DOWNLOAD PDF CAT Electrohydraulic control unit 20 Function Operating & Maintenance Manual

Media-ID: EM027268-00-EN Doc.-No.: 8154 177 000 BA 00 Dec. 2016

Operating and Maintenance Manual Electrohydraulic control unit 20 Functions Part-No.:

4039680

SAFETY.CAT.COM

© 2016 CATERPILLAR ALL RIGHTS RESERVED

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

Table of contents

Table of contents 1 About this manual ....................................................................................... 5 1.1 How to use this manual ........................................................................ 5 1.2 Signs and symbols used....................................................................... 6 2 Safety............................................................................................................ 7 2.1 General safety instructions ................................................................... 7 2.2 Personnel.............................................................................................. 7 2.3 Repair and servicing ............................................................................. 7 2.4 Operating conditions............................................................................. 8 2.4.1 Intended use .............................................................................. 8 2.4.2 Unauthorized use....................................................................... 8

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2.5 Using the machine and working on the machine .................................. 9 2.6 Notes on the hydraulic system............................................................ 10 2.6.1 Recommended storage and use period................................... 11 3 Storage ....................................................................................................... 14 3.1 Transport ............................................................................................ 15 4 Installation.................................................................................................. 17 4.1 Shield hydraulics requirements........................................................... 17 4.2 Installing and removing the control unit .............................................. 18 4.2.1 Removing the control unit ........................................................ 18 4.2.2 Installation of the control unit ................................................... 19 5 Operation.................................................................................................... 21 5.1 Pilot valve ........................................................................................... 22 5.1.1 Operation ................................................................................. 22 5.1.2 Function ................................................................................... 22 5.1.3 Installing and removing the pilot valve ..................................... 23 5.2 Filter cartridge..................................................................................... 24 5.2.1 Maintenance intervals .............................................................. 24 5.2.2 Removing and installing the filter cartridge ............................. 24 5.3 Accumulator cartridge......................................................................... 26 5.3.1 Removing and installing the accumulator cartridge ................. 27 6 Technical data............................................................................................ 29 6.1 Description.......................................................................................... 29 6.1.1 Functions ................................................................................. 29 6.1.2 Design...................................................................................... 30 6.1.3 Materials used.......................................................................... 30 6.1.4 Dimensions and weight............................................................ 30 6.1.5 Pressures................................................................................. 30 6.1.6 Filter ......................................................................................... 31 6.1.7 Fixings...................................................................................... 31 6.1.8 Valves ...................................................................................... 31 6.2 Hydraulic circuit diagram .................................................................... 32 6.3 Connections........................................................................................ 33 6.4 Tightening torques .............................................................................. 34 6.4.1 Screws and bolts with ISO metric thread ................................ 34 Electrohydraulic control unit 20 Functions

Table of contents

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6.5 Permissible media .............................................................................. 35 6.5.1 Hydraulic fluids......................................................................... 35 6.5.2 Quality of the process water .................................................... 37 6.5.3 Greases and lubricating pastes ............................................... 38

Electrohydraulic control unit 20 Functions

About this manual

1

How to use this manual

1 About this manual This chapter contains important information that makes it easier for you to use this manual. You will also get information about the structure of the manual and the symbols, characters and abbreviations used and frequently used terms.

1.1 How to use this manual applicable operating manual

Using an operating manual that was not specifically written for the product concerned can result in a safety hazard for yourself and others. Make sure the information on the product complies with that given in the operating manual.

The operating manual must be accessible at all times to all persons working on or with the control unit. It should always be available at the place of operation.

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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 everyone concerned with installing, servicing, repairing, operating and removal.

The supervisors who initiate the above work or supervise it must also follow this operating manual.

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 activities relating to the product.

Take the time to read this operating manual in its entirety. Pay particular attention to the respective safety instructions. Familiarize yourself well with the appearance and meaning of the safety and information symbols.

Safety

Carefully read through the chapter "Safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

service partner

Please contact your service partner for spare part requests or for the clarification of technical questions.

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1

About this manual Signs and symbols used

1.2 Signs and symbols used DANGER The combination of the signal word DANGER and a corresponding symbol warns you of an immediate danger with a high personal risk.

If not observed, you or your coworkers will be seriously injured or killed.

1. Follow the described instructions.

WARNING The combination of the signal word WARNING and a corresponding symbol warns you of a potential danger with a moderate personal risk.

1. Follow the described instructions.

CAUTION The combination of the signal word CAUTION and a corresponding symbol indicates a potential personal risk.

If not observed, you or your co-workers could suffer minor to moderate injuries.

1. Follow the described instructions.

NOTICE The combination of the signal word CAUTION and the adjacent symbol indicates a potential risk of damage to the machine.

