Amendmentsandalterationstothispublicationarenotsubject tonotification.Caterpillarreservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofCaterpillar.
Caterpillardeclinesanyliabilityfordirectorindirectconsequencesof printingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2012E ACaterpillarInc.Company
3.Storageandtransport Aboutthismanual Aboutthismanual Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Itprovidesyouwithinformationaboutthe structureofthemanualandthesymbolsandcharactersusedinit.
Beforestartingwork Usinganoperatingmanualthatwasnotspecificallywrittenforthe pullingdeviceconcernedcanresultinasafetyhazardforyourself andothers.
Ensurethatthedataonthepullingdevicecomplieswiththedata givenintheoperatingmanual.
Thisoperatingmanualisdesignedfor: PullingdeviceforGleithobelplowchains IDNo.:60240030200000
Theoperationmanualistobeusedonlyforapullingdeviceofthis type!
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththepullingdevice.
Anoperatingmanualforthepullingdeviceshouldalwaysbeavailableattheplaceofoperation.
Sendforanewoperatingmanualimmediatelyifthepresentoperatingmanualisnolongercompleteorhasbecomeillegible.
Personsforwhomtheoperatingmanualisintended
Thisoperatingmanualisintendedforthosepersonswhoworkwith oronthepullingdevice.
Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.
Thisincludespersonswho: carryoutinstallation/dismantlingworkontheplowsystem, carryoutrepairworkontheplow system.
Supervisorypersonnelwho: initiatetheactivitiesnamedaboveand/or supervisetheactivitiesnamedabove.
Purposeofthisoperatingmanual Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtothepullingdevice.
Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontothesafetyinstructions. Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.
Shouldyouhaveanyquestions,pleasecontactour ServiceDepartment.
Beforestartingwork ReadtheChapter“Yoursafety”closely.Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheinstructions.
Charactersandsymbolsused
Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Memorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymbolalertyoutoanimminentdanger.Possibleconsequencesareveryseriousinjury orevendeath.
Warning!
Thesepointscontaininformationonhazardoussituations. Possibleconsequencesareveryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesarelighttomoderatelyseriousinjuriesandmachinedamage.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesinclude:The pullingdevice,plowortheconveyorcouldbedamaged.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtomakeworkeasierforyou.Theydo notwarnaboutharmfulorhazardoussituations.
Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Textpassagesindicatedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Thiswillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.
Yoursafety Thischapterprovidesimportantinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.
Thepullingdevicehasbeenmanufacturedinaccordancewith thestateoftheartandgenerallyrecognizedsafetystandardsand regulations.
Youandotherscanneverthelessbeexposedtodangeroussituations,e.g.,asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Beforeusingthepullingdevice,acheckmustbeperformedbyan expert.Onlyafterthecheckhasdeterminedthatthetoolisinperfectworkingconditionmaythedevicebeused.
OnlyuseoriginalsparepartsfromCaterpillar,sinceonlyoriginal partscanguaranteeperfectoperation.
Notethatuseofpartsfromothermanufacturerswillvoidtheguarantee.
AnyliabilityonthepartofCaterpillarisexcludedifnooriginalspare partsareused.
Thesameappliesforpullingdeviceswhicharenotrepairedby Caterpillarservicepersonnel.
DamagedcomponentsmayberepairedbyCaterpillaronly!
Donotmakeanymodificationsorcarryoutconversionswhich couldimpairthesafetyofthepullingdevice.Allmodificationsand conversionsmustbeapprovedbyCaterpillar.
Thepullingdevicemaybeusedonlybytrainedpersonnel.Reading oftheoperatingmanual,especiallythechapteronsafety,must constituteapartofthistraining.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsforaccidentpreventionin yourcountry.
Observethesafetyandaccidentpreventionregulationsofthefollowingparties: ofthemine, oftheminesinspectorateand ofminingsupervisoryauthorities.
