Professional Documents
Culture Documents
ID-Nr. BI628355-02-EN
July 2015
Technical
Information
Hydraulic Components Longwall
Serial-N.: LFX, LFY, LWZ, LFZ, LMJ, LWB, LML, LMX, LWD
SAFETY.CAT.COM
SAFETY.CAT.COM
BI628355
Technical information
Hydraulic components
Table of content
Table of content
1. About this technical information
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Persons for whom this technical information is intended . 1.1
Personnel qualification (in accordance with DIN 31000) . 1.1
Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Other instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2. Safety instructions
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Operator obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Potential hazards when working on hydraulic
equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
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Table of content
4. Valves
General information about valve design . . . . . . . . 4.1
Basic tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Dual 3/2-way pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4/3-way hand-lever valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Marking of pressure relief valves . . . . . . . . . . . . . . . . . . . . . 4.5
Color code of pressure relief valves . . . . . . . . . . . . . . . . . . 4.5
Check valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Throttle check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Shuttle check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Prop control valves, DN 20 and DN 13 . . . . . . . . . . . . . . . . 4.9
Twin check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Spraying valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Compensating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Pressure relief valve / plug . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Measuring adapter with pressure relief . . . . . . . . . . . . . . . . 4.14
Testing device for hydraulic props and valves . . . . . . . . . . 4.15
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5. Accumulator cartridges
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Working with accumulator cartridges / hydraulic
accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Maintenance / servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Safety instructions for working with accumulator
cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
6. Ball valves
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Color code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
2-way ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
3/2-way ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
5/2-way ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
5/3-way ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
7. Controls
Hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Electrohydraulic controls . . . . . . . . . . . . . . . . . . . . . 7.2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Working with/on (electro)hydraulic controls . . . . 7.3
Table of content
8. Filters
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Examples for high pressure filters . . . . . . . . . . . . . 8.1
Gap filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Double filters (here: can be backflushed) . . . . . . . . . . . . . . 8.2
Return filter examples . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Bag filter, 4x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Water filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Filter cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
Dismantling / disposal . . . . . . . . . . . . . . . . . . . . . . . . 8.7
9. Hydraulic cylinder
Design of hydraulic cylinders . . . . . . . . . . . . . . . . . . 9.1
Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Hydraulic cylinders on the shield support . . . . . . 9.2
Telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
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Table of content
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Removing hydraulic props . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
General
General
instructed person An instructed person is someone who has been instructed with re-
gard 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 protect-
ive measures.
layman A layman is someone who is neither a skilled worker nor an instruc-
ted person.
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minent danger. Possible consequences if not observed are
WARNING
Warning!
Points in the text marked with this symbol alert you to a threat-
ening danger. Possible consequences if not observed can be
very serious injuries or even death.
CAUTION
Caution!
Points in the text marked with this symbol alert you to a threat-
ening hazard. Possible consequences if not observed are injur-
ies and/or machine damage.
Other instructions
To emphasize special issues, the signal word IMPORTANT is
used in combination with the following symbol.
Important!
Text passages which are marked with this symbol provide you
with useful tips and instructions which will make your work
easier.
General
Safety instructions
General
When working on hydraulic systems or pieces of equipment, the
manufacturer information concerning knowledge and training, as
well as commissioning and servicing, is to be observed.
Danger!
Working on the electrical equipment of the system
Possible consequences: death or very serious injuries
Work on the electrical equipment of the system may only be
carried out by trained, skilled electricians or under the instruc-
tion of a trained, skilled electrician.
Warning!
Modifying/converting the hydraulic equipment
Possible consequences: death, serious injuries, machine
damage.
Modifications to the machine/system are only allowed after
consulting with Caterpillar. Modification without approval will
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Terms
maximum working pressure The highest pressure at which the system or parts of the system
may be operated under uniform (steady) conditions.
impermissible pressure The application of impermissibly high pressure to the hydraulic
components.
contamination The permissible contamination (non-dissolved foreign particles in
the hydraulic fluid) is based on the most contamination-sensitive
component of the hydraulic system. The specified purity class is
the maximum permissible value which must not be exceeded under
the aspect of operational safety (e.g. clogging of gaps, panels) and
the service life.
Operator obligations
protective measures The operator must take protective measures for work on hydraulic
systems. This includes, for example, work instructions for how to
work with the hydraulic systems.
work instructions Based on this technical information, supplemented with operator-
specific instructions, these work instructions should contain infor-
mation on the following subjects:
General
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ments are disconnected,
Safety rules
Always carry out work on hydraulic systems or equipment accord-
ing to the following safety rule (five-finger rule).
General
Explosion-prone environment
When operating hydraulic systems/components in explosion-
prone areas, make sure of the corresponding ATEX marking.
