360

707

170

60 170 1060 1610 1660

Notice!

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

*) EWN = works standard

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.27

Description Fig. 109: Caving shield, items S1 c

S1, 14, a

S1

S1, 14, a

E

6

Caterpillar Global Mining Europe GmbH, Lünen 2013

b 7 1

d e, f

S2 2 S2

11, 13

1 caving shield 2 pin holder 6 lemniscatic link pin 154.3x527 7 lemniscatic link pin 144.3x527 11 locking plate 13 locking clip 5.6 26 spring cotter 5

6.28

b S1 load ring, load capacity: 3000 kg S2 load ring, load capacity: 8000 kg a dowel 3000 kg b screw holder M 12 c name plate d pin holder e hex. head screw M 12x30-A 2-70

Shield support 2400/4300-3x5330-2050

Accessories Accessories Antitopple device “canopy/canopy” Before aligning, the shield to be aligned should be lowered. The neighboring shield to which the alignment cylinder is attached must be set.

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

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

Antitopple device 1 “canopy/canopy” according to drawing number 7427 115 000 00 00 and hydraulic system drawing 8112 374 082 00 00 can be used for the gate end shield with the shield numbers 003 (GS001) and Caterpillar Global Mining Europe GmbH, Lünen 2013

E

004 (GS002).

Antitopple device 2 “canopy/canopy” according to drawing number 7427 116 000 00 00 and hydraulic system drawing 8112 374 083 00 00 can be used for the gate end shield with the shield number 003 (GS001) and the segment shield with the shield number 002 (BS002).

The shields for the antitopple devices are located on the head gate.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.29

Accessories Antitopple device 1 “canopy/canopy” The antitopple device connects two gate end face shields with 3 legs.

Fig. 110: Antitopple device 1 “canopy/canopy”, dimensions

Shield No. 004

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield No. 003

2050

6.30

Shield support 2400/4300-3x5330-2050

Accessories Fig. 111: Antitopple device “canopy/canopy”

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield No. 004

Shield No. 003

a

a antitopple device canopy/canopy

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.31

Accessories Fig. 112: Antitopple device 1 “canopy/canopy”, items 3

1 A

13

3

2

1 13

View A 23 b

a

24

15, 21

11, 20 10 12 1 hydraulic cylinder ZE 135/80-800 retracted: 1120 mm extended: 1920 mm 2 terminal bracket 3 terminal bracket 10 pin Ø 69.8x220 11 pin Ø 16x150 12 universal joint 13 universal joint

6.32

14 14 hinge piece 15 pin 55/40x125 20 locking clip 3.2 21 spring clip 4 23 hammer head bolt M24x80-12.9 24 hex. nut M 24-8 a load ring load capacity 1000 kg b screw holder M 12

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

2

Accessories Warning!

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

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 200 mm!

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

Fig. 113: Hydraulic control for antitopple device 1 “canopy/canopy”

6

5

10x3200

10x4900 Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1 10x4600

1

8 a

10x3000

1 2

3

1 plug-in elbow socket DN 10 2 double nipple DN 10 3 Y-manifold socket DN 10 5 SHL-LTG 4SP-DN10x4900-ST

Doc. No.: 7420 245 000 BA 00

VUSP / 01

7

6 SHL-LTG 4SP-DN10x3200-ST 7 SHL-LTG 4SP-DN10x3000-ST 8 SHL-LTG 4SP-DN10x4600-ST a electrohydraulic control unit, 6-function

6.33

Accessories Antitopple device 2 “canopy/canopy” The antitopple device connects a 3-legged gate end shield to a 4-legged segment shield.

Fig. 114: Antitopple device 2 “canopy/canopy”, dimensions

2200

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield No. 002

Shield No. 003

6.34

Shield support 2400/4300-3x5330-2050

Accessories Fig. 115: Antitopple device 2 “canopy/canopy”

a

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Shield No. 003 Shield No. 002 a antitopple device canopy/canopy Fig. 116: Antitopple device 2 “canopy/canopy”, items 15

16, 21

14

12 13

14 10

X

1 11, 20

a

23, 24 2

1 hydraulic cylinder ZE 135/80-800 retracted: 1120 mm extended: 1920 mm 2 terminal bracket 10 pin Ø 69.8x220 11 pin Ø 16x150 12 universal joint 13 universal joint 14 hinge piece

Doc. No.: 7420 245 000 BA 00

VUSP / 01

15 hinge piece 16 pin 55/40x125 20 locking clip 3.2 21 spring clip 4 23 hammer head bolt M24x80-12.9 24 hex. nut M 24-8 a load ring load capacity 1000 kg X components of antitopple device 1

6.35

Accessories Warning!

