Technical Manual
© Bucyrus All Rights Reserved
R
BI622211
BUCYRUS
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Industriestraße1Telefon:+49(0)2306/709-0e-mail:infodbt@dbt.de D-44534LünenTelefax:+49(0)2306/709-1421Internet:www.dbt.de DBTGmbH OperatingManual DBT-Shield 2550/5500-2X4319-1750 Doc.No.:7420169000BA00 BI622211
Amendmentsandalterationstothispublicationarenotsubjectto notification.DBTGmbH(DBT)reservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws,bothdomesticandinternational.Nopartofthispublicationmaybereproducedortransmittedinanywayorformwithoutthepriorwrittenapprovalofthe DBT.
DBTdeclinesallliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsobtainedby technicaldevelopmentwithoutpreviousnotice!
DBTGmbH,Lünen2006 E
BI622211
Contents Doc.No.:7420169000BA00VRVL/01 Contents 1.Aboutthismanual Beforestartingwork 1.3 ............................. Personsforwhomtheoperatingmanualisintended1.3 Purposeofthisoperatingmanual1.4 Charactersandsymbolsused1.4 ....................... 2.Yoursafety Personnel 2.3 ...................................... Operationandmaintenance 2.3 Repair 2.4 Conditionsofoperation 2.5 .......................... Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.6 Overviewofthesafetyinstructions 2.16 3.Storageandtransport Storage 3.3 ......................................... Storageofnewequipment 3.3 Usedequipment 3.5 Transport 3.6 ....................................... 4.Installation Pre-assemblyoftheshieldunits 4.3 .................. Installationoftheshieldunits 4.3 .................... Supplyconnections 4.5 Couplingbetweentheconnections 4.6 Requirementsforthefacehydraulicsystem 4.7 ....... Start-up 4.8 ......................................... Tobeobservedpriortostart-up 4.8 Start-upoftheshields 4.10 Corrosionprotectionofhydrauliccomponents4.10 ..... DBTGmbH,Lünen2006 E BI622211
5.Operation
6.Technicaldata
Contents DBT-Shield2550/5500-2X4319-1750
Basicrequirements 5.3 .............................. Conditionsforoperation 5.3 Safetyrequirements 5.6 Operationoftheshield 5.9 ........................... Safeworking 5.14 .................................... Operationoftheshieldhydraulics 5.15 ................ Locationofhydrauliccomponentsontheshield 5.15 Shieldcomponents 5.22 Extendingorretractingthesideseal 5.30 Canopyspraying system 5.32 ............................ Operationofthedualbackflushfilter 5.33 .................. Repairandemergencyoperation 5.34 ..................... Operationandfunctionsofthecontrolvalveblock 5.36 ...... Maintenance 5.40 .................................... Specialmeasures 5.40 .................................. Dailymaintenance 5.41 Weeklymaintenance 5.41 Tobedoneeverysixmonths 5.42 Assessmentofdamageaccordingtoschedule 5.42 Troubleshooting 5.43 ................................ Faultfindingonshieldhydraulicsystem 5.43 Faultlocalization 5.43 3/2-Wayvalveorpilotvalve 5.46 Pilot-operatedcheckvalves 5.46 ......................... Internalby-passinprops 5.47 ............................ Faultypressurereliefvalve 5.47 .......................... Defectiveorblockedfilter 5.47
Shielddescription 6.3 Mainassemblies 6.5 ................................... Basewithlemniscaticlinksandcentralshiftingunit 6.7 Shieldcanopy 6.10 Flipper 6.14 Sideseal 6.15 Cavingshield 6.17 Technicaldataoftheshield,steelstructure 6.18 Hydraulicsystem 6.20 ................................ Shieldhydraulics 6.21 Double-telescopicprop 6.27 DBTGmbH,Lünen2006 E BI622211
Contents Doc.No.:7420169000BA00VRVL/01 Hydrauliccylinder 6.29 ............................... Design 6.29 Stabilizingcylinder 6.30 Shiftingram 6.30 Baseliftcylinder 6.31 Sealcylinder 6.31 Flippercylinder 6.32 Technicaldataofhydrauliccylinders 6.33 Pressurereliefvalves 6.35 ............................ Shieldcontrolsystem 6.37 ............................ Electrohydrauliccontrolunit 6.37 ElectronicshieldcontrolPMC®-R 6.37 .................... Anglesofinclinationofthecanopy 6.39 ............... Permissiblemedia 6.40 ............................... Hydraulicfluids 6.40 .................................... Lubricatinggreasesandpastes 6.43 ...................... Tighteningtorques 6.45 .............................. ScrewswithISOmetricthread 6.45 7.Foryourinformation Serviceaddresses 7.3 Europe 7.3 ........................................... Northamerica,Canada,Southamerica 7.4 ................ Australia 7.4 SouthAfrica 7.4 Asia 7.5 Identificationofshields 7.6 .......................... Typeplate 7.6 Shieldnumber 7.6 Standardsandguidelines 7.7 ........................ Referencednationalstandardsandguidelines 7.7 Europeanstandardsandguidelines 7.7 DBTGmbH,Lünen2006 E BI622211
Contents DBT-Shield2550/5500-2X4319-1750 DBTGmbH,Lünen2006 E BI622211
1 Aboutthismanual BI622211
BI622211
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthesymbolsused.