General
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Definition
Use
Hydraulic hose lines are used in almost all machines and systems
with hydraulically-controlled subassemblies, particularly where rigid
pipes for fluid transmission are out of the question.
used as the materials for the inner tube and outer layer. Braided
steel wire or braided fibers are used in the reinforcement layer.
Fig. 1: Basic structure of a hydraulic hose
1 2 3
Hose markings
Hoses are marked differently, depending on the country where they
are used.
Germany / Europe The marking is permanent with max. 50 cm spacing with:
manufacturer mark,
no. of the corresponding standard,
hose type,
nominal diameter in [mm],
quarter and year of manufacture.
Definition
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Hose line marking
1 2 3 4
1 manufacturer 3 year
2 calendar week 4 max. working pressure
Australia The marking is on the crimped-on strip (both sides) using a marking
punch as follows:
manufacturer mark,
working pressure in [bar],
date of manufacture (YY, MM),
Caterpillar marking.
Important!
Due to the cold-flow properties (creep) of the hose lines ex-
hibited after installation of the fittings, ready-assembled hose
lines should be stored for a short a period as possible prior to
use.
extension The operator can define an extension of the guide values men-
tioned above. This requires the following measures:
A risk and hazard analysis must be written by the operator,
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!
An extension of the replacement interval may not result in a
dangerous situation which could cause harm to employees or
other persons.
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cause of the fault.
reduction The operator must define a reduction in the above-mentioned
guide values if:
inspections show there is significant wear on the hydraulic hose
lines, indicating a reduced service life.
. Make sure that hose lines are not damaged by the movement
of the component (kinking, tearing out, crushing, twisting).
Fig. 3: Laying hydraulic line, connections to moving parts
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1.5 x d
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. Avoid abrasion of the hose material on unprotected edges,
corners or when hoses cross over each other.
Fig. 7: Laying hydraulic line, crossing
2
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1 socket 3 staple
2 plug nipple
Application
Mounting staples
To establish a reliable connection between a hose line and a con-
nector, the nipple is pushed into the socket and is then secured
with a staple. The staple must not be deformed under any circum-
stances.
. Place the staple on the socket.
. Pound the staple in with a suitable tool without deforming it.
Fig. 9: Press the staple together to align the ends with the holes and pound
it in
Caution!
Re-pounding of the staple
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Possible consequences: machine damage due to leaky or
Caution!
Repairing staples
Possible consequences: machine damage due to leaky or
loosened hydraulic connections.
Never repair deformed staples! These can fall out of the socket
due to faulty internal stress.
Staple clips
Staple clips prevent the staples from coming loose or falling out. In
the following figures, the various staple clip designs are shown.
Notice!
The size of the staple clip must match the staple size and the
corresponding fitting (OEM fitting). If other fittings are used,
the usability of the staple clip in the application must be
checked.
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Staple DN 10-Niro with clip 1651540
Application
To establish a reliable connection between a hose line and a con-
nector, the nipple is pushed into the socket of the hose sleeve and
fastened with the clamp collar. Then, the locknut is screwed against
the clamp collar and the red retaining ring is inserted.
All nominal sizes have the same design.
Components of the SSKV system
Fig. 16: SSKV system
3
2
1 a 2 a 1
1 hose sleeve with nipple a o-ring (greased)
2 double socket
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3
3 clamp collar
4 locknut 4
5 retaining ring
Warning!
Spraying of hydraulic fluids under high pressure as a result of
leaks, damage or tearing off
Possible consequences: very serious to serious injuries
Always work on hydraulic lines while wearing appropriate pro-
tective clothing (particularly safety goggles).
Warning!
Repairing hose lines
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The repair of hose lines using the used hose and/or fitting
(tie-in area) is not permitted!
Always exchange defective hose lines.
Warning!
Whipping hose lines due to pressure pulse
Possible consequences: serious bodily injuries due to whip-
ping hose lines
Keep a sufficient distance away from pressurized hose lines.
Notice!
Due to pressure pulses, wear, aging, bubble formation, dam-
age, faulty tie-ins, etc., hydraulic hose lines pose special haz-
ards.
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Valves
General information about valve design
definition Valves are components for controlling hydraulic functions. They are
subdivided into designs A, B, C and D.
Valves of design A limit the internal hydraulic pressures of
working cylinders (pressure relief valves). Valves of this design
are subdivided into 4 classes, according to their capacity.
Tab. 5: Valve classification, design A
Basic tips
Important!
When working with valves, observe the general safety rules for
hydraulic components in chapter 2.
Important!
Make sure the working environment and tools are clean.
Important!
Observe the separate shield support operating manual.
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1
4
3
1 pilot valve 3 cover
Mat. no.:344857 Mat. no.: 4384815
Reman Mat. no.: 20R3403
4 circuit diagram
2 protectivecap
Mat. no.:365763
Possible errors
The valve cannot be switched or a bypass has formed due to in-
ternal leakage. The latter can normally be detected on the solenoid
valves of the electrohydraulic control unit by a clearly audible hiss-
ing noise.