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

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 200 mm!

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

E

Fig. 117: Hydraulic control for antitopple device 2 “canopy/canopy”

Caterpillar Global Mining Europe GmbH, Lünen 2013

1

5 a

DN10x3200

DN10x3000

6 1

1 plug-in elbow socket DN 10 5 SHL-LTG 4SP-DN10x3200-ST 6 SHL-LTG 4SP-DN10x3000-ST

6.36

a electrohydraulic control unit, 6-function

Shield support 2400/4300-3x5330-2050

Accessories Anchoring device “canopy/canopy” The “canopy/canopy” anchoring device is an antitopple device responsible for the four last gate end shields on the tail gate.

Before aligning, the shield to be aligned should be lowered. The neighboring shield to which the alignment cylinder is attached must be set.

By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

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

The “canopy/canopy” anchoring device according to drawing number 7427 111 000 00 00 and hydraulic system drawing 8112 374 081 00 00 can be used for the gate end shield with the shield numbers 146 (GS004) shield variant 02 Caterpillar Global Mining Europe GmbH, Lünen 2013

E

147 (GS005) shield variant 01 148 (GS006) shield variant 01 and 149 (GS007) shield variant 01 The shields for the antitopple devices are located on the tail gate.

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.37

Accessories Anchoring device “canopy/canopy” The antitopple device connects four 3-legged gate end face shields to the tail gate.

Fig. 118: Anchoring device “canopy/canopy”, dimensions

Shield No. 148

1000

Caterpillar Global Mining Europe GmbH, Lünen 2013

1000

E

Shield No. 146

Shield No. 149

Shield No. 147

6.38

2150 300

2050 300

300

1950

Shield support 2400/4300-3x5330-2050

Accessories Fig. 119: Anchoring device “canopy/canopy” 149

148 147

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

146

a

a antitopple device canopy/canopy

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.39

Accessories Fig. 120: Anchoring device “canopy/canopy”, items

2

13

1

1

A

3

View A 23 b

a

24

15, 21

11, 20 10 12 1 hydraulic cylinder ZE 135/80-800 retracted: 1120 mm extended: 1920 mm 2 terminal bracket 3 terminal bracket 10 pin Ø 69.8x220 11 pin Ø 16x150 12 universal joint 13 universal joint

14

14 hinge piece 15 pin 55/40x125 20 locking clip 3.2 21 spring clip 4 23 hammer head bolt M24x80-12.9 24 hex. nut M 24-8 a load ring load capacity 1000 kg b screw holder M 12

Warning!

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

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 200 mm!

6.40

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

13

Accessories By pressing the button on the electrohydraulic control unit, the corresponding alignment cylinder is retracted and the shield is aligned.

Fig. 121: Hydraulic control for the “canopy/canopy” anchoring device

5

1 10x4900

6

1

10x4600

2 10x3200

8

1 a

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

10x3000

7

3

5

10x3200

1

8 10x4900

6

10x4600

10x3000

2 1

1

7

a

1 3

10x4900

5

2 8

1

6

10x4600

10x3200

1 a 10x3000

3 1 plug-in elbow socket DN 10 2 double nipple DN 10 3 Y-manifold socket DN 10 5 SHL-LTG 4SP-DN10x4900-ST

Doc. No.: 7420 245 000 BA 00

VUSP / 01

7 6 SHL-LTG 4SP-DN10x3200-ST 7 SHL-LTG 4SP-DN10x3000-ST 8 SHL-LTG 4SP-DN10x4600-ST a electrohydraulic control unit, 6-function

6.41

Accessories Outrigger ram The outrigger ram according to drawing number 7427 113 000 00 00 and hydraulic system drawing 8112 374 040 00 00 can be used for the gate face end shield with the shield number 003 (GS001) shield variant 01 The outrigger ram is on the head gate.

