CAT Bucyrus Shield support 1143/3048-2X4113-1750 Operating Manual

Translation of the original operating manual

Operating manual Shield support 1143/3048-2X4113-1750 Doc. No.: 7420 205 000 BA 00

Bucyrus Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

Translation of the original operating manual.

Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus assumes no liability for direct or indirect consequences of misprints.

We reserve the right to introduce modifications as a result of technical development without prior notice.

Bucyrus Europe GmbH, Lünen 2010E

Contents

Contents 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.4 1.4

2. Your safety 2.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 2.5

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

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Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.4

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Load units; dimensions and weights . . . . . . . . . . . . . . . . . .

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.8

4. Installation Pre-assembly of the shield units . . . . . . . . . . . . . . . . . .

4.3

How to install the shield units . . . . . . . . . . . . . . . . . . . .

4.3

Pressure equalization of the electronic control system . . .

Supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing a link between connections . . . . . . . . . . . . . .

4.5 4.6 4.10

Requirements for the face hydraulic system . . . . . . . 4.11 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 To be observed prior to startup . . . . . . . . . . . . . . . . . . . . . .

How to put the support into operation . . . . . . . . . . . . . . . . .

Corrosion protection of hydraulic components . . . . . . . . . .

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4.12 4.14 4.14

Contents 5. Operation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.6

Operation of the shield support . . . . . . . . . . . . . . . . . . .

5.9

Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.15 Arrangement of hydraulic components on the support . . .

Shield components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug with pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair and emergency operation . . . . . . . . . . . . . . . . . . . . .

Operation and functions of the electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15 5.23 5.33 5.35 5.37 5.40 5.41 5.42 5.42 5.42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

Fault localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/2-way or pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piloted check valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal bypass in props . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure relief valve defective . . . . . . . . . . . . . . . . . . . . . . .

Defective or blocked filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.43 5.43 5.46 5.46 5.47 5.47 5.47

6. Technical data Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Main subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base frame with lemniscatic links and relay bar assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, steel structure . . . . . . . . . . . . . . . . . . . . . . .

6.4 6.6 6.7 6.11 6.13 6.15 6.16

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R electronic control system . . . . . . . . . . . . . . . . . . .

Two-stage telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18 6.19 6.20

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Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular, scheduled damage assessment . . . . . . . . . . . . . .

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40

Contents Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinders . . . . . . . . . . . . . . . . . . .

6.22 6.23 6.23 6.24 6.25

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.29 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quality of the process water . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating greases and pastes . . . . . . . . . . . . . . . . . . . . . .

6.30 6.32 6.34

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.36

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7. For your information

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Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Referenced standards and directives . . . . . . . . . . . . . . . . .

7.3

Identification of the shield . . . . . . . . . . . . . . . . . . . . . . . .

7.5

Name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 7.6

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Contents

Shield support 1143/3048-2X4113-1750

1

About this manual

Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols and characters used in it.

Before starting work applicable operating manual

shield type

Using an operating manual that is not written for the shield support at hand can result in a safety hazard for yourself and others. Ensure that the data on the shield agrees with the data given in the operating manual.

This operating manual belongs to the: Shield support 1143/3048-2X4113-1750 * ID No.:

7420 205 000 00 01

and is only permitted to be used for shields of this type!

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The operating manual must be accessible at all times to all persons working on or with the shield.

There should, if possible, always be an operating manual for the shield available at the place of operation. new operating manual

Send for a new operating manual immediately if the present operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields.

All persons working on the face, at the edge of the face or at the entry must read this operating manual.

This includes persons who: J are in charge of transport, J prepare the rise heading, J perform assembly/disassembly work, J operate the shields, J correct malfunctions, J perform daily routine work on the face, J monitor/look after for the hydraulic system, J perform maintenance work, J perform repair work.

Supervisory personnel who: J initiate the activities named above and/or J supervise the activities named above.

* The shield support is referred to as the “shield” in the following text

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1.3

Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work economically and safely with our product. It contains important information on all the activities related to the shield support.

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our Service Department.

safety

Pay special attention to chapter 2, “Your safety”. This chapter contains important information indicating possible hazards.

Observe this information and follow the procedural instructions.

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

Notice!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are damage to the shield or damage in its immediate vicinity.

Important!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or hazardous situations.

J Items in lists are marked with bullets.

– Points in sub-lists are marked with a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

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Danger!

Points in the text marked with this symbol point out immediately impending danger. Possible consequences are very serious injury or even death.

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Try to memorize the symbols and their meanings.

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state-of-the-art technology

The shield support has been manufactured using state-of-the-art technology and in accordance with the generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations, e.g., as a result of environmental influences, machine damage or operator errors.

Do not make any modifications or carry out conversions which could impair the safety of the shield support. All modifications and conversions must be approved by Bucyrus.

Use only original spare parts from Bucyrus. Note that use of parts from other manufacturers will void the guarantee.

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In addition to this operating manual be sure to also observe the respective legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations of the following parties: J of the mine, J of the mines inspectorate and J of mining supervisory authorities. additional operating manuals

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

Personnel Operation The shield support may be operated only by trained personnel. training

The shield support may only be operated by qualified personnel who can provide proof of having been trained on the control system installed.

Reading of the operating manual, especially the chapter on safety, must constitute a part of this training.

They must possess and furnish proof of adequate familiarity with the J mechanical system, J hydraulic system and J control technology.

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2.3

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

Installation and repair work on: J safety components (pressure relief valves, extinguishers, etc.), J the electrical systems (control systems, signaling devices, etc.), J the hydraulic system.

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may only be carried out by Bucyrus service engineers or by specially trained personnel of the mining company.

2.4

Shield support 1143/3048-2X4113-1750

Operating conditions Operating conditions Intended use The shield has been designed and manufactured exclusively for use as a shield unit for longwalls.

Use the shield only as intended.

Intended uses are: J propping the roof against the mine floor, J ensuring an adequate travel way, J the following shield operations:

– lowering, – pulling up, – aligning, – setting, J the following conveyor operations:

– advancing, Bucyrus Europe GmbH, Lünen 2010

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– retracting, J forming a thrust bearing for:

– the conveyor and mining equipment, – conveyor steering devices, – devices for raising the conveyor, – conveyor steering cylinders.

Unauthorized use All uses which are not expressly included in the list of “intended uses” are considered to be unauthorized uses and are not permissible with the shield.

Unauthorized use includes: J pushing the shield rear into the caving area, J raising the conveyor by means of the hydraulic force of the

shield, J setting of the canopy in roof falls.

Further information about this can be found in the “Operation” section of this chapter and in chapter 5 in the “Operation of the shield support” section.

Bucyrus does not accept any liability for damage resulting from any such unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment.

Inform your colleagues of: J your exact location, J the work you are performing, J the time which you will probably require.

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and protective devices in a functional condition.

Observe the acoustic and visual start-up warnings. Pay special attention to the start-up warnings for the conveyor and for the mining equipment.

EMERGENCY STOP

support lock-out switch

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

- Only applies for version with the electrohydraulic shield control system: Actuate the support lockout switch (repair switch) before: J maintenance work, J inspection work, J repair work, J and during prolonged presence in the shield.

moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: J skids and relay bar assemblies, J canopies, J lemniscatic links, J side seals, J front cantilevers, J hydraulic props and cylinders, J steering devices.

automatic mode

2.6

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals sent by the control unit in the shield unit currently operated.

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signaling systems and safety equipment

Maintain the lighting systems in a functional condition.

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lighting system

Safety instructions Storage and transport For this purpose, thoroughly read chapter 3, “Storage and transport”.

Never stand under unsecured or suspended loads.

Observe the specified storage periods and the storage instructions.

Never store materials of any kind in the travel way or in your working area.

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

Inform the persons concerned about the intended transport route and the probable duration of the transport. transport safety device

Ensure that the transport safety devices have been correctly installed. In particular, ensure that the following are secured for transport: J side seals,

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J flippers, J relay bars (both face side and gob side). transporting

Connect the means of attachment only at the lifting points provided for the purpose. Observe the different load limits of the lifting points. Also observe the instructions for transport given on the spare part drawings which are included in the spare parts catalog.

Nonstandard transport units are shown in special figures which are added in the Appendix of the operating manual, if required.

Do not damage the polished surfaces of the cylinders and the props. Damage of this kind necessitates elaborate and expensive repair work.

For round components, such as cylinders and props, which are not provided with lifting points, only use transport straps. Never use chains or steel cables for this purpose.

Only use means of attachment which are in good condition and have been designed for the loads involved.

Firmly secure all components which might start moving on their own.

Observe the position of the center of gravity, especially during transport with floor conveying devices. The center of gravity must be as low as possible, in order to prevent tipping of the transport unit.

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2.7

Safety instructions Installation Only use appropriate loading equipment for the safe transfer of the transport units.

Prior to commencing any work on the shield, make sure that the shield is secured to prevent it from retracting automatically.

Mechanically secure the caving shield against involuntary lowering during: J installation of the props and cylinders, J installation of the canopies, J work on the open hydraulic system.

The shield can be secured, for instance, by placing hardwood wedges between the pairs of lemniscatic links.

Self-blocking hardwood wedges between the lemniscatic links stabilize the position of the caving shield

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Fig. 1:

transport safety device

If the shield is provided with movable side seals these are pretensioned by spring force! Therefore do not use force to remove the transport safety device of the side seals! Use the hydraulic control system to adjust the seal cylinders such that the locking pins either drop down or can be pulled out without the use of excessive force.

When removing the transport safety device of the flipper ensure that nobody is present in the swiveling area of the latter as the flipper may swing downward.

travel way

Make sure that the minimum dimensions specified for the travel way with the shield are maintained at all times. The minimum dimensions are: J width: 600 mm, J height: 400 mm.

Any devices added to the shield later, such as steering devices, must not reduce the minimum travel way. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travel way is maintained.

2.8

Shield support 1143/3048-2X4113-1750

Safety instructions Operation shield control

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the shield unit currently operated.

Check whether all protective devices are present on the shield and capable of functioning, see also chapter 6 “Technical data”.

You may only operate the shield control system if you have extensive knowledge of the control elements and their functions.

You must have been trained on the respective control and know the contents of the respective operating manual for that control.

You should not be in the same shield as the one you wish to operate. Always operate the shield only from a neighboring shield.

Make sure that no persons are present in the area of the shield being actuated.

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During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the support is being moved, and prevent any hazards by acting with caution.

Always set the shield until the full setting pressure has been reached, since good roof support can only be ensured in this manner.

Extend the flipper towards the coal face as far as possible to prevent coal or surrounding rock from falling into the travel way.

Clean the operating controls of the control units regularly. Ensure that the operating symbols are clearly recognizable This measure avoids operating errors and accidents which would result from this.

Keep the floor as clean as possible. Keep the mine floor free of debris. This way you will be able to extend the relay bar assembly without obstacles and to advance the conveyor without problems.

Ensure that the water spraying system responds during advancement. inclined faces

On an inclined face, the conveyor must be anchored neighboring to the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. And it reduces the risk of the relay bar assembly jamming between the skids.

Hydraulic anchorages must always be charged to the specified working pressure since only thus is a sufficient anchorage between support and conveyor ensured.

When advancing the shields, always observe the specified sequence of steps to prevent the shields from colliding with the anchorage cylinders.

On inclined faces, always advance the shields from the bottom to the top. Operate the shield to be advanced always from within the neighboring shield above. This reduces your risk of injury by falling rocks and also gives you a better view of the advancing operation.

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2.9

Safety instructions shield alignment

The shields must be aligned at right angles with respect to the conveyor and parallel with respect to each other. Use the aligning devices or the side seals for aligning the shields.

Align the shields as early as possible. Use the aligning devices or the side seals for aligning the shields.

Early alignment prevents: J getting under the canopy of the neighboring shield, J canting of the shields, J slipping of the shields, J delays in supporting the newly mined roof.

roof falls

Prevent roof falls by supporting the newly mined roof as early as possible.

Never set the tip of the canopy into a roof fall so that J the maximum admissible angle of inclination of the canopy is

exceeded, J the stabilizing cylinder locks, J the canopy will be loaded excessively in the longitudinal direc-

as this may cause damage due to excessive stress and strain on the components.

During the temporary support of a roof fall, ensure that the sloping canopy does not get in the way of passing mining equipment. residual stroke

retracting the conveyor

Ensure that sufficient residual stroke is still present in the props as the seam height decreases. This prevents the shields from jamming between the roof and floor.

If possible, pull the conveyor back by operating the respective functions of the electronic shield control system. If this isn't possible, do as specified in the applicable work instructions of the mine.

Secure all mining equipment against unauthorized starting.

Isolate your working area so that no unauthorized persons may enter this area.

Check to determine whether the shields are set sufficiently tightly between the roof and floor.

raising the conveyor

Secure your working area against falling rock. This measure is especially important if the conveyor must be lifted on the coal face side.

Only use the points of attachment intended for that purpose.

Never attach loads to hydraulic cylinders or to their points of attachment.

Reset all shields in the area where the conveyor is to be raised.

Check the setting pressure again. Do not under any circumstances loosen the canopy from the roof; it must be in place the entire length.

If you raise the conveyor in the area of several shields, the shields to which lifting tackle is attached must not be located next to one another.

2.10

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tion,

Safety instructions For raising the conveyor, use only: J high-strength, undamaged chain slings, J the lifting points provided for the purpose.

Check that the lifting points are undamaged before attaching the load.

J lifting tackle of adequate load-carrying capacity.

