CAT Bucyrus Shield support 1920/4420-2/2x5655/1414-1825 Operating Manual - PDF DOWNLOAD

Operating manual Shield support 1920/4420-2/2x5655/1414-1825 Doc. No.: 7420 188 000 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 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 2.3

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

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

2.3 2.4

Conditions for operation . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

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

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

2.5 2.5

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

2.6

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

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

3.3

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

Storage of used equipment . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.5

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

3.6

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

4.3

Installation of the shield units . . . . . . . . . . . . . . . . . . . .

4.3

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

Coupling between the connections . . . . . . . . . . . . . . . . . . .

4.5 4.9

Requirements for the face hydraulic system . . . . . . . 4.10 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

4.11 4.12

Corrosion protection of hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

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

5.3

Conditions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.3 5.6

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

5.9

Safe working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Doc. No.: 7420 188 000 BA 00

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Contents Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.15 Location of hydraulic components on the support . . . . . . .

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

Bracket for PMC®-R and control unit . . . . . . . . . . . . . . . . .

Operation of the dual backflush filter . . . . . . . . . . . . . . . . . .

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

Operation and functions of the control valve block . . . . . .

Shield functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.15 5.17 5.25 5.29 5.30 5.32 5.33 5.35

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Carry out every six months . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.36 5.37 5.37 5.38 5.38 5.39 5.39 5.42 5.42 5.43 5.43 5.43

6. Technical data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

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

Shield canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

6.4 6.6 6.9 6.12 6.14 6.15

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double-telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17 6.23

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Baselift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Alignment cylinder (seal cylinder) . . . . . . . . . . . . . . . . . . . .

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

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

6.26 6.27 6.27 6.28 6.28 6.29 6.30

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.33 Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 Electrohydraulic control units . . . . . . . . . . . . . . . . . . . . . . . .

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

6.35 6.35

Shield support 1920/4420-2/2x5665/1414-1825

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Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

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

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

Pilot-controlled check valves . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39

Contents Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.37 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 Anti topple system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.38

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.41 6.44

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.46

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7. For your information

Doc. No.: 7420 188 000 BA 00

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 shields . . . . . . . . . . . . . . . . . . . . . . .

7.6

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

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

7.6 7.6

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

7.7

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

Referenced European standards and guidelines . . . . . . . .

7.7 7.7

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Contents

Shield support 1920/4420-2/2x5665/1414-1825

1

About this manual

Before starting work

About this manual This chapter contains important information making it easier for you to use this manual. It provides you with information on the structure of the manual and the symbols used.

Before starting work applicable operating manual

Take care to ensure that the operating manual available to you is applicable to the shield support being used. Compare the data given below with the data given on the type plate of the shield.

Where to find the type plate on the shield is described in chapter 7 of this operating manual.

This operating manual is designed for: Shield support 1920/4420-2/2x5655/1414-1825 and is only permitted to be used for shields of this type. Only use the operating manual applicable to the respective shield. If you don’t you will endanger yourself and others.

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Tab. 1: Type specification for shield support 1920/4420-2/2x5655/1414-1825 Year of Application Device number Prop, prop force manufacturing 7420 188 000 00 01 2 x 5655 kN availability of operating manual

2008

End shield

It is absolutely necessary to ensure that all persons working with or on the support have access to the contents of the applicable operating manuals for the shields at any time and without any restrictions.

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

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.

J supervisory personnel who.

– initiate and/or – supervise the activities just indicated.

Everybody working on the shield support must have read this operating manual beforehand.

Any persons visiting or inspecting the face must have received adequate instructions.

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1.3

Before starting work Purpose of this operating manual operating manual

This operating manual contains general information on the safe and economical 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 leisure.

Pay special attention to the safety instructions.

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

questions?

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 draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

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 the 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.

. The hand symbol prompts you to take action.

Several successive paragraphs marked with the hand symbol represent a sequence of actions which must be executed in the order specified. Follow these instructions step-by-step in order to perform the work safely and efficiently.

1.4

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The following characters 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 in accordance with the state-of-the-art technology and 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 the 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 J of the mining company, J of the mines inspectorate, and 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 be a part of this training.

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

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2.3

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

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

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may only be carried out by Bucyrus service engineers or by specially trained mine personnel.

2.4

Shield support 1920/4420-2/2x5665/1414-1825

Conditions for operation Conditions for operation 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 floor; J ensuring an adequate travel way J The following shield operations:

– lowering, – pulling up, – alignment, and – setting; J the following conveyor operations:

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– advancing – retracting J forming an abutment for:

– the conveyor and mining machine, – Conveyor steering devices – devices for raising the conveyor – conveyor steering cylinders. two-prop operation

The shield has been designed and manufactured as a four-prop shield. Under certain circumstance the shield can also be operated using only the rear props. It should be noted that when operating the shield using only the two rear props that supporting force is considerably less (see “Technical data”).

Make sure that during two-prop operation that the supporting force is sufficient for each individual application.

Unauthorized use All uses which are not expressly stated as intended are regarded as unauthorized uses and not permissible with the shield.

Unauthorized uses include, among others: J pushing the shield back into the caving area, J raising the conveyor by means of the hydraulic force of the

shield, J setting of the canopy in areas of fracture.

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”.

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 your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

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

Observe the acoustic and visual start warnings. Pay special attention to the start warnings for the conveyor and for the mining machine.

