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Amendmentsandalterationstothispublicationarenotsubject tonotification.Caterpillarreservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.
Caterpillardeclinesanyliabilityfordirectorindirectconsequencesof printingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2012E ACaterpillarInc.Company
Aboutthismanual
Aboutthismanual
Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Italsoprovidesyouwithinformationonthe structureofthemanualandthesymbolsused.
Beforestartingwork
Usinganoperatingmanualthatwasnotspecificallywrittenforthe controlunitconcernedcanresultinasafetyhazardforyourselfand others.Ensurethatthespecificationsonthecontrolunitcomply withthespecificationsintheoperatingmanual.
Thisoperatingmanualisdesignedfor:
Electrohydr.controlunit-8functions Devicenumber81541490000000
andisonlypermittedtobeusedforcontrolunitsofthistype.Only usetheoperatingmanualwhichappliestotherespectivecontrol unit.Failuretodosowillposeadangertoyourselfandothers.
Itisabsolutelynecessarytoensurethatallpersonsworkingwithor onthecontrolunitalwayshaveunrestrictedaccesstothecontents ofthecurrent,applicableoperatingmanuals.
Personsforwhomthisoperatingmanualisintended
Thisoperatingmanualisintendedforeveryoneconcernedwith installing, servicing, repairing, operatingand removal.
Thesupervisorswhoinitiatetheaboveworkorsuperviseitmust alsofollowthisoperatingmanual.
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtothecontrolunit.
Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontothesafetyinstructions. Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.
Payspecialattentiontochapter2,“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheinstructionsinthisoperatingmanual.Thisistheonlywaythatyoucankeeptheoperating costsdownandretainyourrightstomakeaclaimunderthewarranty.
Beforestartingwork
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationinthisoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare veryseriousinjuryorevendeath.
Warning!
Thesepointscontaininformationonhazardoussituations. Possibleconsequencesareveryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesareminortomoderatelyseriousinjuriesand damagetothemachine.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesareminordamage tothemachineordamageintheimmediatevicinity.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtomakeworkeasierforyou.Theydo notwarnaboutharmfulordangeroussituations.
Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Pointsinthetextmarkedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Itwillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.
Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.
Thecontrolunitwasmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. However,aresidualriskstillexistswhichmayinvolveyougetting intohazardoussituationswhenworkingwithoronthecontrolunit. Thesemay,forexample,becausedbyunforeseeableexternal influences,machinedamageoroperatingerrors.
Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulations: oftheminingcompany, oftheminesinspectorateand oftheminingsupervisoryauthorities
Personnel
Personsemployedintheoperation,repairandoverhaulof hydraulicand/orelectrohydrauliccontrolcomponentsmustbespeciallyqualified.Inadditiontohavinghadtraininginminingtechnologythefollowingminimumrequirementsmustbemet.
Operationandmaintenance
Operationandmaintenanceoftheshieldcontrol systemmayonly beperformedbytrainedpersonnel. Thetrainingmustbespeciallytailoredtothetypeofcontrolunit actuallybeingused.
Thecontentoftheoperatingmanual,especiallythechapteron safety,mustconstituteapartofthistraining.
Theymustpossessandfurnishproofofadequatefamiliaritywith the mechanical system hydraulicsystemand controlsystem.
Repairandmaintenance
Ingeneral,repairworkmayonlybeperformedbypersonswho havetheknowledgeandskillstomeetthespecialrequirements andhavebeenadequatelytrainedintherepairoftheequipment. Repairworkonandoverhaulof: controlunits, workingvalves, pilotvalves, safetycomponentssuchaspressurereliefvalvesetc.
shallbeperformedonlyCaterpillarserviceengineersorbyspecially trainedpersonneloftheminingcompany.
Operatingconditions
Intendeduse
Theelectrohydrauliccontrolunitisexclusivelyconstructedand manufacturedasacomponentoftheshieldsupportcontrol system. Itmayonlyusedinconjunctionwithanelectroniccontrolsystem, forexampleaPMC®-Rcontrolsystem. Onlyusethecontrolunitasintended.
Theintendedusesareasfollows:
Theelectrohydrauliccontrolunit,togetherwithanelectronic controlunit-forinstanceaPMC®-Rcontrolunit-,formsan electrohydraulicshieldcontrolsystem.Thisisusedtocontrol shieldsupportfunctions.Togethertheyarepartofaneighboringcontrolsystemforelectrohydraulicshields upportsandare intendedforuseinundergroundmining.