If not observed, material damage might occur on the machine.

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

This information will help you become more familiar with the machine and allow you to prepare your work more exactly.

1. Observe the provided tips and information.

Important information The combination of the signal words IMPORTANT INFORMATION and the adjacent symbol indicates important information or other operating manuals which must be observed at this place.

1. Observe the information and read the specified operating manuals.

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If not observed, you or your co-workers might be seriously injured or killed.

Safety General safety instructions

2

2 Safety This chapter provides you with important information about 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.

2.1 General safety instructions state of the art technology

The control unit has been manufactured in accordance with the state of the art and 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.

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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 and the mining supervisory authorities. additional operating manuals

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

2.2 Personnel The machine may only be operated by skilled or instructed personnel.

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

The following parts may only be installed or repaired by service technicians authorized by Caterpillar or mining professionals as defined below: safety components (pressure relief valves, etc.), the electrical system (controls, signaling devices, etc.), hydraulic system qualification

A skilled worker is someone who, based on his special training and experience, has sufficient knowledge and is familiar with the relevant regulations.

A skilled worker can carry out the work assigned to him. He can recognize potential hazards and take the necessary measures to eliminate them. He also has the required repair and installation knowledge.

An instructed person is someone who has been instructed with regard to the tasks assigned to him and the potential hazards which arise due to improper behavior, and, if applicable, has been trained/instructed concerning the necessary safety equipment and protective measures. The instructed person is able to work while looking ahead, recognize hazards and act accordingly.

2.3 Repair and servicing In general, repair work may only be performed by persons who have the knowledge and skills to meet the special requirements and have been adequately trained in the repair and servicing of the equipment.

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2

Safety Operating conditions

Repair work on and overhaul of: control units, working valves, Pilot valves, safety components such as pressure relief valves, etc. may only be carried out by Caterpillar service engineers or by specially trained personnel of the mining company or the dealer.

2.4 Operating conditions The electrohydraulic control unit is constructed and manufactured exclusively as a component of the shield support control system. It may only be used in conjunction with an electronic control, for example a PMC®-R control system.

Only use the control unit as intended!

The intended uses are as follows: The electrohydraulic control unit, together with an electronic control - for instance a PMC®-R control unit -, forms an electrohydraulic shield control system. This is used to control shield support functions. Together they are part of a neighboring control system for electrohydraulic shield supports and are intended for use in underground coal mining.

The electrohydraulic control unit is an essential part of the electrohydraulic shield control system. The functions may not be operated directly at the electrohydraulic control unit, but rather on the corresponding electronic control unit located in one of the neighboring supports. The pilot valves on the electrohydraulic control unit are activated manually or via a program using the control unit.

The electrohydraulic control unit is also used as a "control unit" in two types of exceptional cases: emergency operation repair operation The individual functions of the shield support are actuated directly on the pilot valve of the electrohydraulic control unit. In justified exceptional cases and in strict compliance with the corresponding safety regulations of the mine operator for these cases, the functions of a support can also be actuated when the electronic control system is blocked or it has failed.

Do not make any modifications or carry out changes which could impair safety.

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.

2.4.2 Unauthorized use Any use not expressly identified as the intended use represents unauthorized use and is not permitted with the control unit.

Unauthorized use includes:

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2.4.1 Intended use

Safety

2

Using the machine and working on the machine

the use of electrohydraulic control units as “control units” for the operation of support functions during normal shield unit operation.

Actuating the shields exclusively via the pilot valves by pressing a button is regarded as unauthorized use, as it is not possible to control the shield from a neighboring shield, which is not authorized.

DANGER Unauthorized use Unauthorized use of the electrohydraulic control unit can endanger yourself and others. You might be killed or seriously injured.

1. You should thus only use the electrohydraulic control unit as intended.

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Caterpillar will accept no responsibility for the consequences of unauthorized use.

2.5 Using the machine and working on the machine Immediately replace damaged components relevant for safety. Shut down the relevant section 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.

Notify the responsible personnel of the following prior to working on the longwall: your exact location, the work you are carrying out how much time you will probably need emergency stop

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

Actuate the EMERGENCY STOP SWITCH also if safety equipment.

Never reach into or enter areas between machine components which can move.

This applies especially to the: side seals, skids and relay bar assemblies, lemniscatic links, canopies, front cantilevers, hydraulic props and cylinders, steering devices.

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2

Safety Notes on the hydraulic system

2.6 Notes on the hydraulic system hydraulic system protective devices

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 dismantling the protective devices.

pressure relief valves

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

handling hydraulic fluids

Avoid direct skin contact with hydraulic fluids. Hydraulic fluid can penetrate the skin and cause dangerous infections.