Pilot or control valves with a significantly lower volume flow will be-
come noticeably warmer due to the constantly flowing medium.
Defective pilot valves are difficult to detect since no medium
emerges from the control block. There is therefore no recognizable
indication of faults, such as discharged hydraulic fluid.
Troubleshooting procedure:
Valve does not switch off / exchange valve
. Close the main shut-off valve in the pressure feed line for the
shield.
. Then actuate the functions manually at least 10x to relieve the
pressure in the accumulator.
. Exchange the 3/2-way pilot valve.
able for block setup and can be fastened accordingly. It can be ac-
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Danger!
Manipulation of the hand lever by locking in place
Possible consequences: death or very serious injuries due to
uncontrollable shield movement
Never mechanically lock the hand lever of the 4/3-way valve in
place, e.g. by wedging it. The lever must be able to swivel in
both directions at all times.
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1
4
3
Caution!
Setting pressure of pressure relief valves
Possible consequences: machine damage due to overpressure
The setting pressure of pressure relief valves must not be
changed! Only use pressure relief valves which have been fact-
ory-set to the required value and which have a corresponding
color code.
. Always replace pressure relief valves with new valves with the
same properties. For this, observe the hydraulic circuit dia-
gram.
Important!
Always insert new seals when you exchange valves.
420 or 42* 09 03 RP
Setting pressure Week Year Last person who
made changes
*The format for the setting pressure can be 2- or 3-digit. In the case
of the shortened 2-digit format, the 1st digit stands for the hundreds
place and the 2nd for the tens place of the nominal setting pres-
sure.
e.g. 5 for the nominal setting pressure 50 bar, 10 for 100 bar, 16 for
160 bar.
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200 - 249 bar 250 - 299 bar 300 - 349 bar 350 - 399 bar
400 - 449 450 - 499 500 - 549 550 - 599 600 - 649 650 - 699
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brown 100 - 149
1
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Notice!
Pressure relief valves with missing or unrecognizable color
codes must not be used!
Errors on pressure relief valves
Leaky pressure relief valves are recognized by:
leaking hydraulic fluid, even at the working pressure (cause
could be the discharge pressure being set too low)
a pressure drop on the pressure gauge (if there is one).
Important!
Pressure relief valves for different cylinders or for the piston
and ring sides of a cylinder can have different maximum pres-
sure values. Observe the information in the hydraulic circuit
diagrams.
Maintenance / servicing
Maintenance and servicing information can be found in the Testing
and maintenance chapter.
Check valves
Check valves are mainly used in line construction. They block the
flow of hydraulic fluid in one direction without leaking. In the oppos-
ite direction, the hydraulic fluid can flow without obstruction. Check
valves are made in different versions, such as the twin arrange-
ment or as a piloted check valve.
Mode of operation
Piloted check valves work like simple check valves, but can be re-
leased by another supply line as needed.
Fig. 28: Check valve with SteckO connection
A B
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1 check valve 2 check valve circuit diagram
A B
2
1
2
1 shuttle check valve 2 circuit diagram
2
1 prop control valve DN 20 2 circuit diagram
Mode of operation
When there is a flow through the valve from PA to A, the valve
function corresponds to that of a normal check valve. The prop con-
trol valve is released via connection PB. Hereby, first the servo
valve is opened, which relieves the main stage cone pressure,
which allows the prop control valve to open without oscillations.
Possible errors
1) Bypass formation / piloted check valve
The formation of a bypass is indicated by a drop in pressure.
. Try to solve the problem by actuating the function several times
at the electrohydraulic control unit or control unit.
If the problem occurs again, the valve may be defective.
. Check the valve and replace it, if defective.
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2
Mode of operation
If, for example, the piston space of a cylinder is charged with pres-
sure and the first valve is flowed through from A to ZA, the second
valve is simultaneously opened via an internal pilot line by means
of a control piston. As a result, the cylinder space pressure is re-
lieved via ZB to B. If the annular space of a cylinder is charged with
pressure, the same thing happens in the opposite direction.
Spraying valves
Spraying valve (electrohydraulic)
Electrohydraulic spraying valves (water valve units) are used in the
automatic water spraying system in the support. They consist of a
valve block and a flanged electromagnetic pilot valve. Two spraying
functions can be activated independently of one another.
Mode of operation
The double solenoid valve is for the hydraulic actuation of the
2/2-way water valve. It is connected to the HFA face supply and is
supplied with high pressure. Actuating a function opens the valve
and opens the 2/2-way water valve. The water supply is connected
to the water spraying system this way.
