CAT Bucyrus Shield support 1300/3100-2X5104-1750 Operating Manual - PDF DOWNLOAD

Operating manual Shield support 1300/3100-2X5104-1750 Doc. no.: 7420 198 000 BA 00

Bucyrus DBT 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

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 of Bucyrus.

Bucyrus does not accept any liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications obtained by technical development without previous notice!

Bucyrus DBT Europe GmbH, Lünen 2008 E

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

2.3

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

Repair and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions Intended use . . . . . . . . . . . . . . . .

2.5

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

2.5

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

2.6

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

3.3

Storage of new equipment . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3 3.5

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

3.6

Transporting the subassemblies . . . . . . . . . . . . . . . . . .

3.8

Base with relay bar assembly . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 3.9 3.11 3.15 3.15

Transporting the shield support . . . . . . . . . . . . . . . . . . 3.16 Transport safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.18

Contents

4.3

Who is allowed to carry out installation? . . . . . . . . . . . . . . .

Which tools are required for installation? . . . . . . . . . . . . . .

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.3 4.4

Installation of the shield support . . . . . . . . . . . . . . . . . .

4.5

Installing the assembly consoles . . . . . . . . . . . . . . . . . . . . .

Preparing the caving shield for installation . . . . . . . . . . . . .

Mounting the caving shield . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the prop control valves . . . . . . . . . . . . . . . . . . . . .

Preparing the canopy for installation . . . . . . . . . . . . . . . . . .

Mounting the flipper on the canopy . . . . . . . . . . . . . . . . . . .

Mounting the dual check valve on the flipper cylinder . . .

Mounting the flipper on the shield . . . . . . . . . . . . . . . . . . . .

Mounting the stabilizing cylinder . . . . . . . . . . . . . . . . . . . . .

Component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot-operated check valve for shifting ram . . . . . . . . . . . . .

Mounting the double filters . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the hose holder . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the electrohydraulic control unit . . . . . . . . . . . . .

Mounting the solenoid driver module . . . . . . . . . . . . . . . . . .

Mounting the water valve . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the supply block . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the PMC®-R with bracket . . . . . . . . . . . . . . . . . . .

Mounting the protection covers for the prop control valves Mounting the rubber covering . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the additional devices . . . . . . . . . . . . . . . . . . . . . .

Prop protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the hoses of the installation assembly groups that have already been mounted . . . . . . . . . . . . . . .

Mounting the rock burst valve . . . . . . . . . . . . . . . . . . . . . . . .

Setting up the hose connections for additional installation subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . .

Before you release the shield for installation . . . . . . . . . . .

Mounting branch lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 4.9 4.10 4.11 4.13 4.14 4.16 4.19 4.20 4.22 4.23 4.24 4.24 4.25 4.25 4.27 4.28 4.29 4.29 4.31 4.32 4.33 4.34 4.34 4.35 4.36 4.36 4.37 4.38

How to install the shield units . . . . . . . . . . . . . . . . . . . . 4.42 Pressure equalization of the electronic control system . . .

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

Establish a link between the connections . . . . . . . . . . . . . .

4.43 4.44 4.47

Requirements for the face hydraulic system . . . . . . . 4.48 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

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

4.49 4.51 4.51

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Points to observe prior to installation . . . . . . . . . . . . .

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4. Installation

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

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Arrangement of hydraulic components on the support . . .

Functions of the HP ball valves . . . . . . . . . . . . . . . . . . . . . .

Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brackets and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Retracting or extending side seal . . . . . . . . . . . . . . . . . . . . .

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

Operation of the double backflush filter . . . . . . . . . . . . . . . .

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

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

Functions of the water valve unit . . . . . . . . . . . . . . . . . . . . .

5.15 5.17 5.18 5.28 5.30 5.40 5.41 5.43 5.44 5.45 5.48

Bucyrus DBT Europe GmbH, Lünen 2008

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Assessment of damage according to schedule . . . . . . . . .

5.49 5.50 5.50 5.51 5.51

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Internal by-pass in props . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5.52 5.52 5.55 5.55 5.56 5.56 5.56

6. Technical data

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Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

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

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

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

Prop head with peg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Additional device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.4 6.5 6.6 6.10 6.11 6.12 6.13 6.16 6.17 6.18

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Contents Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.19 6.26

Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Flipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pusher cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinder . . . . . . . . . . . . . . . . . . . .

6.28 6.29 6.29 6.30 6.30 6.31 6.31 6.32

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.36 6.37

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.38 6.39 6.41 6.43

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.45

7. For your information Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

North America, Canada, South America . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.5

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

7.6

Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7.6 7.7

Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.8

Referenced national standards and guidelines . . . . . . . . .

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

7.8 7.8

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Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39

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. You will also find information about the structure of the manual and the signs and symbols used in it.

Before starting work applicable operating manual

Using an operating manual that is not written for the product type 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 is for: Shield support 1300/3100-2X5104-1750 * ID No.:

7420 198 000 00 00

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 product 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 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 contains general information on the safe and efficient handling of shield supports and provides you with important instructions on the work performed directly on or with the shield support.

Therefore, 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. Contact details are given in Chapter 7 of this operating manual.

safety

Read Chapter 2 “Your safety” closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the procedural instructions.

Characters and symbols used

Try to memorize the symbols and their meanings.

Danger!

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

Warning!

These points contain information on dangerous situations.

Possible consequences are death or very serious injuries.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to moderately serious injuries and machine damage.

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 dangerous 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.

. Points in the text marked in this way describe individual work steps. Follow this manual step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

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

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 changes must be approved by Bucyrus.

Use only original replacement 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 mining company, J of the mines inspectorate, J of the 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, J control system.

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2.3

Personnel Repair and maintenance In general, repair work may only be performed by persons who have the knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment.

Repair work on and overhaul of: J safety devices, as e.g. pressure relief valves, J hydraulic props and cylinders, J control units, valves, and filters,

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shall be performed only by Bucyrus service engineers or by specially trained personnel of the mining company.

2.4

Shield support 1300/3100-2X5104-1750

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 and – setting, J the following conveyor operations:

– advancing, Bucyrus DBT Europe GmbH, Lünen 2008

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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 safety equipment in working 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 applicable for shields provided with electrohydraulic shield control systems: Actuate the support lock-out 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 bases 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.

Bucyrus DBT Europe GmbH, Lünen 2008

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 devices

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 (face side and gob side). transporting

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

Non-standard transport units are shown in special drawings, which are included 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 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 wedgesbetween the lemniscatic links stabilize the position of the caving shield

Bucyrus DBT Europe GmbH, Lünen 2008

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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 flipper swiveling area 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 in the Czech Republic are: J width: 700 mm J height: 500 mm.

2.8

Shield support 1300/3100-2X5104-1750

Safety instructions 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.

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 equipment is 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 system and know the contents of the respective operating manual for that control system.

E

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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 visible. 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 face

On an inclined face, the conveyor must be anchored opposite 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 bases.

Hydraulic anchorages must always be charged to the specified working pressure since this is the only way sufficient anchorage between the support and conveyor is 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. Always operate the shield to be advanced from within the higher neighboring shield. 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 steering devices or the side seals for aligning the shields.

Early alignment prevents: J getting under the canopy of the adjacent 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,

tion, 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 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 gear is attached must not be located next to one another.

2.10

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

J the canopy will be loaded excessively in the longitudinal direc-

E

J the stabilizing cylinder locks,

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

Check that the points of attachment are undamaged before attaching a load.

J lifting gear with adequate load-carrying capacity.

Maintenance Make sure that all safety and safety equipment of the shield support units are complete and functional. If the safety and protective devices are included in the Bucyrus scope of delivery, refer to Chapter 6, “Technical Data”, for their location.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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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.

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 replacement parts catalog provided for the equipment for the order nos. for the required replacement 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.

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, 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.

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2.11

Safety instructions 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.

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

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

Hydraulic system

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids pose a very serious health hazard. protective equipment - hydraulic system

Note that when dismantling protective equipment that includes hydraulic components, those components may be pressurized.

You could be severely injured by hydraulic fluid squirting out in an uncontrolled manner. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

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 defective protective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check 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 do not leak.

Ensure that no dirt enters the hydraulics system during repair work.

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

Before removing staples to disconnect hydraulic hoses, turn the hose at the coupling socket 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.

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Make sure the line is depressurized.

2.12

Shield support 1300/3100-2X5104-1750

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When handling hydraulic fluids, avoid direct contact with the skin.

Hydraulic fluid can penetrate the skin and cause serious infections.

Bucyrus DBT Europe GmbH, Lünen 2008

handling hydraulic fluids

Safety instructions Secure the connectors of the hydraulic elements with the proper coupling clips 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 hose lines approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Fig. 2:

Example: 4SP hydraulic hose, identification 3 2

Bucyrus DBT Europe GmbH, Lünen 2008

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1

6

5

4

1 manufacturer 2 hose type

4 standard 5 nominal diameter

3 date of manufacture, 1st quarter 2002

6 flame-resistant and antistatic

Never try to hold a hydraulic hose that is thrashing about. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged. installing hydraulic hoses

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

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

Installing hydraulic hoses, slack RIGHT

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WRONG

2.13

Safety instructions J there is no twisting in the hoses, Fig. 4:

Installing hydraulic hoses, twisting RIGHT

WRONG

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter), Fig. 5:

Installing hydraulic hoses, bending WRONG

J cannot chafe, Fig. 6:

Installing hydraulic hoses, crossing RIGHT

WRONG

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

Only push hydraulic hoses into the connector sockets by hand.

Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

2.14

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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RIGHT

Safety instructions When installing the hydraulic hoses, ensure that they cannot be: J torn out, J kinked, J crushed, J driven over, J twisted by the movement of the equipment (Fig.: 7).

Fig. 7:

Installing hydraulic hoses, connections on moving parts WRONG

Bucyrus DBT Europe GmbH, Lünen 2008

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RIGHT

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2.15

Bucyrus DBT Europe GmbH, Lünen 2008

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Safety instructions

2.16

Shield support 1300/3100-2X5104-1750

3

Storage and transport

Storage

Storage and transport This chapter contains important information concerning the proper storage and transport of the shields.

Observance of the instructions and tips will increase the service life of the shields. You will also find instructions on how to carry out transport work safely and efficiently. Reading this chapter carefully will help you to simplify your day-to-day work.

Storage Storage of new equipment corrosion protection

The surfaces of the equipment are coated with temporary corrosion protection. If stored properly, the equipment parts will be protected for a period of six months, starting from the date of delivery.

Bucyrus DBT Europe GmbH, Lünen 2008

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Prior to delivery, hydraulically operated equipment is filled with the anticorrosion and antifreeze fluid HYDROCOR® CV50*) and tested.

The fluid remains in the hydraulic system for the purpose of transport and (if required) subsequent storage.

HYDROCOR® CV50 is frost-free down to -40 °C and protects the metallic materials used from corrosion. It contains a color indicator which reacts when the pH value drops. This changes the color of the medium from “red” to “yellow”. The yellow coloration indicates that the anticorrosion protection is no longer adequate.

Additional information concerning the characteristics of the HYDROCOR® CV50 can be obtained as needed from the respective manufacturer's data sheet.

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 medium if required. short-term storage

During short term storage (approx. 4 weeks) of equipment outdoors, at temperatures above freezing, electrical components need not be removed. They do, however, still need to be protected, particularly against environmental influences, and also against high temperatures, e.g. by suitable protective covers and/or sheathings for the control systems and by supplementary covering of the equipment. If the storage period exceeds four weeks, additional special precautions must be taken, depending on the ambient conditions. For example, it may be necessary to remove the electronic control unit for the purpose of proper storage.

long-term storage

If storage is expected to last longer than six months, then all of the cavities in the hydraulic components must be filled completely with a corrosion inhibitor, such as HYDROCOR® CV 50. The fluid must possess corrosion protection properties and be frost-proof within the temperature range intended for the application. All connections must be sealed with durable and suitable plugs.

It is highly recommended that the equipment not be stored outdoors. It should be stored in a dry, well-ventilated room. If this is not possible for the entire shield unit, for example, then the hydraulic and electronic components might have to be dismantled and stored separately. *) HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal / Germany

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3.3

Equipment which is stored outdoors must be protected against direct sunlight, precipitation and contamination, for example by using tarpaulins. It must also be stored in such a way that liquids will not be able to accumulate in hollow spaces. Liquids which get into hollow spaces during transport or handling must be able to drain freely.

electrical equipment, rubber and plastic parts

Electrical equipment, electronic components, replacement parts made of rubber or plastic - such as seals and hoses - and pressure fluids must be generally stored in closed spaces at 15 °C to 25 °C, and protected against direct sunlight. Exceptions: See section “Short-term storage”.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. A storage period of approximately two years is therefore specified for these parts as an indicative value.

moisture and dirt

All hydraulic elements must be appropriately protected against the penetration of dirt and moisture during storage. The connection surfaces of the hydraulic components that remain in the device must be protected against corrosion and sealed with blind plates.

Hydraulic plug connections and electrical cables must be sealed with suitable caps or plugs.

plastic deformation

When storing subassemblies, such as props and cylinders, which contain sealed contact joints, sealing elements can be plastically deformed since they are constantly subjected to unilateral loads due to the weight of the parts. This can render the sealing element useless or reduce its service life considerably. This effect is mainly influenced by the size and duration of the acting force and the temperature at the time.

For this reason, only store the props, cylinders and similar parts in an upright position. This especially applies when the parts are to be stored for a relatively long period of time.

If you want to store a machine which contains the above-named parts, you might have to dismantle such parts for the purpose of proper storage.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be carried out. This will make it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

This can be checked by Bucyrus upon the request of the mine.

The mining company will bear the cost for this.

HFA fluids

The regulations stipulated by the manufacturer or of the supplier take precedence in every instance involving the storage of HFA fluids and/or concentrates for the production of HFA fluids. Additional information can also be found in Chapter 6, in the section “Permissible media”.

When removing stock from storage or when placing it there, take care to ensure that any new supplies are stored separately from existing stock in such a way that old stock is always taken first when supplies are required for use. Label the containers accordingly.

3.4

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

storage outdoors

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Storage

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

If the hydraulic system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly backflushed in advance and then filled with a suitable corrosion inhibitor (e.g. HYDROCOR® CV 50). If this is not done, then the hydraulic 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.

Bucyrus DBT Europe GmbH, Lünen 2008

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corrosion protection

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3.5

Transport Transport

In consultation with the customer, transport units have been established, taking into account the special local circumstances, as described further below under “Transport units”:

points of attachment

Where technically possible, the load units have suitable, fixed lifting points for transport and installation. Otherwise, corresponding tapped holes or other fastening options are provided for temporarily fixing the points of attachment.

More detailed information about the arrangement and capacity of the points of attachment can be found in the figures of the replacement part catalog or the special figures for transport units which, if applicable, can be found in the appendix of this manual.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic parts which were previously operated with a frostsensitive medium, such as an oil-in-water emulsion (HFAE), must be completely emptied and then filled with a frost-proof corrosion inhibitor, for example HYDROCOR® CV 50. If the fluids could not be completely exchanged due to technical reasons, a corrosion inhibitor is to be selected which can be mixed with the medium originally used and it is to be made sure that the media are sufficiently mixed.

Transport of equipment at temperatures in the range of -21 °C to -40 °C is only permissible when certain measures have been taken to meet these conditions at the design and manufacturing stages.

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. Here, external forces are only to be applied to the lifting points and load bearing surfaces specified in any special drawings.

The equipment may not be transported at temperatures below -40 °C. 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

3.6

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 complete equipment is protected against harmful environmental influences by suitable packaging.

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

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

transport units

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Warning!

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

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Transport transport units

A shield unit can be transported as a completely assembled unit or broken down into subassemblies. The transport units have been planned and defined in close cooperation with the customer.