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

Carry out a visual inspection of all hydraulic components at regular intervals. In particular, please observe the following: the hoses are not pinched. the hoses have no bubbles or blisters. the hoses or the outer sheaths of the hoses are not abnormally hard. the outer sheath of the hose is not damaged. the connectors are securely inserted into the coupling sockets. the 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.

Before removing the staples for disconnecting the hose lines, 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.

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Do not fail to depressurize the hydraulic line.

Always secure the plug 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.

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

Never try to repair damaged hose lines.

Replace hose lines at the first suspicion of damage. permissible hose lines

Only use hose lines approved for the prevailing pressures.

Do not use any hose lines with damaged connectors or worn O-rings.

Replace hose lines only with hose lines of the same or higher quality.

Germany / Europe

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure

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

Safety

2

Notes on the hydraulic system

date of manufacture Caterpillar ID Fig. 1: Example: Hose line, identification

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1

installing hose lines

2

3

4

1

manufacturer ID

3

year

2

calendar week

4

working pressure in [bar]

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

For more concise information, follow the "Technical information on hydraulic components".

Australia

Mark the crimped-on strip (both sides) using a punch as follows: manufacturer ID working pressure in [bar] date of manufacture (YY, MM) Caterpillar ID Additional writing on the label: manufacturer ID material number number of the test record, date of manufacture of the hose line, date of manufacture of the hose working pressure.

2.6.1 Recommended storage and use period The following recommendations apply to the use, storage and manufacture of hydraulic hoses and lines: hose storage period

length of storage time for hose lines

For the manufacture of a hose line, the used hose should not exceed a max. storage period of 4 years.

For hose lines, a maximum storage period of 2 years applies (starting from the time of manufacture).

To prevent signs of aging in hydraulic hoses and hose lines, aim for the following storage conditions: store in a dry, low-dust location in a lying position, the storage temperature should lie between +15°C and +25°C at max. 65% relative humidity, do not store below +10°C,

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Safety

2

Notes on the hydraulic system

avoid direct sunlight or exposure to UV radiation, do not use ozone-forming lights or electrical devices which form sparks in the direct vicinity, avoid contact with acids, bases or solvents, protect from nearby heat sources, when stored coiled up, the radius of the coils may not be smaller than the smallest bending radius indicated by the manufacturer. length of use for hose lines

The service life of hose lines must meet the requirements of DIN 20066. Hose lines must be checked for damage daily by the operator. The test criteria of DIN 20066 must be observed.

The period of use of hose lines should not exceed a period of 2 years.

Tab. 1: Service life Hydraulic hose storage period

Hose line service life

Age

Storage period

Service life

max. 4 years

max. 2 years

max. 2 years

NOTICE Due to the cold-flow properties (creep) of the hose lines exhibited after installation of the fittings, ready assembled hose lines should be stored for as short a period as possible prior to use.

Determination of the service life by the operator

Notice on work safety The hydraulic hose line inspection intervals should be adapted to the operating conditions of the mine.

extension

The operator can define an extension of the guide values mentioned above.

This requires the following measures: The operator must write a risk and hazard analysis which takes into consideration the protective measures to be implemented in the event of hydraulic hose line failure.

Repeated checks for safe working conditions at appropriate and, if necessary, shortened intervals by qualified personnel.

Notice on work safety An extension of the replacement interval may not result in a dangerous situation which could cause harm to employees or other persons.

If hydraulic hose lines fail during operation or if damage or faults are found more frequently during regular checks, the checking and replacement intervals should be shortened in addition to finding the cause of the fault.

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Guide values for service life

Safety Notes on the hydraulic system

reduction

2

The operator must define a reduction in the above-mentioned guide values if:

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inspections show there is significant wear on the hydraulic hose lines, indicating a reduced service life.

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3

Storage Notes on the hydraulic system

3 Storage General This chapter contains important information on correct storage and transport.

Following the instructions and notes will increase the life cycle and service life.

You will be able to carry out transport work more safely and quickly. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storing the equipment

avoid direct exposure to sunlight

dirt and moisture

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

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15oC to 25oC. 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 be specially 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 our service technicians 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.

NOTICE When storing and removing machines and machine parts from storage with a limited service life, make sure to use old deliveries first.

Storing used equipment The above points, with the exception of the one concerning corrosion protection, similarly apply to the storage of equipment parts that have already been used. corrosion protection of hydraulic components

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If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor, e.g. MinetechTM Protection Fluid (Quaker). If this is not done, then the 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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corrosion protection

Storage

3

Transport

corrosion protection of waterconducting components

Equipment parts for conveying water, such as the parts for the water spraying system or motor cooling circuit, must be completely drained, or also filled with antifreeze if required.