Fig. 33: Water valve unit, 4 functions
W P
1 W2
W2
3
W1
W1
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W4
W3
W3
LK
2 4
1 pilot valve 3 filter cartridge
2 water valve 4 circuit diagram
1
1 spraying valve 2 circuit diagram
Compensating valve
Compensating valves limit the protected piston space of a hinge
cylinder to a specific pressure during the setting operation, and do
that until the prop has reached a certain internal hydraulic pressure.
Only when the internal prop pressure continues to rise does the
valve close, so that the piston space of the hinge cylinder can
reach its maximum pressure.
Typical installation site: stabilizing cylinder
Compensating valves usually have three ports which are marked as
follows:
S = prop port
Z = cylinder port
T = return port
Fig. 35: Compensating valve
Z
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S T
1
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Important!
Check the sealing ring regularly to see if it has become porous.
Just to make sure, you can cover the ring with a rag to prevent
hydraulic fluid from spraying out.
Mode of operation
In order to relieve pressure in the system, the set screw is screwed
into the valve.
Fig. 37: Open for pressure relief
Screw in the screw System open, pressure relieved
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Screw in the screw
e
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d
g
a f
Lever positions
The testing device has three lever positions. Depending on the
lever position, the pump fills with hydraulic fluid and presses it into
the prop of the pressure relief valve being tested at a 1.75x higher
pressure.
Fig. 41: Lever positions
3 1
2
Lever position 1) Pump fills with hydraulic fluid
Lever position 2) Pump entry and pressure intensification = zero
Lever position 3) Hydraulic fluid is pressed into the pressure relief valve
(pressure intensifier)
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General
Accumulator cartridges
General
Accumulator cartridges are for stabilizing the pressure in hydraulic
control circuits. Accumulator cartridges/hydraulic accumulators
have an accumulator system (usually as a piston-type accumu-
lator), which is filled with a gaseous medium (usually nitrogen).
Function
By connecting the accumulator cartridge to the control circuit of the
hydraulic system, pressure fluctuations in the hydraulic system are
balanced via the cartridge accumulator system. Here, the gas-filled
cartridge accumulator is stressed or relieved. When the pressure
drops in the actuating circuit, hydraulic fluid is pressed into the sys-
tem by the accumulator cartridge due to the expansion of the gas
accumulator. The pilot pressure is stabilized.
Notice!
Accumulator cartridges / hydraulic accumulators are always
under pressure! Before removing the accumulator cartridge,
the hydraulic circuit must be completely relieved.
To do this, after shutting off the hydraulic supply, actuate the pilot
valve until the residual pressure in the control circuit is relieved. To
check this, a pressure gauge in the control circuit is recommended.
When checking the hydraulic accumulator, the permissible
pressure must not be exceeded.
No gas may flow out after each test or setting.
Fig. 42: Accumulator cartridge
1
Important!
Also read the test criteria for accumulator cartridges in the
Testing and maintenance chapter.
3
1
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Maintenance / servicing
Warning!
Setting/testing the gas filling pressure
Possible consequences: destruction of the hydraulic accumu-
lator, bodily injury due to accumulator bursting
Setting, testing and filling work may only be carried out by
Caterpillar service personnel.
Caution!
Maintenance and filling of accumulator cartridges
Possible consequences: destruction of the accumulator cart-
ridge
Maintaining and filling may only be done by Caterpillar service
personnel!
General
Ball valves
General
Ball valves are usually used to mechanically block hydraulic lines.
By turning the handle, the hydraulic line is blocked or opened.
Caution!
Ensure that the ball valve is engaged at all times. A ball valve
that is not engaged prevents an optimal through-flow. This can
damage the ball valve.
Color code
red handle Ball valves in hydraulic lines have red handles.
Ball valves in water lines have blue handles.
Fig. 45: Color code, ball valves
blue handle
2
Operation
Operation
Notice!
Ball valves are mechanical components. When operating, make
sure that the ball valve is always completely engaged in its re-
spective position.
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open closed
A P
P pressure A consumer
T P T P
A
A
T tank A consumer
P pressure
Operation
T
P
A A
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T tank A consumer
P pressure
A A
P T
T tank A consumer
P pressure
CLOSED depressurized
OPEN working position (pressure open) (pressure relief for output side to the return line)
Operation
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2
A T
ON working position
(pressure open)
medium flow open
Hydraulic controls
Controls
Hydraulic controls
Hydraulic controls are used for controlling hydraulically operated
machines and devices. This kind of control is mainly used in under-
ground hydraulic shield supports. Hydraulic controls can execute
up to 20 functions which are activated via corresponding pilot
valves.
Notice!
In this context, the control may only be used for setting up a
neighboring control system. The control unit, therefore, may
not act on the support in which it itself is located, but must al-
ways be switched so that it only can act on the two directly ad-
jacent supports.