Fig. 122: Outrigger ram, dimensions

Fig. 123: Outrigger ram, items 7, 11

a

10

1 5

6

1 hydraulic cylinder ZE-125/125-880 5 cylinder bearing 6 pin 70/58x162 7 pin 15/12x95

6.42

10 hex. head screw M 16x20-A 2-70 11 spring clip 2.5 a load ring (load capacity 1000 kg)

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

70

225

E

60 300

1715

Accessories Fig. 124: Outrigger ram, position

Fig. 125: Hydraulic system for outrigger ram 1

2

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

3 8 DN20SSX5000

9

DN20SSX5000

5 5

9 8 3

1 plug-in L-socket DN 20 2 plug-in elbow socket DN 20 3 plug

5 SHL-LTG-4SH-DN20x5000 8 staple DN 10 9 staple DN 20

Tab. 21: Overview of antitopple devices and anchoring devices Var.

ID No.

Hydraulic system drawing

Note

-

7427 115 000 00 00

8112 374 082 00 00

Gate end shield 003 (GS001) and gate end shield 004 (GS002)

x

-

7427 116 000 00 00

8112 374 083 00 00

Gate end shield 003 (GS001) and segment shield 002 (BS002)

Anchoring device, canopy/ canopy

x

x

7427 111 000 00 00

8112 374 081 00 00

Gate end shield 146 (GS004) var. 02 Gate end shield 147 (GS005) var. 01 Gate end shield 148 (GS006) var. 01 Gate end shield 149 (GS007) var. 01

Outrigger ram

x

-

7427 113 000 00 00

8112 374 040 00 00

Gate end shield 003 (GS001)

Description

1

2

Antitopple device 1, canopy/ canopy

x

Antitopple device 2, canopy/ canopy

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.43

Accessories Conveyor pulling device Conveyor pulling devices are required to pull up the rear conveyor.

Fig. 126: Conveyor pulling device, items 5 13

E

3 1

4 3 1 9

10, 11 8

6.44

6

1 shifting ram ZE-125/60-1100 3 protection cover cpl.

4 mounting device 5 pin 40/34x130 6 mounting link

9 8 pin 45/33.5x150 9 chain 30x108 10 hex. head screw M 12x50-A 4-80 11 hex. nut M 12-A 4-80 13 staple DN 25

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

4

Accessories Conveyor pulling device, hydraulic system Fig. 127: Hydraulic system for conveyor pulling device 14

2

1

DN10x2600 DN10x2400

10 2 11

12 4

DN10x3000

DN10x2800 DN10x2600

13

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

3

14

1 SHL-LTG 4SP-DN10x2400-ST 2 SHL-LTG 4SP-DN10x2600-ST 3 SHL-LTG 4SP-DN10x2800-ST 4 SHL-LTG 4SP-DN10x3000-ST

Doc. No.: 7420 245 000 BA 00

VUSP / 01

10 Y-manifold socket DN 10 11 plug-in L socket DN 10 12 plug-in elbow socket DN 10 13 plug-in manifold DN 10 14 plug-in elbow socket DN 10/135°

6.45

Accessories Side flaps Side flap on the head gate The side flap is attached to the gate end shield on the head gate.

Fig. 128: Side flap, head gate HG

975

3900

525

3800 c

d

1

4, 13, 15

5, 14, 15

1 side flap cylinder ZE-75/60-290-BN 2 flap 3 bracket 4 pin 50/40x130 5 pin 40/30x110 10 hammer head bolt M 24x80-8.8 11 washer 24 12 hex. nut M 24-8

6.46

b

Caterpillar Global Mining Europe GmbH, Lünen 2013

3

E

2

10, 11, 12

a

13 cyl. head screw M 6x50-A 2-70 14 cyl. head screw M 6x40-1.4301 15 hex. nut M 6-A 4-80 a load ring, load capacity: 3000 kg b screw holder M 12 c clip d name plate

Shield support 2400/4300-3x5330-2050

Accessories Fig. 129: Side flap, hydraulics, HG

DN10x800

DN 10x1000

20

DN 10x700 DN10x800

20

DN 10x2300

20

DN 10x2100

21 DN 10x1800 DN 10x1800

21

20

6

25

24

20 4

28

DN 10x1600

1

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

DN 10x1600

22

23

22 5

11

20

5

20

3 20

2

12

22 20

26 13

1

20 10

1 electrohydr. control unit 2-function 2 accumulator cartridge DN 20 3 dual CV DN 10 4 hydraulic manifold 7-function DN 10 5 PRV 380 bar DN 10 6 measurement coupling SMK20 10 bracket, control for side flap 11 support 12 symbol plate 2-function