Tab. 1: Transport units

Transport unit Base Installation console Prop Caving shield Canopy

Bucyrus DBT Europe GmbH, Lünen 2008

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Flipper face shield Prop valve, right Prop valve, left Shifting ram valve Dual CV for flipper cylinder Backflush filter Hydraulic system lifting cylinder Hydraulic system shifting ram Supply block Electrohydraulic control unit Solenoid driver module Water valve Caving area spraying Hydraulic system pusher Hydraulic system flipper

Remarks With relay bar assembly and pusher cylinder, partially fitted with hoses 1 prop as transport group With stabilizing cylinder, side seal and lemniscatic link, fitted with hoses Without flipper, with side seal, partially fitted with hoses With flipper cylinder Premounted - in crate Premounted - in crate Premounted - in crate Premounted - in crate Premounted - in crate In crate Piloted check valve, with pressure relief valve and mounting bolt - in crate Premounted on support - in crate Premounted on support - in crate

With cable - in crate Premounted - in crate Premounted - in crate Valve - in crate Dual check valve, 2 PRV in crate (prefitted with hoses) ®Bracket for PMC R In crate PMC®-R In crate Protection cover for prop In crate check valve, right Protection cover for prop In crate check valve, left Supply hoses with In crate protective hoses Rubber covering, right With mounting bolts - in crate Rubber covering, left With mounting bolts - in crate Protective prop sleeves With mounting material - in crate

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3.7

Transporting the subassemblies The crates are numbered and provided with packing lists. It should be taken into account that the crates must be set up in a particular sequence during transport for onsite installation.

Transporting the subassemblies The shield support is broken down into transport units which need to be mounted underground. The connecting elements of the subassemblies are partially premounted in the transport units.

Base with relay bar assembly Fig. 8:

Transporting the base

normal transport

S1

S2 S3 perpendicular transport

S1 load ring, load capacity 15 000 kg S2 transport hole, load capacity 15 000 kg S3 long slot, load capacity 15 000 kg

3.8

L = 3 200 mm W = 1 630 mm H = 848 mm weight = 7 250 kg

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

S2

E

S1

Transporting the subassemblies Caving shield The caving shield transport unit consists of the caving shield, lemniscatic link and stabilizing cylinder subassemblies. The lemniscatic link and stabilizing cylinder are additionally secured with chains.

Caving shield transport unit

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 9:

The point of attachment S2 is a piece of transport equipment which has to be mounted before perpendicular transport.

. Push the transport equipment through the inside of the lemniscatic link bore.

. Secure the transport equipment with the pin and both spring cotters.

Fig. 10: Transport equipment for caving shield

5

2

1 5 1 transport equipment, caving shield 2 pin

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5 spring cotter

3.9

Transporting the subassemblies Please use attachment points S2 and S3 for perpendicular transport of the caving shield.

Fig. 11: Transport of caving shield normal transport S1

S1

S1

S1

Variant 01

S2 S3

S1 transport hole, load capacity 5 000 kg S2 transport equipment, load capacity 5 000 kg S3 load ring, load capacity 15 000 kg

3.10

L = 2 606 mm W = 1 670 mm H = 1 014 mm weight = 6 599 kg

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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perpendicular transport

Transporting the subassemblies Canopy The point of attachment S2 is a piece of transport equipment which has to be mounted before perpendicular transport.

. Push the transport equipment through the inside of the bore. . Secure the transport equipment with the pin and both spring cotters.

E

Fig. 12: Transport equipment for canopy

Bucyrus DBT Europe GmbH, Lünen 2008

5 2 S2 5

1 transport equipment, canopy 2 pin

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1 5 spring cotter

3.11

Transporting the subassemblies Fig. 13: Transport of the canopy normal transport S1

S1

S1

S1

S2 Bucyrus DBT Europe GmbH, Lünen 2008

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perpendicular transport

S1

S1 S1 load ring, load capacity 5 000 kg S2 transport equipment, load capacity 5 000 kg

L = 4 920 mm W = 1 630 mm H = 613 mm weight = 6 762 kg

3.12

Shield support 1300/3100-2X5104-1750

Transporting the subassemblies For transport in the mine shaft, use the transport equipment specially designed for that purpose.

Fig. 14: Mounting of the transport equipment

1 2

a

S2

11 12

Bucyrus DBT Europe GmbH, Lünen 2008

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10

12

S2 load ring, load capacity 8 000 kg a canopy 1 transport equipment, mine shaft transport, variant 2

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2 threaded bolt 10 hex. nut M 42-8 11 washer 42 12 locking clip 4.5

3.13

Transporting the subassemblies Fig. 15: Transport equipment, variants 1 and 2 S2 S1

1

2

1 transport equipment, mine shaft transport variant 1 2 transport equipment, mine shaft transport variant 2

S1 load ring, load capacity 15 000 kg S2 load ring, load capacity 8 000 kg

Fig. 16: Canopy transport in the mine shaft (without flipper) 2

S2

Bucyrus DBT Europe GmbH, Lünen 2008

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S2

S2 Load ring, load capacity 8 000 kg

3.14

2 Transport equipment, mine shaft transport variant 2

Shield support 1300/3100-2X5104-1750

Transporting the subassemblies Flipper Fig. 17: Transport of the flipper

1

S1

Bucyrus DBT Europe GmbH, Lünen 2008

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S1

1 cylinder holder S1 load ring, load capacity 1000 kg

L = 1396 W = 1200 H = 344 weight = 657 kg

Prop Fig. 18: Transporting the props S1

S1

S1

S1 load ring, load capacity 1000 kg

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L = 1490 W = 506 H = 566 weight = 1470 kg

3.15

Transporting the shield support Transporting the shield support transport safety devices

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 Quantity

Component

Transport safety devices

Flipper

Chain

1

Side seal, movable

Pin and securing device

4

Face side

Transport rod

1

Gob side

Chain

1

Unused hydraulic connections are protected by protective caps or plugs

-

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.

3.16

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Hydraulic system

E

Relay bar

Transporting the shield support Fig. 19: Transporting the shield support as a complete unit 4740 B

So

X4 H

X3 Sy

X1

X4 X2

S1

930 1630

S2

Sx L

4561 S3

930 S4

S3

Bucyrus DBT Europe GmbH, Lünen 2008

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1200

S4

S6

7336

S5

S1 long slot, 2x on face side on the base, load capacity: 15 000 kg S2 transport hole, 2x on gob side on the lemniscatic links, load capacity: 15 000 kg S3 long slot, 2x at the front on the canopy, load capacity: 15 000 kg S4 load ring, 2x on the caving shield, load capacity 15 000 kg S5 load ring, 2x on base, load capacity 15 000 kg S6 long slot, 2x on base, load capacity 15 000 kg X1, X2 transport safety device for relay bar, face side and gobside X3 transport safety device for the flipper X4 transport safety device for moveable side seals So center of gravity

Tab. 3: Model specification for shield support 1300/3100-2X5104-1750 Order No.

Prop force

7420 198 000 00 01 2 x 5104 kN

Year of manufacture

Application

2008

Face shield

Important!

For transporting, use the attachment lugs S1 and S2.

Tab. 4: Shield support 7420 198 000 00 01, dimensions and weights

1)

Doc. no.: 7420 198 000 BA 00

Device number

Length L in mm

Width W in mm

Height H in mm

Sx/Sy

Weight

in mm

in kg

7420 198 000 00 01

7 204

1 670

1 300

1 362/768

27 0001)

Side flap dismantled

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3.17

Transporting the shield support Transport safety device Relay bar assembly Fig. 20: Relay bar assembly, gobside

142

144

142 chain 6x42 143 hex. head screw M 12x40-8.8

144 hex. nut VM 12-8

Fig. 21: Relay bar assembly, face side

141

141

140

140 transport rod

3.18

141 spring clip 6

Shield support 1300/3100-2X5104-1750

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143

Transporting the shield support Transport safety device, lifting cylinder Caution!

In the transport position (shield completely retracted), the supply block can collide with the cylinder bearing. For this reason, during transport, the cylinder bearing of the lifting cylinder must be folded in.

In order to be able to fold in the cylinder bearing of the lifting cylinder:

. Remove the securing device pin (b) and the staple (c). . Fold the cylinder bearing (a) toward the face side. . Re-insert the securing device into the cylinder bearing to prevent its loss.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 22: Lifting cylinder with cylinder bearing folded in for transport

19

31 50

19 cylinder bearing 31 pin 16x117

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50 staple DN 10

3.19

Bucyrus DBT Europe GmbH, Lünen 2008

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Transporting the shield support

3.20

Shield support 1300/3100-2X5104-1750

4

Installation

Points to observe prior to installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation work may only be carried out by persons who have been adequately trained for these particular requirements.

Work on: J safety components (pressure relief valves, extinguishers, etc.), J the electrics (controls, signaling devices, etc.) and J the hydraulics (cylinders, directional control valves, hoses etc.)

shall only be carried out by service engineers from Bucyrus or by specially trained personnel.

Which tools are required for installation?

Bucyrus DBT Europe GmbH, Lünen 2008

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tool box

You will need a number of tools in order to be able to install the shield support properly.

We recommend that you deposit a tool box at the set-up site.

The box should contain the following tools: J 1 fitter's hammer 1500 gr.

J 1 fitter's hammer 1000 gr.

J 5 cross chisels 200 x 20 x 12 mm J 5 flat chisels 200 x 23 x 13 mm J 3 hex. screwdrivers 1.0 x 5.5 x 100 mm J 3 hex. screwdrivers 1.6 x 10 x 175 mm J 5 water pump pliers J 1 set of split-pin drifts 5, 6, 8, 10, 3 and 16 mm J 1 metal-cutting saw bow with wooden handle J 3 metal-cutting saw blades, HSS FLEX 24 teeth J 1 pair of pliers for retaining rings I VPJ-6 J 1 pair of pliers for retaining rings A VPA-6 J 1 hex. socket offset screwdriver, 1000 CV N/SB J 1 torque wrench 100 - 500 Nm J 1 torque wrench 20 - 100 Nm J 1 socket spanner set 1481 06 MM C J 1 socket spanner set 1672 09 MM C J 1 converter for sockets 1539 C J 1 set of striking box wrenches SG 41, 46, 55, 65 and 75 mm

Doc. no.: 7420 198 000 BA 00

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4.3

Points to observe prior to installation In addition, various items of auxiliary equipment and machines are required at the points of installation. These include, among other things: J lifting gear with sufficient load capacity J means of attachment with sufficient load capacity J impact wrenches incl. accessories J drill incl. accessories

Installation instructions The support surface for the shield support must be flat, sufficiently large in size and able to support the required load.

The sequence of operations during installation must be adapted to the individual conditions on site. Before starting the work a detailed list of all steps to be taken with respect to transport and installation should be prepared and a corresponding plan established.

tightening torques

For tightening torques not stated in the installation instructions for the components, please refer to the list in Chapter 6. Please also observe the tightening torques specified in the spare parts lists provided.

handling instructions - junction points

Bolts, bore holes, screws and securing elements must be lubricated with grease prior to assembly.

The hydraulic connections such as sockets and nipples of the plug-O connections must be treated with the molybdenum disulfidefree B3 lubricating paste in accordance with EWN 70681) before the hydraulic connections are joined with one another.

All of the slide surfaces must be treated with the molybdenum disulfide-free B6 lubricating paste in accordance with EWN 70681) before the transport units of the steel structure are connected with one another.

See also Chapter 6, section “Lubricating greases and pastes”.

1) EWN = works standard

4.4

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

installation plan

E

Caution!

Serious damage can be caused to the shield support as a result of incorrect installation.

Install the shield support only according to the instructions of Bucyrus technicians.

Installation of the shield support Installation of the shield support The shield support is broken down into transport units (see Chap. 3 “Transport”) which must be mounted underground.

The sequence of the onsite transport corresponds with the installation sequence displayed below and should be incorporated into the installation plan. transport units

The transport units/assembly units are defined with respect to the special local conditions, see Table 5.

Tab. 5: Transport units

Transport unit Base Installation console Prop Caving shield Canopy Bucyrus DBT Europe GmbH, Lünen 2008

E

Flipper, face shield Prop valve, right Prop valve, left Shifting ram valve Dual CV for flipper cylinder Backflush filter Hydraulic lifting cylinder Hydraulic system shifting ram Supply block Electrohydraulic control unit Solenoid driver module Water valve Caving area spraying Hydraulic system pusher Hydraulic system flipper Bracket for PMC®-R PMC®-R Protection cover for prop check valve, right Protection cover for prop check valve, left Supply hoses with protective hoses Rubber covering, right

Doc. no.: 7420 198 000 BA 00

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Remarks With relay bar assembly and pusher cylinder, partially fitted with hoses 1 prop as transport group With stabilizing cylinder, side seal and lemniscatic link, fitted with hoses Without flipper, with side seal, partially fitted with hoses With flipper cylinder Premounted - in crate Premounted - in crate Premounted - in crate Premounted - in crate Premounted - in crate In crate Piloted check valve, with pressure relief valve and mounting bolt - in crate Premounted on support - in crate Premounted on support - in crate With cable - in crate Premounted - in crate Premounted - in crate Valve - in crate Dual check valve, 2 PRV in crate (prefitted with hoses) In crate In crate In crate In crate In crate With mounting bolts - in crate

4.5

Installation of the shield support Rubber covering, left Protective prop sleeves

With mounting bolts - in crate With mounting material - in crate

The connecting elements of the subassemblies are partially premounted in the transport units. These must be dismantled for the construction of the subassemblies.

The crate comes with a packing list. Note that the crate must be set up in a particular sequence during transport for on-site installation.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 23: Attachment parts for the shield in the crate

4.6

Shield support 1300/3100-2X5104-1750

Installation of the shield support Installing the assembly consoles

. Remove the spring cotter (10) and pin (5) mounting parts of the pin connection.

. Position the assembly consoles (b) behind the bases (a) so that the you can mount the pin connections.

. Connect the assembly consoles to the base with the two pins and secure the pins with spring cotters.

. Pull the assembly consoles to the rear until there is no play in the long slot.

Fig. 24: Installing auxiliary consoles

Bucyrus DBT Europe GmbH, Lünen 2008

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a

b

10

5

5 pin 10 spring cotter 8

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a base b assembly console

4.7

Installation of the shield support . Remove the pin securing devices (70, 33) and (70, 35) the lemniscatic link pins.

. Pull the lemniscatic link pins (40 and 41) out of the bore holes.

Fig. 25: Removing the lemniscatic link pins 70

a

33

40

70

33 locking plate 35 locking plate 40 lemniscatic link pin 133.5x577 41 lemniscatic link pin 163.5x587

4.8

b 70 locking clip a base b assembly console

Shield support 1300/3100-2X5104-1750

E

35 Bucyrus DBT Europe GmbH, Lünen 2008

41

Installation of the shield support Preparing the caving shield for installation The caving shield must lie with the lemniscatic links on the bottom.

. Remove the transportation chains for the lemniscatic links. . Secure the stabilizing cylinder with a chain to keep it from falling down.

. Mount the two transportation devices (1), secure them with the pins (2) and the pins themselves with two spring cotters each (5).

Fig. 26: Mounting transport equipment to the caving shield 1

Bucyrus DBT Europe GmbH, Lünen 2008

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c

5 2 1

5

2 1 transport equipment 2 pin 5 spring cotter 5

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a

a a safety chain c caving shield

4.9

Installation of the shield support Mounting the caving shield

. Check the transport safety device of the stabilizing cylinder. . Lift up the caving shield slowly.

Caution!

The lemniscatic links could move uncontrollably when lifting the caving shield. You can become seriously injured as a result of this. Make sure you keep a sufficient distance away from the caving shield.

. Position the caving shield above the base frame and mount the pin connections of the front lemniscatic links. Secure the pin connection with the securing elements (33, 70).

Fig. 27: Mounting the caving shield (1) 1

f c

b

E

a 70

e

d 1 transport equipment load capacity 5000 kg 33 locking plate 70 locking clip 41 lemniscatic link pin 163.5x587 a lemniscatic link, front

41 b lemniscatic link, rear c caving shield d base frame e bracket f point of attachment, load capacity 11000 kg

. Lower the rear part of the caving shield until the (rear) lemniscatic links lie on the brackets and can be mounted in the base.

. Mount the pin connections of the (rear) lemniscatic links.

Secure the pin connection with the securing elements (35, 70).

Fig. 28: Mounting the caving shield (2)

b 35 40 70 35 locking plate 70 locking clip

4.10

40 lemniscatic link pin 133.5x577 b lemniscatic link, rear

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

33

Installation of the shield support Danger!

Never work on an unsecured caving shield during assembly!

You could be severely injured or even killed by sudden uncontrolled sinking of the caving shield. Always secure it against dropping down by placing the pieces of hardwood between the lemniscatic links!

. Check the transport safety device of the stabilizing cylinder again.

Warning!

Never work under an unsecured stabilizing cylinder!

Mounting the props

. Remove the pins, locking clips (Fig. 29, items 34, 71) and the prop retainers (Fig. 29, items 17 and 18).

. Position the two props in the prop holders. The valve connections (c) must point toward the face side.

. Place hardwood wedges between the props and the tie-bar that Bucyrus DBT Europe GmbH, Lünen 2008

E

connects the bases. This will keep the props in place.