2
1
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3
1 pilot valve with switch 3 hydraulic connections, rear side
2 distributor block
Electrohydraulic controls
Electrohydraulic controls
Electrohydraulic controls are for controlling a shield support. They
consolidate a group of hydraulic functions in one control block.
Depending on the design, up to 20 functions can be executed in
one block. Electrohydraulic control units may only be used in con-
junction with an electronic control system, for example a PMC-R
control
Fig. 52: Electrohydraulic control unit, 4x
3
1
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5
1 distributor block 4 4 filter cartridge
2 pilot valve 5 hydraulic connections, rear side
3 accumulator cartridge
Operation
Function (electric)
The functions must not be operated directly on the electrohydraulic
control, but on the associated electronic control unit on the neigh-
boring shield. The function is actuated electrically here (lifting mag-
net). Here, a 3/2-way valve in the pilot circuit is switched, whose
hydraulic signal switches the function of the 3/2-way control valve
cartridge, which is in the main control circuit and allows the flow
from P to A. This brings about a volume flow to the consumer (prop,
shifting ram, etc.)
Function 1 Function (manual)
Function 2
The electrohydraulic control unit can also be used as a control
unit for the following exceptions:
emergency operation or repair operation.
The individual functions of the shield support are actuated directly
on the pilot valve of the electrohydraulic control unit.
Notice!
During emergency or repair operation, the valid safety regula-
tions must be strictly complied with.
The main parts of the electrohydraulic control unit are:
distributor block with
working valves,
filter cartridge and check valve,
connection for accumulator cartridge and connecting sockets,
pilot valves.
. Observe the operating manual for the control unit, control and
shield support.
. Make sure that no dirt or impurities can get into the hydraulic
system.
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General
Filters
General
In hydraulic systems, filters have the job of cleaning the medium
that flows through them. They are usually passive elements
(without their own drive), which implement various filter grades. The
unit of measurement is specified in micrometers [m].
micrometer Micrometer is the unit of measurement with which the particle size
in fluids can be determined, which are filtered by the filter. A micro-
meter is a thousandth of a millimeter (1 m = 0.001 mm).
Important!
Make sure you observe the separate operating manual or tech-
nical data for the filter components of the respective manufac-
turer.
Important!
When working on filters, pay attention to orderliness and
cleanliness. Sealing surfaces, in particular, must be free of
contaminants.
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Gap filters
A gap filter system consists of a housing, the filter cartridge with
gap cleaner, a stripper and a handle (rotating handle). The fluid to
be filtered flows through the filter body from the outside toward the
inside. Dirt particles which are bigger than the gap width are filtered
out and either drop to the housing floor or form a filter cake over
time, which is scraped off by turning the filter cartridge. The filter
body can be scraped during running operation.
Fig. 53: Gap filter example
2
Depending on the design, gap filters are also supplied with a motor
drive, which then replaces the (rotating) handle.
Maintenance / servicing
Maintenance and servicing information can be found in the Testing
and maintenance chapter.
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sure gauges or pressure sensors with optical indicators can be in-
1 1
2
3
Caution!
Properly install the solenoid valve
Possible consequences: destruction of the filter
Filters with solenoid valves may not be put into operation with
this.
Important!
Both filters are equipped with an anti-rotation lock, which en-
sures that the filter bells can only be released when depressur-
ized.
3 5
3
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2
1 mounting device, 4 medium inlet/outlet
filter cartridge 5 direction of flow
2 backflushing handle
3 backflushing outlet
Caution!
Shut-off valve in inlet and outlet line
Possible consequences: destruction of the system, since not
possible to change filter
In the inlet and outlet lines, as well as in the line for the separ-
ate pressure supply, there must be a shut-off valve installed
on-site.
Maintenance / servicing
Maintenance and servicing information can be found in the Testing
and maintenance chapter.
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2
Bag filters are combined with return flow prevention devices in the
shield hydraulics. Return flow prevention devices help ensure that
the filter cartridges in the return filter can be exchanged during op-
eration without the return line having to be completely shut off.
Fig. 57: Return flow prevention device
2
3
Before changing the filter, the shut-off valve (1) is closed, so that
the return filter can be opened. If there should continue to be pres-
sure on the filter (> 10 bar), the safety valve opens and connects
the return line directly to the tank (see Fig. 53).
Installation situation for return flow prevention device / return filter
Fig. 59: Installation situation
1
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Caution!
Direction of flow
Possible consequences: in the opposite direction of flow, the
filter bags can be destroyed.
Observe the hydraulic diagrams / directions of flow
Maintenance / servicing
Maintenance and servicing information can be found in the Testing
and maintenance chapter.
Water filters
Water filters consist of a filter housing, in which a filter cartridge is
inserted. Depending on the version, the water filter inlet is designed
as a SteckO connection to the filter housing. A SteckO fitting is
plugged into the filter housing, which forms the filter outlet and ac-
commodates the filter cartridge inside the filter. The fitting is con-
nected to the filter housing with a staple. The filter socket of the fil-
ter cartridge ensures the radial seal between the filter housing and
the fitting, which ensures that the water filter is not operated without
a cartridge inserted. In this case, medium will noticeably flow out of
the filter housing.