Doc. No.: 7420 245 000 BA 00

VUSP / 01

13 staple clip 20 plug-in elbow socket DN 10 21 plug-in elbow socket DN 10 22 plug-in L socket DN 10 23 double nipple DN 10 24 double nipple DN 10-72 lg 25 double nipple DN 10-100 lg 26 reducing socket DN 12/10 27 reducing socket DN 20/10 28 plug DN 10

6.47

Accessories Side flap on tail gate The side flap is attached to the gate end shield on the tail gate.

872

Fig. 130: Side flap, tail gate, dimensions, TG

Notice!

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

6.48

Shield support 2400/4300-3x5330-2050

E Caterpillar Global Mining Europe GmbH, Lünen 2013

2555

6500

Accessories Fig. 131: Side flap, tail gate, items, TG 3 4 b 5

A

6 View A

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

11, 24, 25

20, 21, 22 a 10, 23, 25

c 1 side flap cylinder ZE-75/60-290-BN 3 bracket 4 bracket 5 flap 6 side flap 10 pin 50/40x130 11 pin 40/30x110 20 hammer head bolt M 24x80-8.8 21 washer 24

Doc. No.: 7420 245 000 BA 00

VUSP / 01

22 hex. nut M 24-8 23 cyl. head screw M 6x50-A 2-70 24 cyl. head screw M 6x40-1.4301 25 hex. nut M 6-A 4-80 a load ring, load capacity: 3000 kg b screw holder M 12 c clip d name plate

6.49

6.50

DN 10X3500 DN 10X3200

DN 10X3500 DN 10X3200

DN 10X1600

DN 10X1600

DN 10X1600

DN 10X1600 DN 10X1100

31

C

B

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

DN 10X2100

DN 10X1600

DN 10X2400

DN 10X800

DN 10X2700 DN 10X2400

DN 10X800

DN 10X2700 DN 10X2700 DN 10X2700 DN 10X2700

DN 10X900

DN 10X1100

DN 10X1100

DN 10X2100

DN 10X2300

DN 10X2300 DN 10X2100

DN 10 X1100

Accessories

Fig. 132: Side flap, hydraulics, tail gate, TG

31 36

31

A

23

Shield support 2400/4300-3x5330-2050

Accessories Fig. 133: Side flap, hydraulics, tail gate, TG 11

View A

22

32

21

View B 30

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

12 10

3

View C 1

2

20

32 32 35 5

4

31 5 11 6

31

31 33

1 electrohydr. control unit 4-function 2 accumulator cartridge DN 20 3 dual CV DN 10 4 CV, piloted DN 10 5 PRV 380 bar DN 10 6 measurement coupling SMK20 10 manifold

Doc. No.: 7420 245 000 BA 00

11 manifold 5-function 12 hydraulic manifold 7-function DN 10 20 bracket, control for side flap 21 bracket for manifold 22 bracket for manifold 2x2 23 symbol plate 4-function 24 staple clip

VUSP / 01

34

30 double nipple DN 10 31 plug-in elbow socket DN 10 32 plug DN 10 33 reducing socket DN 25/10 34 reducing socket DN 20SS/10 35 reducing socket DN 12/10 36 plug-in L socket DN 10

6.51

Accessories Side plates Side plate, right The side plate is attached on the right side to shield 4 on the head gate.

Fig. 134: Side plate, right

1567

2645

1 1 side plate 4 countersunk screw M 20x60-8.8 5 hex. nut M 20-A 2-70

a load ring, load capacity: 3000 kg

Notice!

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

6.52

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a 4, 5

Accessories Side plate, left The side plate is attached on the left side to shield 145 on the tail gate.

1538

Fig. 135: Side plate, left

105

2858 a

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

4, 5

1 1 side plate 4 countersunk screw M 20x60-8.8 5 hex. nut M 20-A 2-70

a load ring, load capacity: 3000 kg

Notice!

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.53

Accessories Side plate extensions Side plate extension, right The side plate extension is attached on the right side to shield 4 on the head gate.