3.1 Transport Transport boxes The control units are packed in several transport boxes. They should stay in these boxes until they reach their final place of operation. This protects them from external damage.

Make sure that the boxes are not damaged during transport. During transport, make sure that they are not: dropped, or Media-ID: EM027268-00-EN / Caterpillar Global Mining Europe GmbH 2016 ©

broken open.

Protect the transport boxes from moisture. avoid frost damage

Before the equipment is transported at temperatures below freezing, the Control unit must be completely emptied and then completely filled with a corrosion inhibitor (such as MinetechTM Protection Fluid (Quaker)).

If, during transport, the Control unit is exposed to temperatures below -20 °C, then special measures may have to be taken. In this case, before starting transport, contact Caterpillar Service Department or the dealer to clarify the necessary measures.

Dimensions and weight Depth:

531

Mm

Width:

259,25

Mm

Height:

134

Mm

Weight:

75,7

Kg

plugs The connections for the individual control units are closed off with plastic plugs.

This protects them from moisture, dirt and damage.

NOTICE Remove transport safety devices Impurities in the hydraulic system can lead to the failure of the entire system, making expensive repairs necessary.

1. For this reason, you should only remove the plugs just before the control unit is connected.

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3

Storage Transport

Bracket with control unit

NOTICE Collision of the holder When in transport position (shield retracted completely), the control unit holder can collide with other components.

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1. When transporting the shield ensure that the bracket is fixed to the control unit such that it cannot collide with other components when shield is being retracted.

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Installation

4

Shield hydraulics requirements

4 Installation This chapter contains information on the installation and dismantling of the Control unit. Please pay special attention to the warnings and tips.

WARNING Installation Improper or faulty installation can endanger yourself and others!

1. You may only carry out the installation if you can demonstrate that you have the required knowledge.

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Fig. 2: Electrohydraulic control unit 20 functions

1

Distributor block 20 functions

2

Double 3/2 way magnetic pilot valve

3**

Control valve cartridge NG 13

4*

Check valve NG 2

5*

Filter cartridge

6**** Screw fitting

7***

Plug M 20x1

8

Plug M 18x1

9

Glycerin pressure gauge NG 50

10

Staple DN 10

11

Plug-in elbow socket DN 10

*

Tightening torque MA = 15 Nm

**

Tightening torque MA = 30 Nm

***

Tightening torque MA = 35 Nm

****

Tightening torque MA = 40 Nm

4.1 Shield hydraulics requirements The hydraulic fluid must meet the following conditions for all hydraulic system components included in the Caterpillar scope of delivery: If the test specified in EWN 8350, part 1, is successful, the hydraulic fluid will be classified as suitable.

Contamination class 18 /14 in accordance with ISO 4406.

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4

Installation Installing and removing the control unit

4.2 Installing and removing the control unit 4.2.1 Removing the control unit Before you can start installing or removing the control unit, you must take safety precautions: safety

1. Cordon off the working area from other people.

2. Stop mining in this area.

3. Inform your colleagues about the nature and duration of the repair work and about your exact location.

4. Activate the support lock-out switch.

block hydraulic pressure

1. Now depressurize the hydraulic ports at which the Control unit is to be connected.

2. Check that the hydraulic lines are really depressurized.

WARNING Work on hydraulic lines During work on pressurized hydraulic lines, you can be severely injured due to moving hydraulic hoses or liquid escaping under pressure.

1. Always depressurize the hydraulic line before starting with your work.

If everything is OK so far, then you can continue with the next step.

1. Label the connecting cables and hydraulic hoses to avoid mix-ups later on.

2. Pull off the connecting cable from the cover of the pilot valve.

3. Undo all of the hydraulic connections on the rear side of the Control unit.

Take care not to damage or soil the connections.

The Control unit must be secured with lifting tackle and transport straps.

CAUTION Securing the control unit You may be injured when securing the control unit with chains or ropes.

1. Only use transport straps which sit closely on the control unit and which prevent it from slipping through.

Installation steps: 1. Loosen the mounting bolts of the Control unit.

2. Remove the Control unit.

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5. Secure the shield to stop it sinking by itself; e.g. by using wedges in the lemniscatic links or by propping up or supporting the canopy.

Installation

4

Installing and removing the control unit

4.2.2 Installation of the control unit Installation steps: 1. Move the Control unit into the installation position.

2. Tightening the mounting bolts (M10) hand-tight.

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Fig. 3: Tapped holes

NOTICE Hydraulic connections If the hydraulic connections are not properly connected, it may result in expensive repairs and the failure of the entire machine.