. Mount the previously dismantled prop retainers and secure them with the pin and spring cotter (Fig. 29, Items 34, 71).

. Check whether the mounting devices in the prop head for the fastening pegs are flush with the canopy. If not, rotate the prop head accordingly into the correct position (use for this purpose the turning fixture).

Doc. no.: 7420 198 000 BA 00

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4.11

Installation of the shield support Fig. 29: Mounting the props 71 34 17

Bucyrus DBT Europe GmbH, Lünen 2008

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a

71 34 17

b d

18

c

17 prop retainer, right 18 prop retainer, left 34 pin 35/29x62 71 locking clip 4

4.12

a prop, right b prop, left c valve connection d hardwood wedge

Shield support 1300/3100-2X5104-1750

Installation of the shield support Mounting the prop control valves

. Remove the cover plate on the prop valve connection. . Take care to ensure that the block seal (38) is inserted properly in the valve connection.

The prop control valve with compensating valve is mounted on the right prop:

. Mount the prop valve to the valve connection with the four (1). . Tighten the four cyl. head screws crosswise with a tightening torque of 34 Nm. Caution!

Incorrectly mounted prop control valves might not be leak-proof. Take care to ensure that the block seal is correctly installed and the four mounting bolts are tightened crosswise with a tightening torque of 34 Nm.

. Close the ball valves for the pressure supply to the prop at the E

prop control valve.

Bucyrus DBT Europe GmbH, Lünen 2008

Fig. 30: Mounting the prop control valve (hoses not shown) a

38

d b

1 c 1 cylinder head screw M 10x55-A 2-70 38 block seal 16X23X1.9 a prop, right

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b prop control valve, right c prop control valve, left d compensating valve

4.13

Installation of the shield support Preparing the canopy for installation Before setting up the canopy

. Dismantle the transport components which were required for lateral transport: spring cotters (5), locking pins (2) and the transport equipment (1).

The transport components will be required for other canopies.

Return these to the place for lateral transport.

Fig. 31: Preparing the canopy for installation (1) a 2

1

1 transport equipment 2 locking pins

5 spring cotter a canopy

. Dismantle the transport components for transport in the mine shaft: locking clips (item 12), threaded bolts (item 2), hex. nuts M 42 (item 10) and the washer (Item 11). See Fig. 32.

The transport components will be required for other canopies.

Return these to the place for transport in the mine shaft.

. Make sure that the pegs (item 5) are pushed outward and secured with the pins and locking clip (items 6 and 7) in the groove of the peg. See Fig. 32.

4.14

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Bucyrus DBT Europe GmbH, Lünen 2008

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5

Installation of the shield support Fig. 32: Preparing the canopy for installation (2) 2 1

11

12

a

Bucyrus DBT Europe GmbH, Lünen 2008

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10

5, 6, 7

1 transport equipment 2 threaded bolt 5 peg 68x127 6 pin 20x170 7 locking clip 5

10 hex.nut M 42-8 11 washer 42 12 locking clip 4.5 a canopy

. Connect the hydraulic prop to the auxiliary hydraulic system. . Take care to ensure that the blind plugs in the prop control valve are on hand and that all connections have been made correctly (see Chapter 5, “Shield components”).

Doc. no.: 7420 198 000 BA 00

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4.15

Installation of the shield support Mounting the flipper on the canopy

. Remove the transport safety devices on the flipper. . Lay the main canopy (a) with the rear side on hardwood timbers so that you can guide the screws (22) from below through the canopy.

. Position the flipper in front of the main canopy. . Remove the cylinder holder (4), including its fastening elements.

. Remove the fastening elements (22 and 24) from the flange plate (3).

. Guide the hammer-head screws (23) into the long slots of the main canopy (a).

. Mount the cylinder holder (4) on the main canopy (a).

Fig. 33: Mounting the flipper (1)

E

23

24

4 25

26

24

14 1

22 26

3 14 2

4 25

24

23

b

4.16

1 hydraulic prop ZE-125/90-535 2 flap 3 flange plate 4 cylinder holder 14 securing device 22 screw M24x75 23 hammer-head screw M 24X90-10.9 24 hex. nut V M 24-10 25 hex. head screw M 16x180 A 2-70 26 hex. nut M 16-8 a main canopy b peg

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

a

Installation of the shield support . Push the cylinder holder in the main canopy toward the end of the canopy so that the pegs (b) engage in the main canopy.

. Screw the cylinder holder to the main canopy with the hex. nuts (24).

. Lift the flipper into the main canopy so that it can be screwed to the flange plate (3).

. Screw the flange plate to the main canopy with the fastening elements (22 and 24).

. Lift up the flipper cylinder (1) and swivel it toward the cylinder bearing.

Fig. 34: Mounting the flipper (2) 4 24

Bucyrus DBT Europe GmbH, Lünen 2008

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a

1

b 24

22 2

1 hydraulic prop ZE-125/90-535 2 flap 4 cylinder holder 22 screw M24x75

Doc. no.: 7420 198 000 BA 00

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23 hammer-head screw M 24X90-10.9 24 hex. nut V M 24-10 a main canopy b peg

4.17

Installation of the shield support . Fold the flipper cylinder (1) further in the direction of the main canopy. Pull the cylinder apart while doing so until the bearing pins can be mounted in the bearing shells on the main canopy.

Before doing so, remove the plugs on the flipper cylinder.

. Secure the bearing pins of the flipper cylinder with the securing device (14), the hex. head screw (25) and the hex. nut (26).

. Swivel the flipper toward the main canopy and secure the flipper with the securing devices (x).

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 35: Mounting the flipper (3)

14 25, 26 1

X

1 hydraulic prop ZE-125/90-535 14 securing device 25 hex. head screw M 16x180 A 2-70

4.18

26 hex.nut M 16-8 x flipper securing device

Shield support 1300/3100-2X5104-1750

Installation of the shield support Mounting the dual check valve on the flipper cylinder

. Dismantle the cover plate on the valve connection of the flipper cylinder.

Notice!

Take care to ensure that both block seals (6) are inserted properly in the dual check valve.

. Mount the dual check valve to the valve connection with the two hex. head screws (7).

. Tighten the two hex. head screws with a tightening torque of 17 Nm. Caution!

Incorrectly mounted dual check valves may not be leak-proof.

Take care to ensure that the block seals are correctly installed and the two mounting bolts are tightened with a tightening torque of 17 Nm.

E

Fig. 36: Mounting the dual check valve on the flipper cylinder (shown without hoses)

Bucyrus DBT Europe GmbH, Lünen 2008

1

8

6

7

34 1 hydraulic prop ZE-125/90-535 6 block seal 6X12X1.9 7 hex. head screw M 8X50-A 4-80 8 dual check valve NG 10 34 DN 10 plug with pressure relief

Doc. no.: 7420 198 000 BA 00

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4.19

Installation of the shield support Mounting the flipper on the shield

. Remove the pin from the canopy/caving shield connection. . Connect the auxiliary hydraulic system to the prop valves. . Open the ball valves for the pressure supply to the props. . Position the canopy with its hinge over the caving shield and lower the canopy until the pins can be mounted. Move the hydraulic props into the ball sockets. Use the props to adjust the canopy.

Fig. 37: Mounting the canopy (1)

31

11

1 a

1 base 11 canopy 31 caving shield

41 hydraulic prop a assembly console

. Mount the pin of the canopy/caving shield connection. . Secure the canopy/caving shield pin connections (8) with the securing devices (9), the pins (10) and two locking clips each (Fig. 38, item 7).

. Seal off each of the openings in the side seal with the cover plate (27) and secure these with the securing devices (29), the pins (10) and two locking clips each (7).

4.20

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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41

Installation of the shield support . Dismantle the pin connection (6 and 7) on the pegs (5). . Slide the pegs (5) into the prop head mounting device and secure each of the pegs with a pin connection (6, 7).

Fig. 38: Mounting the canopy (2)

31

11

8

Bucyrus DBT Europe GmbH, Lünen 2008

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27

29

10, 7

9

6 7

5

7

Doc. no.: 7420 198 000 BA 00

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10, 7

5 peg 68x127 6 pin 20x170 7 locking clip 5x32 8 joint pin 133.5X577 9 securing device 250 lg 10 pin 12X120 11 canopy 27 cover plate 29 securing device 240 lg 31 caving shield

4.21

Installation of the shield support Mounting the stabilizing cylinder

. Secure the stabilizing cylinder against falling with the aid of a chain hoist.

. Remove the transport chain. . Fasten the front stabilizing cylinder eyelet with the pin (12) on the canopy.

. Secure the pin on both sides with the circlip (item 13) and the bolted connection (items 14 and 15).

Fig. 39: Mounting the stabilizing cylinder

c

b

13

14, 15

12 pin 53x200 13 circlip 14 hex. head screw M 10x90-A 2-70 15 hex. nut M 10-A 2-70

4.22

14

15

12

13

a stabilizing cylinder b chain hoist c wood

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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a

Installation of the shield support Component overview Fig. 40: Overview of the arrangement for installing the hydraulic system and accessories

10

4

5

2

Bucyrus DBT Europe GmbH, Lünen 2008

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1

7 6

11 9

3 11 12, 8

1 pilot-operated check valve - shifting ram 2 double filter, can be backflushed 3 electrohydraulic control unit 4 solenoid driver 5 water valve 6 supply block

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7 PMC®-R with bracket 8 cover for prop control valves 9 rubber covering 10 lamp 11 additional devices 12 prop control valves

4.23

Installation of the shield support Pilot-operated check valve for shifting ram

. Fasten the pilot-operated check valve (4) to the screw holders at the rear right under the canopy (b) with the two hex. head screws (1) and the two hex. nuts (2).

Fig. 41: Mounting the pilot-operated check valve for shifting ram (hoses not shown) b

1

c

4

a prop, right b canopy c screw holder

Mounting the double filters The double filter is premounted with its bracket.

. Screw the holding strip (b) to the double filter (a) in the recess of the canopy in front of the right prop. Use the fastening elements (8, 10, 12) to do this.

Fig. 42: Mounting the double filter (shown without connections and hoses) 12 10 8

c b 2

1

a

1 hose holder 2 staple DN 10 8 hex. head screw M 12x35-A 4-80 10 hex. nut M 12-1.4571

4.24

12 washer 12 a double filter (can be backflushed) b bracket c screw holder

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

1 hex. head screw M 10x70-A 2-70 2 hex. nut M 10-A 4-80 4 pilot-operated check valve

E

2

a

Installation of the shield support . Fasten the hose holder (see Fig. 42, item 1) to the staple (2) and support the hose fitting of the double filter with this.

Mounting the hose holder

. Mount the 4 hose holders (700 mm lg) to the caving shield and 3 hose holders (500 mm lg) to the relay bar assembly tunnel and secure them with the staples.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 43: Mounting the hose holders

c

d

b

a a hose holder 700 mm lg b hose holder 500 mm lg

c caving shield d base frame

Mounting the electrohydraulic control unit The electrohydraulic control is already fastened to the bracket and is partially fitted with hoses (see Fig. 44).

. Fasten the two fastening hinges (e) to the brackets in the canopy with the fastening elements (b and c) so that the fastening hinges can still be rotated.

. Slip the chains of a chain hoist under the electrohyd. control unit and fasten the chain hoist to the canopy lifting points.

. Remove the pins (5). . Using the chain hoist, lift the electrohydr. control unit with the bracket under the canopy and fasten both of the front bracket suspensions with the pins (5). Secure the pins with the spring cotters (15).

. Lift the electrohyd. control unit further and rotate the fastening hinges in the bore holes of the brackets (1, 2).

. Tighten the fastening elements (b and c) with the required tightening torque (see Chap. 6, section “Tightening torques”).

. Install the hoses which are already fitted on the electrohyd. control unit in the direction in which they are to be installed on the shield.

Doc. no.: 7420 198 000 BA 00

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4.25

Installation of the shield support Fig. 44: Mounting the electrohydraulic control unit and solenoid driver module h

7

15

f

5

a

g

1, 2

d

g

Bucyrus DBT Europe GmbH, Lünen 2008

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e

b, c 7 12

4.26

1 bracket, left for control 2 bracket, right for control 5 pin on chain 7 operating label 12 hex. head screw M 10x20-A 2-70 15 spring cotter 4 a control b hex. screw M 16X50-A 2-70 c hex. nut M 16-A 2-70 d accumulator cartridge e fastening hinge f chain hoist g chain of the chain hoist h canopy lifting point

Shield support 1300/3100-2X5104-1750

Installation of the shield support Mounting the solenoid driver module

. Fasten the stud bolt (1) with the hex. nuts (2) in the brackets to the left under the canopy behind the left prop.

. Mount the solenoid driver module and secure it with the locking clips (3).

Fig. 45: Mounting the solenoid driver module (cable not shown)

2 1

3

Bucyrus DBT Europe GmbH, Lünen 2008

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a

1 stud bolt M10 2 hex. nut M 10-A 2-70

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3 locking clip 2.5 a solenoid driver module

4.27

Installation of the shield support Mounting the water valve The water valve is to be mounted next to the left prop under the canopy.

. Fasten the water valve to the screw holders of the canopy with the angle (1) and the fastening elements (6 and 7).

Fig. 46: Mounting the water valve

b

6 1

Bucyrus DBT Europe GmbH, Lünen 2008

c a

1 angle 6 hex. head screw M 10X25-A 2-70 7 hex. nut M 10-A 2-70

4.28

E

7

a left prop b canopy c water valve

Shield support 1300/3100-2X5104-1750

Installation of the shield support Mounting the supply block

. Fasten the supply block (a) to the screw holders (c) in the middle underneath the canopy (5) with the bracket (4), the four hex. head screws (1) and the four hex. nuts (2).

. Seal off the connections that are not needed with blind plugs.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 47: Mounting the supply block b c

1

2

3 4 1 hex. head screw M 16x45-A 4-80 2 hex. nut M 16-A 2-70 3 hex. head screw M 16x30-A 2-70 4 bracket

a

a supply block b canopy c screw holder

Mounting the PMC®-R with bracket The PMC®-R with bracket is located in front of the left prop under the canopy (see Fig 48).

. Mount the bracket for the PMC®-R to the screw holder (f) with the fastening elements (6 and 7).

. Push the PMC®-R into the housing of the bracket and screw the PMC®-R to the holding strip (d) with the two cyl. head screws (8).

Caution!

During the complete withdrawal of shield supports, the bracket and the control unit could collide with support components and thus become damaged.

Position the control unit and bracket in such a way that they cannot come into contact with other components during the withdrawal of the shield.

See also Chap. 5, page 5.35 “Bracket for the control unit”

Doc. no.: 7420 198 000 BA 00

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4.29

Installation of the shield support Fig. 48: Mounting the PMC-R with bracket f 6 b

7

5, 7

c

8 e

d

5 hex. head screw M 12X35-A 4-80 6 hex. head screw M 12X70-A 4-80 7 hex. nut M 12-A 4-80 8 cylinder head screw M 12x140-1.4301 a bracket

b canopy c PMC®-R d holding strip e spring cotter f screw holder

. Set up the electrical connections between the PMC®-R and the solenoid driver module (see also the separate operating manual for the PMC®-R).

4.30

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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a

Installation of the shield support Mounting the protection covers for the prop control valves

. Mount the protection covers (1 and a) on the prop control valves with the cyl. head screws (2) and the washers (3).

Fig. 49: Mounting the protection covers for the prop control valves

Bucyrus DBT Europe GmbH, Lünen 2008

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1

a

1

2 3 1 protection cover, right 2 cylinder head screw M 10x20-A 2-70

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3 washer 10 a protection cover, left

4.31

Installation of the shield support Mounting the rubber covering

. Stick the five hex. head screws (77) into the screw holders on the base frame (a).

. Position the rubber covering on the base frame. . Screw the rubber covering to the base frame with the hex. nuts (79) and washers (78).

Fig. 50: Mounting the rubber covering

b

79

a

77

75

76

75 covering, right 76 covering, left 77 hex. head screw M 12x40-A 4-70 78 washer 13

4.32

Bucyrus DBT Europe GmbH, Lünen 2008

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78

79 hex. nut V M 12-1.4571 a base frame b prop, left

Shield support 1300/3100-2X5104-1750

Installation of the shield support Mounting the lamp The face lamp is located at the front center under the canopy.

. Fasten the face lamp to the screw holders (b) with the four hex. head screws (5) and four hex. nuts (6).

. Connect the lamp to the electric power supply.