Maintenance Make sure that all safety and protective equipment of the shield units is complete and functional. If the safety and protective equipment is included in the Bucyrus scope of delivery, refer to chapter 6, “Technical data”, for its location.

Be sure to observe the intervals specified for maintenance and inspection. See chapter 5, section “Maintenance”.

Check the shield at least once every shift for externally visible damage.

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Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its probable duration.

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Secure your working area over a wide range, in order to avoid endangering other persons.

Immediately replace damaged components affecting safety. Stop and lockout the respective shield immediately if component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible foreman without delay.

Use only spare parts which conform to the specified technical requirements. This is best ensured by using original Bucyrus spare parts.

Please refer to the spare parts catalog provided for the equipment for the order nos. for the required spare parts.

Do not make modifications or carry out conversions which might impair the safety of the shield. Bucyrus must be informed of all conversions and modifications to check whether they have any effect on the approval or whether it is necessary to apply for a revised approval.

Any modifications carried out without authorization invalidate the Bucyrus declaration of conformity and a new conformity test will be required.

During work on the relay bar assembly, isolate the working area for the mining equipment.

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2.11

Safety instructions You may only carry out work in the mining area if J the roof has been secured against falling rock, J the coal face has been secured against collapsing and J the mining equipment and conveyor have been shut down and

secured against restarting or if you have otherwise ensured that the continuation of the mining work does not affect the safe performance of the repair work.

Before disconnecting the shield from the conveyor, you must: J arrange that the mining operation is either stopped completely

or is done outside the required safety area, J relieve the load on the components which are under hydraulic

pressure or mechanical stress.

Immediately discontinue any work on the shield if conveying and crushing operations are in progress in your working area.

The support must be mechanically secured for all work where there is a danger of the support retracting automatically.

Hydraulic system handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids pose a very serious danger to health.

protective devices hydraulic system

Note that when dismantling protective devices that include hydraulic components, those components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. It is therefore imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repair

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

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace any defective protective caps without delay.

Carry out a visual inspection on all the hydraulic components at regular intervals. Check, in particular, that: J the hoses are not pinched, J the hoses have no bubbles or blisters, J the hoses or the outer sheaths of the hoses are not abnormally-

rigid or hard, J the outer sheath of the hose is not damaged, J the connectors are securely inserted into the coupling sockets, J the connections are leak-tight.

Make sure no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage to the whole system. Flush the hydraulic lines thoroughly before installing them.

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Bucyrus Europe GmbH, Lünen 2010

Immediately after completion of work, reinstall any protective plates or similar items which have been removed, and check them for correct function.

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On inclined faces secure the components to be replaced against slipping by using chains or lifting tackle, for example.

Safety instructions Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the connector to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Make sure the line is depressurized.

Secure the plug connectors of the hydraulic elements with the proper staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials to secure the connectors.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn O-rings.

Replace hydraulic hoses only with hydraulic hoses of the same or higher quality.

Observe the date of manufacture stamped on the hose fitting of the hydraulic hose. Never use hydraulic hoses which are more than 2 years old, even if they show no visible signs of damage.

Example hydraulic hose, identification

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Fig. 2: Bucyrus Europe GmbH, Lünen 2010

2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

Never try to hold a hydraulic hose that is thrashing about. Immediately depressurize the section in concern.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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Safety instructions laying hydraulic hoses

Lay the hydraulic hoses correctly behind the brackets and clips provided for them.

Always lay hydraulic hoses so that they: J always are a little slack, Fig. 3:

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying a hydraulic hose, twisted RIGHT

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter) Fig. 5:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

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Laying hydraulic hoses, crossing RIGHT

WRONG

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WRONG

Safety instructions J are not kinked, J do not have to withstand tensile loads, J are protected against thermal radiation, J are accessible at all times.

Only push hydraulic hoses into the sockets by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, make sure they cannot be: J torn out, J kinked, J crushed, J driven over, J twisted (Fig.: 7).

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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Safety instructions

2.16

Shield support 1143/3048-2X4113-1750

3

Storage and transport

Storage

Storage and transport This chapter contains important information on correct storage and secure transport of the shields.

Following the instructions and the manuals will increase the service life of the shield. You will be able to carry out transport work more safely and quickly.

Paying careful attention to the points in this chapter will also help you to simplify your day-to-day work.

Storage Storage of the equipment Components with temporary anticorrosion protection are protected for about six months.

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, spare parts made out of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15°C to 25°C.

moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, for example with tarpaulins.

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corrosion protection

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs. short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage have prevented damage.

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hoses are subject to natural aging. Do not use these components if they have been stored for more than two years.

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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Storage Storing used equipment The points listed above, with the exception of the one concerning anticorrosion protection, can be applied analogously for the storage of hydraulic components that have already been in use. corrosion protection

If the hydraulic system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor (e.g. HYDROCOR® CV 50*). If this is not done, then the hydraulics components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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Water-bearing parts, such as the parts for the water spraying system of a shield, must be completely emptied, and possibly also filled with an antifreeze fluid if required.

*

3.4

HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

Shield support 1143/3048-2X4113-1750

Transport Transport Load units; dimensions and weights It is imperative that you observe the transport sheet. It includes information on: J dimensions, J weight, J lifting points and J centers of gravity.

The load units are provided with suitable lifting points for transport and installation as far as technically possible.

Warning!

Use only load handling devices which comply with the technical and legal regulations for transporting loads.

Falling components can cause serious injury and death.

Use only suitable load handling devices.

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Before transport freezing temperature

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with by emulsion (HFAE and HFAS) must be completely drained and filled with a corrosion inhibitor (e.g. CV 50).

It is only permitted to transport equipment at temperatures of –21°C to –40°C if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum 25 km/h for truck transport.

electrical and electronic components

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Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors or outdoor storage of the equipment during winter unless these components or the entire equipment is protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully against transport damage and the connectors must be protected against dirt.

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3.5

Transport transport units

A shield unit can be transported as a completely assembled unit or broken down into subassemblies. If it is necessary to disassemble it into transport units, this is planned and agreed upon in close cooperation with the customer.

Tab. 1: Transport units

transport safety devices

Designation

Transport position

Complete shield unit

As for normal use

Remarks

For the purpose of safe transport, the movable parts of every transport unit are to be fastened in addition to the standard available transport safety devices, e.g. on side seals and flipper, so that their positions cannot shift inadvertently. Specifically, the following listed transport safety devices are provided on the transport units.

Tab. 2: Transport safety devices Component

Transport safety device

Quantity

Transport rod

1

Gob side

Chain

1

Unused hydraulic connections are protected by protective caps or plugs

-

Hydraulic system

Caution!

Transport safety devices may get damaged during transport to the mine, for example when loading and unloading the transport units. Therefore, check all transport safety devices for damage and replace damaged ones before allowing the units to be transported into the mine shaft.

Damaged transport safety devices may be the cause of serious damage to the transport unit or to the transport shaft if load units are transported suspended under the cage with damaged or inadequate transport safety devices.

Caution!

If the assembled shield unit is to be transported, then the canopy and skid must first be mechanically connected to each other using an additional transport safety device so that they cannot move apart. A wooden block is to be placed between the rear lemniscatic link and the caving shield in order to ensure that the transport height is attained.

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Face side

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Relay bar

Transport Fig. 8:

Transporting the shield support as a complete unit So H

Sy

Z X1 Sx L

S1 S2 890

900

S3

4740

S3

S2

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S1

View Z B

S1 load ring, 2 x on the face side in the skid, capacity: 8000 kg S2 load ring, 2 x gobside on the caving shield, capacity: 8000 kg S3 transport hole, capacity 15,000 kg 1610

X1 transport safety device for relay bar, face side So center of gravity

Important!

For transporting, use the two lifting points S1 and S2.

Tab. 3: Type specification for shield support 1143/3048-2X4113-1750 Device number Prop, prop force Year of Application manufacturing 7420 205 000 00 01 2 x 4113 kN

2010

Segment shield

7420 205 000 00 02 2 x 4113 kN

2010

Segment end shield

Tab. 4: Shield support 7420 205 000 00 01 and 7420 205 000 00 02 Dimensions and weight Length L in mm

Width W in mm

Height H in mm

Sx/Sy retracted

Sx/Sy extended in mm

Weight in kg

7420 205 000 00 01

8164

1700

1143

1588/655

1538/1593

23 685

7420 205 000 00 02

7389

1700

1143

1588/655

1538/1593

23 155

Device number

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in mm

3.7

Transport Transport safety devices Relay bar assembly Transport safety device, relay bar assembly, face side

141 transport rod

142 spring clip 6

Fig. 10: Relay bar assembly, gobside

146

147 148

71

71 caving flap 146 chain 6x42

3.8

147 hex. nut M 12-8 148 hex. head screw M 12x40-8.8

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142

141

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Fig. 9:

Transport Load hook on skid Caution!

When in transport position (shield retracted completely), the PMC®R can collide with the load hook on the skid. The load hook must therefore be folded forwards during transport.

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Fig. 11: Load hook on skid, face side for transport

a

a Load hook

Hose connections When the shield unit is supplied, the connections for the supply lines are bypassed using the hose lines. These are then later used for connecting to the neighboring shield.

Fig. 12: Transport safety device, hose connections

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Transport

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4

Installation

Pre-assembly of the shield units

Installation In this chapter, you will get information about installing the shield units. Please pay special attention to the warnings and tips.

Warning!

In addition to the safety instructions given in this manual, also make sure you observe the special safety instructions and operation instructions which apply to the operation of the mine.

Failure to do so can lead to extremely serious accidents which may be fatal.

Caution!

Before the hydraulic connections are made, the sockets and nipples of the plug-in connections must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, section “Lubricating greases and pastes”.

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Caution!

Before the transport units of the steel structure are connected with one another, all of the slide surfaces must be treated with the molybdenum disulfide-free B6 lubricating paste in accordance with EWN 70681). See chapter 6, section “Lubricating greases and pastes”.

Pre-assembly of the shield units The shield units are delivered completely preassembled. Accordingly, no further pre-assembly is required on the mechanics and hydraulics of the shield units.

How to install the shield units Caution!

For underground transportation, only those lifting points may be used which are described in detail in chapter 3 “Transport”.

Failure to comply can lead to personal injury and property damage.

Further information about this can be found in chapter 3 “Transport”. installation plan

The shield units are installed in the face according to the installation plan of the mine.

Important!

When installing the shields in the face, be sure to pay attention to the shield numbers. Since some shield units may be provided with different functions, their setup on the longwall is not arbitrary!

identification for installation in the face

In order to identify the shield units or their transport units more easily for the purpose of assembling and installing in the face, they should be labeled with a sequential number. The number should correspond to the order in which the shield units are to be arranged in the face, for example. The numbers should be written in color so that they are clearly visible on the surface of the parts.

1) EWN = works standard

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How to install the shield units Shield number

The shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the left-hand skid on the shield.

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Fig. 13: Shield number on the skid, example

Tab. 5: Allocation of the shield numbers Shield number G1 to G6

4.4

Device number

Use

7420 205 000 00 01

Segment shield

7420 205 000 00 02

Segment end shield

Shield support 1143/3048-2X4113-1750

How to install the shield units Pressure equalization of the electronic control system The shield units can be utilized in a number of different height positions at various prevailing air pressure levels.

These are equipped with a vent screw in order to enable pressure equalization between the internal and external pressure of the electronic control system housing.

. Release the vent screw (hex. socket 4 mm) on the control system with several rotations.

Pressure equalization is signaled by an audible hissing.

Caution!

Make sure that the vent screw for pressure equalization on the control system is released. The foil displays may become damaged if no pressure equalization is established.

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Fig. 14: Example of a vent screw on an electronic control system

a

b a vent screw

b electronic control unit PMC®-R

. Afterwards, rotate the vent screw until it is once again handtight.

Caution!

Take care to ensure that the vent screw is made hand-tight again after pressure equalization at the control system. If this is not done, then dirt and moisture could penetrate the control unit and firedamp protection is no longer ensured.

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How to install the shield units Supply connections During installation, pressure can be applied to the individual shield using the so-called auxiliary supply, allowing the shield to be operated.

The shield is equipped with an auxiliary supply on the supply block.

The auxiliary supply must be connected to connections a and b (Fig. 15).

Fig. 15: View of the auxiliary connection, not connected 34

b

7

7 supply block 34 HP ball valve DN 25, in the pressure supply line 35 HP ball valve DN 12 for auxiliary supply

a

a pressure line of auxiliary supply b return line of auxiliary supply (behind the pressure gauge) c plug on chain for auxiliary supply

Notice!

The auxiliary supplies a and b must be sealed with plugs c during normal operation.

For operating the shield with the help of the auxiliary supply, the shield functions must be activated via an additional external PMC®-R control unit. This is connected to the internal PMC®-R control unit via a corresponding cable (see separate operating manual for the PMC®-R control unit).

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35

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c

How to install the shield units The connections for the auxiliary supply are on the supply block (see Fig. 16 and the hydraulic diagram, Fig. 28, in chapter 5).

Fig. 16: Supply block plug-in socket DN12 plug-in socket DN40SS P

plug-in socket DN20 T

P T

plug-in socket DN50

T

W

plug-in socket DN10

P plug-in socket DN25

T W

plug-in socket DN32

plug-in socket DN25 plug-in socket DN20 P pressure line, 40SS R return line, DN 50

W water line, DN 32

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For utilization of the auxiliary supply, the connections P, R and W (see Fig. 17) on the supply block must with blocked with the hoses that will later be responsible for the connection with the neighboring shield (this corresponds as a rule to the status at the time of delivery).