1. To join the hydraulic connections, use molybdenum disulfide-free lubricating paste B3 in accordance with EWN 7068 (see "Lubricating greases and pastes" for more information).

Installation steps: 1. Join the hydraulic connections, and take care not to mix them up.

2. Follow the hose diagram and the identification of the hoses.

WARNING Hydraulic hose lines The uncontrolled movement of hydraulic hose lines may seriously injure or be fatal to you or others.

1. Always secure the connectors of the hydraulic elements on the hydraulic hose lines with appropriate clamps.

2. Never use wire, nails, or similar materials. safety

1. Check the hose connections.

The hose nipples must be firmly seated in the connector socket and must be locked in place with a staple.

Both arms of the staple must fit in the connector socket.

2. Make sure the connections are leak-tight.

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4

Installation Installing and removing the control unit

3. Insert the connecting cables of the Control unit into the connecting sockets in the pilot valves.

Follow the circuit diagram and the identification of the cables!

4. Check all of the connections again using the hydraulic diagram.

5. Remove the inserted securing devices.

6. Test the shield or machine functions.

WARNING Shield release Installation errors after repair or maintenance work can severely injure you or your associates!

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1. Only release the shield for use once you have checked that all of it works properly and have not found any malfunctions.

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Operation

5

Installing and removing the control unit

5 Operation This chapter provides you with information on the operation of the hydraulic control unit. It is also imperative that you follow the operating manuals for the support and the control unit.

DANGER Staying in the shield support Staying in a moving shield support can lead to severe or fatal injuries!

1. Only operate the controls on the control unit if you possess the necessary knowledge.

WARNING Media-ID: EM027268-00-EN / Caterpillar Global Mining Europe GmbH 2016 ©

Buttons / levers on pilot valves / control units Sticking or locked buttons on pilot valves can cause undesired motions. This could seriously injure or kill you or your associates!

1. Never lock buttons / levers on control units!

2. Always keep the control units free from dust and dirt!

3. Regularly check valves and control units for correct functioning!

Fig. 4: Electrohydraulic control unit, 20 functions

1

Distributor block 20 functions

2

Double 3/2 way magnetic pilot valve

3

Control valve cartridge NG 13

4

Check valve NG 2

5

Filter cartridge

6

Screw fitting

7

Plug M 20x1

8

Plug M 18x1

9

Glycerin pressure gauge NG 50

10

Staple DN 20

11

Plug-in elbow socket DN 10

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5

Operation Pilot valve

5.1 Pilot valve Controlling the shields during repair operation is especially dangerous since you are operating the shield directly and immediately under which you are standing.

It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield control system.

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

5.1.1 Operation There are two pushbuttons on the cover of each pilot valve. If you push one of these buttons, the corresponding valve is immediately operated. As soon as you release the button, the function is ended.

Operating the control Incorrect or negligent operation of the shield control system can result in serious injury or death!

1. Only operate the shield control system if you have detailed knowledge of the operating controls and their method of operation!

Fig. 5: Pushbuttons

5.1.2 Function variable function

The function of each pilot valve is variable and depends on the external circuitry of the Control unit. A symbol strip shows the function of the buttons.

The symbol strip is mounted near the pilot valves.

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DANGER

Operation

5

Pilot valve

5.1.3 Installing and removing the pilot valve WARNING Working on the pilot valve You could be seriously injured or even killed by hydraulic fluid escaping under pressure!

1. Before starting work on the pilot valve, it is essential to depressurized the complete hydraulic system Preparatory work 1. Mechanically secure the shield against involuntary lowering.

2. Close the shut-off valve in the shield hydraulics pressure supply line.

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3. Alternately actuate the two push-buttons of each pilot valve 10 times in order to relieve the pressure in the hydraulic system of the shield.

4. Check if there is any residual pressure in the Control unit.

If the shield hydraulics are depressurized, then you can continue with the next step.

NOTICE Contamination in the hydraulic system Contamination in the hydraulic system can cause serious damage to the whole hydraulic system!

1. Make sure the working environment is clean, when working on the hydraulic system of your machine!

2. Flush hydraulic lines adequately before putting the system into operation!

3. Make sure that your hydraulic fluid is adequately filtered!

Installation steps: 1. Remove dust and other loose contaminants from around the pilot valve in the control unit.

2. Remove the 2 hex. head screws (a).

3. Pull the 1 pilot valve (b) forwards out of the control unit.

Fig. 6: Removing the pilot valve

a

Electrohydraulic control unit 20 Functions

Hex. head screw M 6X20-A 4-80

b

Pilot valve

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5

Operation Filter cartridge

Installing the pilot valve The new pilot valve is installed in the reverse sequence to the removal of the old one.