Fig. 51: Mounting the face lamp

b

5

E

1

Bucyrus DBT Europe GmbH, Lünen 2008

6

a

1 lamp 5 hex. head screw M 12x30-A 2-70 6 hex. nut M 12-A 4-80

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a canopy b screw holder

4.33

Installation of the shield support Mounting the additional devices The additional devices are located to the left and right on the base frame.

. Fasten each of the additional devices to the screw holders (b) on the base frame (a) with the four hex. head screws (149) and four hex. nuts (150).

Fig. 52: Mounting the additional devices

147

a b

149

147 additional device, left 148 additional device, right 149 hex. head screw M 16x45-A 4-80

150 hex. nut V M 16-A 1.4571 a base frame b screw holder

Prop protection

. Mount the prop protection sleeves included in delivery.

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150

Installation of the shield support Installing the hoses of the installation assembly groups that have already been mounted Connect the hoses to the already installed hydraulic components in accordance with the hydraulics and hose diagram (see Chapter 5, starting on page 5.22). It is beneficial to observe the following sequence for the installation.

J pressure line between supply block and double filter and the

pressure line from the double filter to the electrohydr. control unit (DN 25), J return line from the supply block to the electrohydr. control unit

(DN 25), J water supply line from the supply block DN 20 and control unit

line from the double filter to the water valve unit DN 10, J lines for shifting ram, J lines for pusher cylinder, J lines for baselift cylinder, J lines for props.

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The hose lines are color-coded (see Tab. 11, page 5.27).

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4.35

Installation of the shield support Mounting the rock burst valve

. On the prop, dismantle the sealing cap on the connection for the rock burst valve.

Technical data and information concerning installation can be obtained from the technical documentation provided by OSTROJ.

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Fig. 53: Mounting the rock burst valve

b

a

a rock burst valve

b prop, left

Setting up the hose connections for additional installation subassemblies Connect the hoses to the installed hydraulic components in accordance with the hydraulics and hose diagram (see Chapter 5, starting on page 5.22). It is beneficial to observe the following sequence for the installation.

J lines for stabilizing cylinder, J lines for side seal, J lines for flipper cylinder, J lines for water spraying system.

The hose lines are color-coded (see Tab. 11, page 5.27).

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Shield support 1300/3100-2X5104-1750

Installation of the shield support Before you release the shield for installation Check the shield for any installation errors or other sources of error:

. Release the side seal on the moving side (remove transport securing devices).

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

Warning!

Shut-off valves may not be installed in 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.

For operation of the shield, see Chap. 5 “Operation”.

. Check the function of the hydraulics and water supply.

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. Check all functions of the shield control unit.

Important!

Do not release the shield for installation in the face until after all deficiencies have been eliminated and the entire functional capability of the shield has been established.

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4.37

Installation of the shield support Mounting branch lines The roof supports are supplied with hydraulic pressure through four branch lines which are distributed throughout the face. This ensures a more even pressure distribution in the face (see hydraulic system layout).

Caution!

The shield on which the branch line to the conveyor is installed must be set back by 200 mm so that the required travel way is kept.

Fig. 54: Shield connections e c

f

a

d

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E

b

200 a base frame b conveyor c spill plates

d branch lines e relay bar f pins for connecting

Important!

The branch lines have different lengths for various installation heights. The matching hoses are included in delivery and must be used according to the installation height.

. Depressurize the supply lines in the face.

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Installation of the shield support Fig. 55: Configuration of the branch lines

a

b

a branch lines

b spill plate conveyor

. Remove the connection hoses between the shields (pressure and return).

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. Divide the existing protective hoses according to the required

Bucyrus DBT Europe GmbH, Lünen 2008

length and pull these over the hoses (1 - 4).

. Mount the hose segments (1 and 2) with the protective hose to the distributor block of the left shield and secure them with the staples.

. Mount the hose segments (3 and 4) with the protective hose to the distributor block of the right shield and secure them with the staples.

. Connect the hoses (1 and 3) with the T-socket (5) and secure them with the staples (16).

. Connect the hoses (2 and 4) with the T-socket (6) and secure them with the staples (15).

. Mount the hose line (10 with protective hose 18) or (31 with protective hose 32) using the plug-in elbow socket (7) to the T-socket (7) and secure them with the staples (15).

. Mount the hose line (9 with protective hose 18) or (30 with protective hose 32) using the plug-in elbow socket (8) to the T-socket (5) and secure them with the staples (16).

. Mount the hose suspension to the points of attachment on the canopy.

. To do this, connect the chain (12) with the shackles (11) and the protective hose (17).

. Hang the hoses (9 and 10 or 30 and 31 with the protective hoses) over the hose suspension.

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4.39

Installation of the shield support Fig. 56: Connection of the branch line between two shields 10 and 18 or 7, 15 17 2 31 and 32 6, 15

11, 12

9 and 18 or 30 and 32

5, 16

1 hose line 2ST-50x700 2 hose line R13 40SS-OX700 3 hose line 2ST-50x1400 4 hose line R13 40SS-OX1400 5 T-socket DN 50 6 T-socket DN 40 SS-O 7 plug-in angle socket DN 40 8 plug-in elbow socket DN 50 9 hose line R13 40SS-OX3200 10 hose line 2ST-50x3400 mounting branch line to face supply line

8, 16

1

11 shackle 12 chain 8x32, 1120 mm lg 15 staple SSO DN 40 16 staple DN 50 17 protective hose 800 lg 18 protective hose 3000 lg 30 hose line R13 40SS-OX3800 31 hose line 2ST-50x4000 32 protective hose 3600 lg

. Mount the plug-in elbow socket (7) in the supply line to the conveyor and secure it with the staple (15).

. Guide the hose lines (9 and 10) or (31 and 30) with their protective hoses through the hose holder (20).

. Stick the hose line (10 with protective hose 18) or (31 with protective hose 32) in the plug-in elbow socket (7) and secure with the staple (15).

. Secure the line with the hose clip (19) and the chain (14) against falling down on the spill plate of the conveyor.

. Mount the plug-in elbow socket (8) and the HP ball valve (13) and secure them with the staples (16).

. Close the HP ball valve (13). . Stick the hose line (9 with protective hose 18) or (30 with protective hose 32) in the HP ball valve (13) and secure with the staple (16).

. Open the HP ball valve (13).

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4

Installation of the shield support Fig. 57: Connection of branch lines to supply lines 10 and 18 or 31 and 32

9 and 18 or 30 and 32

20 13 8, 16

14

19 7, 15

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14, 19

7 plug-in elbow socket DN 40 8 plug-in elbow socket DN 50 9 hose line R13 40SS-OX3200 10 hose line 2ST-50x3400 13 HP ball valve DN 40 14 chain 6x42, 462 mm lg 15 staple SSO DN 40

16 staple DN 50 18 protective hose 3000 lg 19 hose clip 77 mm 20 hose holder 30 hose line R13 40SS-OX3800 31 hose line 2ST-50x4000 32 protective hose 3600 lg

Caution!

The branch lines are not permitted to collide with the cable guide of the shearer during operation, because this could lead to damage to the supply line.

The branch lines must always be fixed in place by means of the hose holder.

Make sure the hoses are fitted properly.

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4.41

How to install the shield units How to install the shield units Caution!

For transport underground only the attachment detailed in Chapter 3 “Storage and Transport” may be used. Failure to comply can lead to personal injury and property damage.

Further information about this can be found in Chapter 3 “Storage and Transport”. installation plan

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

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. They 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.

shield number

The bases are numbered consecutively. Plates with the shield number are fitted on the base of the shield, at the face side on the right.

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Fig. 58: Shield number on the base, example

a

b a shield number

b CE symbol

Tab. 6: Allocation of the shield numbers

4.42

Shield number

Order No.

Application

1 to 108

7420 198 000 00 01

Face shield

Shield support 1300/3100-2X5104-1750

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 vented cap screw in order to enable pressure equalization between the internal and external pressure of the electronic control system housing.

. Loosen the pressure relief screw (hex socket 4 mm key width) on the control system by several turns.

Pressure equalization is signaled by an audible hissing.

Caution!

Make sure that the vented cap screw for pressure equalization on the control system is released. The foil displays may become damaged if the pressure isn't equalized.

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Fig. 59: Example of a vented cap screw on an electronic control system

a

b a vented cap screw

b electronic control PMC®R

. Afterwards, tighten the pressure relief screw by hand.

Caution!

Take care to ensure that the vented cap screw is tightened by hand again after the control system pressure has been equalized. 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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4.43

How to install the shield units Supply connections During installation, pressure can be applied to the individual shield using the so-called auxiliary supply and the shield can 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. 60: View of the supply block and auxiliary connection, left c a 24

b

24 HP ball valve DN 12, for auxiliary supply a pressure line, auxiliary supply

b return line, auxiliary supply c plug for auxiliary supply

Notice!

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

To operate 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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c

How to install the shield units When the auxiliary supply is used, the connections P, R and W on the supply block must be short-circuited with the hoses that will later be responsible for the connection with the neighboring shield (this is the usual status at the time of delivery). Should short-circuiting the supply hoses not be possible in this way, then the connections must be sealed with corresponding plugs.

Fig. 61: Control units

24 16 a

23

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P R

1

1 electrohydraulic control unit 16 supply block 23 3-way ball valve DN 20, in the pressure supply line 24 HP ball valve DN 12, for auxiliary supply

W

a auxiliary supply P pressure line, DN 40SS R return line, DN 50 W water line, DN 50

To join the shields to each another, proceed as follows:

. Close the HP ball valve, item 24 (Fig. 60), as well as the 3-way ball valve, item 23 (Fig. 61).

. Remove the plugs c from connections a and b (see Fig. 60) of the auxiliary supply.

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

. Afterwards, reopen the ball valve, item 24 (Fig. 60).

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4.45

How to install the shield units Fig. 62: Rear view of the supply block 24 16 1

34a

9 30

E

30 HP ball valve DN 20, for spraying 35a plug DN 10 with relief

24 HP ball valve, for auxiliary supply

Make sure that the HP ball valves, item 22 (see Chapter 5, Fig. 93, Fig. 94) are opened at the prop control valves.

The shield is now movable via the external control units.

. Move the shield to the desired position. . Relieve the pressure hose by closing the HP ball valve, item 24 (Fig. 60) and briefly actuating the “Advance conveyor” function.

Warning!

Pressure may build up in the return line due to incorrect operation. This must be reduced through the pressure release valve by screwing in the pressure relief screw.

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 distribution block!

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

. Release the three connection lines P, R and W on the distributor block and connect them to the neighboring shield.

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1 electrohydraulic control unit 9 PRV, 80 bar, in the return line 16 supply block

How to install the shield units Establish a link between the 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

control unit

The supply block for supplying the shield hydraulics is located in the middle between the two props under the canopy. 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 50). See also the hydraulic circuit diagrams in Chapter 5 of this manual.

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

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 system. An overview of the design of the control system is also given in Chapter 6 of this operating manual in the “Shield control system” section.

The shield units are prepared for the fitting of additional equipment.

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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4.47

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

The hydraulic medium must meet the following conditions for all hydraulic system 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

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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 hydraulics.

E

If the face hydraulics are designed such that they are 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, then, might not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

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 start-up 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.

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Please observe the following items: Bucyrus DBT Europe GmbH, Lünen 2008

J Mechanics:

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

. Position the symbol bar on the brackets 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 clevis assemblies (additional devices) are mounted on the bases to the left and right and are secured.

Note that the shields are equipped with a cooler with the longer clevis assemblies.

J Hydraulic system:

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

. Check whether there can be damage due to movements of the supports, particularly on the to the hinges and hoses.

1) Maximum possible plugging.

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4.49

Commissioning Danger!

Damaged hose lines 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 can't be damaged by movements of the support.

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

. Check the hydraulic supply pressure. . Check the load-carrying function of the prop. The current 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 operation elements to make sure they are working

. Check all signaling systems.

Important!

For further information, please see the corresponding separate operating manual from 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 function 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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J Signaling and lighting systems, information plates:

E

properly. Test whether the function is correctly executed when the corresponding operating element is activated.

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.

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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.

Bucyrus DBT Europe GmbH, Lünen 2008

. Check the function of the hydraulic and water supply for the 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 the section “Permissible media” in Chapter 6 of this operating manual.

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Commissioning

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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 system 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 supervisor 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 Czech Republic, the following values apply with respect to the minimum dimensions of the travel way: Width:

700 mm,

Height: 500 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 slabbing 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 withdrawing.

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.

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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. extra-high spill plates, wire mesh, nets or the like.

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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 when shield units are 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 controlsystem

conveyor steering device

On an inclined face, the conveyor must be anchored opposite the support, if necessary. 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.

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

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5.5

Requirements Safety requirements automatic mode

Exercise special care and caution when traveling a face 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 control unit of the currently controlled shield.

Press the “Support lock-out” switch if you have to be in the shield for a long 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 hasn't been set.

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 must 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.

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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.

E

Never allow body parts to get between the canopy and the roof, bases and the floor, the base and shifting unit or between the side seals of neighboring shield units!

Requirements Fig. 63: W r o n g, support advanced too late

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Fig. 64: 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 doesn't get under the side seal of a neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged. hydraulic system, controls

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 cylinders 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 must 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, replacement parts

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

5.8

Shield support 1300/3100-2X5104-1750

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 that 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 DBT Europe GmbH, Lünen 2008

E

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, whose mounting elements and fulcrum points are on the shield canopy and the caving shield.

Fig. 65: Shield support in normal position

α=0 M

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

Doc. no.: 7420 198 000 BA 00

VTVT / 01

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 isn't sufficient residual stroke available, this could result in serious damage to the support under unfavorable conditions - high force and unfavorable lever ratio.

Fig. 66: Shield support with extremely inclined shield canopy.

α1

M

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 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, that the automatic positive setting function leads 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 the automatic positive set.

5.10

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

s1

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), which is specified in the “Technical data” section of Chapter 6 of this manual, is exceeded, this could lead to damage to props, hydraulic cylinders and their fastening elements, as well as to the part hinges.

Since angle changes in the ends of the shield canopies or base 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 DBT Europe GmbH, Lünen 2008

E

Shield canopies of two-prop shields with stabilizing cylinders must never be set with the tip of the canopy in falls (see Fig. 67), 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. 67: 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. 68) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

5.11

Operation of the shield support Fig. 68: R i g h t: fill out roof falls

RIGHT

supportrangeofadjustment/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 proceed without obstacles and the subsequent return operation isn't 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 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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, which can often cause 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 and aligning devices are used on the shield canopies and the base frame or between the base frame 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 DBT Europe GmbH, Lünen 2008

E

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. You thereby lessen the danger of jamming the relay bar assembly in the base frame, which would hinder the shield advancing.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering device can become damaged and 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 mine 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 doesn't sink into the floor.

For shield units which are equipped with a special hydraulic lifting device, the base frame 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 bases on two-prop shields can usually be lifted hy-

draulically by actively retracting a prop, J shield units with undivided bases must be lifted and supported

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.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

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 unit. 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.

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

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: J malfunction of the electronic controls, J external obstructions:

– Shield is wedged in between the neighboring shields.

– Tip of the canopy is stuck in the roof.

– Floor step or debris is blocking the base.