Theelectrohydrauliccontrolunitisanessentialpartoftheelectrohydraulicshieldcontrolsystem.Thefunctionsmaynotbe operateddirectlyattheelectrohydrauliccontrolunit,butrather onthecorrespondingelectroniccontrolunitlocatedinoneof theneighboringsupports.Thepilotvalvesontheelectrohydrauliccontrolunitareactivatedmanuallyorviaaprogram usingthecontrolunit.
Theelectrohydrauliccontrolunitisalsousedasa“controlunit” intwotypesofexceptionalcases: -emergencyoperationand -repairoperation.
Theindividualfunctionsoftheshieldsupportareactuateddirectlyonthepilotvalveoftheelectrohydrauliccontrolunit.In justifiedexceptionalcasesandinstrictcompliancewiththecorrespondingsafetyregulationsofthemineoperator,thefunctionsofasupportcanalsobeactuatedwhentheelectronic controlunitisblockedorithasfailed.
Unauthorizeduse
Alluse,whichisnotexpresslydeclaredasintended,isregardedas unauthorizeduse.
Unauthorizeduseincludes:
theuseoftheelectrohydrauliccontrolunitsas“controlunits”for theoperationofsupportfunctionsduringnormalshieldunit operation.
Actuatingtheshields exclusively viathepilotvalves bypressingabutton,isregardedasunintendeduseasitisnotpossible, whichisnotauthorized,tocontroltheshieldfroma neighboringshield.
Unauthorizedusecanendangeryourselfandothers.Youmightbe killedorseriouslyinjured.
Youshouldthusonlyusetheelectrohydrauliccontrolunitasintended.
Caterpillarwillacceptnoresponsibilityfortheconsequencesof unauthorizeduse.
Safetyinstructions
Thefollowingalwaysapplies: Alwaysconcentrateonyourwork.
Itisalsoimperativethatyoufollowtheoperatingmanualforthe supportandthecontrolunit.
Alwaysfamiliarizeyourselfwiththeworkingenvironment,before startingwork.
Alwayskeepoutofanyshieldwhichisnotset. Alwayswearpersonalprotectiveequipment.
Observetheacousticandvisualstart-upwarnings.Payspecial attentiontothestart-upwarningsfortheconveyorandfortheminingequipment.
Onlyusecontrolunitswhichareinatechnicallyflawlesscondition. PresstheEMERGENCYSTOPswitchimmediately,intheeventof faultsorirregularitiesinoperation.Notifyyoursupervisorofany peculiarity,sothatnecessaryactioncanbetakenimmediately.
Iftheshieldisequippedwithanelectrohydrauliccontrolunit,you mustlock-outtheshieldbypressingthesupportlock-outswitch (repairswitch).Thismeanstheshieldcannotbecontrolledviathe controlunit.
Pressthesupportlock-outswitchwhenperforming: maintenancework, inspectionwork, repairwork andduringprolongedpresenceintheshield. Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe: sideseals, bases, relaybarassemblies, lemniscaticlinks, hydraulicpropsandcylinders, canopiesand flippers.
Storageandtransport
Neverstorematerialsofanykindinthetravelwayorinyourworkingarea.
Toavoidhinderingorendangeringthefacecrew,immediately removeanyfaultycomponentsfromtheface.
Neverstorefaultypartswithgoodparts.Thiswayyoucanavoid inadvertentreinstallationofthesefaultycomponentssomewhere else.Havethesefaultycomponentsrepaired.
Observethespecifiedstorageperiodsandthestorageinstructions.
Installation
Mechanicallysecureallmovingpartsbeforeyoudepressurizethe hydraulicsystem.
Asamatterofprinciple,onlyworkondepressurizedhydraulic systems.
Makesurethatnodirtorimpuritiescangetintothehydraulicsystem.
Onlyremovetheprotectivecapsfromtheconnectorsimmediately beforeinstallingthecontrolunit.
Operation
Onlyworkinrepairmodeifitisabsolutelynecessary.Ifpossible controltheshieldsfromthecontrolunitoftheneighboringshield.
Checktodeterminewhetherallprotectivedevicesontheshieldare presentandfunctional.
Makesurethatnooneisintheareaoftheshieldbeingactuated.