Beforestartingwork
Takecaretoensurethattheoperatingmanualavailabletoyouis applicablefortheshieldsupportused.Comparethedatagiven belowwiththedataonthetypeplateoftheshield.Wheretofind thetypeplateontheshieldisdescribedinchapter7ofthisoperatingmanual.
Thisoperatingmanualisdesignedfor:
DBT-Shield2550/5500-2X4319-1750
andisonlypermittedtobeusedforshieldsofthistype.Onlyuse theoperatingmanualapplicabletotherespectiveshield.Ifyou don’tyouwillendangeryourselfandothers.
Tab.1:TypespecificationforDBT-Shield2550/5500-2X4319-1750
Identificationno.Propforce Yearof construction Application
742016900000 01 2x4319kN 2006 faceshield
742016900000 02 2x4319kN 2006 transitionshield
Itisabsolutelynecessarytoensurethatallpersonsworkingwithor onthesupporthaveaccesstothecontentsoftheapplicableoperatingmanualsfortheshieldsatanytimeandwithoutanyrestrictions.
Personsforwhomtheoperatingmanualisintended Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.
Thisincludespersonswho:
J areinchargeoftransport,
J preparetheriseheading,
J performassembly/disassemblywork,
J operatetheshields,
J correctmalfunctions,
J performdailyroutineworkontheface,
J monitor/lookafterthehydraulicsystem,
J performmaintenancework,
J performrepairwork;
J supervisorypersonnelwho –initiateand/or –supervise theactivitiesjustindicated.
Everybodyworkingontheshieldsupportmusthavereadthisoperatingmanualbeforehand. Anypersonsvisitingorinspectingthefacemusthavereceived adequateinstructions.
Beforestartingwork Doc.No.:7420169000BA00VRVL/01 1.3
DBTGmbH,Lünen2006 E applicableoperatingmanual availabilityof operatingmanual BI622211
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safety
Purposeofthisoperatingmanual
Thisoperatingmanualcontainsgeneralinformationonthesafeand economicalhandlingofshieldsupportsandprovidesyouwith importantinstructionsontheworkperformeddirectlyonorwiththe shields.
Therefore,readthisoperatingmanualcompletelyandatease.Pay specialattentiontothesafetyinstructions.Trytomemorizethe appearanceandthemeaningofthesafetyandinstructionsymbols. Shouldyouhaveanyquestions,pleasecontactourservicedepartment.Contactdetailsaregiveninchapter7ofthisoperatingmanual.
Readthechapter2”Foryoursafety”withspecialattention.This chaptercontainsimportantinformationindicatingpossiblehazards. Observetheinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesand machinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare: damagetotheshieldordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.
Itemsinlistsaremarkedwithblacksquares.
Pointsinsub-listsaremarkedwithalongdashatthestartofthe line.
Thesymbolofthehandasksyoutodosomething.Severalsuccessiveparagraphsmarkedwiththesymbolofthehandrepresent astringofactionswhichmustbeexecutedintheorderspecified. Followtherespectiveinstructionsstep-by-steptoperformthework safelyandefficiently.
Beforestartingwork DBT-Shield2550/5500-2X4319-1750 1.4
DBTGmbH,Lünen2006 E
operatingmanual questions
J –. BI622211
2 Yoursafety
BI622211
BI622211
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecial attentiontothischapter.Thesafetyinstructionsandrulesofprocedurewillhelpyoutoavoidhazardoussituationsandtoperform thenecessaryworkassafelyaspossible.
Theshieldhasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. However,acertainriskremainswhichmightgetyouintohazardous situationswhenworkingwithorontheshields.Thesemay,for example,becausedbyunforeseeableexternalinfluences,machine damageoroperatingerrors.
Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulations:
J oftheminingcompany, J oftheminingauthority,and J oftheminers’accidentinsuranceassociation.
Personnel
Personsemployedintheoperation,repair,andoverhaulof hydraulicand/orelectrohydraulicshieldsupportsmusthavespecial qualifications.Inadditiontohavingreceivedtraininginminingskills thefollowingminimumrequirementsshallbemet.