If the supply hoses cannot be connected up in this way, then the connections must be sealed with corresponding plugs.

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How to install the shield units Proceed as follows to join the shields to one another:

. Close the HP ball valves, Item 35 and Item 34 (see Fig. 17). . Remove the plugs c from connections a and b (see Fig. 17) of the auxiliary supply.

. Connect the auxiliary supply to the pressure and return line of the pump.

Fig. 17: View of the auxiliary connection, connected 34

A

35

7 a W

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P

c

R

View A a

b

16 7 supply block 16 plug 34 HP ball valve DN 25, in the pressure supply line 35 HP ball valve DN 12 for auxiliary supply P pressure line, DN 40SS

W water line, DN 32 R return line, DN 50 a pressure line of auxiliary supply b return line of auxiliary supply (behind the pressure gauge) c plug on chain for auxiliary supply a pressure relief valve

. Afterwards, reopen the HP ball valves - Items 35 and 34.

Make sure that the HP ball valves (Item 32) are also open on the prop control valves (see chapter 5, Fig. 40).

The shield is now movable via the external control units.

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Shield support 1143/3048-2X4113-1750

How to install the shield units . Move the shield to the desired position. . To relieve the pressure hose, short-circuit the HP ball valve, Item 35 and activate the function “Advance conveyor” briefly until the pressure hose is relieved (support is not yet connected to the conveyor).

Warning!

Pressure may build up in the return line due to incorrect operation. This must be relieved via the pressure release valve (Fig. 17, Item 16) by screwing in the vented cap screw (a).

After relieving the pressure, this screw must be screwed all the way out again.

Make sure that all hose lines are depressurized before you release the connection lines on the distributor block.

See also chap. 5, section “Plug with pressure relief”, Fig. 45.

. Relieve the connections of the auxiliary supply. . Disconnect the connection lines of the auxiliary supply and seal the connections with the plugs.

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. Release the W connection line on the distributor block and con-

Bucyrus Europe GmbH, Lünen 2010

nect it and the P and R connection lines to the neighboring shield.

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How to install the shield units Establishing a link between connections The hydraulic connections on the shield units are designed as plug connections in accordance with DIN 20043, which is standard for German mining. hydraulic system

The supply block for supplying the shield hydraulics is located on the two front lemniscatic links. The connection to the supply block of the neighboring support is made using three hose lines: one pressure line (DN 40SS), one return line (DN 50), and one water line (DN 32); see also the hydraulic circuit diagrams in chapter 6 of this manual.

control unit

The shield units are equipped with a Type PMC®-R electronic control system. The control unit and the electrohydraulic control unit are connected via a solenoid driver module. The connecting cables required for this are included in the delivery of the PMC®-R control.

The shield units are designed to accommodate the installation of additional equipment which is not included in the Bucyrus scope of delivery. For example: J lighting system, J two-way intercom system.

The information required for the installation of additional equipment can be found in the corresponding operating manual from the respective manufacturer.

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additional equipment

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For more details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control. An overview of the design of the control is also given in chapter 6 of this operating manual in the section “Shield control system”.

Requirements for the face hydraulic system Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulics components included in the Bucyrus scope of delivery: Contamination Class 18/14 pursuant to ISO 4406.

Pressure fluids in accordance with the section “Permissible media” in chapter 6 of this operating manual.

permissible pressure

Nominal pressure:

320 bar

Tolerance range:

¦ 10% of nominal pressure

If the face hydraulic system is designed such that it is unstable or too weak, there could be a temporary pressure drop during operation.

In the event that the pressure falls to 180 bar or less, there is a risk of malfunctions occurring in the electrohydraulic control system.

Valve functions might not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

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Caution!

If there is a pressure drop, dangerous situations may arise, leading to accidents involving damage to property and/or injuries to personnel.

Make sure that the system pressure can never fall below 180 bar anywhere in the face hydraulic system.

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4.11

Commissioning Commissioning Warning!

The initial start-up and the test run may only be carried out by a well-trained and experienced crew familiar with the special conditions in underground mining, especially with the safety requirements. The crew must be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

Notice!

Make sure that all of the transport safety devices required for transport have been removed; see also chapter 3, section “Transport”.

To be observed prior to startup Commissioning may only be carried out by trained and qualified personnel. If the support is being used for the first time, it is absolutely imperative that the commissioning be carried out under the direction of the Bucyrus installation service.

Please observe the following items:

. Make sure that all transport safety devices have been removed.

. Remove all plugs from the hydraulic connections of the props and/or hydraulic cylinders. Install the props and/or hydraulic cylinders in accordance with the hydraulic circuit diagram in chapter 5.

. Check whether the plugs in the annular space connection of the props have been removed.

. Position the symbol bar on the bracket of the electrohydraulic control unit so that the symbols are clearly legible.

. Check all mechanical connections on the shield units. . Check the plug-in connections on the relay bar assembly.

When the relay bar assembly is designed with a plug-in crawl pan, it must be made sure that it is plugged in correctly. Under no circumstances may the crawl pan be plugged in for normal operation in the “lowering position” 1)

. Make sure that the additional device is mounted and secured on the skids.

1) Maximum possible plugging

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J Mechanical:

Commissioning J Hydraulic system:

. Check the entire hydraulic system for leaks. Seal any leaky connections immediately.

. Especially check whether hinges and hoses can be damaged due to movements of the support.

Danger!

Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others could be seriously injured or even killed.

Make sure that hydraulic hoses cannot be damaged by movements of the support.

Lay the hydraulic hoses correctly behind the brackets provided for them.

. Check the hydraulic supply pressure. . Check the load-carrying function of the props. The current

Bucyrus Europe GmbH, Lünen 2010

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pressure under the piston of a prop can be queried on the PMC®-R control unit. Here, you can query the pressure for a neighboring support or the support in which you are currently located. The pressure gauge on the prop control valve of the prop indicates the pressure directly.

. Check all operating elements to make sure they are working properly. Test whether the function is correctly executed when the corresponding operating element is activated.

J Signaling and lighting systems, information plates

. Check all signaling devices.

Important!

For further information, please see the corresponding separate operating manual of the respective manufacturer.

. Make sure that the face lighting is sufficient. . Check whether the face area, especially the travel way, is sufficiently marked with signs. It is imperative that you observe the regulations of the responsible mines inspectorate.

J EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems are functioning properly.

J Mining and conveying:

. Before commissioning, check all functions of the face system. . Test to make sure the entire face system (mining equipment, conveying system, supports) is working together perfectly.

Warning!

Bent support canopies may not project into the mining area.

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Commissioning How to put the support into operation Move the shield units to their original positions, i.e.: J shields and conveyors are aligned in a straight line, J the shields are aligned at right angles to the conveyor, J the shield canopies are aligned parallel to the floor.

Check the support for any installation errors or other sources of error:

. Check all line connections made during the installation of the shields, especially all supply lines of the shield hydraulics, for completeness and correctness.

face.

. Check all functions of the shield control unit.

Do not allow the support to be operated until all deficiencies have been eliminated and the support has been found to be in perfect working order.

Corrosion protection of hydraulic components The Bucyrus hydraulic components are tested before delivery with an anticorrosion medium.

No special provisions need to be made with respect to anticorrosion protection at the time of initial installation of the components because the testing and anticorrosion medium used is completely compatible with the released operating media of the HFA Group; see section “Permissible media” in chapter 6 of this operating manual.

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. Check the function of the hydraulic and water supply for the

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Warning!

Shut-off valves must not be installed into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in persons being seriously injured or even killed.

5

Operation

Requirements

Operation This chapter provides general information on the operation and maintenance of the shields. This information is to be regarded as preparation for or addition to hands-on training. It is recommended that you read this chapter as a supplement to the training, but this in no way releases the operator from participating in the training.

Danger!

You are only allowed to operate the shield control system if you have extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control and have consolidated your knowledge during a corresponding hands-on training session.

Should this not be the case, you are not allowed to operate the control system! Inform your superior immediately and request the required training.

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Warning!

Ignoring the safety regulations will cause accidents and may result in serious bodily injuries or death.

The regulations concerning the safe operation of your mine must be strictly followed. Apply the following instructions in addition to and in accordance with the individual safety regulations of the mine.

Requirements Operating conditions face crew

face equipment

The face crew must be informed about possible hazards. The safety measures to be taken must be laid down in writing and must be made known to the face crew.

The face must be sufficiently illuminated.

To warn the face crew and for crew communication, intercommunication systems must be provided.

travel way

The minimum dimensions for the travel way specified must be maintained at all times.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travel way: Width:

600 mm

Height: 400 mm If the support is used in countries other than the Federal Republic of Germany, the respective regulations applicable in those countries must be observed.

Debris or objects lying in the travel way must be removed immediately. This applies particularly for low seam heights.

If variable-length crawl pans are used, care has to be taken that a safe travel way of adequate width is maintained.

If the height of the travel way is restricted by the use of additional equipment, e.g. for conveyor steering devices, care has to be taken that a safe travel way of adequate height is maintained.

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5.3

Requirements If the area behind the front props is to be used as a travel way, e.g. in cases of thick seams, in the presence of steeply inclined faces or if the shield support can be advanced up to the conveyor, then travel way must be marked at the ends of a longwall by a sign. roof support work

Roof support work must be carried out so that the filling section of the face conveyor remains unobstructed. This means that the shield canopies of the shield units must be set against the roof immediately after the shield unit has been lowered and advanced.

work in the mining area

Work in the mining area must not be carried out unless the mining equipment and the face conveyor have first been locked-out and secured to prevent restarting. Work in the mining area may only be carried out from a safe position.

The conveyor and the space above the conveyor may only be entered if the roof has been secured against falling rock.

In thick seams, the coal face must also be protected against collapsing in these places. On faces equipped with shield supports, this is best done by using flippers.

Work which has to be performed in the immediate vicinity of the face conveyor at or above the spill plates may also only be carried out after the place of work has been secured against falling rock and coal layers.

With inclined faces, additional barricades, such as air cushions, must be set up above the work area in the conveyor to protect against the following material. The design and amount of required safety equipment depends on the local conditions. repair work

Before you start work on the hydraulic system, you must always first make sure that the respective section of the system has been depressurized. Also, take appropriate measures to prevent the pressure from being reactivated by unauthorized personnel.

If the shield units are to be detached from the conveyor, mining must either be completely stopped or it must be otherwise ensured that mining can be continued only outside of the safety zone required for safely carrying out repair work.

Parts which are under mechanical or hydraulic pretension must be relieved before they can be released or dismantled. The pretension can be relieved, for example, by aligning, lifting, or lowering.

If, in exceptional cases, the pretension cannot be relieved completely, it must be reduced as far as possible, and the respective part must be secured by suitable means, such as chains or locking elements, so that the tension can be safely absorbed as it is released. All work in this area may only be carried out from a safe position.

Safety equipment increases security and may only be removed if it is required for carrying out work. The safety equipment should be reinstalled immediately following completion of the work.

5.4

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

If flippers are not used, some other kind of protection must be applied to shield the mining area from the rest of the face, e.g. extrahigh spill plates, wire mesh, nets or the like.

E

Care must be taken that the flippers are always extended towards the coal face far enough to achieve the desired protection. This does not apply during shield unit advancing.

Requirements water spraying system

The water spraying system serves to actively counteract dust.

Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily, depending on the operating state of the system, for example, when pushing the shield and when the mining equipment passes the support. The spraying valves are controlled by the program of the electronic shield control system or directly by means of the hydraulic shield control system.

conveyor steering device

On inclined faces it may be necessary to anchor the conveyor with respect to the support. This way, you can prevent the conveyor from shifting to the side with respect to the support. This allows you to reduce the risk that the relay bar assembly will get stuck in the base frame.

The intended working pressure must always be applied to the hydraulic conveyor steering device. This is the only way to guarantee that there will be sufficient bracing between the support and conveyor.

Bucyrus Europe GmbH, Lünen 2010

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When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering device can be damaged and become unfit for use.

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5.5

Requirements Safety requirements automatic mode

Exercise special care and caution when traveling a face that is working in automatic mode. Make sure you observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be aware that the shield which you are in is controlled by the automatic system. For this reason, make sure you observe the acoustic and visual warnings from the electronic control system of the currently controlled shield.

Press the “Support lockout” switch if you have to be in the shield for a longer period of time.

operating the shield unit

The shield unit must always be operated from a safe position and from a neighboring shield unit.

Never stand in a shield unit which has not been set.

Never allow body parts to get between the canopy and the roof, skid and the floor, the skid and relay bar assembly or between the side seals of neighboring shield units.

No one may be in a shield unit while it is being advanced.

You may not lower or advance a shield unit if there is any person in the vicinity of the shield unit or in the shield unit.

You may not lower or advance a shield unit manually if the mining equipment is directly in front of or in the range of action of the support!

Advancing should be started in the lower section in the case of inclined faces. The neighboring control offers the operator in the above-lying shield unit protection and allows the shield unit being pulled up to be monitored.

The props of the shield units must always be set until the setting pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as abutments for conveyor steering devices.

The supports must be advanced as soon as possible to prevent the potential danger of roof falls.

5.6

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

E

During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the support is being moved, and prevent any hazards by acting with caution.

Requirements Fig. 18: W r o n g, support advanced too late

Bucyrus Europe GmbH, Lünen 2010

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Fig. 19: R i g h t, support advanced in time

When taking down a step in the roof, a shield canopy which is angled downwards must not get in the way of mining equipment passing by.