Water filters are used in the pressure circuit. The medium to be
cleaned flows through the inlet port to the inside of the water filter,
flows through the filter mesh of the filter cartridge (from the outside
in) and, cleaned, exits the water filter via the outlet.
Caution!
Faulty assembly
Possible consequences: escape of medium under pressure
Make sure when assembling that the o-rings and supporting
rings of the filter cartridge and the plug-in reducing sleeve are
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not damaged!
1
1 fitting connection 2 staple
3 filter housing 4 direction of flow arrow
Caution!
Incorrect direction of flow
Possible consequences: destruction of the filter cartridge
Pay attention to the direction of flow arrow on the filter hous-
ing.
Medium must not flow through the filter cartridge of the water
filter in the direction opposite the intended direction of flow!
Important!
If you loosened or removed additional connections during the
course of maintenance work, then these are to be reinstalled
completely after the maintenance work is finished!
Insert new staples and check all connections for complete-
ness.
Dismantling / disposal
Filter cartridges
A filter cartridge is located in the distributor block of the control unit.
It protects the control unit's valves from damage caused by impurit-
ies in the hydraulic fluid.
The filter cartridges on the electrohydraulic control unit of the shield
control system protect the downstream hydraulic components
against damage caused by contaminants in the hydraulic medium.
Fig. 61: Filter cartridge example
2
1
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Maintenance / servicing
Maintenance and servicing information can be found in the Testing
and maintenance chapter.
Dismantling / disposal
Filter systems and/or used filter elements must be disposed of ac-
cording to the national environmental protection regulations and/or
the regulations of your mine.
Dismantling / disposal
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Hydraulic cylinder
This chapter contains important information on the operation and
maintenance of the hydraulic cylinders. The design of the hydraulic
cylinders varies depending on the shield support.
1 2 4 5 3
Mode of operation
If the piston space is charged with hydraulic fluid, the piston rod
moves out.
Fig. 63: Extension function
Fig. 65: Hydraulic cylinder items on the shield support, schematic diagram
Z5
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Z1
Z2 Z3 Z4
In the area around the shield support, there are other hydraulic cyl-
inders on the following components:
conveyor steering device (block anchorages)
steering device canopy/canopy, skid/skid
outrigger steering system as well as anchoring devices and end
shield steering devices
Telescopic prop
The following figure shows the basic construction of a telescopic
prop. Depending on the version, the design and external connec-
tions can vary.
Fig. 66: Double-telescopic prop
d
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Possible defects
Internal bypass formed inside the prop
If an internal bypass in a prop is suspected, this procedure should
be followed:
. Set the prop until the setting pressure has been reached.
. Make sure that the annular space of the prop is depressurized.
. Actuate the set prop function from the neighboring support.
Important!
If there is an internal bypass in the prop, for example due to
damaged piston packing, hydraulic fluid will flow out of the
prop's annular space connection. If this happens, the prop
must be replaced. If fluid should escape from the detached
hose lines, the piloted check valve is defective.
Lifting cylinder
The following figure shows the basic construction of a lifting cylin-
der. Depending on the version, the design and external connections
can vary.
Fig. 67: Lifting cylinder
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Stabilizing cylinder
The following figure shows the basic construction of a stabilizing
cylinder. Stabilizing cylinders are installed individually or in pairs.
Depending on the version, the design and external connections can
vary.
Fig. 68: Stabilizing cylinder
b
a
Important!
Information about dismantling / installing stabilizing cylinders
can be found in the Testing and maintenance chapter.
Shifting ram
The following figure shows the basic construction of a shifting ram.
Shifting rams are usually combined with a length measuring system
(reed rod) in order to be able to determine the path of the piston rod
that is still available.
Fig. 69: Shifting ram
h
c
e f a
g
d
d
c piston rod
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Important!
Information about dismantling / installing the shifting ram can
be found in the Testing and maintenance chapter.
Seal cylinder
The following figure shows the basic construction of a seal cylinder.
Seal cylinders are installed perpendicular to the longitudinal axis of
the shield. Depending on the shield size, up to 5 seal cylinders can
be installed per side in the canopy and caving shield.
Fig. 70: Seal cylinder
c
b
Danger!
Shut-off valves in return lines
Possible consequences: death or very serious injuries due to
bursting hoses as a result of overpressure.
Never install shut-off valves in return lines or on annular space
connections!
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Important!
annular space
connection
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Important!
Make sure you observe the information on how to operate the
shield hydraulics in the respective shield operating manual.
Right-hand prop
. Lock the left-hand prop with HP ball valve (annulus space and
piston space)
. Retract right-hand prop.