Fig. 136: Side plate extension, right

1200

100

2

1

a

1 side plate extension 2 countersunk screw M 20x40-8.8 4 countersunk screw M 20x60-8.8

5 hex. nut M 20-A 2-70 a load ring, load capacity: 3000 kg

Notice!

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

6.54

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

4, 5

E

1800

Accessories Side plate extension, left The side plate extension is attached on the left side to shield 145 on the tail gate.

(900)

Fig. 137: Side plate extension, left

(1750)

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

2

4, 5

a

1 1 side plate extension 2 countersunk screw M 20x40-8.8 4 countersunk screw M 20x60-8.8

5 hex. nut M 20-A 2-70 a load ring, load capacity: 3000 kg

Notice!

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.55

Accessories Brackets Hose holder, 8-function Fig. 138: Hose holder, 8-function

1

(80)

7

8

6

(180)

248,5

4

5

3

108

2

30

6 countersunk screw M 8x16-A 2-70 7 hex. head screw M 12x25-A 2-70 8 hex. nut M 12-A 4-80 9 countersunk screw M 12x110-A 2-70

1 fastening 2 hose clip, 4-function 3 hose clip, 4-function 4 flat bar 5 flat bar

Hose holder, 6-function Fig. 139: Hose holder, 6-function 14

7

190

13

11 3

10 12

100

6

135 1 hose clip, 3-function 2 hose clip, 3-function 3 hose clip, 1-function 5 flat bar 6 intermediate plate 7 fastening

6.56

1

10

2

5

15 10 countersunk screw M 8x16-A 2-70 11 countersunk screw M 6x12-A 2-70 12 hex. head screw M 12x80-A 2-70 13 countersunk screw M 12x110-A 2-70 14 countersunk screw M 12x25-A 2-70 15 hex. nut M 12-A 4-80

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

9

Accessories Hose holder, 6-function (on edge) Fig. 140: Hose holder, 6-function 10 1

15 11

14

6

306.5

2

12 3

13

5

1 hose holder 2 hose clip, 1-function 3 hose clip, 3-function 4 hose clip, 3-function

107.5

4

10 hex. head screw M 12x25-A 2-70 11 hex. head screw M 12x100-A 2-70 12 hex. head screw M 12x70-A 2-70 13 countersunk screw M 8x16-A 2-70

5 flat bar 6 flat bar

14 countersunk screw M 6x12-A 2-70 15 hex. nut M 12-A 4-80

Wind holder Fig. 141: Wind holder 10

(260)

(350)

11

350

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

30

1

1 wind holder 10 hex. head screw M 12x30-A 2-70

Doc. No.: 7420 245 000 BA 00

VUSP / 01

11 hex. nut M 12-A 4-80

6.57

Accessories Guides Belt guide

6

120

Fig. 142: Belt guide

150

160 5 7

2

6

4 1 belt guide 2 deflection roller 4 hex. head screw M 12x25-A 2-70

6.58

5 hex. head screw M 10x80-A 2-70 6 hex. nut M 12-A 4-80 7 hex. nut, M 10-A 2-70

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

Accessories Hose guides Fig. 143: Hose guide, right 60

1 a

5, 6

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1 hose guide, right 5 hex. head screw M 12x30-A 2-70

6 hex. nut M 12-1.4571 a screw holder M 12

Fig. 144: Hose guide, left 60

a

1

5, 6

1 hose guide, left 5 hex. head screw M 12x30-A 2-70

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6 hex. nut M 12-1.4571 a screw holder M 12

6.59

Accessories Covers Hose cover, canopy Fig. 145: Hose cover, canopy

(210)

(170)

(410)

10

11 1 1 hose cover 10 hex. head screw M 12x30-A 2-70

11 hex. nut M 12-A 4-80

Fig. 146: Hose cover, canopy

(170)

(210)

(230)

10

(67,.5)

80

11 1

1 hose cover 10 hex. head screw M 12x30-A 2-70

6.60

11 hex. nut M 12-A 4-80

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

(67,5)

225

Accessories Technical data, steel structure Shield support, device number 7420 245 000 00 01 Height, retracted . . . . . . . . . . . . . . . . . . . . mm

2400

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

4300

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

1800

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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

1800

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

---

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

1000

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

1800

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

---

Leg clearance on inclines . . . . . . . . . . . . mm

1060

Leg clearance between front leg and third, rear leg (base) . . . . . . . . . . mm

1685

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

4245

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

4455

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

1950

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

8700

Caving shield inclination:

Doc. No.: 7420 245 000 BA 00

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

11.8

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

54.5

Width of caving shield . . . . . . . . . . . . . . . mm

1610

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

1666

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

37 867

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

2050

Supporting force of support with average thickness of . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN

---

b) at 450 bar nominal pressure . . . . . . . . kN

---

Support resistance per m2 roof surface with average thickness of . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN/m2

---

b) at 450 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

---

VUSP / 01

6.61

Accessories

2400

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

4300

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

1800

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

1800 ---

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

1000

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

1080

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

---

Leg clearance on inclines . . . . . . . . . . . . mm

1060

Leg clearance between front leg and third, rear leg (base) . . . . . . . . . . mm

1685

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

4245

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

4455

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

1950

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

8700

Caving shield inclination:

6.62

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

11.8

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

54.5

Width of caving shield . . . . . . . . . . . . . . . mm

1610

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

1666

Total surface area of the bases . . . . . . . cm2

37 867

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

2050

Supporting force of support with average thickness of . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN/

---

b) at 450 bar nominal pressure . . . . . . . . kN

---

Support resistance per m2 roof surface with average thickness of . . . . . . . . . . . . mm

3500

a) at 350 bar setting pressure . . . . . . . . . kN/m2

---

b) at 450 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

---

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

E

Shield support, device number 7420 245 000 00 02

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 catalogue 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 shields 7420 245 000 0x are each provided with two electrohydraulic control units: Caterpillar Global Mining Europe GmbH, Lünen 2013

E

8154 182 000 00 00 has 12 functions, 8154 180 000 00 00 has 6 functions.

Fig. 147: Electrohydraulic control unit, 12-function 2

1

9

10

15

3, 7 4, 8

5 1 manifold block 12-function 2 double 3/2-way pilot solenoid valve 3 control valve cartridge NG 20 4 control valve cartridge NG 13 5 check valve NG2

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6

A

6 filter cartridge 7 screw fitting 8 screw fitting 9 plug M 16x1 10 plug M 18x1 15 name plate

6.63

Hydraulic system Fig. 148: Electrohydraulic control unit, 6-function 1

9

15

3, 7

2

1 manifold block, 6-function 2 double 3/2-way pilot solenoid valve 3 control valve cartridge NG 20 4 control valve cartridge NG 13 5 check valve NG2

4, 8

6

A

6 filter cartridge 7 screw fitting 8 screw fitting 9 plug M 16x1 10 plug M 18x1 15 name plate

Warning!

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

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

6.64

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

5

E

10

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.

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

Fig. 149: Double-telescopic leg, type SD-5300-380-1465/3285 b

6 E

21 Caterpillar Global Mining Europe GmbH, Lünen 2013

e 2 5

1

d

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. 22: Telescopic leg Length in mm ID No. Telescopic leg 8250 210 000 00 00

Doc. No.: 7420 245 000 BA 00

VUSP / 01

Stroke in mm

retracted

extended

upper stage

lower stage

1465

3285

840

980

6.65

Hydraulic system 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.

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).

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 transferred mechanically from the shield canopy via the leg head to the piston rod.

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

6.66

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

set leg

E

Function

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. 150: Hydraulic cylinder, typical example Type a)

2 1

3

5

4

1

4

6

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Type b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

4 guide bushing 5 connection 6 connection

Notice!

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

Warning!

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

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

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

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

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

6.67

Hydraulic cylinder Fig. 151: Items of hydraulic leg Flipper

Canopy Caving canopy

Z7 Z1

Z5

Z9

Z1

Flap

Z4b

Z4a

Tab. 23: Leg and hydraulic cylinder, position ID

Qty/ var.

01 02

Name

Z1

3

3

Leg

Z2

1

1

Shifting ram

Z4a Z4b Z5 Z7 Z9

3 2 3 2 1

3 3 3 2 1

Z10

3

-

Z11

9

-

Side seal cylinder Side seal cylinder Caving canopy cylinder Flipper cylinder Base lifting cylinder Side flap cylinder, main gate Side flap cylinder, tail gate

6.68

Location Base -

2x front, 1x rear On the relay bar assembly On the canopy On caving canopy On caving canopy Canopy-flipper Between the bases

Dr. No.