Before a shield unit can be pulled up, the flipper must be completely folded in. Under no circumstances may the support be advanced against the coal face with the flipper extended. Failure to observe this can lead to serious damage, especially to the flipper cylinders and the flipper suspension.

When advancing the support, make sure that the shield canopy does not get under the side seal of a neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged. control, hydraulic system

Take care to avoid incorrect operation of the shield control system.

The symbol plates on the control units indicate the functions of the shield control system. They should be legible at all times and may not be removed or damaged.

Hoses must remain free to move. They may not be squeezed or overstretched. Make sure the hose lines are bundled properly.

Damaged hydraulic hoses and hose connections must be replaced immediately. This work may only be carried out by skilled personnel.

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5.7

Requirements The shield canopy and caving shield must be mechanically secured against falling when replacing hose lines between piloted check valves and props or other hydraulic props lying in the flow of force, such as stabilizing cylinders or adjusting cylinders. Analogously, this also applies for work on the hinges of the shield unit.

Shut-off valves may not be installed in the return lines.

To make sure the return lines can't be clamped shut, safety valves must be installed in the return line (see hydraulic layout, if prepared

by Bucyrus). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line.

The valves should be set to 25 bar sprayed in the atmosphere. damage, spare parts

Special incidents, especially any found deficiencies and damage, must be reported immediately.

Bucyrus Europe GmbH, Lünen 2010

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Machine and hydraulic parts may only be replaced with original parts.

5.8

Shield support 1143/3048-2X4113-1750

Operation of the shield support Operation of the shield support Well-trained operating personnel, knowledge and compliance with the safety regulations, as well as the operating instructions listed below largely prevent dangerous situations from arising, and are good preconditions for the fail-safe interaction of the support and mining within the face system.

If the support is equipped with an electrohydraulic control unit, it is imperative that the operator be familiar with the separate operating manual for this control system.

The shield units must always be set until the setting pressure has been reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as abutments for anchoring devices.

In general, the supports should be advanced to support the exposed roof surface as quickly as possible.

The shield units must be aligned at right angles to the conveyor.

Bucyrus Europe GmbH, Lünen 2010

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shield canopy position

The shield units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible. Within the framework of the maximum inclination and swivel angles specified on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

Caution!

Never exceed the permissible angle of inclination of the canopy!

Exceeding the permissible angle of inclination of the canopy specified in the “Technical data” section of chapter 6 can lead to the support becoming damaged. This especially applies for stabilizing cylinders for which the fastening elements and fulcrum points are on the shield canopy and the caving shield.

Fig. 20: Shield support in normal position

α=0 M

M = height of the set shield support α = angle of inclination of the canopy

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5.9

Operation of the shield support Caution!

Never extend or retract the stabilizing cylinders of the shield support completely!

Stabilizing cylinders must always have sufficient residual stroke!

Guide value: at least 20 mm!

The same applies to the adjusting cylinder of the front cantilever.

This is the only way that any potential, suddenly occurring load surges can be “cushioned” by the hydraulic safeguard of the stabilizing cylinders.

If there is not sufficient residual stroke available, this could result in serious damage to the support under unfavorable conditions - high force and unfavorable lever ratio.

Fig. 21: Shield support with extremely inclined shield canopy.

α1

s1

s2 α2 M

M = height of the set shield support α = angle of inclination of the canopy s = residual stroke of the stabilizing cylinder

Caution!

Ensure that the stabilizing cylinder has sufficient residual stroke when there is a tendency toward roof falls and/or an extremely soft mine floor!

This is especially true if the shield control system is equipped with an automatic positive setting function. Then there is a danger that under unfavorable conditions, for example a soft floor and possibly an additional inclination toward roof falls, the automatic positive setting function could lead to the stabilizing cylinders not having enough residual stroke or that they even are completely extended.

Therefore, in such or similar cases, move the support without automatic positive setting.

5.10

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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M

Operation of the shield support Caution!

Keep the canopy from being excessively inclined by filling out the roof falls, for example, or by underpinning smaller roof falls with a horizontally positioned shield.

At this point, we again explicitly emphasize that any damage caused by not complying with these instructions is not covered by the warranty.

Caution!

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield), specified in chapter 6, section “Technical data” of this manual, is exceeded, this could lead to damage to props, hydraulic props and their fastening elements, as well as to the part hinges.

Since angle changes in the ends of the shield canopies or skid ends involve major height changes, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the mine floor and roof, or fill roof falls.

Bucyrus Europe GmbH, Lünen 2010

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Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in falls (see Fig. 22), when the stabilizing cylinder is completely extended. There must always be enough residual stroke available so that dynamic loads from the roof can be absorbed by the hydraulically secured stabilizing cylinder.

Fig. 22: W r o n g: do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended.

WRONG

Roof falls can be overcome by filling them (see Fig. 23) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

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5.11

Operation of the shield support Fig. 23: R i g h t: fill out roof falls

RIGHT

support range of adjustment/ changing face thickness

The retracted height of the shield units must be suitable for the lowest seam height.

The support must be operated so that there is always sufficient residual stroke remaining for lowering the shield unit. Otherwise, the shield unit can get stuck between the roof and floor and be seriously damaged by suddenly occurring load surges, caused by a rock burst, for example. Load surges cannot be hydraulically cushioned if there is not sufficient hydraulic fluid under the piston of the prop or if it is already in the lower end position.

The minimum residual stroke required for lowering the shield unit can be maintained by: J keeping the longwall opening sufficiently large using the mining

equipment, J avoiding the accumulation of debris and fine coal on the floor, J removing accumulated piles of rock on the shield canopies.

Before advancing a shield unit, the floor should be free of rough debris so that the entire forward movement can be done without obstacles and the subsequent return operation is not hindered for the conveyor. Also, aligning operations can be carried out more easily.

If the seam height increases considerably and the hydraulic stroke is not sufficient, the props must be extended in time or replaced by props with greater stroke. Here, only approved parts can be used.

When the props are extended or shortened, the shield canopy must be securely supported. Before a prop can be lowered for the purpose of dismantling, it must be secured against tipping over.

5.12

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

Accumulation on the shield canopy can be avoided by grinding while advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy.

E

When underpinning a step in the roof, ensure that a shield canopy angled downward doesn't get in the way of the mining equipment passing by.

Operation of the shield support operating on inclines

Especially when operating on inclines, the shield units must be prevented from slipping and jamming by correcting their alignment in time by using side seals and aligning devices. This prevents a shield canopy from underpinning its neighboring unit, often causing considerable damage.

Since, in operations where there are inclines, the shield unit advance usually begins in the lower-lying part of the face, it is important that the face end shields are well-aligned. Usually, hydraulic end supports, as well as alignment devices are used on the shield canopies and base frames or between the base frames and shield canopies.

Automatic controls can be used for the side seals which prevent a lowered shield unit from tipping over during the advancing operation. Other aligning operations which might be necessary are only possible using manual control, however.

The side seal of the caving shield must only be used for aligning with respect to the neighboring shield when that shield has been aligned to the same extent.

Bucyrus Europe GmbH, Lünen 2010

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On an inclined face, the conveyor must be anchored with respect to the support. This way, you can prevent the conveyor from shifting to the side with respect to the support. This way you lessen the danger of jamming the relay bar assembly in the base frame, which would hinder pulling up and advancing the shield.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering device can be damaged and become unfit for use. Further information can be found in chapter 6, in the “Accessories” section, or in the operating manual for the conveyor steering device. unfavorable floor conditions

In the case of unfavorable floor conditions, the base frame of the shield unit can sink into the floor. Then the base frame must be lifted when the shield is pulled up so that the system follows the course of the seam and does not sink into the floor.

For shield units which are equipped with a special hydraulic lifting device, it is lifted out by actuating a valve, or automatically during advancing.

For shield units without a lifting device, the procedure is different, depending on the design model: J Individual skids on two-prop shields can usually be lifted hy-

draulically by actively lowering a prop.

J Shield units with undivided base frames must be lifted and sup-

ported using standard mining methods.

Important!

Familiarity with the circuit diagram and skilled personnel are required for both procedures. Make sure that you observe the safety regulations under all circumstances.

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5.13

Work safety Work safety For the purpose of safe operation, the supports are equipped with a neighboring control. This means that the support functions are operated using the control unit on the right or left neighboring support or with the automatic sequential phase control system.

Warning!

Never be on a support which is currently being moved. Circumstances which are not always apparent may lead to unexpected movements in the shield units. This could result in serious injury or even death.

For example, the shield canopy may jerk free during lowering if it was stuck between the canopies of the neighboring shields.

Caution!

Take care not to damage the pilot valve buttons. Sticking buttons might lead to malfunctions and cause an accident.

Observe the following safety regulations:

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: J Malfunction of the electronic control system, J External jamming:

– shield is wedged in between the neighboring shields, – tip of the canopy is stuck in the roof, – floor step or debris is blocking the skid.

2. If the automatic function of the electronic control system is not working properly, the support can be manually controlled using the individual control of the control unit of a neighboring shield. See the separate operating manual for the electronic control system.

3. If the cause is an external obstruction, try to get the shield free by manually moving the neighboring shields.

5.14

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

If groups of shields are automatically advanced, no one may be in the area between the operator and the moved shield.

E

Make sure that your body is completely under a set shield. Keep away from shields which are in the process of being moved or which are to be moved soon.

Operation of the shield hydraulics Operation of the shield hydraulics Warning!

During normal operation, the support may only be moved by means of the control unit of the electrohydraulic neighboring control system. Always observe the instructions in the control unit's separate operating manual.

Arrangement of hydraulic components on the support The following table indicates the hydraulic components for the support Tab. 6: Hydraulic components Item 01 02 03 04 06

Bucyrus Europe GmbH, Lünen 2010

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07

Quantity Designation Electrohydraulic control unit, 1 8 functions 1 Prop CV, NG 20 1 Prop CV, compact NG 20 1 Dual CV 1 CV, NW 25 Supply block 1 DN 50, 40SS, 32

Arrangement

Remarks

In the middle beneath the canopy

On a bracket

On the right-hand prop, face side On the left-hand prop, face side On the stabilizing cylinder (Z3) On the supply block (7)

Without compensating valve With compensating valve For stabilizing cylinders In the return line

On the right beneath the canopy

On a bracket

On the electrohydraulic control unit (1) 2x on the dual CV (4) of the stabilizing cylinder (Z3)

08

1

Accumulator cartridge

09

2

PRV, 450 bar

10

2

PRV, 450 bar

2x, on each prop a) 2x, on each prop (Z1) b) On the left beneath the canopy on CV (14) c) 1x on the lifting cylinder (Z4)

For the piston/annular space of each stabilizing cylinder In the piston space of the props a) In the annular space of the props b) For shifting ram (Z2)

11

4

PRV, 380 bar

12

1

PRV, 80 bar

14

1

CV, piloted

15

1

Throttle CV, DN 20

16 22 23

1 1 1

31

2

32

2

Plug DN 10 Hose lines Brackets and accessories HP ball valve DN 10, red handle HP ball valve DN 20, red handle

34

1

HP ball valve DN 25, red handle To the left in the supply block

Interrupts the main pressure line to the shield

35

1

HP ball valve DN 12, red handle

On the left next to HP ball valve DN 25 (34)

For auxiliary supply

37

1

Water filter 4 SCD

Behind the supply block (7)

In the supply line to the water spraying system

38

2

39

3

On each prop CV a) On each prop RV b) On the supply block (7)

Z1 Z2 Z3 Z5 S1

2 1 1 1 1

Pressure gauge port Glycerine pressure gauge NG 50 Prop Shifting ram Stabilizing cylinder Lifting cylinder Pressure sensor

Behind the supply block (7) On the left beneath the canopy, behind the electrohydraulic control unit (1) In the middle beneath the canopy, behind the electrohydraulic control unit (1) 1x on the supply block (7)

a) 1x on the left-hand prop (Z1) b) 1x on the lifting cylinder (Z4)

c) For lifting cylinder (Z4) In the return line

Throttles the speed of the relay bar assembly With pressure relief valve Subassembly Subassembly a) For lifting cylinder (Z3) b) For lifting cylinder (Z5)

2x, on each prop (Z1)

On the right-hand prop

CV = check valve, PRV = pressure relief valve, HP = high pressure

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5.15

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 31a, 31b, 32, 34, 35 Tab. 7: HP ball valves Item

Color

Designation

31a

Red

HP ball valve DN 10

31b

Red

HP ball valve DN 10

32

Red

HP ball valve DN 20

34

Red

HP ball valve DN 25

35

Red

HP ball valve DN 12

Function Interrupts the connection of the stabilizing cylinder/ compensation valve Used for shutting off the pressure supply to the lifting cylinder Used for shutting off the pressure supply to the prop piston space Used for shutting off the pressure supply line to the shield Pressure supply during startup and for auxiliary devices

Use To deactivate the compensating function of the stabilizing cylinder Used for holding the baselift cylinder in a certain position and for deactivating the lift function During maintenance work on the prop and any prop disassembly During maintenance and repair work on the shield For moving the shield during startup and for connecting hydraulically operated auxiliary devices

open

closed

through-flow for medium enabled

5.16

Bucyrus Europe GmbH, Lünen 2010

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Fig. 24: HP ball valve, shown opened and closed

through-flow for medium stopped

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Shield hydraulics Fig. 25: Shield hydraulics, layout (1a) Legend: see Table 6 7

34

35

39b

11a 31a 10 10

Bucyrus Europe GmbH, Lünen 2010

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39a

39a

32

38

2

32

38 3 11c 31b

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5.17

Operation of the shield hydraulics

22 6 16

23

12 37

1 15 14

8

11b

4

9

5.18

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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Fig. 26: Shield hydraulics, layout (1c) Legend: see Table 6

Operation of the shield hydraulics Fig. 27: Electrohydraulic control unit, 8 functions, symbol plates for all shield variants X8

8

8 X7 7

7 X6

6 X5

6

5 X4 5

4 X3 3 X2

4

2 X1 1

3 X2

2

2

T

1

P

Bucyrus Europe GmbH, Lünen 2010

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SP

8 functions D.A. ram pull

D.A. ram push extending link-cyl.