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 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

Observe the following safety regulations:

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. 7: Hydraulic components Item 1

Bucyrus DBT Europe GmbH, Lünen 2008

E

2 3 4

Quantity Designation 1 Electrohydr. control unit, 12-way 1 Prop CV, NG 20 1 Prop CV, NG 20 1 CV, hydraul. piloted DN 13

Arrangement Under the canopy, behind the supply block On the prop, left, face side On the prop, right, face side Behind the right prop under the canopy On the respective prop

Remarks On the support

On the stabilizing cylinder (Z3)

For piston space side and annular space side In the return line In the return line For the flipper cylinder (Z6)

5

2

7

2

Rock burst valve VR 7100, 530/450 bar Pressure relief valve, 450 bar

8 9 10

1 1 1

CV, NW 25 PRV, 80 bar Dual CV NG 10

Behind the supply block (16) Behind the supply block (16) Flanged to the flipper cylinder (Z6)

11 12

1 4

Dual CV Pressure gauge

Flanged to stabilizing cylinder (Z3) a) 2x, each on prop check valve, face side b) 1x on the double filter c) 1x on the 3-way HP ball valve (23) in the pressure supply line

13 14 15 16

1 1 1 1

Hose lines Water spraying system Brackets and accessories Supply block

17 18

1 6

Accumulator cartridge PRV, 380 bar

19

1

Water valve unit

20

1

21

3

Double filter, can be backflushed HP ball valve DN 10 red handle

22

2

23

1

24

1

25

2

HP ball valve DN 20 red handle 3-way HP ball valve DN 20, red handle

HP ball valve DN 12, red handle Pressure gauge port

Centered in front of the props under the canopy On the electrohydr. control unit (1) a) 2x on the flipper cylinder (Z6) b) 1x on the shifting ram CV (4) c) 2x on the seal cylinder (Z4) d) 1x on the lifting cylinder (Z5) To the left, next to the electrohydr. control unit (1) under the canopy Under the canopy, in front of the right prop a) 1x under the caving shield on the distributor (27) b) 1x on the lifting cylinder (Z5) c) 1x on the right prop (Z1) Each on prop CV (2 or 3) On the supply block (16)

Behind the supply block (16)

Without compensating valve With compensating valve For shifting rams (Z2)

For stabilizing cylinders (Z3)

Subassembly group Subassembly group Subassembly group On the support

a) For flipper cylinder (Z6) b) For shifting ram (Z2) c) For seal cylinder (Z4) annular space circuit d) For lifting cylinder (Z5) Water spraying system control On the support, manually actuated a) For seal cylinder (Z4) b) For lifting cylinder (Z5) c) For stabilizing cylinder (Z3) In the pressure supply line to the prop, piston side Position I: Supplies the shield with pressure Position II: Immediately depressurizes the shield For auxiliary device

Each on prop check valve, face side

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

Doc. no.: 7420 198 000 BA 00

VTVT / 01

5.15

Operation of the shield hydraulics Quantity 2 1 1 1

Designation Distributor Water filter HP ball valve DN 20, blue CV, hydraulically piloted

34

5

Plug DN 10 with pressure relief

S1

1

Pressure sensors

Z1 Z2 Z3 Z4 Z5 Z6 Z7

2 1 1 4 1 1 1

Prop Shifting ram Stabilizing cylinder Seal cylinder Lifting cylinder Flipper cylinder Pusher cylinder

Arrangement In the back, under the canopy, left Behind the supply block (16) Behind the supply block (16) Under the canopy next to the distributor (27) a) 1x under the supply block (16) next to the HP ball valve (30) and PRV (9) b) 2x on the flipper cylinder (Z6) c) 2x on the stabilizing cylinder (Z3)

Remarks In the seal cylinder circuit In the water feed line For spraying For seal cylinder (Z4) For pressure relief

On the prop CV, only on the righthand side

Bucyrus DBT Europe GmbH, Lünen 2008

E

Item 27 29 30 31

5.16

Shield support 1300/3100-2X5104-1750

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 21a, 21b, 21c, 22, 23, 30

The following ball valves are closed during normal operation: J 24

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 8: HP ball valves Item

Color

Designation

Function

21a

Red

HP ball valve DN 10

Used for blocking the annular spaces of the seal cylinder

21b

Red

HP ball valve DN 10

Used for blocking the pressure supply to the lifting cylinder

21c

Red

HP ball valve DN 10

22

Red

HP ball valve DN 20

23

Red

3-way HP ball valve DN 20

24

Red

HP ball valve DN 12

Pressure supply during start-up and for auxiliary devices

30

Blue

HP ball valve DN 20

Used for shutting off the water supply

Interrupts the connection of the stabilizing cylinder/compensating valve Is used for blocking the pressure supply to the piston space of the right/left prop Is used for blocking the pressure supply line to the shield

Use Close when transporting the shield, so that the side seal doesn't extend and the mechanical interlock can be installed Used for holding the baselift cylinder in a certain position and for deactivating the lift function To deactivate the compensating function of the stabilizing cylinder During maintenance work on the prop and any possible disassembly During maintenance and repair work on the shield For moving the shield during start-up and for connecting hydraulically operated auxiliary devices To deactivate the function of the water spraying system

Fig. 69: HP ball valve, shown opened and closed

open

closed

Through-flow for medium enabled

Doc. no.: 7420 198 000 BA 00

VTVT / 01

Through-flow for medium stopped

5.17

Operation of the shield hydraulics Shield hydraulics Fig. 70: Shield hydraulics, layout (1a) Image caption: see Table 7 A

14

18a

34b

10

15

18c

13

E

View A

23 12c

Bucyrus DBT Europe GmbH, Lünen 2008

20 8 4

34a

9

18b 21a

17

12b

3 31 7

16

7

24

30

5

29

19

5 25

5.18

2

18b

27

Shield support 1300/3100-2X5104-1750

Operation of the shield hydraulics Fig. 71: Shield hydraulics, layout (1b) Image caption: see Table 7

1

19

31

21a

27

23 15

7

13 11 12a

Bucyrus DBT Europe GmbH, Lünen 2008

E

22 25 3

34c

18d 16

30

13

21b 19

29

2 25

22 24

25 12a 34a 27

5

7

11

34c

12b

20

23

Doc. no.: 7420 198 000 BA 00

12c

8

VTVT / 01

9

25

17

4

5

5.19

Operation of the shield hydraulics

12 functions D.A. ram pull 1

2 Extending legs

D.A. ram push 3

Canopy tip up

Extending flipper cyl.

5

4

6

Extending lift cyl.

Canopy tip down

Extending seal cyl.

7

9

8

10

Retracting flipper cyl.

Retracting seal cyl.

Extending pusher cyl.

11

12 Retracting legs

Tab. 9: Electrohydraulic control unit with 12 functions, allocation of functions Function, designation

5.20

Function No.

Advance shield

1

Set props

2

Slide conveyor

3

Extend lifting cylinder

4

Extend stabilizing cylinder

5

Retract stabilizing cylinder

6

Extend flipper cylinder

7

Retract flipper cylinders

8

Extend seal cylinder

9

Retract seal cylinder

10

Extend pusher cylinder

11

Lower props

12

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 72: Functions of the electrohydraulic control unit, symbol plate

Operation of the shield hydraulics Fig. 73: Functions of the water valve unit, symbol plate water spray canopy/gob

1 2 water curtain

Tab. 10: Water valve unit with 2 functions, assignment of functions Function, designation

Function No. 1

Water curtain

2

Bucyrus DBT Europe GmbH, Lünen 2008

E

Canopy roof, caving shield water spraying system

Doc. no.: 7420 198 000 BA 00

VTVT / 01

5.21

Operation of the shield hydraulics Fig. 74: Shield hydraulics, Image caption, see Table 7 PTO

16

23

24

12c

1

2

3

4

5

6

7

8

9

11

10

12

SP

17

iI

9

DN 50 R DN 40-SS P DN 50 W

27

25 mm

X2

34a

P

20

29

8

12b

Pusher

21a

31

Z7

W2 W1

Z4

Backflush filter

X1

X3 X2

X4

X5 X6

X7 X8

X10

30

12 11 10 9 8 7 6 5 4 3 2 1 2 P T

X12

1

X9

X11

i

E

Waterspray gob

7

19

Z4 Z4

11 18c

14

Z3

Waterspray canopy

7

34c

S1

Lifting cyl.

100 bar 200 bar

PI

3

Z2

18b

25 12a 22

13

25 12a

2

22

PI

4

D.A.ram cyl.

s I

Water curtain

Z5

Z1

5.22

21b 18d

34b

Z6

10 34b

18a

leg

5 18a

Flipper cyl.

5

Prop

21c

Z1

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

34c

Left cyl.

Seal cyl.

Z4

Operation of the shield hydraulics Fig. 75: Hose lines (1), overview

10

10 10

6 7

1

2 10

10 10

10

10 10 20

10 20 10

10 10

10 10

20

25

20

10 10

10

25

10 NIRO

25

10 NIRO

10

5 10 NIRO

25

5

10 10

20 NIRO

12

50 NIRO 50 40SS

10 NIRO

12

4

10 NIRO 10 NIRO

10 NIRO

10

10

1 hose lines 2 plug-in parts 3 cable binder LK 5 4 protective hose DN 50-1900 lg, gr.

Doc. no.: 7420 198 000 BA 00

10 NIRO

10

10 NIRO

Bucyrus DBT Europe GmbH, Lünen 2008

E

20

10 10 10

12

10

10

20

10 10

10 NIRO 10 NIRO

12

12

VTVT / 01

5 protective hose DN 50-2100 lg 6 protective hose DN 25-2100 lg 7 protective hose DN 32-2100 lg, gr.

8 protective hose DN 32-2100 lg, bl.

5.23

10x3200 NIRO

10x1600

10x2800 NIRO

10x1400 10x600

10x900 10x900

10x800

10x600

E 10x1600

40 20x3000 10x800

10x1200

10x3000

23

10x600

10x1200 20x1000

12x700

10x3000 10x3000

20x1000

10x1100 20x3000 10x3000 10x1400 10x1200

25x250

20x1700 NIRO

10x4000 10x4000 10x4000

25x600

10x3200 NIRO

10x1200 NIRO

10x120010x2000 NIRO NIRO

34 25x1400

12x3600

10x5000 NIRO

10x3600 NIRO

10x5200 NIRO

12x700

9

10x800 NIRO

10x800 NIRO

32

32

10x2200

10x1700

16 15

36 50 x 2300 Niro 4SP 50 x 2200 2ST 40SS x 2200 R13 25x250

38 10x600

22

41 24

40

26

27

37 8

10x3000 - CAUTION! 4SP 20x3000

3

Shield support 1300/3100-2X5104-1750

5.24

10x1400 10x3600

30

29 20x1000

42 1

6

21 10x3600

12x800

10x3000

19 18

5 18 20 20

22 17

33 6 5

23 6

22

39 5

18 18 9

23 28

10x1400 12x3000

11

20 28 12

Bucyrus DBT Europe GmbH, Lünen 2008

Operation of the shield hydraulics Fig. 76: Hose lines (2), face shield, overview

17

Note: the respective items can be found in the spare parts list.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

1

10 NIRO

8

10 NIRO

10

10 NIRO

2 1

50 NIRO 50 40SS 5

10 NIRO

2

10 10 10

3

23 26

26

50

28 20

28

10 NIRO

25

20 NIRO

10 NIRO

68 67

23

33

25

28

12

12

60

51

11 10 10

20

18 62 40 23

25

37

10 10 10 20 10

29

20 10 20

23 26 11

33

40

62

35

26 43

10

66 29 51 10 20

26 43

40

10 10 10

12

10

10 10

61

10 10

20

40

10

26

26

62

36

35 63

10 NIRO 10 NIRO

31

26

40

10

11 12

10

10 NIRO

10 NIRO

62

6 65 31

42 21 4

51

19 51

29

25

13

44 7 5 41

12

42 27 26

27 64

10

16 19 26 29

23 51 42 29

18

32 24

10 10

E

12

23

23

51

17

10

1

8

10 NIRO

54 26

12

Bucyrus DBT Europe GmbH, Lünen 2008

10

10

10

23 62

23

Operation of the shield hydraulics

Fig. 77: Plug-in parts (1), face shield, overview

10

Note: the respective items can be found in the spare parts list.

5.25

Operation of the shield hydraulics Fig. 78: Water spraying system accessories, overview 6 9

10

10

10

6 9

Bucyrus DBT Europe GmbH, Lünen 2008

E

10

10

10

20

10 10 10

12

10

10

10

10

10 10

20

12

10 NIRO 10 NIRO

10

12

10 10

20 10 10

25

50 NIRO 50 40SS

10 NIRO

12

10 NIRO

10

1 8

10 NIRO

10 NIRO

1 8

3 7

1 water spraying fitting DN 10 3 spray distributor 6 nozzle head

5.26

10 NIRO

10

10

10 NIRO

12

25

10 NIRO

10 NIRO

25

10

25

10 10

20 NIRO

10 NIRO

10 20 10

20

20

10 10

10

3 7

7 nozzle, compl.

8 solid steel nozzle 9 ball valve

Shield support 1300/3100-2X5104-1750

Operation of the shield hydraulics The following Table illustrates how the color code and the connection to the piston (KFL) or annular space surface (RFL) of the cylinders and subassemblies are related to one another.

Tab. 11: Overview of the color codes for the hose connections of the hydraulic components KFL

RFL

Alignment cylinder

Brown

Brown - white

Water line

Blue

Blue

Flipper cylinders

Green

Green - white

Dozer cylinder

Yellow

Yellow - white

Stabilizing cylinder

Gray

Gray - white

Prop

Red

Red - white

Shifting ram

Violet

Violet - white

Yellow - green

Yellow - green - white

Component

Pusher Retract lifting cylinder Extend lifting cylinder

Red (setting prop) Red - white - red Red - brown - white

Return

Green- brown - white

Bucyrus DBT Europe GmbH, Lünen 2008

E

Pump

Doc. no.: 7420 198 000 BA 00

Canopy piston space cover

Brown - yellow

Water spraying system, canopy top section

Blue - white

VTVT / 01

5.27

Operation of the shield hydraulics Brackets and accessories Fig. 79: Brackets and accessories, layout (1a) A

1

2 4 3 6 7 21

5

11 9

24

26

27

8 1

21 1 bracket for the control 2 bracket for double filter 3 PMC®-R support 4 supply support 5 nozzle head support 6 protection cover for prop valve right 7 protection cover for prop valve left 8 lever 9 hinge 10 hose holder

5.28

11 bracket for water valve unit 20 solenoid drivermodule fastener 21 prop valve NG 20 fastener 22 shifting ram valve fastener 23 chain fastener 24 fastener for distributor side seal 25 fastener for waterspray filter 26 hinge fastener 27 lamp fastener

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

View A

Operation of the shield hydraulics Fig. 80: Brackets and accessories, layout (1b)

Bucyrus DBT Europe GmbH, Lünen 2008

E

25

10 23 8

27

2

3

4 20 6 21

7

9

1

26

24 9

22

26

5

5

Doc. no.: 7420 198 000 BA 00

VTVT / 01

For positions, see Fig. 79

5.29

Operation of the shield hydraulics Shield components Main components Fig. 81: Main assemblies b

c

a

21

51

d 11 61, e

31

g 1

f

71

1 base (base frame) 11 canopy 21 side seal 31 caving shield 41 hydraulic prop 61 electrohydraulic shield control system 71 caving flap

5.30

a PMC®-R control unit b electrohydr. control unit c flipper d flipper cylinder e supply block f lifting cylinder g pusher cylinder

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

41

Operation of the shield hydraulics Supply block Fig. 82: View of the supply block 16 a

20

R

P

Bucyrus DBT Europe GmbH, Lünen 2008

E

W

P pressure line, DN 40SS R return line, DN 50 W water line, DN 50

16 supply block 20 double filter a PMC®-R with bracket Fig. 83: Supply block

24

23

16

16 supply block 23 3-way ball valve DN 20 in the pressure supply line

Doc. no.: 7420 198 000 BA 00

VTVT / 01

24 HP ball valve, for auxiliary supply

5.31

Operation of the shield hydraulics Fig. 84: Rear view of the supply block 24 16 1 Cutout A

34a

A

9 30

30 HP ball valve DN 20, for spraying 34a plug DN 10 with relief

24 HP ball valve, for auxiliary supply

Double filter Fig. 85: View of the double filter

20

20 double filter, can be backflushed

5.32

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

1 electrohydraulic control unit 9 PRV, 80 bar, in the return line 16 supply block

Operation of the shield hydraulics Lifting cylinder Fig. 86: View toward lifting cylinder

21b

18d

Bucyrus DBT Europe GmbH, Lünen 2008

E

Z5

18d PRV, 380 bar, for lifting cylinder 21b HP ball valve DN 10 for lifting cylinder

Z5 baselift cylinder

Control units Fig. 87: Control units

b 16

a

1

a PMC®-R control unit b adjustable support for PMC®-R

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1 electrohydraulic control unit 16 supply block

5.33

Operation of the shield hydraulics Fig. 88: PMC®-R control unit on exchangeable support

b

c

d

c emergency stop switch d support lock-out switch

Fig. 89: Electrohydr. control unit, view from the side

1

17

a

1 electrohydr. control unit 17 accumulator cartridge

5.34

a symbol plate

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

a PMC®-R control unit b support for PMC®-R

E

a

Operation of the shield hydraulics Fig. 90: Water valve unit

E

a

Bucyrus DBT Europe GmbH, Lünen 2008

a water valve unit

Also observe the separate operating manual for the water valve unit.

Bracket for control unit Before you put the shield support into operation, you must adjust the support in such a way that you can operate the PMC®-R control unit easily.

Important!

Installation info: For a shield strength of 1 300 to 2 500, only item 1 is installed.

For a shield strength of 2 500 to 3 100, items 1 and 2 are installed.