While the prop is retracted, the middle step is retracted.
. When the middle step has reached the desired position, set the
prop.
. Once the right-hand prop is set, reopen the HP ball valve of the
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left-hand prop.
. Once the left-hand prop is set, reopen the HP ball valve of the
right-hand prop.
Fig. 72: Retracting the middle step on a set prop
General
Hydraulic fluids
General
Hydraulic fluids are used for transferring energy in hydraulic sys-
tems. They must be selected so that they withstand the occurring
stresses, particularly the mechanical, chemical and thermal types,
and are compatible with the materials used in the hydraulic system.
Hydraulic fluids must meet the specifications of the manufacturer of
the hydraulic system.
Prerequisites for using hydraulic fluid (suitability test)
The starting point for a functioning hydraulic system is clean hy-
draulic fluid. If difficulties arise in the preparation of hydraulic fluids,
which would compromise their properties, all of the liquid in the hy-
draulic system must be replaced as a precaution. We recommend
creating a maintenance plan for hydraulic fluids to minimize accu-
mulation in the hydraulic components, such as filters.
Important!
Only use hydraulic fluids for which you have a valid certificate
in accordance with EWN 8350 or a special permit issued by
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Important!
Changes in the composition of the water will lead to the loss of
the certificate even if they are within the limit values men-
tioned.
If system parts from different manufacturers should be used in a
mine, a special permit can be issued for operating all hydraulic
components with the same hydraulic fluid after consulting with
Caterpillar.
Important!
Caterpillar will not accept any warranty claims for any compon-
ents which have been or are operated with a different hydraulic
fluid without Caterpillar approval.
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maintenance plan
Behavioral measures
Depressurize the hydraulic system before starting work.
Wear oil-resistant gloves and safety goggles.
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. Flush the eye with water or eye rinsing fluid (eye wash) for at
least 15 minutes, and consult a doctor, if necessary.
Disposal
Disposal
Important!
Dispose of hydraulic fluid according to the national regulations
of your country and/or mine.
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. Collect hydraulic fluid in appropriate containers and then prop-
erly dispose of the fluid.
Prerequisites
Caution!
Changing sealing rings
Possible consequences: leaks and damage due to leaks
When you exchange hydraulic components which have sealing
rings, always exchange the used sealing rings for new ones.
Prerequisites
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Are hydraulic hose lines each marked with the name or abbrevi-
Prerequisites
of a hose line.
Caterpillar Global Mining Europe GmbH, Lnen 2015
Prerequisites
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ried out after making changes to the machine and hydraulic
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pilot valves. Exchange the pilot valve in the event of defective
Notice!
Always insert new seals when you exchange the valves!
Grease the O-rings with Hydrocore SF.
Possible errors:
Valve does not switch off / exchange valve
. Valve function on the electrohydraulic control unit continues to
respond although the function is not being actuated.
Close the main shut-off valve in the P line of the shield supply.
Relieve residual pressure (actuate functions 10x). This valve is
defective and must be exchanged.
Valve does not switch
. Actuate the valve function on the (electrohydraulic) control unit
several times to release the blocked parts of the valve.
Internal leaks - bypass formation
(can be detected on the working valves of the electrohydraulic
control unit by a clearly audible hissing noise).
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8220 127 000 00 00 8220 127 000 RA 00 8220 127 020 00 00
Warning!
Setting/testing the gas filling pressure
Possible consequences: destruction of the hydraulic accumu-
lator, bodily injury due to accumulator bursting
Setting, testing and filling work may only be carried out by
Caterpillar Service personnel.
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Notice!
Make sure that closed isolating equipment cannot be opened
by accident during the maintenance periods.
Notice!
When changing the filters, pay attention to sealing surfaces
and seals. Replace any damaged seals.
Important!
Depending on the filter type and manufacturer, the following
descriptions can deviate from your filter version. Always read
the original operating manual of the respective manufacturer.
Important!
Used filter cartridges are contaminated by emulsion residue
and deposits. Dispose of used filter cartridges according to the
environmental regulations of your country and/or mine.
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defined individually. We recommend backflushing double filters
(both filter inserts) regularly once a shift.
If there is external leakage, exchange the corresponding seal. If the
leakage is not remedied by doing this, all sealing surfaces must be
checked and defective parts exchanged immediately.
Filter elements and valves are subject to normal wear during use.
Therefore, they should be checked accordingly at appropriate inter-
vals.
Worn or damaged parts must be exchanged immediately.
Important!
During commissioning, first the shut-off valve on the inlet side
is to be opened slowly, and afterwards that on the outlet side.
Opening suddenly can destroy the filter!
. First close the shut-off valve in front of the bag filter (inlet), and
then the shut-off valve after the bag filter (outlet).