Type

8250 210 000 00 00 SD-5300-380-1465/3285 8241 535 000 00 00 ZE-240/100-1080 8241 352 000 00 00 8241 352 000 00 00 8241 336 000 00 00 8241 521 000 00 00 8241 487 000 00 00

ZE-63/50-215 ZE-63/50-215 ZE-225/140-530 ZE-125/90-600 ZE-165/100-310

On the side flaps

8241 553 000 00 00 ZE-75/60-290

On the side flaps

8241 553 000 00 00 ZE-75/60-290

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Z2

Hydraulic cylinder Shifting ram (Z2) Fig. 152: Hydraulic cylinder, type ZE-200/100-1080

72 L c a

b

1

2 6

3

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1 cylinder tube 2 reed rod 1080 lg.

3 piston rod 100 6 screw fitting a piston space connection

b annular space connection c load ring 1000 kg L retracted: 1905 extended: 2985 stroke: 1080

Side seal cylinder (Z4a) Fig. 153: Hydraulic cylinder, type ZE-63/50-215

30 L

a 2

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

Doc. No.: 7420 245 000 BA 00

VUSP / 01

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

6.69

Hydraulic cylinder Side seal cylinder (Z4b) Fig. 154: Hydraulic cylinder, type ZE-63/50-215

30 L

a 2

b 1 1 cylinder tube

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

2 piston rod

Caving canopy cylinder (Z5) Fig. 155: Hydraulic cylinder, type ZE-225/140-530

72

72 L a 11

b

25

2

c 31, 32 1 cylinder tube 2 reed rod-535 11 piston rod 140 25 cylinder eye 31 cyl. head screw M 24x50-10.9 32 locking washer 24

6.70

d

1

a piston space connection b annular space connection c load ring 1000 kg d cylinder bottom L retracted 1055 extended 1585 stroke: 530

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

a piston space connection

Hydraulic cylinder Flipper cylinder (Z7) Fig. 156: Flipper cylinder ZE-125/90-600

60 L a 7

2

c

1

E

4

b annular space connection

1 cylinder tube 2 reed rod 4 piston rod 7 screw-in socket DN 20 a piston space connection

Caterpillar Global Mining Europe GmbH, Lünen 2013

b

c load ring 1000 kg L retracted 930 extended 1530 stroke: 600

Base lifting cylinder (Z9) Fig. 157: Hydraulic cylinder, type ZE-165/100-310

55 L

140 d

4

a

b c 1 cylinder tube 4 piston rod a piston space connection b annular space connection c load ring 1000 kg

Doc. No.: 7420 245 000 BA 00

VUSP / 01

1 d holding peg L retracted 500 extended 810 stroke: 310

6.71

Hydraulic cylinder Side flap cylinder HG (Z10) Fig. 158: Side flap cylinder, type ZE-75/60-290