Fig. 91: Support for PMC®-R control unit

2

1

a

1 bracket for PMC®-R 2 bracket for PMC®-R, long

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a PMC®-R

5.35

Operation of the shield hydraulics Fig. 92: Support for PMC®-R control unit 1* 6* 7* 2* 5*, 7* 5*, 7*

1** 5**

3*

6**

10**, 11**, 12**

3* clevis assembly 5* hex. head screw M12x35-A 4-80 6* hex. head screw M12x70-A 4-80 7* hex. nut M 12A 4-80 * belongs to item 2, Fig. 91

1** bracket for PMC®-R 2** cover plate 5** spring cotter 5 6** tube 10** hex. head screw M12x130-A 4-80 11** washer 12 12** hex. nut M 12-1.4571 ** belongs to item 1, Fig. 91

Caution!

During the complete withdrawal of shield supports, the bracket and the control unit could collide with support components and thus become damaged.

Position the control unit and bracket in such a way that they cannot come into contact with other components during the withdrawal of the shield.

Caution!

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

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

5.36

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

1* support I 2* support II

E

2**

Operation of the shield hydraulics Props Fig. 93: View of the left prop from the face side (with and without out protective plate)

12a

Bucyrus DBT Europe GmbH, Lünen 2008

E

22

25 2 2 prop control valve 12a pressure gauge

22 HP ball valve DN 20 pressure line 25 pressure gauge port

Fig. 94: View of the right prop from the face side (with and without out protective plate)

12a 21c

22

25 3 a

3 prop control valve 12a pressure gauge 21c HP ball valve DN 10

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22 HP ball valve DN 20 pressure line 25 pressure gauge port a compensating valve

5.37

Operation of the shield hydraulics Fig. 95: Prop with annular space connection

a

a

E

a annular space connection, lower stage

Bucyrus DBT Europe GmbH, Lünen 2008

Flipper Fig. 96: Flipper

34b 10

18a

34b Z6 Z6 flipper cylinder 10 dual CV

5.38

18a PRV 380 bar 34b plug with pressure relief

Shield support 1300/3100-2X5104-1750

Operation of the shield hydraulics Stabilizing cylinder Fig. 97: View of stabilizing cylinder Cutout A 7 7

11

Z3 34c

A 7 PRV 450 bar 11 dual CV

Z3 stabilizing cylinder 34c plug DN 10 with relief

Bucyrus DBT Europe GmbH, Lünen 2008

E

Water filter Fig. 98: Water filter on the supply block

24 16 9

29

34a

30

9 PRV 80 bar

29 water filter

16 supply block

30 HP ball valve DN 20, for spraying

24 HP ball valve, for auxiliary supply

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34a plug DN 10 with relief

5.39

Operation of the shield hydraulics Retracting or extending side seal The side seals seal the gaps between neighboring shield units.

They are also used to align a shield unit to the adjacent shield units.

The HP ball valve (21a) is located on the left-hand side of the shield in the rear area under the canopy. This shut-off valve is always open during normal operation. The moving side seals are then extended because of the permanently acting suspension forces.

With the aid of the HP ball valve, the annular space sides of all of the seal cylinders of a shield are blocked off simultaneously. The moving side seals can thus be temporarily held in a retracted intermediate position against the permanently active force of the springs. As soon as the shut-off valve is opened, the side seals will be pressed abruptly outwards by the permanently active forces of the springs.

Danger!

For that reason, never stand in the movement range of the side seals. Otherwise, you could be severely injured or even killed by sudden movements of the side seals.

If the side seals - e.g. for transport purposes - are to be kept in retracted configuration, then they must always be mechanically engaged with the aid of the transport securing devices.

Fig. 99: View of the distributor and HP ball valve for the side seal cylinder

31

27

21a

21a HP ball valve DN 10, for seal cylinder 27 distributor

5.40

31 CV, hydr. piloted

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

Actuation of the function “Extend side seal” extends the side seal abruptly outwards, despite closed HP ball valve (21a) because the pressure relief valve is triggered and sprays.

E

Danger!

There is an increased danger of injury caused by sudden and unexpected movements of the side seals, in view of the fact that the side seals are permanently pressed outward by the suspension force.

Operation of the shield hydraulics Fig. 100: View into the side seal, left

18c

18c

Bucyrus DBT Europe GmbH, Lünen 2008

E

18c PRV 380 bar

Plug with pressure relief The shield is equipped with five plugs DN 10 with vented cap screws.

The plug (34a) with pressure relief located on the supply block is for reducing any pressure that may arise in the return line. This can be necessary, for instance when the supply line connections have been bypassed for transport and increased pressure has built up in the return line during installation.

Fig. 101: Plug on the supply block

16 34a

30 16 supply block 30 HP ball valve DN 20, for spraying

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34a plug DN 10 with relief

5.41

Operation of the shield hydraulics Two plugs (34 b) DN 10 with vented cap screws are located on the flipper cylinder (Z6).

Fig. 102: Plug on the flipper cylinder 18a 34b

18a 10 34b

Z6

Two plugs (34 c) DN 10 with vented cap screws are located on the stabilizing cylinder (Z3).

Fig. 103: Plug on the stabilizing cylinder

7

Z3 11 34c 34c

7 PRV 450 bar 11 dual check valve

5.42

34c plug DN 10 with relief Z3 stabilizing cylinder

Shield support 1300/3100-2X5104-1750

E

34b plug DN 10 with pressure relief Z6 flipper cylinder

Bucyrus DBT Europe GmbH, Lünen 2008

10 dual check valve 18a PRV 380 bar

Operation of the shield hydraulics Operation of the double backflush filter Warning!

Do not put the filter into operation before making sure that all connections have been properly established. Be sure to observe the separate operating manual for the filter. normal operation

The filter is in normal mode when both levers are parallel. It must be backflushed when the contamination of the filter elements leads to reduced flow or pressure loss.

backflushing

Since the intervals between backflushing depend on the degree of contamination of the emulsion used (HFA fluid), the frequency of backflushing cannot be predetermined. We recommend backflushing the dual backflush filters regularly once per shift.

Warning!

Never put both levers into the backflush position simultaneously. Always backflush one filter element at a time. Otherwise, the flow of the emulsion can be completely interrupted and the filter elements won't be backflushed.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Only one filter element may be backflushed at a time. For this, simply turn one of the levers by 90° and after about 2 seconds, put it in its original position. Then repeat the procedure with the other lever.

Note that a volume flow of at least 70 l/min is required.

Fig. 104: View of the double filter

B

B

20

A

20 double filter, can be backflushed A normal operation: both levers in position “A”

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VTVT / 01

A

B backflushing: one of the levers in position “B”

5.43

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 system is shown in Chapter 6, “Technical data”, section “Description”, of this manual.

Caution!

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.

The drawings Fig. 105 and 106 show the arrangement 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. 105: Control units 16

a

1 a PMC®-R control unit 1 electrohydraulic control unit

5.44

16 supply block

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

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.

Operation of the shield hydraulics Fig. 106: Electrohydr. control unit c

17

a

b

d

Bucyrus DBT Europe GmbH, Lünen 2008

E

1 1 electrohydraulic control unit 17 accumulator cartridge

b pilot valve c connecting cable

a button

d symbol plate

The symbol plate is located on the electrohydraulic control unit underneath the pilot solenoid 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. 107: Symbol plate for electrohydraulic control unit with 12 functions D.A. ram pull 1

D.A. ram push 3

5

4

2 extending legs

canopy tip up

6

extending lift cyl.

canopy tip down

extending flipper cyl.

extending seal cyl.

7

9

8

10

retracting flipper cyl.

retracting seal cyl.

Extending pusher cyl.

11

12 retracting legs

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 unit.

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 because you are then operating the shield directly and immediately under where you are standing. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

5.45

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

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.

1

Advance shield Before executing this function, the side seal of the shield unit must be released and the function “Lower prop” (function 12) 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 pilot-operated check valve, which hydraulically blocks the annular space of the shifting ram, is opened automatically.

2

Setting both 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.

The baselift cylinder is actively retracted during the performance of this function.

Compensating valve

The compensating valve (see Fig. 94, item a) and the associated shut-off valve (21c) are located on the right prop as seen when looking in the direction of 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 doesn't 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 the roof then automatically.

5.46

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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 “Pull 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.

E

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.

Operation of the shield hydraulics 3

Slide 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

Extending 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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Retracting stabilizing cylinder 6

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.

Extending flipper cylinder

7

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.

Retracting flipper cylinders

8

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.

Extending seal cylinder

9

Before executing this function, the function “Retract prop” must have been carried out for both props with the side seal in place.

The function serves to align the shield unit to the adjacent support.

The seal cylinders are only extended as long as the button is kept pressed down until there is a balance of forces or the end position has been reached.

In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

10

Retracting seal cylinder The seal cylinders are only retracted as long as the button is held down, until there is a balance of forces or until the end position is reached.

In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

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5.47

Operation of the shield hydraulics 11

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

12

Withdraw shield supports (actively trigger support) 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.

Functions of the water valve unit Fig. 108: Functions of the water valve unit, symbol plate (2 functions) water spray canopy/gob

1

The function is executed as long as the button is pushed.

2

Water spraying system, face side The function is executed as long as the button remains pressed.

5.48

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

Water spraying system canopy - caving shield

E

water curtain

Maintenance Maintenance Warning!

If the 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

one week after start-up

No later than one week after start-up, 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 DBT Europe GmbH, Lünen 2008

E

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

The piston rods of cylinders, which 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 on all shields which are equipped with a water spraying system.

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 fluid, there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation.

E. g., 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.

Doc. no.: 7420 198 000 BA 00

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5.49

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 of the section planned to be minded 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 depend 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,

– hinge, steering and flipper cylinders.

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

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

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”.

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Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

– shifting rams and lifting cylinders,

E

– props,

Maintenance Fig. 109: Lubricating nipples on the hydraulic props

b

a

b grease escaping at dirt stripper

Bucyrus DBT Europe GmbH, Lünen 2008

E

a lubricating nipples on the guide bushing

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”.

Assessment of damage according to schedule 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.

Doc. no.: 7420 198 000 BA 00

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5.51

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 schematics and hose diagrams for the shield hydraulics. Also refer to the “Operation of the shield hydraulics” section 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.

Fault localization support cannot be lowered

5.52

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 isn't working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 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.

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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.

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

E

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

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 chamber is closed.

Open the shut-off valve.

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

Bucyrus DBT Europe GmbH, Lünen 2008

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.

support cannot be advanced

Doc. no.: 7420 198 000 BA 00

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.

Control piston on the prop control valve isn't working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 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 base.

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 approximately 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.

VTVT / 01

5.53

canopy cannot be positioned

canopy cannot be lowered

5.54

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 lower 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 isn't 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 exchange, 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 isn't 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 exchange, if necessary.

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

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Troubleshooting

Troubleshooting 3/2-way or pilot valve The valve is jammed or a by-pass 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, for example discharged fluid.

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

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

internal leakage

in sequence.

If the noise stops while a function is initiated, this valve is faulty.

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

E Bucyrus DBT Europe GmbH, Lünen 2008

. Locate the faulty valve by actuating the functions individually

replace valve

. Close the main shut-off valve in the pressure line on the distributor 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 by-pass is shown by a drop in pressure.

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

If the problem occurs again, 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.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

5.55

Troubleshooting Internal by-pass in props If an internal by-pass in the 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 props) of the piloted check valve.

. Activate the “set props” function.

If there is an internal by-pass 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.

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 of 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 replacement 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.

5.56

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

Pressure relief valve defective

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 Model 1300/3100-2X5104-1750 The two-prop shield mainly consists of the following listed main subassemblies: J base frame with lemniscatic links, relay bar assembly and

baselift cylinder, J canopy with flipper, J caving shield, J side seal, moveable on right side, J hydraulic prop,

Bucyrus DBT Europe GmbH, Lünen 2008

E

J hydraulic equipment with hose lines and control.

Tab. 12: Model specification for shield support 1300/3100-2X5104-1750 Order No.

Prop force

7420 198 000 00 01 2 x 5104 kN

Year of manufacture

Application

2008

Face shield

Tab. 13: Shield support, dimensions, weights Application

Order No.

Face shield

7420 198 000 00 01 6 511 x 1 8201) x 3 100 7 204 x 1 6702) x 1 300

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

Approximate weight in kg 27 000

Tab. 14: Shield support, numbering Application

Shield No.

Special design

Face shield

1 to 108

Side seal, movable to the right, pusher right

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

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

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.

All shield canopies are 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 optimally coordinated. The multistage hydraulic props have the same load capacity at any stage and act on both sides.

1) 2)

Doc. no.: 7420 198 000 BA 00

Side seal fully extended Side seal fully retracted

VTVT / 01

6.3

Technical description 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 is provided with a pusher cylinder which is fitted on the right-hand side.

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

Main subassemblies Fig. 110: Main assemblies

b

c

a

21

51

d

E

11 Bucyrus DBT Europe GmbH, Lünen 2008

e

41

61

31

g 1

f

71 1 base 11 canopy 21 side seal 31 caving shield 41 hydraulic prop 51 stabilizing cylinder 61 electrohydraulic shield control system 71 caving flap

6.4

a PMC®-R control unit b electrohydr. control unit c flipper d flipper cylinder e supply block f lifting cylinder g pusher cylinder

Shield support 1300/3100-2X5104-1750

Technical description Tab. 15: Shield 7420 198 000 00 01, main assemblies Item

Description

ID No.

Approximate weight in kg

Remarks

0001

Base

7420 198 300 00 01

8 743 Shifting ram Ø 180 mm 8241 388 000 00 00 Lifting cylinder 8241 224 000 00 00 Relay bar assembly, 3 581 long 7420 198 330 00 01 Pusher 8241 046 000 00 00

0011

Canopy 4 870 long, (flipper, folded out)

7420 198 400 00 01

7 572 Flipper Flipper cylinder

7420 198 420 00 00 8241 390 000 00 00

0021

Gap seal

7420 198 700 00 01

2 412 Seal cylinder

8241 352 000 00 00

0031

Caving shield

7420 198 800 00 01

3 831

0041

Hydraulic prop

8250 158 000 00 00

1 470 Prop apron

0051

Stabilizing cylinder

8241 389 000 00 00

0061

Shield control system - 12 functions -

8112 291 000 00 00

17

Caving flap

7420 185 890 00 00

150 Electrohydr. control unit Lines Water spraying system Brackets Water valve unit

8154 120 000 00 00 8112 291 010 00 00 8112 291 020 00 00 8112 291 030 00 00 8401 007 250 00 00

56

Main dimensions Fig. 111: Face shield, dimensions L1 L3

HA

HE

H

Bucyrus DBT Europe GmbH, Lünen 2008

E

L2

L 1750 B

B2

300 930 B1

Count. no.

HA height, extended HE height, retracted L transport length M support center distance = 1750 B width

CE no.

Tab. 16: Shield variants, dimensions L

L1

L2

L3

H

HA

HE

B

B1

B2

7 204

4 740

1 190

3 550

2 400

3 100

1 300

1 670

1 630

150

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.5

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

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

An important aspect of the base frame is the placement of the relay bar assembly in the middle between the bases. 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 pushed with the smaller force, which is generated via the annular surface.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

15

13

1 17

2 3 11

5

For items, see Fig 113

6.6

E

Fig. 112: Base for face shield, dimensions

Shield support 1300/3100-2X5104-1750

Technical description Fig. 113: Base for all shield variants, items 165 135

1320 70, 33, 41

19 61, 62

50, 31

1155

444

21

290

160

200

635

30

1520

72

8, 60, 62 18

850 1526

40, 35, 70

930 1630

17, 34, 71 42, 43, 52

Bucyrus DBT Europe GmbH, Lünen 2008

105

E

22, 72

50

20

23, 72

32, 51

1 shifting ram ZE-165/100-900 2 lifting cylinder ZE-135/90-240 3 pusher cylinder ZE-135/120-300 5 relay bar assembly 8 retainer 11 base 13 lemniscatic link, front 15 lemniscatic link, rear 17 prop retainer, right 18 prop retainer, left 19 cylinder bearing 20 running board, left 21 running board, right 22 cover 23 cover 30 pin 60/50x116 31 pin Ø16x117

Doc. no.: 7420 198 000 BA 00

VTVT / 01

32 pin 40/30x170 33 locking plate 34 pin 30/29x62 35 locking plate 40 lemniscatic link pin 133.5x577 41 lemniscatic link pin 163.5x587 42 pin 60/50x363 43 filler piece 47 staple DN 10 45 staple DN 20 45 staple DN 40 60 hex. head screw M 16x80-A 4-80 61 hex. head screw M 16x120-A 4-80 62 hex. nut M 16-A 2-70 70 locking clip 5.6 71 locking clip 4 72 spring cotter 5

6.7

Technical description Relay bar assembly The relay bar assembly is located in the middle of the base. It consists essentially of the relay bar, shifting ram, baselift cylinder, and the required connecting elements. It serves to advance the conveyor and to pull up the shield.

