Technical Manual
© Bucyrus All Rights Reserved
R
BI621855
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 1700/3500-2X4412-1750 Doc.No.: 7420163000BA00 BI621855
Amendmentsandalterationstothispublicationarenotsubjectto notification.DBTGmbH(DBT)reservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws,bothdomesticandinternational.Nopartofthispublicationmaybereproducedortransmittedinanywayorformwithoutthepriorwrittenapprovalofthe DBT.
DBTdeclinesallliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsobtainedby technicaldevelopmentwithoutpreviousnotice!
DBTGmbH,Lünen2006 E
BI621855
Contents Doc.No.:7420163000BA00VLVL/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 2.17 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 4.10 Requirementsforthefacehydraulicsystem4.10 ....... Start-up 4.11 ......................................... Tobeobservedpriortostart-up 4.11 Start-upoftheshields 4.12 Corrosionprotectionofhydrauliccomponents4.13 ..... DBTGmbH,Lünen2006 E BI621855
5.Operation
6.Technicaldata
Contents DBT-Shield1700/3500-2x4412-1750
Basicrequirements 5.3 .............................. Conditionsforoperation 5.3 ............................ Safetyrequirements 5.6 Operationoftheshield 5.9 ........................... Safeworking 5.14 .................................... Operationoftheshieldhydraulics 5.15 ................ Locationofhydrauliccomponentsontheshield 5.15 ........ FunctionsoftheHDballvalves 5.17 BracketforPMC®-Rcontrolunit 5.32 Operationofthedualbackflushfilter 5.34 Repairandemergencyoperation 5.35 ..................... Operationandfunctionsofthecontrolvalveblock5.38 Shieldfunctionsfortheshieldvariants01and02 5.39 Shieldfunctionsfortheshieldvariants03to05 5.41 Maintenance 5.44 .................................... Specialmeasures 5.44 Dailyinspection 5.45 Weeklymaintenance 5.45 ............................... Tobedoneeverysixmonths 5.45 Assessmentofdamageaccordingtoschedule 5.46 Troubleshooting 5.46 ................................ Faultfindingonshieldhydraulicsystem 5.46 Faultlocalization 5.46 3/2-Wayvalveorpilotvalve 5.49 ......................... Pilot-operatedcheckvalves 5.49 ......................... Internalby-passinprops 5.50 Faultypressurereliefvalve 5.50 Defectiveorblockedfilter 5.50 ...........................
Shielddescription 6.3 ............................... Mainsubassemblies 6.5 Basewithlemniscaticlinksandcentralshiftingunit6.9 Shieldcanopy 6.13 Frontcantilever 6.18 Sideseal 6.19 Cavingshield 6.22 Sideflipper 6.23 Protectivewall 6.24 Technicaldataoftheshield,steelstructure 6.25 Hydraulicsystem 6.28 ................................ Shieldhydraulics 6.29 Double-telescopicprop 6.39 Hydrauliccylinder 6.41 ............................... Design 6.41 DBTGmbH,Lünen2006 E BI621855
Contents Doc.No.:7420163000BA00VLVL/01 Stabilizingcylinder 6.42 Baseliftcylinder 6.42 Shiftingram 6.43 Sealcylinder 6.44 Flippercylinder 6.44 .................................... Adjustingcylinder 6.45 .................................. Slidingcylinder 6.45 .................................... Technicaldataofhydrauliccylinders 6.46 Pressurereliefvalves 6.50 ............................ Electrohydrauliccontrolsystem 6.52 .................. Electrohydrauliccontrolunits 6.52 ElectronicshieldcontrolPMC®-R 6.53 Anglesofinclinationofthecanopy 6.56 ............... Accessories 6.57 .................................... Anti-toppledevice“canopy-canopy” 6.57 Endanchorage 6.58 Endanchoragebase-base 6.59 Operatingmedia 6.61 ................................ Hydraulicfluids 6.61 Lubricatinggreasesandpastes 6.64 Tighteningtorques 6.66 .............................. ScrewswithISOmetricthread 6.66 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 Referencedeuropeanstandardsandguidelines 7.7 DBTGmbH,Lünen2006 E BI621855
Contents DBT-Shield1700/3500-2x4412-1750 DBTGmbH,Lünen2006 E BI621855
1 Aboutthismanual BI621855
BI621855
applicable operatingmanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthesymbolsused.
Beforestartingwork
Takecaretoensurethattheoperatingmanualavailabletoyouis applicablefortheshieldsupportused.Comparethedatagiven belowwiththedataonthetypeplateoftheshield.Wheretofind thetypeplateontheshieldisdescribedinchapter7ofthisoperatingmanual.
Thisoperatingmanualisdesignedfor:
DBT-Shield1700/3500-2X4319-1750
andisonlypermittedtobeusedforshieldsofthistype.Onlyuse theoperatingmanualapplicabletotherespectiveshield.Ifyou don’tyouwillendangeryourselfandothers.
Tab.1:TypespecificationforDBT-Shield1700/3500-2X4319-1750
availabilityof operatingmanual
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;
Beforestartingwork Doc.No.:7420163000BA00VLVL/01 1.3
Yearof construction Application 742016300000 01 2x4319kN 2006 faceshield 742016300000 02 2x4319kN 2006 transitionshield 742016300000 03 2x4319kN 2006 faceendshield,rightwith sideflipperandprotective wall 742016300000 04 2x4319kN 2006 faceendshield 742016300000 05 2x4319kN 2006 faceendshield,leftwith sideflipperandprotective wall
Identificationno.Propforce
DBTGmbH,Lünen2006 E
BI621855
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
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CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
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J supervisorypersonnelwho –initiateand/or –supervise theactivitiesjustindicated.
Everybodyworkingontheshieldsupportmusthavereadthisoperatingmanualbeforehand. Anypersonsvisitingorinspectingthefacemusthavereceived adequateinstructions.
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.
Beforestartingwork DBT-Shield1700/3500-2x4412-1750 1.4
DBTGmbH,Lünen2006 E operatingmanual question safety BI621855
Itemsinlistsaremarkedwithblacksquares.
Pointsinsub-listsaremarkedwithalongdashatthestartofthe line.
Thesymbolofthehandasksyoutodosomething.Severalsuccessiveparagraphsmarkedwiththesymbolofthehandrepresent astringofactionswhichmustbeexecutedintheorderspecified. Followtherespectiveinstructionsstep-by-steptoperformthework safelyandefficiently.
Beforestartingwork Doc.No.:7420163000BA00VLVL/01 1.5
DBTGmbH,Lünen2006 E J –. BI621855
Beforestartingwork DBT-Shield1700/3500-2x4412-1750 1.6 DBTGmbH,Lünen2006 E BI621855
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.:7420163000BA00VLVL/01 2.3
DBTGmbH,Lünen2006 E residualrisk supplementaryregulations qualification BI621855
Repair
Ingeneral,repairworkshallbeperformedonlybypersonswho havetherespectiveknowledgeandskillstomeetthespecial requirementsandhavebeenadequatelytrainedintherepairofthe equipment.Repairworkonandoverhaulof
J safetydevices,ase.g.pressurereliefvalves
J hydraulicpropsandcylinders
J controlblocks,valves,andfilters shallbeperformedonlybyDBTservicetechniciansorbyspecially trainedpersonneloftheminingcompany.
Personnel DBT-Shield1700/3500-2x4412-1750 2.4
DBTGmbH,Lünen2006 E BI621855
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
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