3 5

1

4

2 extending legs

6

7

8

extending lift-cyl. retracting link-cyl. retracting legs

Tab. 8: Electrohydraulic control unit with 8 functions, allocation of functions Function, designation

Doc. No.: 7420 205 000 BA 00

Function No.

Advance shield

1

Set props

2

Advance conveyor

3

Extend lifting cylinder

4

Extend stabilizing cylinder

5

Retract stabilizing cylinder

6

No function

7

Lower props

8

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5.19

Operation of the shield hydraulics

39b W1W3 R1 R3 P1P3

W1W2 R1 R2 P1P2

6

X1

X3

X5

X7

1

R5

SP

34

1

2

3

4

5

6

7

8

8

7 P4 P5 R4

35

PTO

Fig. 28: Shield hydraulics Legend: see Table 6

DN 40-SS P DN 50 R DN 32 W

X2

X2

X4

X6

X8

37 12

31b

Bucyrus Europe GmbH, Lünen 2010

lifting cyl.

E

T P

8 7 6 5 4 3 2 1 2

16

Z4

14

3

11b

32

Z2 38

15

pi

39a

38

22

2

39a 32

pi

D.A.ram cyl.

s i

11c

Z1 Z1

31a leg

10 leg

10

9 11a link cyl.

11a

4

5.20

Z3

9

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 29: Hydraulic line diagram Legend: see Table 6 35

34

7

39b DN20

37

6

16

DN25

DN25

1

DN10

DN12

12

DN20

8

11*

11*

DN10

Z4 DN40-SS DN50 DN32

11c 31b DN10

10*

15*

Z2

DN20 DN20

DN12

DN10

14 15 11b

39a

11a

2 38

31

DN10

38

Z1

DN10

11a 39a 32

DN20

DN20

Z1

DN12

DN10

DN12

DN10 DN10 DN25 DN20 DN10 DN20

2*

3 10

10

12* 15* 1* DN10 - 4SP

Bucyrus Europe GmbH, Lünen 2010

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12*

Z3 4 9

9 1* hose lines 2* plug-in parts 10* protective hose DN 32-2500 green 11* protective hose DN 50-2550 green

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12* protective hose DN 32-1800 green 13* protective hose DN 25-1800 blue 15* protective hose DN 25-1800 green

5.21

Operation of the shield hydraulics Fig. 30: Bracket and accessories 3

2 9 5

Bucyrus Europe GmbH, Lünen 2010

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9

13 10

8

7 14

6 1

12

1 bracket for the electrohydraulic control unit 2 protection cover for prop valve, right 3 protection cover for prop valve, left 5 support 6 bracket on the supply block

5.22

7 support for SKK connector 8 bracket for the control unit 9 prop valve NG 20 fastener 10 supply block fastener 12 shifting ram valve fastener 13 chain fastener 14 solenoid driver module fastener

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Shield components Main components Fig. 31: Main subassemblies

a

11, 21*

51

b

41 a 61 c

Bucyrus Europe GmbH, Lünen 2010

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d

20

1

31

71

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1 skid 11 canopy 20 round steel 21* canopy 31 caving shield 41 hydraulic prop 51 stabilizing cylinder

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61 shield control system 71 caving plate a electrohydr. control unit b supply block c lifting cylinder d relay bar assembly * for shield variant 02

5.23

Operation of the shield hydraulics Control units The three shield variants are equipped with the following control units: J supply block, J electrohydraulic control unit, 8 functions, J PMC®-R control unit.

Fig. 32: Control units on the shield

a

7

5.24

a PMC®-R control unit

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

1 electrohydr. control unit 7 supply block DN 50, 40SS, 32

E

1

Operation of the shield hydraulics Supply block Fig. 33: View of the supply block

39b 34 35

a

Bucyrus Europe GmbH, Lünen 2010

E

7

P

W

8 1

R

Z3

1 electrohydr. control unit 7 supply block DN50, 40SS, 32 8 accumulator cartridge 34 HP ball valve DN25, for shutting off the pressure supply line to the shield

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35 HP ball valve DN 12 39b pressure gauge P pressure line, DN 40SS W water line, DN 32 R return line, DN 50 Z3 stabilizing cylinder a PMC®-R control unit

5.25

Operation of the shield hydraulics Fig. 34: View underneath the supply block

34 35 37 39b

a 7

8 1 electrohydr. control unit 6 check valve NW 25 7 supply block DN50, 40SS, 32 8 accumulator cartridge 34 HP ball valve DN25, for shutting off the pressure supply line to the shield

5.26

1 35 HP ball valve DN 12, for auxiliary supply 37 water filter 4 SCD 39b pressure gauge a PMC®-R control unit

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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6

Operation of the shield hydraulics Fig. 35: View behind the supply block

6

37

16

34

12 35

Bucyrus Europe GmbH, Lünen 2010

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7

6 check valve NW 25 7 supply block DN50, 40SS, 32 12 PRV, 80 bar 16 plug DN 10 with pressure relief

34 HP ball valve DN25, for shutting off the pressure supply line to the shield 35 HP ball valve DN 12, for auxiliary supply 37 water filter 4 SCD

PMC®-R Fig. 36: PMC®-R control unit

b c a

a PMC®-R control unit b emergency stop switch

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c support lockout switch

5.27

Operation of the shield hydraulics Electrohydraulic control unit Fig. 37: Electrohydraulic control unit, front 8

1

a symbol plate

Bucyrus Europe GmbH, Lünen 2010

1 electrohydr. control unit 8 accumulator cartridge

E

a

Fig. 38: Electrohydraulic control unit, side

14 11b

1

1 electrohydr. control unit 11b PRV, 380 bar

5.28

14 CV, piloted

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 39: Solenoid driver

a

1

1 electrohydr. control unit

a solenoid driver module

Bucyrus Europe GmbH, Lünen 2010

E

Bracket for PMC®-R and control unit Caution!

The protective plates could collide with support components during the lowering of the shield and thus become damaged.

Close all protective plates so that they can't touch other parts while the shield is being lowered.

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5.29

Operation of the shield hydraulics Props Fig. 40: View of props from the face side right-hand prop

left-hand prop

10 10 39a 39a

31a

32

32

38

3

a 2

2 prop CV (without compensating valve) 3 prop CV (with compensating valve) 10 PRV, 450 bar 31a HP ball valve DN 20

32 HP ball valve DN 20 38 pressure gauge port 39a pressure gauge a compensating valve

Fig. 41: Props with cover right-hand prop

5.30

left-hand prop

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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38

Operation of the shield hydraulics Fig. 42: View of props from the gob side

11a

Bucyrus Europe GmbH, Lünen 2010

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11a PRV, 380 bar

Lifting cylinder Fig. 43: View of relay bar assembly

11c

Z2

31b

Z5

11c PRV, 380 bar 31b HP ball valve DN 10

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Z2 shifting ram Z5 lifting cylinder

5.31

Operation of the shield hydraulics Dual CV on stabilizing cylinder Fig. 44: Stabilizing cylinder

Bucyrus Europe GmbH, Lünen 2010

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Z3

9

9 4

4 dual CV 9 PRV, 450 bar

5.32

Z3 stabilizing cylinder

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Plug with pressure relief Via a pressure relief valve, the enclosed pressure can be relieved by screwing in the vented cap screw.

After relieving the pressure, this screw must be screwed all the way out again.

Fig. 45: Plug DN 10 with pressure relief Open pressure relief: screw in screw

Bucyrus Europe GmbH, Lünen 2010

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Close pressure relief: screw out screw

a

b

a hex. head screw M 6x16-A 2-70

b O-ring

Important!

Check the porosity of the sealing ring (b) regularly. Just to make sure, you can cover the ring with a rag to prevent hydraulic fluid from spraying out.

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5.33

Operation of the shield hydraulics The shield is equipped with a plug DN 10 with vented cap screw.

The plug (16) with pressure relief located on the supply block is for reducing any pressure that may arise in the return line. This can be necessary, e.g. when the supply line connections have been closed off for transport and increased pressure has built up in the return line during installation.

Fig. 46: View of plug on the supply block

16

7

16 plug DN 10 with pressure relief

Bucyrus Europe GmbH, Lünen 2010

7 supply block 12 DBV, 80 bar

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12

5.34

Shield support 1143/3048-2X4113-1750

Operation of the shield hydraulics Repair and emergency operation This section contains information on the functions and operation of the hydraulic control system, which may only be used in exceptional cases such as for repair and emergencies.

In the following, it is assumed that the shield has already been correctly installed. It is also assumed that all shut-off valves are open as during normal operation.

Operation of the control unit of the electronic control system is not described here, but in a separate operating manual for the control unit.

The fundamental design of the shield unit and the shield control is shown in chapter 6, “Technical data”, “Description” section of this manual.

Furthermore, it is assumed that the reader is familiar with the fundamental principles of the hydraulic shield support and the operation of the control unit.

Bucyrus Europe GmbH, Lünen 2010

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Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special work instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury or death.

The shield support is operated in normal operation exclusively by means of the electronic control system. It is imperative that you observe the instructions in the control unit's separate operating manual.

Fig. 47 above shows the layout of the PMC®-R control unit and the electrohydraulic control unit on the support.

Operation of the PMC®-R control unit is not described in this operating manual. For information on this, please refer to the separate operating manual for the PMC®-R control unit.

Fig. 47: Control units on the shield

a

7 1 1 electrohydr. control unit 7 supply block DN 50, 40SS, 32

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a PMC®-R control unit

5.35

Operation of the shield hydraulics Fig. 48: Electrohydraulic control unit, front 8

c

a

b 1

b pilot valve c connecting cable d symbol plate

The symbol plate is located on the electrohydraulic control unit underneath the pilot valves. The symbols correspond to the various functions which are initiated by actuating the respective button.

The meaning of the symbols and functions are described below.

Fig. 49: Symbol plate for electrohydraulic control unit with 8 functions D.A. ram pull 1 2 extending legs

5.36

D.A. ram push extending link-cyl.

3 5 4

6

7

8

extending lift-cyl. retracting link-cyl. retracting legs

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

1 electrohydr. control unit 8 accumulator cartridge a button

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d

Operation of the shield hydraulics Operation and functions of the electrohydraulic control unit This section provides information on the functions of the electrohydraulic control unit. Always observe the instructions contained in the operating manuals of the electrohydraulic control unit and the electronic control system.

Warning!

You are only allowed to operate the controls of the electrohydraulic control unit when you know exactly what effects the functions have with respect to the shield support. You must have attended a special training course to this purpose. Otherwise, there is a risk of operating errors. This could result in serious injury and even fatal accidents.

Controlling the shields during repair operation is especially dangerous since you are then operating the shield directly and immediately under which you are standing. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

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

Bucyrus Europe GmbH, Lünen 2010

There are two pushbuttons on the cover of each individual pilot valve. When you press a button, the corresponding work valve is operated immediately.

The function stops as soon as you release the button.

Danger!

Jammed or locked buttons can cause uncontrolled movements of the shield. This could seriously injure or kill you.

For this reason never lock the buttons and ensure that damaged pilot valves are replaced immediately.

Warning!

Manual actuation of a button on one of the pilot valves initiates the direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order.

For example, the function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”. This can cause dangerous situations which can result in very serious injuries.

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5.37

Operation of the shield hydraulics 1

Advance shield Before executing this function, the side seal of the shield unit must be released and the function “lower props” (function 8) must have been executed for both props.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

As long as the function is activated, the piloted check valve, which hydraulically blocks the annular space of the shifting ram, is opened automatically.

2

Set props Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

3

Move conveyor Before initiating this function, ensure that the shield unit is completely set.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

4

Extend lifting cylinder The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

5

Extend stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

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Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

The compensating valve a (see Fig. 40) and the associated shut-off valve (Fig. 40, Item 31a) are on the left prop when looking at the coal face.

When the shut-off valve is open (lever in the direction of flow), the compensating valve is activated. When the shut-off valve is closed (lever perpendicular to direction of flow), the compensating valve has no function.

While the props are being set, the compensating valve limits the pressure of the stabilizing cylinder to 200 bar as long as the pressure under the piston of the prop does not exceed 100 bar. This means that the stabilizing cylinder retracts if the canopy is set too steeply. The canopy only presses with the tip against the roof and aligns itself to it automatically.

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Compensating valve

Operation of the shield hydraulics 6

Retract stabilizing cylinder Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

7

No function

8

Lower props

Bucyrus Europe GmbH, Lünen 2010

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Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

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5.39

Maintenance Maintenance Warning!