The shifting ram is reverse-mounted with the force of the cylinder transmitted 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 ring 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 baselift cylinder is located in the center of the base frame.

The force of the baselift cylinder acts on the floor via the relay bar.

Fig. 114: Shifting unit, dimensions

200 200 660 Fig. 115: Relay bar assembly, positions

15

13

14

12

a 2 3

10

1

10

a

4

9

8 11 5, 6, 7

a

11

1 beam 2 relay bar 3 clevis assembly for conveyor 4 pin 80/50x265 5 retaining washer 6 hex. head screw M 12x90-A 4-80 7 hex. nut M 12-A 4-80 8 pin 70/53x144 9 shear pin 55/48.5x173

10 pin 25/16X138 11 locking clip 3.2 12 pin 65/58x193 13 pin 15/12x95 14 locking clip 2.5 15 lifting eye, compl. with hex. head screw M 16 a Load ring, load capacity: 3 000 kg

Notice!

Apply lubricant B6 to all connecting points and slide surfaces in accordance with EWN 7068.1) 1) EWN = works standard

6.8

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

240

280

105

290

E

395

160

240 385

3616

Technical description Function description: 1. Original position of the shield The shifting ram is retracted.

2. Advancing the shield While the shield is being advanced, the baselift cylinder presses on the relay bar, causing the bases to be lifted up off the floor.

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.

3. Setting the support When setting the shield, the baselift cylinder retracts again automatically.

Bucyrus DBT Europe GmbH, Lünen 2008

E

4. Advancing the conveyor The shifting ram is retracted.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.9

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 canopy of the shield variant is equipped with one moving side seal on the right-hand side and one flipper.

Bucyrus DBT Europe GmbH, Lünen 2008

550

613

195

0 180

240

1190

4740

5734

E

1630

Fig. 116: Canopy for face shield, dimensions

a, 16 1

a

b

8 2 12

6, 7 1 canopy 2 flipper 5 peg Ø68x127 6 pin Ø20x170 7 locking clip 5x32 8 lemniscatic link pin Ø133.5x577 9 securing device 10 pin Ø12x120

6.10

5

13, 14, 15

9, 10, 11

11 locking clip 2.5 12 pin Ø53x200 13 circlip 14 hex. head screw M 10x90-A 2-70 15 hex. nut M 10-A 2-70 16 spring cotter 5 a load ring 5 000 kg b load ring 3 000 kg

Shield support 1300/3100-2X5104-1750

Technical description Prop head with peg Before installing the prop head, put the pegs of the prop head fixture into the bore holes of the mounting device. Secure the pegs with the securing devices (pins, locking clips) in the second groove.

After installing the prop head, push the pegs in the bore holes of the prop head. Secure the pegs in the first groove by using the securing devices.

Fig. 117: Mounting the prop head 6, 7

Bucyrus DBT Europe GmbH, Lünen 2008

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5

6

7

5

5 peg 68x127 6 pin 20x170

Doc. no.: 7420 198 000 BA 00

VTVT / 01

7 locking clip 5x32

6.11

Technical description Flipper

1200

250

910

Fig. 118: Flipper

985

Bucyrus DBT Europe GmbH, Lünen 2008

E

215

2 17, 20, 21

retracted 822 (stroke 535)

19, 20 21 3

22, 24 15, 20, 21

4

16, 20, 21

23, 24

1

18, 27 9 12

11 13 1 flipper cylinder ZE-125/90-535 2 flap 3 flange plate 4 cylinder holder 11 fork 12 lemniscatic links 13 lemniscatic links 14 securing device 15 pin Ø44.5x304 16 pin Ø44.5x250 17 pin Ø44.5x184

6.12

14, 25, 26 18 pin 45/30.5x115 19 pin 55/44.5x180 20 cylinder head screw M 10x60-A 2-70 21 hex.nut M 10-8 22 screw M24x75 23 hammer-head screw M 24x90-10.9 24 hex. nut V M 24-10 25 hex. head screw M 16x180.A 2-70 26 hex. nut M 16-8 27 locking clip 4

Shield support 1300/3100-2X5104-1750

Technical description Side seal The side seals seal the gaps between neighboring shield units.

In addition, they are also used to align a shield unit to the adjacent shield units.

The right side (viewed in the shifting direction) of the side seal is pin-locked with bolts to the shield canopy or caving shield. The left side is attached so that it is movable. It is guided through using guiding pins and pressed permanently against the neighboring shield using compression springs. The side seals can be extended and retracted using hydraulic cylinders.

Warning!

Risk of injury due to unexpected movements of the side seal!

The moveable side seal is under spring pressure. Never remove connecting elements of the side seal before the side seal is pulled together and secured using clamp clips.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Caution!

Before putting the shield unit into operation, the transport safety devices (see Fig. 120 marked with a *) of the side seal must be removed.

For transport the movable side seals are retracted and locked mechanically with pins. The pins are secured with staples.

Tab. 17: Side seal used for the shield variants Description

ID No.

Weight ca. in kg

Side seal for face shield

7420 198 700 00 01

2 412

Notice!

When putting the transport safety devices into operation, remove items (42*, 14*), (43*, 22*) and (41*, 24*) on the movable side! Apply lubricant B6 according to EWN70681) to all connecting points and slide surfaces.

Notice!

If you want the side seal on the other side to be movable, the seal cylinders and their respective guiding pins are to be installed symmetrically (mirror image).

Warning!

Risk of injury! The moveable side seal is under spring pressure. Secure the side seal using clamps before dismantling the side seal cylinders and their guiding pins.

1) EWN = works standard

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.13

Technical description Fig. 119: Side seal

250

1670

left

right

6.14

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

2410

800

E

110

750

3360

Technical description Fig. 120: Side seal for face shield, items from 23, 43

16, 38

18, 40 28

27 21, 42 13, 37, 40

43*, 22*

42*, 14*

3

27

17, 36, 40 15, 38 20, 35 1

Bucyrus DBT Europe GmbH, Lünen 2008

E

5 41*, 24* 9

11

12 25, 45

4

30

31 10

1 side seal cylinder ZE-63/50-215 3 side seal, canopy, right 4 side seal, canopy, left 5 side seal, caving shield, right 6 side seal, caving shield, left 8 cover 9 guiding pin 10 guiding pin Ø90x1035 11 guiding pin Ø103x690 12 guiding pin Ø103x1025 13 pin 40/34x232 14 pin Ø22x128 15 cover plate

Doc. no.: 7420 198 000 BA 00

6

26, 44

19, 43

29

8

16 cover plate 17 pin 40/34x282 18 pin 40/34x64

29 securing device 30 compression spring, 12x79x560 31 compression spring, 12x64x621

19 pin Ø22x196 20 pin Ø28x74 21 pin 30/25x175

35 spring dowel pin Ø5x50 36 screw pin M 8x12-A 4-80 37 screw pin M 10x12-45 H

22 pin Ø22x135 23 pin Ø22x177 24 transport safety device 22x128

38 hex. head screw M 12x20-A 4-80 40 staple DN 25 41 staple DN 12

25 pin Ø28x93 26 pin Ø12x120 27 cylinder liner, 103x105

42 staple DN 12 43 locking clip 44 locking clip 2.5

28 cylinder liner, 92x105

45 split pin, 6.3x40

VTVT / 01

6.15

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

It is hinged to the shield canopy, and also to 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 has retainers for the cylinders and guiding pins for the side seal.

Fig. 121: Caving shield for all shield variants 1600 930

265

370

380 1

930 1630

380 8

Bucyrus DBT Europe GmbH, Lünen 2008

E

2606

1070

370

520 3

11

12, 13 4

S2 S1 9, 10

7

S1

S2

14 1 caving shield 3 lemniscatic link pin Ø163.5x507 4 lemniscatic link pin Ø133.5x507 7 pin Ø53x200 8 circlip

9 hex. head screw M 10x90-A 2-70 10 hex. nut M 10-A 2-70 11 securing device 12 pin 15/12x120 13 locking clip 2.5

14 spring cotter 5 S1 load ring, load capacity: 3 000 kg S2 load ring, load capacity: 15 500 kg

Notice!

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

1) EWN = works standard

6.16

Shield support 1300/3100-2X5104-1750

Technical description Additional device The additional devices limit the shields in their retraction height to protect neighboring components from getting damaged.

J On shields with a cooler, the longer clevis assemblies are

mounted with a retraction height of 1 870 mm: – Clevis assemblies, left, drawing no. 7420 198 093 00 00 – Clevis assemblies, right, drawing no. 7420 198 094 00 00.

J On shields without a cooler, the shorter clevis assemblies are

mounted with a retraction height of 1 600 mm: – Clevis assemblies, left, drawing no. 7420 198 091 00 00 – Clevis assemblies, right, drawing no. 7420 198 092 00 00.

Caution!

Make sure that during mining, the clevis assemblies are mounted on each side of the support. Parts of the support can be seriously damaged if the clevis assemblies are missing.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 122: Clevis assembly

146, 148

a

145, 147

b

149, 150

145 clevis assembly, left, long 146 clevis assembly, right, long 147 clevis assembly, left, short 148 clevis assembly, right, short

Doc. no.: 7420 198 000 BA 00

VTVT / 01

149 hex. head screw M 16x45-A 4-80 150 hex. nut VM 16-A 2-70 a round steel b side plate

6.17

Technical description Technical data, steel structure Face shield

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

1 300

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

3 100

Height adjustment . . . . . . . . . . . . . . . . . . . mm

1 800

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

850

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

900

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

930

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

3 550

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

1 320

Width of canopy with side seals . . . . . . . mm

1 670

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

4 870

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

5.18

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

48.33

Width of caving shield with side seals . . mm

1 670

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

1 630

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

36 680

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

1 750

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

2 400

a) For 320 bar setting pressure . . . . . . . kN

6 563

b) For 450 bar nominal pressure . . . . . . kN

9 230

Support resistance for every m2 of roof surface for average thickness of . . . . . . mm

2 400

Face shield

6.18

a) For 320 bar setting pressure . . . . . . . kN/m2

709

b) For 450 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

859 / 997

Shield support 1300/3100-2X5104-1750

E

15

Bucyrus DBT Europe GmbH, Lünen 2008

Securing from tipping permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

Hydraulic system Hydraulic system

normal and exceptional operation

The following section provides an overview of the parts of the shield hydraulics. You can find additional information in the replacement parts catalog of the shield support.

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

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

Warning!

During normal operation, the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Failure to observe this warning can result in 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 exceptional cases, for example for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations.

Shield hydraulics Bucyrus DBT Europe GmbH, Lünen 2008

E

The following table specifies the hydraulic components for the support.

Tab. 18: Hydraulic components Item 1 2 3 4

Quantity Designation 1 Electrohydr. control unit, 12-way 1 Prop CV, NG 20 1 Pop CV, NG 20 1 RV, hydraul. piloted DN 13

Arrangement Under the canopy, behind the supply block On the prop, left, face side On the prop, right, face side Behind the right prop under the canopy On the respective prop

Remarks On the support

On the stabilizing cylinder (Z3)

For piston space side and annular space side In the return line In the return line For the flipper cylinder (Z6)

5

2

7

2

Rock burst valve VR 7100, 530/450 bar Pressure relief valve, 450 bar

8 9 10

1 1 1

CV, NW 25 PRV, 80 bar Dual CV NG 10

Behind the supply block (16) Behind the supply block (16) Flanged to the flipper cylinder (Z6)

11 12

1 4

Dual CV Pressure gauge

Flanged to stabilizing cylinder (Z3) a) 2x, each on prop check valve, face side b) 1x on the double filter c) 1x on the 3-way HP ball valve (23) in the pressure supply line

13 14 15 16

1 1 1 1

Hose lines Water spraying system Brackets and accessories Supply block

17 18

1 6

Storage cartridge PRV, 380 bar

Centered in front of the props under the canopy On electrohydr. control unit (1) a) 2x on the supply block (Z6) b) 1x on the shifting ram CV (4) c) 2x on the seal cylinder (Z4) d) 1x on the lifting cylinder (Z5)

Without compensating valve With compensating valve For shifting rams (Z2)

For stabilizing cylinders (Z3)

Subassembly group Subassembly group Subassembly group On the support

a) For flipper cylinder (Z6) b) For shifting ram (Z2) c) For seal cylinder (Z4) Annular space circuit d) For lifting cylinder (Z5)

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

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.19

Hydraulic system

20

1

21

3

Double filter, can be backflushed HP ball valve DN 10 red handle

22

2

23

1

24

1

25

2

HP ball valve DN 12, red handle Pressure gauge port

27 29 30 31

2 1 1 1

Distributor Water filter HP ball valve DN 20, blue CV, hydraulically piloted

34

5

Plug DN 10 with pressure relief

S1

1

Pressure sensors

Z1 Z2 Z3 Z4 Z5 Z6 Z7

2 1 1 4 1 1 1

Prop Shifting ram Stabilizing cylinder Seal cylinder Lifting cylinder Flipper cylinder Pusher cylinder

6.20

HP ball valve DN 20, red handle 3-way HP ball valve DN 20, red handle

Arrangement To the left, next to the electrohydr. control unit (1) under the canopy Under the canopy, in front of the right prop a) 1x under the caving shield on the distributor (27) b) On the lifting cylinder (Z5) c) On the right prop (Z1) Each on prop CV (2 or 3) On the supply block (16)

Behind the supply block (16) Each on prop check valve, face side In the back, under the canopy, left Behind the supply block (16) Behind the supply block (16) Under the canopy next to the distributor (27) a) 1x under the supply block (16) next to the HP ball valve (30) and PRV (9) b) 2x on the flipper cylinder (Z6) c) 2x on the stabilizing cylinder (Z3)

Remarks Water spraying system control On the support, manually actuated a) For seal cylinder (Z4) b) For lifting cylinder (Z5) c) For stabilizing cylinder (Z3) In the pressure supply line to the prop, piston side Position I: Supplies the shield with pressure Position II: Immediately depressurizes the shield For auxiliary device

In the seal cylinder circuit In the water feed line For spraying For seal cylinder (Z4) For pressure relief

On the prop CV, only on the righthand side

Shield support 1300/3100-2X5104-1750

E

Quantity Designation 1 Water valve unit

Bucyrus DBT Europe GmbH, Lünen 2008

Item 19

Hydraulic system Shield hydraulics Fig. 123: Shield hydraulics, layout (1a) Image caption: see Table 18 A

14

18a

10

34b

15

18c

13

Bucyrus DBT Europe GmbH, Lünen 2008

E

View A 20 23 12c

8 4

34a

9

18b 21?

17

12b

3 31 7

16

7

24

30

5

29

19

5 25

Doc. no.: 7420 198 000 BA 00

VTVT / 01

2

18b

27

6.21

Hydraulic system Fig. 124: Shield hydraulics, layout (1b) Image caption: see Table 18

1

19

31

21??

27

23 15

7

13 11 12a

25 3

34c

18d 16

30

13

29

21b 19

2 25

22 24

25 12a 34a 27

5

7

11

34c

12b

6.22

20

23

12c

8

9

25

17

4

5

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

22

Hydraulic system

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 125: Functions of the electrohydraulic control unit, symbol plate

12 functions D.A. ram pull 1

D.A. ram push 3

extending flipper cyl.

5

4

2 extending legs

canopy tip up

7

8

6

extending lift cyl.

canopy tip down

retracting flipper cyl.

extending seal cyl.

Extending pusher cyl.

9

11

10

12

retracting seal cyl.

retracting legs

Tab. 19: Electrohydraulic control unit with 12 functions, allocation of functions Function, designation

Doc. no.: 7420 198 000 BA 00

Function No.