40.5

40.5

L a b

21

1 cylinder tube

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

b annular space connection L retracted 505 extended 795 stroke: 290

21 piston rod a piston space connection

Side flap cylinder, TG (Z11) Fig. 159: Side flap cylinder, type ZE-75/60-290

40.5

40.5

L a b

21

1

1 cylinder tube 21 piston rod a piston space connection

6.72

b annular space connection L retracted 505 extended 795 stroke: 290

Shield support 2400/4300-3x5330-2050

Hydraulic cylinder Technical data, hydraulic cylinders

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

telescopic leg Z1 double acting, 2-stage

shifting ram Z2 double acting, reverse mounted

side seal cylinder Z4 double acting

Doc. No.: 7420 245 000 BA 00

Type SD-7150-450-1625/3875

Device no. 8250 210 000 00 00

Leg length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1465

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

3285

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

1820

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

380 / 270

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

350 / 250

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

1134.1 / 573

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

172 / 82

Leg force at setting pressure, 350 bar . . kN

3969

Setting pressure, 470 bar . . . . . . . . . . . . kN

5330

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

602

Type ZE-200/100-1080 version with reed rod

Device no. 8241 535 000 00 00

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

1080

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

240

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

100

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

452.4

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

373.9

Thrust force at 320 / 180 bar . . . . . . . . . kN

1448/ 814

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

1196 / 1 421

Type ZE-63/50-215

Device no. 8241 352 000 00 00

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

215

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

63

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

50

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

31.2

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

11.5

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

100 / ---

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

37 / 43.7

VUSP / 01

6.73

Hydraulic cylinder

base lifting cylinder Z9 double acting

6.74

Device no. 8241 536 000 00 00

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

535

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

220

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

140

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

397.6

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

243.7

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

1272/ 1511

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

780 / 926

Type ZE-125/90-600

Device no. 8241 521 000 00 00

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

600

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

125

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

90

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

122.7

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

59.1

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

393/ 466

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

189 / 225

Type ZE-165/100-310

Device no. 8241 487 000 00 00

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

310

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

165

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

100

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

213.8

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

135.3

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

684/ 812

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

433 /---

Shield support 2400/4300-3x5330-2050

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flipper cylinder Z7 double acting

Type ZE-225/140-530

Caterpillar Global Mining Europe GmbH, Lünen 2013

caving canopy cylinder Z5 double acting

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. 24: Pressure relief valves, use of the various types Application

Design

Setting pressure in bar

Device No.

For return line

Spring-loaded

80

8220 042 080 00 00

For water spraying system

Spring-loaded

180

8220 138 180 00 00

For cylinders

Spring-loaded

380

7337 486 380 00 00

For legs

Spring-loaded

450

7337 486 450 00 00

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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.

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6.75

Pressure relief valves Tab. 25: 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 160 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

a

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

Tab. 26: Color codes for pressure relief valves, overview

1)

6.76

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

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

b

a color code b protective cap

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Fig. 160: Pressure relief valve, example

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

Fig. 161: Angles α 1 / α 2

α1 α2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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M

Tab. 27: Change angle α 1 / α 2 at height M Inclination α at height M

Shield ID No. 7420 245 000 00 01 7420 245 000 00 02

α1 in °

α2 in °

M in mm

15°

15°

2700 to 4000

----

----

> 2400 to 2700 > 4000 to 4300

It can only be bent when the front or rear leg is extended pivot point “canopy/caving shield”.

Caution!

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

Important!

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

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6.77

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.

6.78

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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.

E

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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 162: Certificate, example

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VUSP / 01

6.79

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 28 are maintained, it can be assumed that the water is basically suitable.

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

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

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

for use as spraying water

6.80

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 μm.

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

Shield support 2400/4300-3x5330-2050

Caterpillar Global Mining Europe GmbH, Lünen 2013

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concentrate content

Hydraulic fluids limit values

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

Caution!

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Tab. 28: 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 μS/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 μm 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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6.81

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. 29: 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. 30: 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. 31: 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

6.82

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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. 32: 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.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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lubricant B6

Tab. 33: 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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6.83

Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 34: Tightening torques at μtot. = 0.14 Tightening torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

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).

6.84

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(mm)

Caterpillar Global Mining Europe GmbH, Lünen 2013

Thread 1)

7

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. 35: Standards and directives, excerpt

Caterpillar Global Mining Europe GmbH, Lünen 2013

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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 DIN EN 60445 Basic and safety principles for man-machine interfaces 2007-11 Underground mining machinery DIN EN 12321 2009-07 Safety requirements for chain scraper conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shearer loaders and 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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7.3

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

Caterpillar Global Mining Europe GmbH, Lünen 2013

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

1985-02

1) EWN = works standard

7.4

Shield support 2400/4300-3x5330-2050

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

E

Fig. 163: 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

7.5

Identification of the shield Shield number The shield number serves as an identification feature. All shields are numbered consecutively. The corresponding shield number is on the face side, on the left side of the base.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 164: Shield number, centered, face side

a

b

a shield number

b shield weight

Tab. 36: Shield support 0010 700 000 00 00, numbering Device No.

Quantity Use

Shield

Shield number

Special design Conveyor pulling device

7420 242 000 00 01

138

Face shield

8 to 143

SH001 to SH138

7420 243 000 00 01

1

Transition shield HG

5

TS001

7420 243 000 00 02

1

Transition shield TG

144

TS001

3

GS001

4

GS002

147 to 149

GS005 to GS007

145

GS003

146

GS004

1 to 2

BS001 to BS002

Gate end shield HG 7420 245 000 00 01

5 TG

7420 245 000 00 02

7420 244 000 00 01

7.6

2

2

Gate end shield TG

Segment shield HG

Extension, right Extension, left Side plate extension, right, side plate, right

Side plate extension, left side plate, left

Shield support 2400/4300-3x5330-2050