Watchtheshield'srangeofmotionsothatpotentialhazardscanbe recognizedintimeandpreventativeactioncanbetaken.
Maintenance
Informthesupervisorypersonnelandthefacecrewaboutmaintenanceandrepairwork.Providethemwithinformationontheintendedworkanditsprobableduration.
Keepyourworkingareacleartoavoiddangertoyourselfandother persons.
Blockofftheworkingareafortheminingequipmentorstopthe miningequipmentandtheconveyorandlockthe system,topreventitfrombeingturnedonagain.
Beforeperformingwork,mechanicallysecuretheshieldtoprevent itfromaccidentallysinkingintothefloor,e.g.by: proppinguporsupportingthecanopy, placingwoodenwedgesbetweenthelemniscaticlinks.
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handlinghydraulic fluids maintenance,repair
Immediatelydiscontinueanyworkontheshield,ifconveyingand miningoperationsareinprogressinyourworkingarea.
Immediatelyaftercompletingwork,refitanyremovedprotective devicesandcheckthattheyworkproperly.
Makesurethattheprescribedmaintenanceandinspectionintervals areobserved.Alsoseechapter5,“Operation”.
Useonlysparepartswhichconformtothespecifiedtechnical requirements.ThisisbestensuredbyusingoriginalCaterpillar spareparts.
Pleaserefertothesparepartsfolderfortheordernumbers.
Donotmakeanymodificationsorchanges.Modificationsand changesmustbeapprovedbyCaterpillar.
Neverusethecontrolunitwithoutafiltercartridge.Ifthefilteris missingorifitisnotfineenough,thiscanleadtomalfunctionsand damagetothecontrolunit.
Hydraulicsystem
Avoiddirectcontactbetweenyourskinandhydraulicfluids. Hydraulicfluidwhichpenetratestheskincancauseseriousinfections.
Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids poseaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstratespecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Inparticularcheckthat:
Thehosesarenotpinched.
Thehoseshavenobubblesorblisters.
Thehosesortheoutersheathsofthehosesarenotabnormallyrigidorhard.
Theoutersheathofthehoseisnotdamaged.
Theconnectorsarefirmlyinsertedinthecouplingsockets.
Theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicssystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamagetothewhole system.Flushoutthehydrauliclinesthoroughlybeforeconnecting.
Beforeremovingstaplestodisconnecthydraulichosesturnthe hoseattheconnectortocheckwhetherthelineispressurized. Ifthehoseisdifficulttoturnordoesnotturnatallthelineisstill pressurized.Makesurethelineisdepressurized.
Ifstaplescannotbepulledoutorcanonlybepulledoutwithdifficulty,thehydrauliclinemightstillbeunderpressure.Makesurethe lineisdepressurized.
Securetheconnectorsofthehydraulicelementswiththeproper staplesonly.Alwaysfastenthestaplescompletelywithbothsides. Neverusenails,wireorsimilarmaterials.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystem again.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamaged connectorsorwornO-rings.
Replacehydraulichosesonlywithhosesofthesameorahigher quality.
Observethedateofmanufacturestampedonthehosefittingofthe hydraulichose.Neverusehydraulichoseswhicharemorethan2 yearsold,eveniftheyshownovisiblesignsofdamage.
Nevertrytoholdahydraulichosethatisthrashingabout.Depressurizetheaffectedlinesectionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesevenifyouonlysuspecttheyhavebeen damaged.
Fig.1:Examplehydraulichose,identification
Safetyinstructions
layinghydraulic hoses
Laythehydraulichosescorrectlybehindthebracketsandclips providedforthem.
Alwayslayhydraulichosessothatthey: alwayshavealittleslack,
Fig.2:Layinghydraulichoses,slack RIGHT WRONG arenottwisted,
Fig.3:Layinghydraulichoses,twisting WRONG RIGHT
arenotbentdirectlybehindtheconnectors(distanceminimum 1.5xnominaldiameter),
Fig.4:Layinghydraulichoses,bending RIGHT WRONG cannotchafe,
Fig.5:Layinghydraulichoses,crossing RIGHT WRONG
arenotkinked, donothavetowithstandtensileloads, areprotectedagainstthermalradiation, areaccessibleatalltimes.
Onlypushhydraulichosesintothesocketsbyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagetheconnections.