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

If you have checked the hydraulic circuit and found no faults, then you can reapply pressure to the control unit.

A filter cartridge is located in the distributor block of the control unit. It protects the control unit's valves from damage caused by impurities in the hydraulic fluid.

5.2.1 Maintenance intervals NOTICE Maintenance intervals The recommended maintenance intervals are for guidance only. Particular operating conditions may require other maintenance intervals.

1. Be sure to modify the maintenance intervals to the specific operating conditions. after commissioning

Filter cartridges on a Control unit must be replaced immediately after startup or restart (e.g. after changing to another face or working on the hydraulic system).

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.

according to a schedule

If problems occur during preparation of the medium, there will be an increased risk of malfunctions due to clogged filters. Measures which have to be carried out regularly may become necessary to ensure reliable and safe operation. If necessary, the filter cartridges should be replaced at regular intervals, as a precaution.

5.2.2 Removing and installing the filter cartridge NOTICE Filter cartridge Only use each filter cartridge once and do not attempt to clean it. Contamination in hydraulic systems is a common reason for expensive repairs.

You must always only use new filter cartridges and seals.

Preparatory work 1. Mechanically secure the shield against involuntary lowering.

2. Close the shut-off valve in the shield hydraulics pressure supply line.

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5.2 Filter cartridge

Operation

5

Filter cartridge

3. Alternately actuate the two push-buttons of each pilot valve 10 times in order to relieve the pressure in the hydraulic system of the shield.

4. Check if there is any residual pressure in the control unit.

If the shield hydraulics are depressurized, then you can continue with the next step.

Demontage Filterpatrone

NOTICE Contamination in the hydraulic system Contamination in the hydraulic system can cause serious damage to the whole hydraulic system!

1. Make sure the working environment is clean, when working on the hydraulic system of your machine!

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2. Flush hydraulic lines adequately before putting the system into operation!

3. Make sure that your hydraulic fluid is adequately filtered!

Installation steps: 1. Remove dust and other contaminants from the control unit.

2. Unscrew the filter cartridge using a screwdriver.

Fig. 7: Exchanging the filter cartridge

NOTICE Disposing of the filter cartridge The filter cartridge has been soiled by residual emulsion and deposits.

1. Make sure that you dispose of the filter cartridge in an environmentally acceptable way!

Installing the filter cartridge Installation steps: 1. Screw in a new filter cartridge.

2. Tighten the cartridge hand-tight (15 Nm).

3. Check whether this connection leaks.

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5

Operation Accumulator cartridge

If you have checked the hydraulic circuit and found no faults, then you can reapply pressure to the Control unit.

Only remove the securing devices which you introduced to carry out the work when you are sure that the hydraulic system is working perfectly.

5.3 Accumulator cartridge The accumulator cartridge is used to stabilize the pressure in hydraulic control circuits. It is pretensioned with nitrogen and is connected directly with the system pressure of the control circuit. If there is a drop in pressure within the control circuit, fluid will be topped up from the accumulator cartridge and the control pressure will be stabilized.

NOTICE The accumulator cartridge or hydraulic system may be damaged if the accumulator cartridge is improperly maintained or filled.

1. The accumulator cartridges may only be maintained and filled by Caterpillar service personnel.

Accumulator cartridges must be checked, at regular intervals, for proper functioning: 20% of the accumulator cartridges spot-checked annually and all accumulator cartridges every two years.

To do this, the selected units have to be replaced by new accumulator cartridges and they can then be tested. The tested units can be put back if no faults were found.

The accumulator cartridge is located on the rear side of the distributor block.

Fig. 8: Accumulator cartridge

a

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Accumulator cartridge

Electrohydraulic control unit 20 Functions

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Filling the accumulator cartridges

Operation

5

Accumulator cartridge

5.3.1 Removing and installing the accumulator cartridge WARNING Depressurized accumulator cartridge The accumulator cartridge is permanently pressurized. You could be seriously injured or even killed by pressurized components and escaping hydraulic fluid.

1. Before starting work you must thus be absolutely certain that the hydraulic system is depressurized.

Preparatory work 1. Mechanically secure the shield against involuntary lowering.

2. Close the shut-off valve in the shield hydraulics pressure supply line.

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3. Alternately actuate the two push-buttons of each pilot valve 10 times in order to relieve the pressure in the hydraulic system of the shield.

4. Check if there is any residual pressure in the control unit.

If the shield hydraulics are depressurized, then you can continue with the next step.

Removing accumulator cartridges

NOTICE Cleanness Contamination in the hydraulic fluid can cause serious damage to the whole system!

You should thus always ensure that your working area is clean.