Pleasealsoreadtheoperatingmanualsofcomponentsrequiredfor operation,e.g.conveyor,Gleithobelplow,etc.carefullyandthoroughly.Clarifyanyquestions before startingwork.
Operatingconditions Intendeduse Thepullingdeviceisdesignedforpullingtheplowchainintothe bottomraceoftheGleithobelguidesinconnectionwiththeconveyorchain.Here,theconveyorchainactsasadrawelement.
Thedevicesaredesigned exclusively foruseonthefollowing Gleithobelplow systems:
GH42andGH1600(IDnumber60240030200000)
GH800(IDnumber60240030700000)
Theyaresuitableforthefollowingchainassemblies:
Usethepullingdevicesonlyasintended.
Unauthorizeduse
Applicationsnotexplicitlylistedasintendedusesareunauthorized usesandarenotpermittedwiththepullingdevice.
Unauthorizeduseincludes:
theuseofplowsduringinstallationforwhichthedeviceisnot approved, pullinginplowchainsforwhichthedeviceisnotdesigned.
Caterpillardoesnotacceptanyliabilityfordamageresultingfrom anysuchunauthorizeduse.
Safetyinstructions Basicprinciples
Alwaysworkwithutmostconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Secureyourworkingareaoverawiderange,inordertoavoid endangeringotherpersons.
Informyourcolleaguesof: yourexactlocation, theworkyouarecarryingoutand theamountoftimeyouwillprobablyrequire.
Securetheconveyorsystembeforeallwork againstunauthorized andunintentionalrestarting.
Beforeinstallingthepullingdevice,theworkingareamustbesecuredagainstfallingrockandagainstobjectsthatcouldfalldown.
Secureawideareaaroundtheconveyorandplow.Nopersonnel arepermittedtobeinthehazardousareasduringthecoupling (pullingtogether)oftheplowchain.
Theplowcouldsuddenlystarttomoveevenifitisnotintheimmediatevicinityoftheopensectionofthechain. Alwaysmaintainasufficientdistancefromthepullingdevice.
Sincetheplowchainispretensionedwhenitisclosed,itistoo shortwhenitisuncoupled.
Inorderforyoutobeabletocoupletheendsoftheplowchain afterachainbreak,anadjustingchainmustbeinstalled(eitherat theheadgateorthetailgate).
Asabasicrule,thepullingdevicemayonlybeservicedorrepaired byCaterpillarservicepersonnel.Thepresettriggeringpowerofthe couplingcould,forexample,comebecomedistortedastheresult ofincorrectrepairwork.
Defectivecomponents(e.g.U-locks)mayonlybereplacedwith Caterpillaroriginalpartssinceonlytheymeetthetechnicalrequirements.Iforiginalcomponentsarenotused,anyliabilityonthepart ofCaterpillarisexcluded.
Safetyinstructions 3 Storageandtransport Storageandtransport Thischaptercontainsimportantinformationaboutthecorrectstorageandtransportofthepullingdevice. Followingtheinstructionsandtipswillincreasethelifecycleand servicelifeofthepullingdevice.
Storage Thepullingdevice,inparticulartheoverloadcoupling,mustbe storedinthetoolboxprovided,alongwithallofthepapers.
Protectallequipmentagainstmoistureandcontamination.
Transport Transportthepullingdeviceonlyinthesuppliedtoolbox,inorder toprotectitagainstdamageduringtransport.
Caution!
Thepullingdevicecouldbedamagedordestroyedasaresult ofimproperstorageandtransport. Youendangeryourselfandothersbyusingdefectiveparts. Intheeventofimproperstorageandtransport,anyliabilityon thepartofCaterpillaris excluded. Storeandtransportthepullingdeviceonlyinthetoolboxsupplied!
4 Installation Installation Installationofthepullingdevice Beforeusingthepullingdevice Beforeusingthepullingdevice,acheckmustbeperformedbyan expert.Onlyafterthecheckhasdeterminedthatthetoolisinperfectworkingconditionmaythedevicebeused.