If operational safety is endangered, damaged components must be replaced immediately. If this is not possible, you must immediately shut down the shield and secure it. Immediately notify the entire face crew and your superiors. electronic control system

Refer to the separate original operating manual for the PMC®-R control unit.

hydraulic controlsystem

Special measures

After extensive work on the hydraulics system or after the start-up of a new face, there is an increased risk of dirt having found its way into the hydraulics system. Depending on the degree of contamination, this can cause the filter cartridges in the system to become clogged. As a result, it is possible that functions run slowly or even can no longer be carried out. We therefore recommend that the measures outlined above be taken in order to avoid malfunctions in the operation of the shield hydraulics. piston rods

On all shields which are equipped with a water spraying system, the piston rods of cylinders that are usually only rarely extended and retracted completely, for example props and stabilizing cylinders, must be thoroughly cleaned every 6 months and then treated with a suitable corrosion inhibitor.

filter cartridges

The filter cartridges on the supply block and on the electrohydraulic control unit of the shield control system protect the downstream hydraulic components against damage caused by contaminants in the hydraulic medium. These only have to be regularly replaced if the filtering system of the face supply unit is inadequate.

Therefore, it is very important to ensure the required hydraulic medium quality.

If problems occur in the preparation of the hydraulic medium, there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation.

For example, the filters described above should be spot-checked regularly for contamination. If necessary the filter cartridges must be replaced regularly as a precautionary measure.

pressure relief valves

All pressure relief valves must be subjected to a functional test at the latest after one year of operation, or when the equipment is moved to another face. If it is not possible to keep this deadline because the end of the section planned to be mined will only be reached shortly after the deadline, the pressure relief valves can, as an exception, be checked after the respective section has been completed.

Pressure relief valves which are pretensioned with gas pressure must be additionally spot checked at regular intervals to ensure their correct function. We recommend such spot checks at quarterly intervals.

5.40

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No later than one week after startup, the filter cartridges on the electrohydraulic control units of the control system in the entire face must be spot checked for contamination. If inspection indicates that the probability of malfunctions caused by contaminated filter elements is high, all filter cartridges along the face must be replaced.

Bucyrus Europe GmbH, Lünen 2010

one week after startup

Maintenance high pressure hydraulic hoses

All high-pressure hydraulic hose lines must be replaced irrespective of any visible damage at the latest after two years of operation for safety reasons and to ensure correct function of the system. If this deadline cannot be met because the end the section planned to be mined will only be reached shortly after this deadline, the hose lines, can as an exception, be replaced after the respective section has been completed.

double filter, can be backflushed

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid), the frequency of backflushing cannot be predetermined. We recommend backflushing both filters routinely once per shift.

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid at the following points: – hose lines, – electrohydraulic control unit, – valves, – props,

Bucyrus Europe GmbH, Lünen 2010

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– shifting rams and lifting cylinders, – hinge, alignment and flipper cylinders.

. Check the pressure gauges on the props for visible damage and correct function. steel structure

. Check all shields by visually inspecting them for damage to the steel structure, for instance: – on the relay bar assembly, – on pin connections and retaining devices, – on the side seal, – on brackets, etc.

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5.41

Maintenance Weekly maintenance control system

. Check each control system for correct functioning. . Replace defective control systems or individual components immediately.

. Clean the control systems, especially the operating panel.

Notice!

It is important that the control system symbols be easily legible. This prevents the risk of operational errors and any resulting accidents. hydraulic prop

. Lubricate the dirt strippers of both telescope stages via the lubricating nipples. Use the lubricating grease A2 in accordance with EWN 7068. See chapter 6, section “Lubricating greases and pastes”.

Fig. 50: Lubricating nipples on the hydraulic prop

a

a lubricating nipples on the guide bushing

b grease escaping at dirt stripper

Every six months

. Apply a corrosion inhibitor to the piston rods of the hydraulic cylinders. Further details are contained in this chapter in the section “Special measures”.

Regular, scheduled damage assessment We recommend keeping a record of any damage found. The records should be evaluated regularly, for example every month, and summarized in a damage report. This will enable you to detect frequently occurring damage and take preventative action. This will heighten system availability and lower operating costs accordingly.

5.42

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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b

Troubleshooting Troubleshooting Instructions for troubleshooting The shield hydraulics of a shield unit consists of a multitude of individual components. The linking of the components with each other is shown in the diagrams and hose diagrams for the shield hydraulics. Also refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

Functional errors can, in principle, occur in all components.

Most faults on hydraulic valves, however, are caused by hydraulic bypass flows. These are normally audible to the operator.

The following information is provided to assist you in the detection and elimination of faults.

Bucyrus Europe GmbH, Lünen 2010

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Warning!

There is a heightened risk of accidents when performing troubleshooting work on hydraulic systems In particular, malfunctions in the hydraulic system and hydraulic medium escaping at high pressure can cause serious injury.

Therefore, take special care and always wear the specified protective clothing and equipment.

Failure to comply with these instructions can result in serious injury.

Fault localization support cannot be lowered

Doc. No.: 7420 205 000 BA 00

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the prop piston chamber is closed.

Open the shut-off valve.

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

Control piston on the prop control valve is not working.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Replace the hose lines if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

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5.43

Troubleshooting support cannot be set

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the prop piston space is closed.

Open the shut-off valve.

Lines to the piston and annular space of the prop must be open.

5.44

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Control piston on the prop control valve is not working.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Replace the hose lines if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The support is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the support.

Step on roof or floor blocking the support.

Lower canopy sufficiently to clear the step or lift the skid.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

The control piston on the piloted check valve does not work.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked shifting ram hose lines. Replace the hose lines if necessary. Make sure hoses are laid properly.

Shifting ram is defective.

Check whether the - shifting ram is damaged - the piloted check valve is working properly Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressure fluid escapes, replace the shifting ram.

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

support cannot be advanced

The pressure of the hydraulic supply is too low.

E

The shield canopy is stuck Find the cause. If required, lower neighboring between the neighboring supports. supports and align them in order to free the canopy.

Troubleshooting setting pressure is not reached/ prop pressure drops again after setting

Bucyrus Europe GmbH, Lünen 2010

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canopy cannot be positioned

canopy cannot be lowered

Doc. No.: 7420 205 000 BA 00

Possible cause

Measure required

Prop control valve is defective.

Replace prop control valve. Continue troubleshooting if the pressure continues to drop.

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lowering connection and check whether pressure fluid is escaping even though the prop is no longer being extended. If applicable: piston packing defective, replace prop.

Pressure relief valve defective

Monitor pressure drop on the pressure gauge.

Is pressure fluid leaking from the pressure relief valve? If so: Replace the pressure relief valve and retest the function.

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum is approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly, - all shut-off valves are open, - the system pressure is sufficient.

Piloted check valve is not working.

Check whether the pressure for controlling the valve is sufficient. Minimum is approx. 80 bar.

The check valve may be defective.

Damaged or trapped hose lines.

Check hose lines for controlling the prop / stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

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5.45

Troubleshooting 3/2-way or pilot valve The valve is jammed or a bypass has formed due to internal leakage. The latter can normally be detected on the work valves of the electrohydraulic control unit by an easily audible hissing noise.

Pilot or control valves with a significantly lower volume flow will become noticeably warmer due to the constantly flowing medium.

Defective pilot valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, such as discharged fluid, for example.

The 3/2-way valve or the pilot valve can therefore be faulty. valve sticks

. Try to solve the problem by activating the function several times on the electrohydraulic control unit or electronic control system.

internal leakage

. Locate the faulty valve by actuating the functions individually in

. Close the main shut-off valve in the pressure feed line on the supply block.

. Then operate the functions manually to depressurize the system.

. Replace the 3/2-way valve or pilot valve.

Piloted check valves The formation of a bypass is shown by a drop in pressure.

. Try to solve the problem by activating the function several times on the electrohydraulic control unit or electronic control system.

If the problem occurs once more, the valve may be defective.

. Check the valve and replace if defective.

Checking the check valves on the props To check the prop check valves please proceed as follows:

. Set the prop until the setting pressure has been reached. . Remove the “set prop” hose line on the piloted check valve.

If fluid escapes from the connection of the piloted check valve, it is defective.

5.46

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

replace valve

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sequence.

If the noise stops while a function is actuated, that valve is faulty.

You may have to press the button for the faulty function for several seconds before the noise ceases.

Troubleshooting Internal bypass in props If an internal bypass in a prop is suspected, this procedure should be followed:

. Set the prop until the setting pressure has been reached. . Depressurize the annular space side of the prop to be checked.

To do this, remove the two hose lines from the prop annular space connections (located on the prop head and prop pipe) and apply pressure to the control connection (extend prop) of the piloted check valve.

. Activate the “set props” function.

If there is an internal bypass in the prop, for example due to damaged piston packing, fluid will flow out of the prop lower connection.

If this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

Pressure relief valve defective

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Leaking pressure relief valves can normally be detected by the discharge of fluid, or a pressure drop is displayed on the pressure gauge. If fluid is already discharged at working pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

In the hydraulic circuit of a shield unit, various models of pressure relief valves are used. For example, pressure relief valves with a high flow rate are used on the props, while the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow.

Pressure relief valves for different cylinders or for the piston and ring sides of a cylinder can be set to different maximum pressure values. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

Defective or blocked filter Operation of the shield is slow although the system pressure lies in the normal range.

It is also possible that the hydraulic system has been contaminated, for example during repair work on the hydraulic system.

. Check the filters in the hydraulic system.

Backflush filters can be cleaned by backflushing. The filter elements must be replaced on fine-mesh filters, such as on the electrohydraulic control unit.

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5.47

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Troubleshooting

5.48

Shield support 1143/3048-2X4113-1750

6

Technical data

Technical description

Technical data This chapter contains the technical description of the support and its main subassemblies as well as the technical data for the described subassemblies.

Technical description Type1143/3048-2X4113-1750 The two-prop shield mainly consists of the following listed main subassemblies: J base frame with lemniscatic links, relay bar assembly and lifting

cylinder, J canopy, J caving shield, J hydraulic props, J hydraulic equipment with hose lines and control.

Tab. 9: Shield support, dimensions, weights

Bucyrus Europe GmbH, Lünen 2010

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Var.

Application

Device number

Dimensions, L x W x H max. / min. in mm

01

Segment shield

7420 205 000 00 01

02

Segment end shield

7420 205 000 00 02

8164 x 1700 x 1143 x 1700 x 3048 7389 x 1700 x 1143 x 1700 x 3048

Approximate weight in kg 23 685 23 155

Tab. 10: Shield support, numbering Var.

Application

01

Segment shield

02

Segment end shield

Shield no.

G1 to G6

Special design Canopy, 6005 long Canopy, 5230 long

The two-prop shield is equipped with a one-piece base frame. This consists of two skids which are tightly connected to each other, in the middle of which is the channel for the relay bar assembly.

The caving shield is a one-piece steel construction connected by means of the so-called lemniscatic links to the base frame.

The shield canopy transmits the support load of the props into the roof. The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

The shield canopy is equipped with a flipper.

Programmed methods of calculation ensure the best possible support. This ensures that the support resistance and range of vertical adjustment is coordinated in optimum fashion. The multistage hydraulic props have the same load capacity at any stage and act on both sides.

The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

The shield units are equipped with all components required for realizing an electrohydraulic neighboring control with the electronic PMC®-R control unit.

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6.3

Technical description Main subassemblies Fig. 51: Main subassemblies

a

11, 21*

51

b

41 a 61 c

20

1

31

71

1 skid 11 canopy 20 round steel 21* canopy 31 caving shield 41 hydraulic prop 51 stabilizing cylinder

61 shield control system 71 caving plate a electrohydr. control unit b supply block c lifting cylinder d relay bar assembly

* for segment shield variant 02

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Shield support 1143/3048-2X4113-1750

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Technical description Tab. 11: Shield support 7420 205 000 00 0x, main subassemblies Approximate weight in kg

Item

Designation

ID No.

Remarks

01

Skid

7420 205 300 00 01

Shifting ram 9514 Lifting cylinder Relay bar assembly, 4512 long

Canopy, 6005 long

7420 205 400 00 01

7661

Canopy, 5100 long

7421 002 690 00 01

7085

31

Caving shield

7420 096 800 00 00

3850

41

Hydraulic prop

8250 100 000 00 00

1158

51

Stabilizing cylinder

8241 222 000 00 00

140

0061

Shield control system - 8 functions -

8112 298 000 00 00

Electrohydr. control unit 256 Lines Brackets

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8154 124 000 00 00 8112 298 010 00 00 8112 298 030 00 00

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11 21*

8241 317 000 00 00 8241 224 000 00 00 7420 205 330 00 01

6.5

Technical description Main dimensions Fig. 52: Shield, dimensions L1 L2 L3

1275

130

120

HE

H

HA

L4

Bucyrus Europe GmbH, Lünen 2010

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L

4650

M B

HA height, extended HE height, retracted L transport length

B2 B1

M support center distance B width

Tab. 12: Shield variants, dimensions

6.6

Var.

L

L1

L2

L3

L4

HA

HE

H

B

B1

B2

M

01

8164

6005

5875

4600

3407

3048

1143

1981

1700

1610

890

1750

02

7389

5230

5100

3825

2631

3048

1143

1981

1700

1610

890

1750

Shield support 1143/3048-2X4113-1750

Technical description Base frame with lemniscatic links and relay bar assembly The one-piece base frame transmits the shield load of the hydraulic props into the floor. The props are hinged in the ball sockets in the skids and are held on both sides by prop retainers.

Both pairs of lemniscatic links are hinged to the base frame with a pin connection.

Characteristic for the base frame is the placement of the relay bar assembly in the middle between the two skids. The relay bar assembly is reverse-mounted so the force of the piston surface area of the shifting ram is used to advance the shield. Correspondingly, the conveyor is advanced with the smaller force generated via the annular surface.