WARNING Depressurized hydraulic line If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized.

1. Do not fail to depressurize the hydraulic line.

Installation steps: 1. Remove dust and other loose contaminants from around the accumulator cartridge in the control unit.

2. Remove the staple (a).

3. Pull the accumulator cartridge (b) out of the socket.

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5

Operation Accumulator cartridge

a

Accumulator cartridge

b

Staple

Installing the accumulator cartridge The new accumulator cartridge is installed in the reverse sequence to the removal of the old one.

NOTICE Installation Apply lubricant B6 to all connecting points and slide surfaces.

If you have checked the hydraulic circuit and found no faults, then you can reapply pressure to the control unit.

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Fig. 9: Exchanging the accumulator cartridge

Technical data

6

Description

6 Technical data This chapter contains important and useful information on the type of Control unit and the materials used. At the end of this chapter, you will find information about permissible hydraulic fluids and recommendations on lubricants.

Please refer to the corresponding replacement parts catalog for the details necessary to order spare parts.

WARNING Genuine replacement parts Unauthorized repairs or using replacement parts from other manufacturers can cause serious damage to persons or the machine. The warranty is voided by third-party replacement parts and repairs.

1. Only use original replacement parts from Caterpillar.

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2. Repairs should only be performed by dealers authorized by Caterpillar.

6.1 Description 6.1.1 Functions 20 functions can be controlled using the hydrauliccontrol unit.

The working valves of the Control unit are driven via electromagnetic pilot valves. An electronic control system is required to control the pilot valves, for example a type PMC®-R control unit.

Fig. 10: Electrohydraulic control unit, front view

a

Electrohydraulic control unit 20 Functions

Distributor block

b

Pilot valves

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6

Technical data Description

6.1.2 Design The main parts of the hydraulic control unit are: Distributor block with Work valve, check valve,, Filter cartridge, Connection for accumulator cartridge, Connection sockets, Pilot valves.

a

Connecting sockets on the rear side

b

Distributor block

c

Pilot valve

d

Pushbuttons

e

Connecting sockets for control unit

6.1.3 Materials used The Control unit is made of corrosion-resistant materials such as stainless steel, brass, bronze, etc.

The seal materials are designed for operation with HFA hydraulic fluids (oil in water emulsions).

6.1.4 Dimensions and weight Depth:

531

Mm

Width:

259,25

Mm

Height:

134

Mm

Weight:

75,7

Kg

Permissible working pressure:

350

Bar

Test pressure:

400

Bar

6.1.5 Pressures

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Fig. 11: Electrohydraulic control unit, 20 functions

Technical data

6

Description

6.1.6 Filter The filter cartridge protects the pilot control circuit from contamination. Only use new cartridges. Do not use any “cleaned” filter cartridges.

The required filter characteristics are only guaranteed with new filter cartridges (fineness = 25 m).

6.1.7 Fixings There are 4 tapped holes (M 10) located on the upper side of the distributor block of the Control unit and 2 holes (M 10) each on each side.

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Fig. 12: Fastening

6.1.8 Valves Working valves: 20 x 3/2 directional control valves (NG 13) They are driven via pilot valves.

Pilot valves: 10 x double -3/2 directional control valves (NG 0.5) The pilot valves are driven by a control unit (e.g. PMC®-R). In an emergency, or for repairs, they can also be operated directly. Two pushbuttons are fitted in each valve cover for this purpose.

The power supply to the pilot valve comes from the electronic control unit. In the housing cover of each pilot valve there are 4-pin contacts, which serve to attach a suitable connecting cable.

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6

Technical data Hydraulic circuit diagram

Double 3/2 directional control valve parameters Classification according to Directive 94/9/EC (ATEX):

Group I, category M2

Protection class:

EExib l

Connector type:

OS4

Type of magnet:

Electromagnet, around 57 Ohm, Type: DMA3

Nominal voltage:

12 V, DC

Permissible deviation

--2 V+10%

Switching current:

approximately 190 mA

Lowest current:

min. 40 mA

NOTICE As soon as the current falls to a level below 40 mA, the switch positions will become unstable.

This can lead to malfunctions or to the failure of the control unit.

Tab. 2: Mining approvals Apply in

Approval authority

Approval no.