Whenlayingthehydraulichoses,ensurethattheycannotbe: tornout, kinked, crushed, drivenover twistedasaresultofmovingequipment.(Fig.6).
Fig.6:Layinghydraulichoses,connectionsonmovingparts RIGHT WRONG
3
Storageandtransport
Storageandtransport
Thischaptercontainsimportantinformationaboutthecorrectstorageandtransportoftheelectrohydrauliccontrolunit.
Followingtheinstructionsandtipswillincreasethelifecycleand servicelifeoftheelectrohydrauliccontrolunit.Youwillbeableto carryouttransportworkmoresafelyandquickly.
Payingcarefulattentiontothepointsinthischapterwillalsohelp youtosimplifyyourday-to-daywork.
Storage
Storingtheequipment
Componentswithatemporaryanticorrosioncoatingareprotected foraboutsixmonths.
Protecttheequipmentfromdirectexposuretosunlight.
Onlystoretheelectricalequipment,electroniccomponents, replacementpartsmadeoutofrubberorplasticsuchassealsand hosesaswellashydraulicfluidsinclosedroomsat15
Cto25 C.
Protectallpartsoftheequipmentstoredoutdoorsagainstmoisture anddirt,e.g.,usingtarpaulins.
Themountingsurfacesofhydrauliccomponentsmustbeprotected againstcorrosionandsealedwithblindplates.Protectthehydraulic plug-typeconnectionsandtheconnectorsoftheelectricalcables withthecapsandplugssupplied.
Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors,butattemperatures above freezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirtandmoisture.
Duringlong-termstorage(morethan4weeks),theequipmentmust notbestoredoutdoors.Itneedstobestoredinadry,well-ventilatedroom.
Afterastorageperiodofapproximatelytwoyears,arandom sampleinspectionmustbeperformedtodeterminewhetherthe measurestakenandthemethodofstoragehavepreventeddamage.
ThisinspectioncanbecarriedoutbyCaterpillaruponrequest.
Evenwithproperstorage,sealsandhoselinesaresubjecttonaturalaging.Donotusethesecomponentsiftheyhavebeenstored formorethantwoyears.
Important!
Ensureduringstoragethatanynewsuppliesarestoredseparatelyfromexistingstocksinsuchawaythatonremoval,old stocksarealwaystakenfirst.
Storage
Storingusedequipment
Thepointslistedabove,withtheexceptionoftheoneconcerning anticorrosionprotection,canbeappliedanalogouslyforthestorage ofhydrauliccomponentsthathavealreadybeeninuse.
Ifthehydraulicssystemistobeputoutof operationtemporarily, theentirehydraulicssystemmustbethoroughlyflushedoutin advanceandthenfilledwithasuitableanticorrosiveandantifreeze liquid(e.g.HYDROCOR® CV50*).Ifthisisnotdone,thenthe hydraulicscomponentsmaysufferconsiderabledamagewithin ashorttime,becausethepropertiesofthemediumusedcan undergoveryrapid,verynegativechanges,e.g.duetomicrobial infestation.
Transport Transportboxes
Thecontrolunitsarepackedinseveraltransportboxes.They shouldstayintheseboxesuntiltheyreachtheirfinaloperatinglocation.Thisprotectsthemfromexternaldamage.
Makesurethattheboxesarenotdamagedduringtransport.During transport,makesurethattheyarenot: droppedor brokenopen.
Protectthetransportboxesfrommoisture.
Beforetransportingtheequipmentattemperaturesbelowfreezing,allofthehydrauliccomponentsmustbecompletelyemptiedandthencompletelyfilledwithacorrosioninhibitor (e.g.HYDROCOR® CV50).
If,duringtransport,thecontrolunitisexposedtotemperatures below-20 C,thenspecialmeasuresmayhavetobetaken.Inthis case,beforestartingtransport,contactCaterpillar'sservicedepartmenttoclarifythenecessarymeasures.
Dimensionsandweight
Plugs
Theconnectorsfortheindividualcontrolunitsareclosedoffwith plasticplugs.Thisprotectsthemfrommoisture,dirtanddamage.
Notice!
Impuritiesinthehydraulicsystemcanleadtothefailureofthe entiresystem,makingexpensiverepairsnecessary. Forthisreason,youshouldonlyremovetheplugsjustbefore thecontrolunitisconnected.
Bracketwithcontrolunit
Important!