OnlyoriginalsparepartsfromCaterpillarmaybeusedforservicing andrepair,becauseonlyoriginalpartscanensureproblem-free operation.
DamagedcomponentsmayberepairedbyCaterpillaronly!
Important! AnyliabilityonthepartofCaterpillaris excludedif non-originalsparepartsareused.Thesameappliesforpulling deviceswhicharenotservicedbyCaterpillarservicepersonnel.
Fig.1:Pullingdevicemaincomponents
1pull-insledge
2couplingholder
3thrustpiece300kN
4guidesledge
8retainer
9U-lockTBSS26/8 14hex.nutM24-10
20chain(tackle)26x78
242overloadcomponents(overload couplings),each150kNFA1)
Howtomountthepullingdevice
Pleaseproceedasfollows:
. Runtheconveyorempty.
. Shutdowntheconveyorandplowsystemandsecurethem againstbeingswitchedonagain.
Warning!
Blockoffawideareaaroundtheworkingarea.Whileworking inthecoalfacearea,theconveyormustnotbeabletobe advancedbythesupport.Actuateifnecessarythesupport lock-outswitchesoftherespectiveshields.
. Securethecoalfaceagainstfallingrockandrunningout.It mightbenecessarytopulltheconveyorbackintotheworking areaofthecoalface.
Notice!
Inordernottohavetopulltheplowalongwhenpulinginthe plowchains,theplowchainmustalwaysbepulledinthedirectionoftheplow!
. Mountthepull-insledgeintheGleithobelguidewiththeflap valvewhichliesjustbehindtheplowchainendwhichistobe pulledinthedirectionoftheplow.Toaccomplishthis,insertthe pull-insledge(withoutitssupport)throughthegapbetweenthe guidebeamandtheGleithobellowerendguide.
. Releasetheconnectionscrewsoftheflapvalve.Afterwards, foldopeninthedirectionofthecoalface.
. Hitchtheplowchainendinthehookofthepull-insledge.
Notice!
Sincetheplowchainispretensionedwhenitisclosed,itistoo shortwhenitisuncoupled.
Anadjustingchain(onthemaingateorthetailgate,dependingonthedirectionofpulling)mustbeinstalledinorderto movetheplowchainendstogether(e.g.afterachainbreak).
. Mountthesupportonthepull-insledge.
. Afterwards,foldtheflapvalveclosed.Tightentheconnection boltswiththerequiredtorque.
Warning!
Neverusethepullingdevicewithouttheguidesledge,because otherwisethetacklecouldbecomecaughtbetweenthepan facesandhaveitslinksjamtogether.
Fig.2:Insertingthepullinsledge
Fig.3:Installingthe guidesledge chain(tackle)
. Settheguidesledgeontheupperguidestrip.
. Connectthepull-insledgewiththeguidesledgeusingthe tackle.UsetheassociatedU-lock.
. Pullthetackletaut.
Thepull-insledgeisnowconnectedwiththeguidesledgebythe tackle.
. Afterwards,usetheU-locktomountthecouplingholdertothe chainoftheDMKbeltwhichislyingclosertothecoalface (seeFig.4).
. Settheoverloadcouplinginthecouplingholderandsecureit withthehelpoftherespectivehex.headscrew.
Fig.4:Mountingtheoverloadcoupling
Danger!
Donotmounttheoverloadcouplingontheguidesledge, becauseotherwisethetacklewillracetothegobside(travelingtrack)andnottothecoalfacewhenthecouplingis released.
Alwaysmounttheoverloadcouplingdirectlytotheconveyor chain.
. Afterwards,usethetackletoconnecttheguidesledgetothe thrustpieceoftheoverloadcoupling.UsethesuppliedU-lock forthispurpose.
Afterthedisassemblyofthepullingdevice Fig.5:Connectingguidesledgeandoverloadcoupling
Warning!