Europe

INERIS, ATEX

05 ATEX 0049

USA

MSHA

18-ISA050002-0

Australia

Testsafe, ANZEx

05.4015X

---

---

6.2 Hydraulic circuit diagram Fig. 13: Electrohydraulic control unit, 20 functions

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Current drop

Technical data Connections

6

6.3 Connections The connecting sockets for the hydraulic lines are on the rear side of the control unit.

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Fig. 14: Control block, rear view

Hydraulic connections consumer of medium quantities

connections for pressure feed and return

Accumulator cartridge

Connections:

20 x DN 13 socket, Steck-0

Identification:

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,

Flow rate:

max. 180 l/min at Δp = 100 bar

Use:

consumer of medium quantities

Connections:

1 x DN 20 socket, Steck-0

Identification:

P (pressure feed)

Connections:

1 x DN 25 socket, Steck-0

Identification:

T (tank line)

Flow rate:

max. l/min at Δp = 100 bar

Use:

Pressure feed into the system or return line to the tank

Connections:

1 x DN 20 socket, Steck-0

Identification:

SP (connection for accumulator cartridge)

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6

Technical data Tightening torques

6.4 Tightening torques 6.4.1 Screws and bolts with ISO metric thread Tab. 3: Tightening torques at µtot. = 0.14 Pitch P (mm)

d

Coarse thread

M8

Tightening torque 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

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27)

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

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

NOTICE Tightening torques Incorrect torque may cause considerable machine damage.

1. Also follow the tightening torques for installation and maintenance stated in the spare parts lists.

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Thread (mm)

Technical data Permissible media

6

6.5 Permissible media 6.5.1 Hydraulic fluids Permissible hydraulic fluids

NOTICE Hydraulic fluid If impermissible hydraulic fluids are used, and the warranty expires and serious machine damage may arise.

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1. Use only hydraulic fluids and gear oils approved by Caterpillar.

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

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

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

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

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

The suitability test is carried out by an independent testing institute authorized

by Caterpillar. The criteria as specified in EWN 8350 are applied for the test.

The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: stability, sealing materials, corrosion.

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

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

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6

Technical data Permissible media

Certificate The customer will be issued a certificate attesting the suitability of the hydraulic fluid for the operation of Caterpillar hydraulic systems for each product tested.

Certificates are valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate is no longer valid if one or several of the requirements for obtaining the certificate are no longer fulfilled.

This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

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Fig. 15: Certificate, example

Maintenance of the hydraulic fluid Consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH value, concentrate content and microbial load.

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Technical data

6

Permissible media

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 concentrate content setpoint: see certificate microbial load setpoint: ≤ 105 Kol/ml

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

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

6.5.2 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 are complied with, 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

limit values

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

NOTICE Quality of the process water Poor quality process water can seriously damage the surface of the components and the hydraulic components of the machine.

1. Only use water that complies with the specified limit values.

Tab. 4: Properties of the process water, limit values Test criterion

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Limit value

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6

Technical data Permissible media

Appearance, color, odor

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

electrical conductivity

< 1800 mS/cm

pH

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

2-

SO4 content

≤ 145 mg/l

NO3- content

≤ 20 mg/l

Fe content

≤ 1 mg/l

Bacteriological requirements

≤ 105 col/ml

- / 18 / 14 1)

Contamination class according to ISO 4406: 1999

The values listed for bacteriological requirements, the amount of solids and contamination class must be observed during the production of hydraulic fluids.

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

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

Important information 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. 5: Greases A1

grease A2

Supplier

Type

Base

NLGI class

Fuchs

Renolit MP

lithium soap

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-40 to +120 °C

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

Tab. 6: Grease A2

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Supplier

Type

Base

NLGI class

Flashpoint °C

Shell

Alvania E.P. grease 2

lithium soap

2

205

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Ratio of solid foreign matter at 1.2 mm - ≤ 10 mg/l 1) filtering in conformity with DIN EN 12662

Technical data Permissible media

grease A8

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-15 to +120°C

6

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.

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Tab. 7: Grease A8 Supplier

Type

Base

NLGI class

Flashpoint °C

Castrol

Molub-Alloy 3036/680-1

lithium soap

1

210

worked penetration:

310 to 340 (0.1 mm)

behavior in the presence of water:

insoluble at 90°C

temperature range of application:

-20 to +120°C

Lubricating pastes lubricating paste B3

Lubricating pastes free of molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 8: Lubricating paste B3 Supplier

Type

Lubricant carrier

NLGI class

Flashpoint °C

Gleitmolybdän

gleitmo 805

lithium soap

2

220

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

insoluble

temperature range of application:

-20 to +120°C

Lubricants lubricant B6

Parting agents and lubricants with organic lubricating media on synthetic base material for greasing threaded areas and fitting points on props and hydraulic props, on pin connections and similar connecting elements on the support.

Tab. 9: Lubricant B6 Supplier

Type

Lubricant carrier

Flashpoint °C

Chesterton

parting agent/lubricant 785

petroleum base

132

behavior in the presence of water:

insoluble

temperature range of application:

-34 to +120°C

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