Advance shield

1

Set props

2

Slide conveyor

3

Extend lifting cylinder

4

Extend stabilizing cylinder

5

Retract stabilizing cylinder

6

Extend flipper cylinder

7

Retract flipper cylinders

8

Extend seal cylinder

9

Retract seal cylinder

10

Extend pusher cylinder

11

Lower props

12

VTVT / 01

6.23

Hydraulic system Fig. 126: Functions of the water valve unit, symbol plate water spray canopy/gob

1 2 water curtain

Tab. 20: Water valve unit with 2 functions, assignment of functions Function, designation

Function No. 1

Water curtain

2

Bucyrus DBT Europe GmbH, Lünen 2008

E

Canopy roof, caving shield water spraying

6.24

Shield support 1300/3100-2X5104-1750

Hydraulic system Fig. 127: Shield hydraulics, Image caption, see Table 18

23

PTO

24

16 DN 50 R DN 40-SS P DN 50 W

12c

1

2

3

4

5

6

7

8

9

11

10

12

SP

17

27

25 mm

X2

34a

P

20

29

8

12b

Pusher

21a

31

Z7

W2 W1

Z4

Backflush filter

X1 X2

X3

X5 X4

X6

X7 X8

X10

30

12 11 10 9 8 7 6 5 4 3 2 1 2 P T

X12

1

X9

X11

9

34c

Waterspray gob

7

19

Z4 Left cyl.

Seal cyl.

Z4

11 18c

14

Z3

Waterspray canopy

7

34c

S1

Lifting cyl.

100 bar 200 bar

PI

3

Z2

18b

25 12a 22

13

25 12a

2

22

PI

4

D.A.ram cyl.

s I

Water curtain

Z5 5

21b 18d

Z1

Doc. no.: 7420 198 000 BA 00

VTVT / 01

34b

18a

Flipper cyl.

5

Z6

10 34b

18a

Prop

21c Prop

Bucyrus DBT Europe GmbH, Lünen 2008

E

Z4

Z1

6.25

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 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 “Technical data, hydraulic cylinders” section.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 128: Double-telescopic prop, Model SD-5100-3800-1175/2715

21 b 2

a e 1

d c

1 prop base 2 piston pipe 21 piston rod a valve connection plate

b annular space connection c safety cam d piston space PRV connection e load ring 3 000 kg

Tab. 21: Telescopic props on the shield variants Length in mm

6.26

Stroke in mm

ID No. Telescopic prop

Shield variant

Retracted

Extended

Upper stage

Lower stage

8250 158 000 00 00

01

1 175

2 715

780

760

Shield support 1300/3100-2X5104-1750

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're 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, whereby 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 (base).

Bucyrus DBT Europe GmbH, Lünen 2008

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: 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 (and set), 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 198 000 BA 00

VTVT / 01

6.27

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. 129: Hydraulic cylinders, typical examples Type a)

2 3

1

5

4

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, when extending the cylinder, pressure can build up in the annular space which is several times more than the set pressure!

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 clamping sleeve 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.

6.28

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

Type b)

Hydraulic cylinders Stabilizing cylinder Fig. 130: Hydraulic cylinder ZE-165/100-480

55

55 L a

b

10

c

E

1 Bucyrus DBT Europe GmbH, Lünen 2008

1 cylinder tube

c load ring 1 000 kg L retracted 870 extended 1 350 stroke: 480

10 piston rod a valve connection plate b PRV connection, annular space

Shifting ram Fig. 131: Shifting ram model ZE-180/100-900

72

62 L d a b

2 4 1 c 7 1 Cylinder tube 2 Reed rod 4 Piston rod 7 Screw fitting a Annular space connection

Doc. no.: 7420 198 000 BA 00

VTVT / 01

b Piston space connection c Relay bar adaptor d Load ring 1 000 kg L Retracted 1 239 - extended 2 139 Stroke: 900

6.29

Hydraulic cylinders Lifting cylinder Fig. 132: Hydraulic cylinder ZE-135/90-240

355

c

a

2

b 1 L

1 cylinder tube 2 piston rod 3 wearing bottom

Bucyrus DBT Europe GmbH, Lünen 2008

E

3

b annular space connection c load ring 1 000 kg L retracted 525 - extended 765

a piston space connection

stroke: 240

Flipper cylinder Fig. 133: Hydraulic cylinder ZE-125/90-535

32

70 L a 3

7

4

c

2 1

1 cylinder tube 2 reed rod 3 plug-in angle for shifting ram 4 piston rod 7 screw fitting

6.30

a valve connection plate c load ring 1 000 kg L retracted 822 extended 1357 stroke: 535

Shield support 1300/3100-2X5104-1750

Hydraulic cylinders Seal cylinders Fig. 134: Hydraulic cylinder ZE-63/50-215

30 L b 2

a

Bucyrus DBT Europe GmbH, Lünen 2008

E

1

1 cylinder tube 2 piston rod a piston space connection

b annular space connection L retracted 440 extended 655 stroke: 215

Pusher cylinder Fig. 135: Hydraulic cylinder ZE-135/120-300

35 L

a

2

b

3

2 piston rod 3 cylinder tube a piston space connection

Doc. no.: 7420 198 000 BA 00

VTVT / 01

b annular space connection L retracted 620 - extended 920 stroke: 300

6.31

Hydraulic cylinders Technical data, hydraulic cylinder

shifting ram double-acting, el. connection, configuration: reverse-mounted

6.32

Length a) Retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1 175

b) Extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2 715

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1 540

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

380/270

Piston rod diameter . . . . . . . . . . . . . . . . . mm

350/250

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

1 134.1 / 573

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

172/ 82

Prop force at setting pressure, 320 bar . . . . . . . . . . . . . kN

3 629

Setting pressure, 450 bar . . . . . . . . . . . . kN

5 103

Retracting force at 320 bar . . . . . . . . . . . kN

550,4

Model ZE-165/100-480, device no. 8241 389 000 00 00

E

stabilizing cylinder, double-acting

Model SD-5100-380-1175/2715, Device No. 8250 158 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

480

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 320 / 450 bar . . . . . . . . . kN

684 / 962

Pulling force at 320 / 450 bar . . . . . . . . . kN

432.9 / 608.7

Model ZE-165/100-900, device no. 8241 388 000 00 00 version with reed rod Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

900

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 320/--- bar . . . . . . . . . . . kN

684 / ---

Pulling force at 300 / 380 bar . . . . . . . . . kN

433 / 514

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

telescopic prop, double-acting, 2-stage

Hydraulic cylinders lifting cylinder, double-acting

seal cylinder,

Bucyrus DBT Europe GmbH, Lünen 2008

E

double-acting

flipper cylinder, double-acting

pusher cylinder, double-acting

Doc. no.: 7420 198 000 BA 00

Model 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 320 / --- bar . . . . . . . . . . kN

458 / ---

Pulling force at 320 / --- bar . . . . . . . . . . kN

244.5 / ---

Model ZE-63/50-215, device no. 8241 352 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

63

Piston rod diameter . . . . . . . . . . . . . . . . . mm

50

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

31.2

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

11.5

Thrust force at 320 / --- bar . . . . . . . . . . kN

100 / ---

Pulling force at 320 / 380 bar . . . . . . . . . kN

37 / 43.7

Model ZE-125/90-535, device no. 8241 390 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

535

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

125

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

122.7

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

59.1

Thrust force at 320 / --- bar . . . . . . . . . . kN

392.6 / ---

Pulling force at 320 / 380 bar . . . . . . . . . kN

189.1 / 205.3

Model ZE-135/120-300, device no. 8241 046 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

135

Piston rod diameter . . . . . . . . . . . . . . . . . mm

120

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

143.1

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

30

Thrust force at 320 bar . . . . . . . . . . . . . . kN

458

Pulling force at 320 bar . . . . . . . . . . . . . . kN

96.1

VTVT / 01

6.33

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 circuit diagram and replacement parts catalog.

Tab. 22: Pressure relief valves, use of the various models Application

Design

Setting Device No. pressure in bar 80

8220 042 080 00 00

General application, Spring-loaded not for props and stabilizing cylinders

380

7337 486 380 00 00

For stabilizing cylinders

Spring-loaded

450

8220 027 450 00 00

Rock burst valve VR 7100

Spring-loaded

530/450

Ostroj VR 7100

Caution!

The set 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's circuit 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.

Failure to comply with these instructions can lead to leaky plug connections and impair the operational safety of the hydraulics. marking

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The text code includes the following information: J setting pressure, target value, J the week the setting was made, J the year the setting was made, J person who made last changes.

6.34

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

General application, Spring-loaded not for props and stabilizing cylinders

Pressure relief valves Tab. 23: Letter code, example 420 or 42 1)

09

03

xy

Set pressure

Week

Year

Last changes made by:

Color-coding is with either one or two colors. It indicates the range within which the setting pressure is located. The following Fig. 136 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. 136: Pressure relief valve, example

Bucyrus DBT Europe GmbH, Lünen 2008

E

b

a

a color code b protective cap

The following table shows the relationship between the color code and the pressure range.

Tab. 24: Color codes for pressure relief valves, overview

1)

Doc. no.: 7420 198 000 BA 00

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” means 420 bar, “08” means 80 bar

VTVT / 01

6.35

Shield control system Shield control system Electrohydraulic control unit The electrohydraulic control unit has 12 functions.

1 a connection (DN 20) for storage cartridge 1 distributor block

2

3

4 2 pilot valve actuated electromagnetically 3 button for manual operation 4 contact for electrical connection to the solenoid driver module

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Failure to observe this warning can result in 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.

6.36

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

a

E

Fig. 137: Electrohydraulic control unit, 12 functions

Shield control system PMC®-R control unit Fig. 138: PMC®-R control unit, input allocation, PMC®-R inputs Front view A1 = neighbor unit, left hand A2 = not assigned B1 = not assigned B2 = not assigned C1 = pressure sensor, left Rear view A2

B2

C2

D2

E2

F2

C2 = pressure sensor, right D1 = reed rod shifting ram D2 = flipper E1 = not assigned

A1

B1

C1

D1

E1

F1

E2 = not assigned F1 = neighboring shield, right F2 = solenoid driver module

Fig. 139: PMC®-R control unit, schematic diagram 1, 3 REAR VIEW Bucyrus DBT Europe GmbH, Lünen 2008

E

A2 B2 C2 D2 E2 F2

A1 B1 C 1 D1 E1 F1

F1

A1

4

SOLENOID DRIVER MODULE

P2 5 RIGHT

P1 5 LEFT

a

FACE SHIELD

b

1 PMC®-R control unit, compl.

3 holding strip 4 solenoid drivermodule

a reed rod, shifting ram b flipper For other components: see replacement parts catalog

5 pressure sensor

Notice!

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

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.37

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the 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. 140: Angles α 1 / α 2

α1 α2

Tab. 25: Angles α 1 / α 2 at height M Inclination α at height M

Shield ID No. 7420 198 000 00 01

α1 in °

α2 in °

M in mm

3

0

1 300 to 1 800

15

15

>1 800 to <2 800

0

8

2 800 to 3 100

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 positioned.

6.38

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

M

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only 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, for operating 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.

In addition, national – and sometimes also regional – regulations on health and safety at work and any environmental regulations must be observed for operation.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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, e.g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by Bucyrus on request.

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.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be 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 the following: J stability, J sealing materials, J corrosion.

In addition if required a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive a corresponding certificate from Bucyrus.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.39

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 will no longer be 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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 141: Typical certificate

6.40

Shield support 1300/3100-2X5104-1750

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, but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept 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

– Target value: 7.5 to 9.5 E

J Concentrate ratio Bucyrus DBT Europe GmbH, Lünen 2008

– Target value: see certificate 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 operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water using 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 26 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.41

Permissible media using 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.

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 μS/cm

pH value

6.5 to 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 at 1.2 μmfiltering in conformity 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 liquids.

They do not apply when the water is used exclusively as spraying water.

6.42

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Bucyrus DBT Europe GmbH, Lünen 2008

Test criterion

E

Tab. 26: Properties of the process water, limit values

Permissible media Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

Grease base: . . . . . . . . . . . . . . . . . . . . Lithium soap NLGI class: . . . . . . . . . . . . . . . . . . . . . 2 Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presenceof water: . . practically insoluble in water Temperature of application: . . . . . . . -20 oC to +120 oC Flashpoint: . . . . . . . . . . . . . . . . . . . . . . ≧ 200 oC

lubricating grease A1

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths, and for installation (according to EWN *) 7068).

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 27: Lubricating greases for general application

lubricating grease A2

Flashpoint in °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. 28: Lubricating 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. 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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6.43

Permissible media Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 29: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

Gleitmolybdän

gleitmo 805 *)

Li

NLGI Class

Flashpoint in °C

2

220

When the equipment is lubricated at our 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, of pin connections and similar connecting elements at the support.

When the equipment is treated at our 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 parting and lubricating material 785 (flashpoint 132 ºC) Important!

The instructions for mixing lubricating greases also apply to the lubricating pastes.

*) The products listed in table 27 are suitable lubricating greases for filling of adjacent cavities.

6.44

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Bucyrus DBT Europe GmbH, Lünen 2008

Application temperature range: . . . . . -34 oC to +120 oC

E

Behavior in the presence of water: . . non-soluble in water

Tightening torques Tightening torques Screws with ISO metric thread Tab. 30: Tightening torques for μtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

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

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Bucyrus DBT Europe GmbH, Lünen 2008

Torque 4)

Pitch P

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 replacement 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 in-house works standard (EWN 6110, edition February 1985).

3) Only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

4) The tightening torques comply with the Bucyrus works standard (EWN 6003).

Doc. no.: 7420 198 000 BA 00

VTVT / 01

6.45

Bucyrus DBT Europe GmbH, Lünen 2008

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Tightening torques

6.46

Shield support 1300/3100-2X5104-1750

7

For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestraße 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 – 0 Fax: +49 / 23 06 70 9 – 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tel: Fax: Email:

+44 / 11 59 51 - 2500 +44 / 11 59 32 - 9683 info@gb.bucyrus.com

Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44/16 98 83 5 - 000 +44/16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus DBT Europe GmbH Office Moscow Bolshoi Cherkassy Per. No. 15, Office 310 103626 Moscow Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 – 3441 Fax: +7 / 38 43 35 – 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

Doc. no.: 7420 198 000 BA 00

VTVT / 01

7.3

Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 – 1200 Fax: +1 / 72 47 43 – 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd.

+61/24 91 4 - 7144 +61/24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 – 8212 Fax: + 27 / 11 82 5 – 7389 E-mail: hetta.fuller@za.bucyrus.com

7.4

Shield support 1300/3100-2X5104-1750

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

E

Customer Service 20 Killara Close, Beresfield, New South Wales 2322

Service addresses Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 – 2998 Fax: +86 / 10 65 88 – 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 – 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 – 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

E

No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

Doc. no.: 7420 198 000 BA 00

VTVT / 01

7.5

Identification of the shield Identification of the shield Type plate The main subassemblies of the shields are identified by a type plate.

Fig. 142: Type plate, example

3

12345 05/08

678

7420 198 000 00 01 6

2

1 manufacturer 2 SAP/Order No. 3 date of manufacture 4 serial No.

7.6

7

4 5

5104 kN

5 device number 6 number of props 7 prop force

Shield support 1300/3100-2X5104-1750

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2

Bucyrus DBT Europe GmbH

Bucyrus DBT Europe GmbH, Lünen 2008

1

Identification of the shield Shield number The bases are numbered consecutively. Plates with the shield number are fitted on the base of the shield, at the face side on the right.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 143: Shield number on the base, example

a

b a shield number

b CE symbol

Tab. 31: Allocation of the shield numbers

Doc. no.: 7420 198 000 BA 00

Shield number

Order No.

Application

1 to 108

7420 198 000 00 01

Face shield

VTVT / 01

7.7

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 32: National standards and directives, extract

EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 33: European standards and directives, extract

Designation

Title EC Directive of the European Parliament and Council on Directive 98/37/EEC the streamlining of the laws of the Member States with regard to machinery Directive of the European Parliament and the Council on the approximation of the laws of the Member States Directive 94/9/EC 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 Non-electrical equipment for potentially explosive DIN EN 13463-1 atmospheres - 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 Preparation of instructions DIN EN 62079 - Structuring, content and presentation.

Petroleum products and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Equipment and components intended for use in DIN EN 1710 potentially explosive atmospheres in underground mines Mobile extracting machines at the face - safety DIN EN 1552 requirements for shear loaders and plough systems 1)

7.8

Date of issue 1998-06-22

1994-03-23 2004-04 2004-04 2002-04 2004-12 2000-08 2001-11 2003-02 2006-01 2003-09

EWN = Bucyrus works standard

Shield support 1300/3100-2X5104-1750

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EWN 6003 1)

Title Quality of drinking water Documentation System Plug connectors for hydraulics Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - Design principles Determination of the neutralization number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for bolts Hammer-head bolts Lubricating greases & solid lubricants Nonmetallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

Bucyrus DBT Europe GmbH, Lünen 2008

Designation DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575