Whentransportingtheshieldensurethatthebracketisfixedto thecontrolunitsuchthatitcannotcollidewithothercomponentswhenshieldisbeingretracted.
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4 Installation
Installation
Thischaptercontainsinformationontheinstallationanddeinstallationofelectrohydrauliccontrolunits.Pleasepayspecialattentionto thewarningsandtips.
Warning!
Improperorfaultyinstallationcanendangeryourselfandothers.
Youmayonlycarryouttheinstallationifyoucandemonstrate thatyouhavetherequisite,specialknowledge.
Requirementsforthefacehydraulicsystem Notice!
Thehydraulicandelectronicpartsoftheshieldcontrolsystem aredealtwithinseparateoperatingmanuals.
Youwillfinddetailsonthecommissioninganduseofthe shieldcontrolsystemintheoperatingmanualontheelectronic controls.
Thehydraulicmediummustmeetthefollowingconditionsforall hydraulicsystemcomponentsincludedintheCaterpillarscopeof delivery:
IfthetestspecifiedinEWN8350,part1,issuccessful,the hydraulicfluidwillbeclassifiedassuitable.Seethesection “Operatingmedia”inchapter6ofthisoperatingmanual ContaminationClass18/14pursuanttoISO4406.
Installationofthecontrolunit
Removingthecontrolunit
Beforeyoucanstartwiththeinstallationorexchangeofthecontrol unit,youmusttakesafetyprecautions:
. Sealoffyourworkingareatokeepallotherpersonnelout.
. Haveminingstoppedinthisarea.
. Informyourcolleaguesaboutthenatureanddurationofthe repairworkandaboutyourexactlocation.
. Pressthesupportlock-outswitch.
. Securetheshieldtostopitsinkingbyitself;e.g.byusing wedgesinthelemniscaticlinksorbyproppinguporsupporting thecanopy.
. Depressurizethehydraulicsystemoftheshieldconcerned.
. Checkthatthehydrauliclinesarereallydepressurized. IfeverythingisOKsofar,thenyoucancontinuewiththenextstep.
. Labeltheconnectingcablesandhydraulichosestoavoidmixupslateron.
. Pullofftheconnectingcablefromthecoverofthepilotvalve.
Danger!
Neverworkonahydraulicline,ifyouarenotsurethattheline iscompletelydepressurized. Ifloosehydraulichosesarethrashingaboutandhydraulicfluid isescaping underpressure,youcouldbeseriouslyinjuredor evenkilled.
Itisthusvitalthatyoudepressurizehydrauliccomponents beforeyoustarttodismantlethem. Ifastaplecan'tbepulledout,orisverystiff,thenyoushould beverycareful.Itispossiblethatthehydrauliclineisstill underpressure.
. Undoallofthehydraulicconnectionsontherearsideofthe controlunitandmakesurethattheconnectionsarenotdamagedorsoiledwhendoingthis.
. Securethecontrolunitwithliftinggearandtransportstraps.
Notice!
Donotsecurethecontrolunitwithchainsorsteelcables.It couldbedamagedbythat. Onlyusetransportstrapswhichsitcloselyonthecontrolunit andwhichpreventitfromslippingthrough.
. Undothescrewsonthecontrolunitmounting.
. Pullthecontrolunitoutofthemounting.
Installationofthecontrolunit
. Placethecontrolunitinthemountingandtightenthescrews (M10)byhand.
Fig.7:Tappedholes
Important!
Beforecommissioningtheshield,ensurethatthesymbolbar ispositionedsuchthatthesymbolsareclearlylegible.
Caution!
Beforethehydraulicconnectionsarejoinedwithoneanother, thecouplingsocketsandnipplesoftheplug-Oconnections mustbetreatedwiththemolybdenumdisulfide-freeB3lubricatingpasteinaccordancewithEWN7068. Seechapter6,Section“Lubricatinggreasesandpastes”.
. Connectthehydraulichoses.Ensurethatyoudonotmixup theconnections. Followthehoseplanandthelabelingofthehoses.
Danger!
Youcouldbeseriouslyinjuredorevenkilledbyahydraulic hosethatisthrashingabout!
Onlyusethecorrectsizeofstapletosecureconnectorsockets.Pushthestaplesoncompletely,usingbothsidesofthe staple.Neverusenails,wireorsimilarmaterials.
M10
M10
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