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. Check all external connections and seals of the piston rod and
piston pipe for leaks at appropriate intervals.
water spraying system On hydraulic cylinders which are within range of a water spraying
system, the piston rods must be thoroughly cleaned every six
months, at latest, and be re-preserved.
Important!
Make sure you observe the information on how to operate the
shield hydraulics in the respective shield operating manual.
. Remove the prop aprons and secure the defective prop against
falling over with chain hoists and wooden wedges, if necessary.
. Remove the prop head fastening.
. Completely retract the defective prop via the control unit.
. Close the ball valve on the supply block, in order to shut off the
pressure supply to the shield.
. Alternately actuate the opposing push-buttons in the control
unit 10x to reduce the pressure in the shield hydraulic system.
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. Briefly turn the vented cap screw on the prop control valve in-
. Briefly open the screw on the pressure gauge port so that the
residual pressure can escape from the piston space (special
tool required).
. Remove the hose lines from the defective prop and seal these
with plugs.
. Remove the check valve from the defective prop.
. Mount the cover plate to the defective prop and seal the annu-
lar space connection with a blind plug.
. Remove the prop retainer from the skid.
. Remove the defective prop from the shield.
. Remove any contamination from the prop seat before you
mount a new prop.
Important!
Installation is done in the reverse order!
Important!
Only release the shield for use once you have checked the
functions and no malfunctions occurred.
. Remove the pin retainer of the stabilizing cylinder from the can-
opy.
. Retract the stabilizing cylinder via the control unit.
. Close the ball valve on the supply block, in order to shut off the
pressure supply to the shield.
. Alternately actuate the opposing functional pair of push-buttons
on the control unit 10x to reduce the pressure in the shield hy-
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draulic system.
. Briefly turn the two vented cap screws of the twin check valve
on the stabilizing cylinder inward so that the residual pressure
can escape from the stabilizing cylinder.
. Remove the two pressure relief valves from the stabilizing cyl-
inder.
Important!
Only release the shield for use once you have checked the
functions and no malfunctions occurred.
. Bring the shifting ram into the floating position so that the con-
necting elements can be released more easily.
. Then extend the shifting ram to relieve the pressure in the shift-
ing ram.
. Close the ball valve on the supply block, in order to shut off the
pressure supply to the shield.
. Alternately actuate the opposing functional pair of push-buttons
on the control unit 10x to reduce the pressure in the shield hy-
draulic system.
. Remove the hose lines from the shifting ram and seal these
with plugs.
Important!
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Only release the shield for use once you have checked the
Important!
To evaluate damage cases and to take the corresponding coun-
termeasures, we recommend that any damage be recorded.
A weekly or monthly evaluation of the records will allow you to
detect weak points and to avoid errors early on, e.g. by carry-
ing out the appropriate maintenance.
Permissible media
Permissible media
The media indicated in the tables are recommendations that meet
the required specifications. Other media may well be used,
provided they are approved by Caterpillar and comply with the re-
quirements of the respective EWN*). When using media which do
not meet the requirements, the operator and the respective manu-
facturer accept liability for any damage.
Important!
Observe the data sheet of the respective manufacturer. This in-
cludes specifications and specific safety instructions for safe
handling of the product.
Greases
Meets the requirements of Caterpillar to EWN 7068
Grease A2 Greases containing additives for high pressure applications, e.g. for
dirt strippers of the hydraulic props.
Tab. 11: Grease A2
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class in C
Cleaning agent
Cleaning agent Cleaning agent for cleaning piston rods of the hydraulic props or
hydraulic cylinders.
Tab. 14: Cleaning agent
Dismantling / disposal
Dismantling / disposal
Warning!
Depressurizing components and systems
Possible consequences: serious injuries to the face, hands and
upper body due to hydraulic fluid spraying out
Always carry out work on hydraulic components when they are
depressurized. Make sure that the system/component is de-
pressurized before starting work.
Dismantling / disposal
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Commissioning information
Commissioning information
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Fig. 74: Diagram of a hydraulic supply
The working pressure in the pressure supply (P) may not fall
below 20% of the indicated value.
P=100%
P=85%
=P
=T
P=65%
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Fig. 76: Hydraulic supply with a ring line and without a branch line
P=100%
=P P=80%
=T
Fig. 77: Optimum supply: Hydraulic supply with a ring line and with a branch line
P=100% P=95%
P=90%
=P
=T
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Date of
Designation Title
issue
EC Directive of the European Parliament and Council on
Directive 2006/42/EC the approximation of the laws of the Member States relat- 2006-05
ing to machinery
EC directive of the European Parliament and the Council
on the approximation of the laws of the Member States
Directive 94/9/EC 1994-03
concerning equipment and protective systems intended for
use in potentially explosive atmospheres
DIN 31000 General principles for the safe design of products 1979-03
DIN EN ISO 12100 Safety of machinery 2011-03
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