The fork joint of the relay bar assembly establishes the connection to the conveyor.

With the help of the lifting cylinder, the shield can be lifted during shield advance.

Fig. 53: Skid, dimensions 1510 890

120

824 615

Bucyrus Europe GmbH, Lünen 2010

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X

270

340 1610

secure X with KN 3 - 20 lg. after installation

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6.7

Technical description Fig. 54: Skid, component positions 12

6

19, 24

7

A

5

8 27 26

17, 20

11 10

13, 15, 25

13, 14, 25

18, 24

View A

2

3

21, 22 1 9 4 1 shifting ram ZE-200/125-1130 2 lifting cylinder ZE-135/90-240 3 skid 4 relay bar assembly 5 lemniscatic link, front 6 lemniscatic link, back right 7 lemniscatic link, back left 8 cylinder bearing 9 protective flap 10 prop retainer, right 11 prop retainer, left (not visible) 12 securing device 13 locking plate

6.8

14 lemniscatic link pin, 155x533 15 lemniscatic link pin, 130x533 16 pin Ø50x135 17 pin 40/34x85 18 pin Ø16x117 19 pin 30/20x191 20 spring clip 6 21 hex. head screw M 16x110-A 2-70 22 hex. nut M 16-1.4571 23 locking element 24 staple DN 10 25 spring clip 4.5 26 pin Ø70x284 27 securing device

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

E

16, 23

Technical description Relay bar assembly The relay bar assembly is located in the middle of the base frame.

It consists mainly of the relay bar, shifting ram, lifting cylinder and the required connecting elements. It serves to advance the conveyor and to pull up the shield.

The force of the reverse-mounted shifting ram is applied directly to the relay bar. Here, the force on the piston surface side is used to advance the shield, while the smaller force of the annular surface is used to advance the conveyor.

With the help of the lifting equipment, the base frame can be lifted from the floor when advancing.

The lifting cylinder is located in the center of the base frame. The force of the lifting cylinder acts on the floor via the relay bar.

Fig. 55: Relay bar assembly 4512 58

120

240 300 370

110

215

280

230

105

4033

300

Bucyrus Europe GmbH, Lünen 2010

E

53

48

a 9

3

2

6

1

a

21 10, 11

4

5

7, 8

1 relay bar 2 clevis assembly for conveyor 3 pin 80/48x290 4 washer 48 5 spring clip 17x60 6 shear pin 70/53x144 7 hex. head screw M 16x140-A 4-80

8 hex. nut M 16-A 4-80 9 pin 65/58x180 10 hex. nut M 12-A 4-80 11 hex. head screw M 12x110-A 4-80 21 sealing compound a load ring, load capacity: 3000 kg

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.1)

1) EWN = works standard

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.9

Technical description Functions of the relay bar assembly

The shield is used as the thrust bearing, meaning that the shield must be set. The gobside part of the relay bar assembly, the cylinder bearing (4), supports itself with the yoke (1) on the set shield.

The face side part of the relay bar assembly moves in the direction of the face when the shifting ram is extended. The conveyor is advanced. The power required for advancing the conveyor is generated by the piston surface of the shifting ram (Figure 1).

advance shield

The conveyor is used as the thrust bearing, meaning that the shield must be lowered. The face side part of the relay bar assembly supports itself on the conveyor. The gobside part of the relay bar assembly moves in the direction of the face when the shifting ram is retracted. The conveyor is pulled up. The power required for advancing the shield is generated by the annular surface of the shifting ram (Figure 2).

Fig. 56: Relay bar assembly retracted and extended, principle diagram with conveyor steering device 4

1

Figure 1

Figure 2

1 yoke

4 cylinder bearing

For the conveyor steering device, see separate operating manual 7427 094 000 BA 00.

6.10

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

advance conveyor

E

Warning!

Body parts which get between moving parts of the relay bar assembly and support can be crushed.

For this reason, make sure that you keep a distance from shields which are being advanced or are to be advanced soon.

Technical description Canopy The canopy transfers the supporting force of the props to the roof.

It is hinged to the caving shield by means of pin connections. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the props are fastened to the canopy and can be rotated.

Caution!

To avoid overloading the stabilizing cylinder, you must make sure that the setting angle of the shield canopy doesn't exceed the maximum permissible value, e.g. when the canopy is set in a roof fall.

The canopies of the two variants differ in that the canopy of variant 02 is shorter than the canopy of variant 01 and is equipped with a front plate.

994

480

195

0 130

240

1275

5875

994

480

195

0 130

240

1275

890 1700

Fig. 58: Canopy, shield variant 02, dimensions

5100

Bucyrus Europe GmbH, Lünen 2010

E

890 1700

Fig. 57: Canopy, shield variant 01, dimensions

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.11

Technical description Fig. 59: Canopy, component positions S1 10 5

S2 S1

6

7

S2 a 1

1 canopy 5 pawl 6 pin 30/24.5x136 7 locking clip 5x32 8 pin Ø53x155 9 locking element with connector 10 spring cotter 5

S1 load ring, load capacity: 3000 kg S2 load ring, load capacity: 1000 kg a abutment plate b screw holder c clip load capacity: 8000 kg

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.1) Prop head with pawl Fig. 60: Mounting the prop head

6 7

5

5 pawl R90 6 pin 30/24.5x136

7 locking clip 5x32

1) EWN = works standard

6.12

Shield support 1143/3048-2X4113-1750

E

8 Bucyrus Europe GmbH, Lünen 2010

c

9

b

Technical description Caving shield The caving shield protects the face area toward the caving area.

It is connected to the shield canopy and with the base frame via the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the shield canopy to provide stability for the articulation.

The caving shield is equipped with mounting devices for the cylinders.

Bucyrus Europe GmbH, Lünen 2010

1698

E

520

1654 975

153

370

Fig. 61: Caving shield, dimensions

2426

950

X secure X with KN 3 - 20 lg. after installation

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.13

Technical description Fig. 62: Caving shield, component positions View A 6 1

21

S2

33

5

S1

7

A S2

15, 32, 16 10

15, 32, 16

15, 32, 17 1 caving shield 5 lemniscatic link pin Ø155x533 6 lemniscatic link pin Ø130x533 7 pin Ø53x155 10 joint pin Ø133.5x328 15 pin, 15/12x120 16 securing device

17 securing device 21 locking element with connector 32 spring clip 2.5 33 spring cotter 5 S1 load ring, load capacity: 3000 kg S2 load ring, load capacity: 8000 kg

Notice!

Apply B6 lubricant in accordance with EWN 70681) to all connecting points and slide surfaces

1) EWN = works standard

6.14

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

E

S1

Technical description Caving plate

Fig. 63: Caving plate, component positions

Bucyrus Europe GmbH, Lünen 2010

E

2

1

3 4 1 caving flap 2 retaining device

Doc. No.: 7420 205 000 BA 00

VTSV / 01

3 hex. head screw M 16-60-A 2-70 4 hex. nut M 16-1.4301

6.15

Technical description Technical data, steel structure Face shield, device number 7420 205 000 00 01 Securing from tipping Permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

15 1143

Height, extended . . . . . . . . . . . . . . . . . . . mm

3048

Height adjustment of shield . . . . . . . . . . . mm

1905

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

1067

Shifting ram stroke . . . . . . . . . . . . . . . . . . mm

1130

Prop clearance in inclines . . . . . . . . . . . mm

890

Forepole of canopy . . . . . . . . . . . . . . . . . . mm

4600

Rear projection of canopy . . . . . . . . . . . . mm

1405

Canopy width , . . . . . . . . . . . . . . . . . . . . . mm

1700

Canopy length . . . . . . . . . . . . . . . . . . . . . . mm

6005

Caving shield inclination: Support retracted . . . . . . . . . . . . . . . . . . . degrees

3.97

Support extended . . . . . . . . . . . . . . . . . . . degrees

49.8

Width of caving shield . . . . . . . . . . . . . . . mm

1700

Base frame width . . . . . . . . . . . . . . . . . . . mm

1610

Total area of the base frame . . . . . . . . . . cm2

40 081

Support center distance . . . . . . . . . . . . . . mm

1750

Supporting force of support for average seam of . . . . . . . mm

1829

a) with 310 bar setting pressure . . . . . . . kN

4780

b) with 440 bar nominal pressure . . . . . . kN

6784

Support resistance per m2 roof surface

6.16

of support for average seam of . . . . . . . mm

1829

a) at 310 bar setting pressure . . . . . . . . . kN/m2

455

b) at 440 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

548/645

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

E

Height, retracted . . . . . . . . . . . . . . . . . . . . mm

Technical description Face shield, device number 7420 205 000 00 02 Securing from tipping Permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

15

Height, retracted . . . . . . . . . . . . . . . . . . . . mm

1143

Height, extended . . . . . . . . . . . . . . . . . . . mm

3048

Height adjustment of shield . . . . . . . . . . . mm

1905

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

1067

Shifting ram stroke . . . . . . . . . . . . . . . . . . mm

1130

Prop clearance in inclines . . . . . . . . . . . mm

890

Forepole of canopy . . . . . . . . . . . . . . . . . . mm

4600

Rear projection of canopy . . . . . . . . . . . . mm

1405

Canopy width , . . . . . . . . . . . . . . . . . . . . . mm

1700

Canopy length . . . . . . . . . . . . . . . . . . . . . . mm

5230

Bucyrus Europe GmbH, Lünen 2010

E

Caving shield inclination: Support retracted . . . . . . . . . . . . . . . . . . . degrees

3.97

Support extended . . . . . . . . . . . . . . . . . . . degrees

49.8

Width of caving shield . . . . . . . . . . . . . . . mm

1700

Base frame width . . . . . . . . . . . . . . . . . . . mm

1610

Total area of the base frame . . . . . . . . . . cm2

40 081

Support center distance . . . . . . . . . . . . . . mm

1750

Supporting force of support for average seam of . . . . . . . mm

1829

a) with 310 bar setting pressure . . . . . . . kN

4780

b) with 440 bar nominal pressure . . . . . . kN

6784

Support resistance per m2 roof surface

Doc. No.: 7420 205 000 BA 00

of support for average seam of . . . . . . . mm

1829

a) at 310 bar setting pressure . . . . . . . . . kN/m2

522

b) at 440 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

615/741

VTSV / 01

6.17

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. Supplemental information can be found in the spare parts catalog for the shield support or the hydraulic components listed in chapter 5.

normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

Shield hydraulics Electrohydraulic control unit The electrohydraulic control unit has 8 functions.

The pilot valves of the electrohydraulic control unit are equipped with buttons which allow the shield functions to be actuated manually. A symbol plate shows the function of the buttons.

Fig. 64: Electrohydraulic control unit, 8 functions 1 Bucyrus Europe GmbH, Lünen 2010

E

d

a

2

1 distributor block 2 double 3/2 way magnetic pilot solenoid valve a connection for accumulator cartridge

b

c b button c connecting socket for control unit d connecting sockets on the rear side

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Noncompliance can cause unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

The buttons on the pilot valves should only be used in special exceptional cases, for example for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations.

6.18

Shield support 1143/3048-2X4113-1750

Hydraulic system PMC®-R electronic control system Notice!

Please observe the instructions in the PMC®-R control unit's separate operating manual.

Control unit PMC®-R, input allocation; Face shield device number 7420 205 000 00 01/2 Fig. 65: Control unit PMC®-R, input allocation PMC®-R inputs Front view A1 = neighboring shield, left A2 = not assigned B1 = not assigned B2 = code plug C1 = pressure sensor, right C2 = pressure sensor, left D1 = reed rod, shifting ram D2 = not assigned

Bucyrus Europe GmbH, Lünen 2010

E

Rear view A2

B2

C2

D2

E2

F2

E1 = not assigned E2 = not assigned F1 = neighboring shield, right

A1

B1

C1

D1

E1

F1

F2 = solenoid driver module

Fig. 66: Control unit PMC®-R, segment shield, schematic diagram

19

1

A2 B2 C2 D2 E2 F2

A1 B1 C1 D1 E1 F1

F1

A1 4

P2 5b

P1 5a

FACE END SHIELD a

1 control unit PMC-R 4 solenoid driver module 5a pressure sensor, right

19 code plug a reed rod, shifting ram other components: see spare parts catalog

5b pressure sensor, right

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.19

Hydraulic system Two-stage telescopic prop The two-stage telescopic prop is double acting and is designed for equal load-bearing capacity on both stages. Equal load-bearing capacity of the two stages is ensured by a piloted check valve which is installed in the piston pipe.

The bottom and top of the prop are designed as a globe joint. This allows the prop to be joined to the support via a rotatable fastening.

The head is fastened using two pegs each that are inserted into the bore holes in the retainer before the prop head is installed. The pegs are secured in the second groove by a pin and locking clip.

After the prop head is installed, the pegs are pushed into the bore holes of the prop head and secured in the first groove with a pin and locking clip.

The technical data can be found in the section “Technical data, hydraulic cylinders”.

Fig. 67: Hydraulic prop, 2-stage, type SD-4100-345-1195/2775-BN

X

Bucyrus Europe GmbH, Lünen 2010

E

21

2 b Detail X b

41

e a

e

c 1 c

1 prop base 2 piston pipe 21 piston rod 41 lubricating nipple

a valve connection plate b annular space connection c safety cam e load ring 3000 kg

Tab. 13: Telescopic prop Length in mm

6.20

Stroke in mm

ID No. Telescopic prop

Retracted

Extended

Upper stage

Lower stage

8250 100 000 00 00

1195

2775

785

795

Shield support 1143/3048-2X4113-1750

Hydraulic system Warning!

Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never close the lowering connections on double acting props so that they are pressure-tight! Otherwise, pressure might build up in the annular space when extending the prop which is several times more than the set pressure.

Function Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, while the pressure fluid in the annular space is conducted away into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressure fluid is supplied at the same time via the check valve in the bottom of the piston pipe.

load props

a) Piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. Further transmission of the force is hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the base frame (skid).

Bucyrus Europe GmbH, Lünen 2010

E

set props

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated check valve. If the pressure set on the pressure relief valve is exceeded, the pressure fluid flows out of the prop and the prop is pushed in under the nominal prop force. b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure fluid, which is blocked by the check valve in the bottom of the piston pipe.

Further transmission of force up to the setting of the piston pipe is as described under a). lower props

The pressure fluid is connected to the return under the piston pipe via the control valve for the prop.

Both stages of the prop can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston rod can then retract.

A few millimeters before the piston pipe is “fully retracted”, the check valve is opened by a tappet, whereby the pressure fluid underneath the piston pipe acts like a spring lifting the piston pipe to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.21

Hydraulic cylinders Hydraulic cylinders Construction The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod.

Fig. 68: Hydraulic cylinders, typical examples Type a)

2 3

1

4

5

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

1

4

6

4 guide bushing 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical data, hydraulic cylinders” section for the shield unit used.

Warning!

Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, pressure that is several times higher than the set pressure can build up in the annular space when extending the cylinder.

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against working loose using clamping screws or a spring pin connection.

The pressure fluid is fed through the connections either on the outer cylinder (Type a) or on the piston rod (Type b).

If a double-acting cylinder is only to be operated as a single-acting cylinder, the annular space connection must be protected against the penetration of dirt with a filter screw. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

6.22

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

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Type b)

Hydraulic cylinders Stabilizing cylinder Fig. 69: Hydraulic cylinder ZE-165/100-420

55

55 L

21 a

d

1 d load ring 1000 kg L retracted 860 - extended 1280 stroke: 420

1 cylinder tube 21 piston rod a valve connection plate

Bucyrus Europe GmbH, Lünen 2010

E

Shifting ram Fig. 70: Shifting ram, model ZE-200/125-1130

72

62 L d b

a

2 3

6 1 c 1 cylinder tube 2 reed rod 3 piston rod 6 screw fitting a annular space connection

Doc. No.: 7420 205 000 BA 00

VTSV / 01

b piston space connection c relay bar adaptor d load ring 1000 kg L retracted 1579 - extended 2709 stroke: 1130

6.23

Hydraulic cylinders Lifting cylinder Fig. 71: Hydraulic cylinder ZE-135/90-240

355

c

2

a

b 1 L

6.24

b annular space connection c load ring 1000 kg L retracted 525 - extended 765 stroke: 240

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

1 cylinder tube 2 piston rod 3 wearing bottom a piston space connection

E

3

Hydraulic cylinders Technical data, hydraulic cylinders telescopic prop, double acting, 2-stage

Bucyrus Europe GmbH, Lünen 2010

E

stabilizing cylinder, double acting

shifting ram double acting, el. connection, configuration: reverse-mounted

Doc. No.: 7420 205 000 BA 00

Type SD-4100-345-1195/2775, device number 8250 100 000 00 00 Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1200

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2780

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1580

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

345/250

Piston rod diameter . . . . . . . . . . . . . . . . . mm

320/265

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

934.8/490.9

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

130.6/75.4

Prop force for setting pressure, 310 bar kN

2898

Setting pressure, 440 bar . . . . . . . . . . . . kN

4113

Retracting force at 310 bar . . . . . . . . . . . kN

405

Type ZE-165/100-420, device no. 8241 122 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

420

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust at 310/450 bar . . . . . . . . . . . . . . . . kN

663/962

Pulling force at 310/450 bar . . . . . . . . . . kN

419/609

Type ZE-200/125-1130, device number 8241 317 000 00 00, version with reed rod Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

200

Piston rod diameter . . . . . . . . . . . . . . . . . mm

125

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

314

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

191

Thrust force at 310/--- bar . . . . . . . . . . . kN

973.4/---

Pulling force at 310/--- bar . . . . . . . . . . . . kN

592.1/---

VTSV / 01

6.25

Hydraulic cylinders Type ZE-135/90-240, device no. 8241 224 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

135

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

143.1

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

79.5

Thrust force at 310/--- bar . . . . . . . . . . . . kN

443.7/---

Pulling force at 310/--- bar . . . . . . . . . . . . kN

236.8/---

Bucyrus Europe GmbH, Lünen 2010

E

lifting cylinder, double acting

6.26

Shield support 1143/3048-2X4113-1750

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic diagram and spare parts catalog.

Tab. 14: Pressure relief valves, use of the various models Application

Design

Setting pressure in bar

Device No.

For return line

Spring-loaded

80

8220 042 080 00 00

General application, not for props and stabilizing cylinders

Spring-loaded

380

7337 486 380 00 00

For props

Spring-loaded

450

8220 027 450 00 00

For stabilizing cylinders

Spring-loaded

450

7337 486 450 00 00

Bucyrus Europe GmbH, Lünen 2010

E

Caution!

The setting pressure of pressure relief valves should not be changed. Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Noncompliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system diagram. Noncompliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Noncompliance can lead to leaks on the staple locks and compromise the operational safety of the hydraulic system. identification

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The text code includes the following information: J setting pressure, setpoint, J the week the setting was made, J the year the setting was made, J person who made last changes.

Doc. No.: 7420 205 000 BA 00

VTSV / 01

6.27

Pressure relief valves Tab. 15: Letter code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

Color coding is with either one or two colors. It indicates the range within which the setting pressure is located. The following Fig. 72 shows a pressure relief valve provided with a blue/white color code.

This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 72: Pressure relief valve, example

b

The following table shows the relationship between the color code and the pressure range.

Tab. 16: Color codes for pressure relief valves, overview

1)

6.28

Color

Pressure range (bar)

Black

0 - 49

Black/white

50 - 99

Brown

100 - 149

Brown/white

150 - 199

Green

200 - 249

Green/white

250 - 299

Blue

300 - 349

Blue/white

350 - 399

Red

400 - 449

Red/white

450 - 499

Yellow

500 - 549

Yellow/white

550 - 599

Orange

600 - 649

Orange/white

650 - 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” equals 420 bar, “08” equals 80 bar

Shield support 1143/3048-2X4113-1750

Bucyrus Europe GmbH, Lünen 2010

E

a

a color code b protective cap

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the mine floor level are at least 15 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

Fig. 73: Angles α 1 / α 2

α1 α2

Bucyrus Europe GmbH, Lünen 2010

E

M

Tab. 17: Angle α 1 / α 2 change at height M Inclination α at height M

Shield ID No. 7420 205 000 00 01 7420 205 000 00 02

α1 in °

α2 in °

M in mm

5

5

1143 to 1400

10

10

1400 to 1650

15

15

1650 to 3048

Caution!

Exceeding the permissible angles specified can lead to damage to the props and cylinders and their fastening elements as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the canopy/caving shield crosspoint moves correspondingly when the canopy is lowered or aligned/positioned.

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6.29

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Only use hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, to operate hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

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

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

The suitability test is carried out by an independent testing institute authorized by Bucyrus. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

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

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

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If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit is issued by Bucyrus on request.

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

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate is no longer valid if one or several of the requirements for obtaining the certificate are no longer fulfilled.

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

The following illustration shows a typical certificate.

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Fig. 74: Typical certificate

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Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. Ideally, the most important properties of the hydraulic fluid are monitored automatically and documented continuously in order to directly counter any harmful development.

These properties include: temperature, foaming, pH value, concentrate ratio and microbial load.

The operator of the equipment must prepare a hydraulic fluid maintenance plan for the specific application. The maintenance plan should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– setpoint: 7.5 to 9.5 J concentrate ratio

J microbial load

– setpoint: ≤ 105 col/ml.

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

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

Quality of the process water use for hydraulic fluids

The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid.

Accordingly, the requirements for monitoring the water quality are very high.

If the limits shown in the table 18 are maintained, it can be assumed that the water is basically suitable.

If one or several of the specified limit value are not maintained, this should be taken into consideration when selecting a suitable concentrate. Furthermore, water treatment may also be necessary.

However, the customer must in any case provide a sample of the original water to allow the tests required for the issue of the certificate to be performed.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

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– setpoint: see certificate

Permissible media use as spraying water

limit values

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

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Use only water that conforms to the specified limit values.

Bucyrus Europe GmbH, Lünen 2010

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Tab. 18: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

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

Electrical conductivity

< 1800 μS/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+ content

Not specified

Water hardness

< 750 mg/l CaCO3 equivalent (≤ 42° dH)

Cl- content

≤

201 mg/l

SO42- content

≤

145 mg/l

NO3- content

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml 1)

Ratio of solid foreign matter with 1.2 μm filtration in accordance with DIN EN 12662

≤

10 mg/l 1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1) The values listed must be observed during the production of hydraulic fluids.

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

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Permissible media Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. Installation, Maintenance.

Greases properties

Base: . . . . . . . . . . . . . . . . . . . . . . lithium soap NLGI class: . . . . . . . . . . . . . . . . . 2 Worked penetration: . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . . . . . . . . . . . . . . . . . . practically insoluble in water Temperature range of application: . . . . . . . . . . . . . . . -20 to +120°C Flashpoint: . . . . . . . . . . . . . . . . . . ≧ 200°C Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths, and for installation (according to EWN *) 7068).

lubricating grease A2

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Tab. 19: Lubricating greases for general application Flashpoint °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications, e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 20: Greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

The greases listed in the same table can be mixed with one another. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. If in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

*) EWN = Bucyrus works standard

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lubricating grease A1

Permissible media Lubricating pastes lubricating paste B3

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

Tab. 21: Lubricating pastes free of molybdenum disulfide Supplier

Type

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at the factory for the first time, the lubricant type used as lubricating paste B 3 in accordance with the Bucyrus works standard EWN 7068 is: gleitmolybdän “gleitmo 805” lubricating paste B6

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

Behavior in the presence of water: . . insoluble in water

Bucyrus Europe GmbH, Lünen 2010

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Application temperature range: . . . . . -34 to +120°C When the equipment is treated at the factory for the first time, the lubricant type used as lubricating paste B 6 in accordance with the Bucyrus works standard EWN 7068 is: Chesterton 785 parting and lubricating material (flashpoint 132°C) Important!

The instructions for mixing greases likewise apply to the lubricating pastes.

*) The greases listed in Table 19 are suitable for filling adjacent cavities.

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Tightening torques Tightening torques Screws with ISO metric thread Tab. 22: Tightening torques at μtot. = 0.14 Tightening torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed during installation and maintenance work.

1) The dimensions listed in brackets are used in exceptional cases only.

2) According to the Bucyrus works standard (EWN 6110, February 1985 edition) 3) Only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

4) The tightening torques comply with the works standard (EWN 6003).

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(mm)

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Thread 1)

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For your information

Standards and directives

For your information If you require spare parts or technical problems occur, contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Standards and directives Referenced standards and directives Tab. 23: Standards and directives, extract

Bucyrus Europe GmbH, Lünen 2010

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Designation

Date of issue

Title

EC Directive of the European Parliament and the Council Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery EC Directive on the approximation of the laws of the MemDirective 94/9/EC ber States concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery DIN EN ISO 12100-2 Safety of machinery Petroleum products and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Non-electrical devices for use in potentially explosive atDIN EN 13463-1 mospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces Underground mining machinery - Specification DIN EN 12321 for the safety requirements for armored face conveyors Equipment and components intended for use in potentially DIN EN 1710 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 ments for shearer loaders and plow systems DIN EN 1804 Safety requirements for hydraulic self-advancing support Preparation of instructions DIN EN 62079 - Structuring, content and presentation DIN 2000 Quality of drinking water DIN 6789 Documentation System DIN 20043 Plug Connectors for Hydraulics DIN 24320 Fire-resistant hydraulic fluids DIN 24343 Maintenance and inspection list for hydraulic systems DIN 24346 Hydraulic Systems - Design Principles DIN 51558-1 Determination of the acid number DIN 51575 Determination of sulfate ash

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2006-06-09

1994-03-23 2004-04 2004-04 2003-02 2007-05 2004-12 2000-08 2003-08 2008-08 2003-09 2003-2006 2001-11 2000-10 1990-09 2003-09 2006-12 1982-02 1984-12 1979-07 1984-11

7.3

Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Greases & solid lubricants Nonmetallic surface protection Approval procedure for fire-resistant HFA fluids in mining

1985-02 1992-06 1985-02 2008-01

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EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = works standard

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Identification of the shield Identification of the shield Name plate The main subassemblies of the shields are identified by a name plate.

Fig. 75: Name plate, example

1 2

Bucyrus Europe GmbH 3

12345 08/10

678

7420 205 000 00 0x 6

2

Bucyrus Europe GmbH, Lünen 2010

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1 manufacturer 2 SAP/order No. 3 date of manufacture

7

4 5

4 113 kN

5 device number 6 number of props 7 prop force

4 serial No.

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7.5

Identification of the shield Shield number The shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the left-hand skid on the shield.

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Fig. 76: Shield number on the skid, example

Tab. 24: Allocation of the shield numbers Shield number G1 to G6

7.6

Device number

Application

7420 205 000 00 01

Segment shield

7420 205 000 00 02

Segment end shield

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