Operationandmaintenance
Operationandmaintenanceoftheshieldsisonlyallowedtobeperformedbytrainedpersonnel.
Thetrainingshallbematchedtothetypeofshieldactuallyused. Theelectrohydraulicandhydrauliccontrolsystemsshallbe operatedonlybypersonnelwhohavebeenadequatelytrainedtooperatethepresentcontrolsystem. Thecontentoftheoperatingmanual,especiallythechapteron safety,shallconstituteapartofthistraining.
Theyshallpossessandfurnishproofofadequatefamiliaritywith the J mechanical, J hydraulic,and J controlsystems.
Personnel Doc.No.:7420169000BA00VRVL/01 2.3
DBTGmbH,Lünen2006 E residualrisk supplementaryregulations qualification BI622211
Repair
Ingeneral,repairworkshallbeperformedonlybypersonswho havetherespectiveknowledgeandskillstomeetthespecial requirementsandhavebeenadequatelytrainedintherepairofthe equipment.
Repairworkonandoverhaulof
J safetydevices,ase.gpressurereliefvalves
J hydraulicpropsandcylinders
J controlblocks,valves,andfilters
shallbeperformedonlybyDBTservicetechniciansorbyspecially trainedpersonneloftheminingcompany.
Personnel DBT-Shield2550/5500-2X4319-1750 2.4
DBTGmbH,Lünen2006 E BI622211
Conditionsofoperation Intendeduse
Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasasupportunitforlongwallfaces.
Usetheshieldonlyasintended!
Intendedusesare:
J proppingtheroofagainstthefloor;
J ensuringanadequatetravelway;
J thefollowingshieldoperations: –lowering, –pullingup, –alignment,and –setting;
J thefollowingconveyoroperations: –advancing, –retracting;
J forminganabutmentfor: –theconveyorandtheminingmachine, –conveyorsteeringdevices, –devicesforraisingtheconveyor, –conveyorsteeringcylinders.
Unauthorizeduse
Useswhicharenotexpresslystatedasintendedareregardedas unauthorizedusesandarenotpermissiblewiththeshield.
Unauthorizedusesinclude,amongothers:
J pushingtheshieldbackintothecavingarea,
J raisingoftheconveyorbymeansofthehydraulicforceofthe shield,
J settingofthecanopyinareasofrooffracture. Furtherinformationinthisrespectisgiveninthesection”Operation”ofthischapterandinchapter5ofthismanualinthesection”Operationoftheshield”.
DBTdoesnotacceptanyliabilityfortheconsequencesofunauthorizeduses.
Conditionsofoperation Doc.No.:7420169000BA00VRVL/01 2.5
DBTGmbH,Lünen2006 E BI622211
Safetyinstructions
Basicprinciples
Alwaysconcentrateonyourwork. Familiarizeyourselfwithyourworkingenvironment. Alwayswearyourpersonalprotectiveclothingandequipment.
Informyourcolleaguesof: J yourexactlocation, J theworkwhichyouareperforming, J thetimewhichyouwillprobablyrequire. Employonlyshieldswhichareinatechnicallyflawlesscondition. Alwayskeepoutofanyshieldwhichisnotset. Maintainthelightingsystemsinafunctionalcondition.
Maintainthesignalling systemsandprotectivedevicesinafunctionalcondition.
Observetheacousticandvisualstartwarnings.Payspecialattentiontothestartwarningsfortheconveyorandforthemining machine.
Presstheemergencystopswitchimmediatelyintheeventofmalfunctionsorirregularitiesinoperation.Notifyyourforemanofany peculiarity,inorderthatnecessaryactionbetakenimmediately.
-Onlyapplicableforshieldsprovidedwithelectrohydrauliccontrol systems-
Actuatethesupportlock-outswitch(repairswitch)beforeperforming.
J maintenancework, J inspectionwork, J repairwork,andbefore J prolongedpresenceintheshield.
Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe: J baseskidsandshiftingunits
J canopies, J links, J sideseals, J frontcantilevers, J hydraulicpropsandcylinders, J steeringdevices.
Inautomaticmode,thesupportunitsofalongwallfacearecontrolledbyanautomaticprogrammewithoutanyhumaninterference. Whentravellingthefaceyoushouldthereforealwayskeepinmind thatthesupportunitsmaymoveautomatically.Thereforeitisvital thatyouobservethewarningsatthefaceentriesaswellasthevisualandacousticwarningsignalssentbythecontrolunitinthesupportcurrentlyoperated.
DBT-Shield2550/5500-2X4319-1750 2.6
Safetyinstructions
DBTGmbH,Lünen2006 E general prerequisite lighting
EMERGENCY STOP
signallingsystemsand protectivedevices
BI622211
supportlock-outswitch movingparts automaticmode
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