Takecaretoensurethatthetackledoesnotbecometwisted whenitisinstalled.
Thepullingdeviceisnowmounted.Forinformationontherestof theprocedure,pleaserefertoChapter5“Operation”.
Afterthedisassemblyofthepullingdevice Afterdisassembly,takecaretoensurethatallofthepartsofthe pullingdevicehavebeenremoved.
Thecouplingelementshouldremaininreleasedstatus,because thennotsomuchtimewillberequiredtoeffectitsreutilization.
5 Operation Operation Operationofthepullingdevice Howtopullintheplowchain
Allpersonnelmustexitthehazardousareabeforeyouswitchon theconveyor.Takeparticularcaretoensurethatnopersonnelare presentintheminingareaorinthevicinityoftheplow.
Notice!
Noadditionalpullingdevicesmaybeusedforpullingtheplow chainintothebottomrace!
. Pulltheplowchain slowly tothemountingpositionwiththe helpofthepullingdeviceandtheconveyor.Pullthechaininfar enoughthatyouareabletoconnectthetwoplowchainends withoneanother.
Caution!
Duringinstallationorretractionoftheplowchain,individual chainlinkscanbecometwisted.Thismayresultduringnormal operationindamagetotheplowchainsprocket,thesupport roller,ortheplowchainitself.
Makesurethattheplowchainisnottwistedwhenitisinstalled.
Danger!
Theoverloadprotection(overloadcoupling)istriggeredas soonasthepresetdecouplingforceof300kNhasbeenexceeded.
Assoonasthecouplinghasbeentriggered,thetackle under pressure,togetherwiththethrustpiece,willraceinthedirectionofthecoalface.
Youorotherscouldbeseriouslyinjuredorevenkilledbythe partsbeingflungabout.
Alwaysmaintainasafedistancebetweenyourselfandthe pullingdevice.
Dismantlingthepullingdevice Assoonasyouhavepulledtheplowchainintothedesiredposition,youcandismantlethepullingdeviceandconnecttheplow chainends.
Toaccomplishthis,pleaseproceedasfollows:
. Movetheconveyorsomewhatagainstthetractivedirectionup tothenextGleithobelguidewithflapvalve.
. Shutdowntheconveyorandsecureitagainstrestarting.
. Releasetheconnectionscrewsoftheflapvalve.Afterwards, foldopeninthedirectionofthecoalface.
. Removetheentirepullingdevice.
. Jointheendsoftheplowchain.Todothis,onlyusepermissiblechainconnectors.
. Afterwards,foldtheflapvalveclosed.Tightentheconnection boltswiththerequiredtorque.
Operationofthepullingdevice Theplowchainisnowretractedandconnected.Tofindouthowto tightentheplowchain,pleaseconsulttheseparateoperating manualofthechaintensionerused!
Overloadelement(overloadcoupling)
Whenistheoverloadcouplingtriggered?
Theoverloadcouplingistriggeredassoonasthepresetdecouplingforce(300kN)isexceeded,e.g.whentheplowchainis blocked.
Danger! Assoonasthecouplinghasbeentriggered,thetackle under pressure,togetherwiththethrustpiece,willraceinthedirectionofthecoalface.Youorotherscouldbeseriouslyinjured orevenkilledbythepartsbeingflungabout. Alwaysmaintainasafedistancebetweenyourselfandthe pullingdevice.
Howtoresettheoverloadcoupling
Todoso,proceedasfollows:
. Shutdowntheconveyorandsecureitagainstrestarting.
. Secureyourworkingareasufficientlyagainstfallingstoneand coallayers.
. Movetheconveyoragainstthetractivedirectionasfaras necessaryforyoutobeabletofreetheblockedplowchain.
. Slidethethrustpiece(Fig.6)intothecouplingholder.Take caretoensurethatthetackleisnottwisted.
Important! Ifthecouplingshouldprovedimpossibletoplugtogether,then theoverloadcomponentisstilltensioned.Theoverloadcomponentisreleasedby undoingthesixscrews(Fig.7,Pos.4). Afterwards,tightenthescrewsagainwiththerequiredtorque of76Nm.
Fig.6:Slidinginthethrustpiece
. Onceyouhaveslidinthethrustpiece(Fig.7,Item3),you mustapplyahammerblowtoreengagethepressurebolt (Fig.7,Item1).
Fig.7:Resettingtheoverloadcomponent
Position1:Pressureboltnotengaged
Position2:Pressureboltengaged
1pressurebolt 2couplingholder 3thrustpiece300kN 4allenscrews M12-8.8
5overloadcomponent150kNFA1) 1) FA=decouplingforce
6 Technicaldata Technicaldata Thischaptercontainsthemostimportanttechnicaldataforthe pullingdevice.Furtherinformationcanbefoundinthespareparts lists.Information abouttighteningtorquesisgivenattheendofthis chapter. Pullingdevicecomponents
Fig.8:Pullingdevicemaincomponents
1pull-insledge
2couplingholder
3thrustpiece300kN
4guidesledge
8retainer
9U-lockTBSS26/8
14hex.nutM24-10 20chain(tackle)26x78
242overloadcomponents(overload couplings),each150kNFA1)
1) FA=decouplingforce
Loadcapacityofthecomponentsofthepulling device
pull-insledge:300kN(factorycertification) chainDIN5687-826x78-15:300kN(nominalloadcapacity) thrustpiece:300kN(nominalloadcapacity) couplingholder:300kN(nominalloadcapacity)
foreachoverloadcoupling: ≦ 150kN(Fdecouplingforce) (factory-set)
Important!
Theuseofthetwooverloadcouplingsresultsinatotal decouplingforceofFtotal 300kN!
Tighteningtorques ScrewswithISOmetricthread
Tab.1:Tighteningtorquesat tot. =0.14
Thread 1) PitchP
4) (mm)(mm)
Important! Thetighteningtorquesstatedinthesparepartslistsmustbe observedduringinstallationandmaintenancework.
1)Thedimensionslistedinbracketsareusedinexceptionalcasesonly. 2)Accordingtoworksstandard(EWN6110,February1985edition). 3)Onlyforexpansionboltshavingareducedshaftcross-sectionof24.2mm. 4)Thetighteningtorquescomplywiththeworksstandard(EWN6003).
7 Foryourinformation Foryourinformation Ifyoushouldrequiresparepartsoriftechnicalproblemsoccur, pleasecontactourafter-salesservicepersonnelorcontactusdirectly(homepage: www.mining.cat.com).
Standardsanddirectives
Referencedstandardsanddirectives
Tab.2:Standardsanddirectives,extract
DesignationTitle
Directive2006/42/EC
Directive94/9/EC
DirectiveoftheEuropeanParliamentandtheCouncil ontheapproximationofthelawsoftheMemberStatesrelatingtomachinery
ECDirectiveontheapproximationofthelawsofthe MemberStatesconcerningequipmentandprotective systemsintendedforuseinpotentiallyexplosive atmospheres
Non-electricaldevicesforuseinpotentiallyexplosive atmospheres -Part1:Basicmethodandrequirements-
Equipmentandcomponentsintendedforuseinpotentially explosiveatmospheresinundergroundmines
Mobileextractingmachinesattheface-safetyrequirementsforshearerloadersandplow systems-
Designation
Title
Dateof issue
EWN6003 1) Tensioningforce,tighteningtorquesandsurfacepressure forbolts 1985-02
EWN6110 1) Hammerheadbolts 1985-02
EWN7068 1) Greases&solidlubricants 1992-06
EWN7069 1) Nonmetallicsurfaceprotection 1985-02
EWN8350-1 1) Approvalprocedureforfire-resistantHFAfluidsinmining 2008-01