EMERGENCY STOP

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

support lock-out switch

- Only applicable for shields provided with electrohydraulic shield control systems Actuate the support lock-out switch (repair switch) before performing: J maintenance work.

J inspection work, J repair work, J 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.

2.6

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signaling systems and protective devices

Maintain the lighting systems in a functional condition.

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lighting system

Safety instructions automatic mode

In automatic mode, the shield units of a 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 currently operated.

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

Never stand under unsecured or suspended loads.

Observe the specified storage time limits 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.

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Inform the persons concerned about the intended transport route and the probable duration of the transport. transport securing devices

Ensure that the transport securing devices have been correctly installed. In particular, ensure that the following are secured for transport: J Side seal, J Flipper, J The relay bar (face and gob sides).

transporting

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

Non-standard transport assemblies are shown on special drawings which are added in the annex to the 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 eyes 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 concerned.

Firmly secure all components which might start moving.

Observe the position of the center of gravity, especially during transport with floor-mounted equipment. 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 safe transfer of the transport units.

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

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

For securing the shield, hardwood wedges, for instance, can be placed between the pairs of lemniscatic links.

Securing by means of hardwood wedges

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Fig. 1:

transport securing devices

If the shield is provided with movable side seals these are pretensioned by spring force. Therefore do not use force to remove the transport securing 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 physical force.

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

travel way

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

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

2.8

Shield support 1920/4420-2/2x5665/1414-1825

Safety instructions Operation shield controlunit

In automatic mode, the shield units of a 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 currently operated.

Check to determine whether all protective devices on the shield are present and functional. See also chapter 6.

You may only operate the shield control system if you have an extensive knowledge of the control elements and their functions. It is necessary that you have been trained on the respective control system and know the contents of the respective operating manual.

Do not stay in the shield the functions of which you are to operate.

Always operate the shield only from an adjacent shield.

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

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

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

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

Clean the operating controls of the control units regularly. Ensure that the operating symbols are clearly recognizable This measure avoids faulty operation and any resulting accidents.

Keep the floor as clean as possible. Keep the floor free from debris.

This way you will be able to extend the relay bar assembly without hindrance and to advance the conveyor without problems.

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

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

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

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

On inclined faces, always advance the shields from the bottom to the top. Operate the shield to be advanced always from within the adjacent shield above. This reduces the risk of you getting hurt 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 another. Use the steering devices or the side seals for aligning the shields.

Align the shields as soon 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 max. admissible angle of inclination of the canopy is ex-

ceeded J the stabilizing cylinder locks

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

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

pulling back the conveyor

Ensure that sufficient residual stroke is still present in the props when the seam thickness 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 respective operating instructions of the mine.

Secure the entire mining machine against unauthorized starting.

Isolate your place of work such to prevent any unauthorized persons entering this area.

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

raising the conveyor

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

Only use the points of attachment intended for that purpose.

Never attach loads to hydraulic cylinders or their fastening points.

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

Check the setting pressure again. By no means, disengage the canopy from the roof. It must always be in full contact over the entire length.

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J the canopy will be loaded excessively in longitudinal direction

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

For raising the conveyor, only use: J high-strength, undamaged chain slings.

J the fastening points provided for the purpose.

Check that the fastening points are undamaged before attaching a load.

J Lifting gear with adequate load-carrying capacity. attaching loads

Use only permitted attachment points. Reset all shields to which you wish to attach loads. Make sure that the entire length of the canopy always fits closely against entire length of the roof.

Afterwards, check the setting pressure once again.

Maintenance

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Make sure that all safety and protective devices of the shield supports are complete and functional. If the safety and protective equipment is included in the Bucyrus scope of delivery, refer to chapter 6 for their location.

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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 the component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible foreman without delay.

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

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

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

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

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

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2.11

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

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

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

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

pressure or mechanical stress.

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

Immediately after completion of work, reinstall protective devices which have been removed, and check them for correct function.

Hydraulic system handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

protective equipment hydraulic system

When removing protective equipment which includes hydraulic components keep in mind that these components may be pressurized. You could be severely injured by hydraulic fluid jetting 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 a special knowledge of hydraulics are allowed to work on the hydraulic system.

pressure relief valves

Make sure that pressure relief valves are always provided with protection caps. Replace defective 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 or trapped, J the hoses have no bubbles or blisters, J the hoses or the outer sheathes of the hoses are not abnor-

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

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On inclined faces secure the components to be replaced against slipping by using e.g. with chains or lifting gear.

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

Safety instructions Ensure that no dirt enters the hydraulic system during repair work.

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

Before removing staples to disconnect hydraulic hoses turn the hose at the coupling 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. Be sure to depressurize the line.

Secure the connectors of the hydraulic elements only with the proper staples. Always fasten the clamps completely.

Never use nails, wire or similar materials for securing.

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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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, designation 3 2 1

6

1 Manufacturer 2 Hose type 3 Date of manufacture, 1st quarter 2002

5

4

4 Standard 5 Nominal diameter 6 Flame-resistant and antistatic

Never try to hold a pulsing hydraulic hose. 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.

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2.13

Safety instructions laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying hydraulic hoses, twisting RIGHT

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter) Fig. 5:

laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

Laying hydraulic hoses, crossing RIGHT

WRONG

J are not kinked J do not have to withstand tensile loads

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WRONG

Safety instructions J are protected against thermal radiation J are accessible at all times.

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

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

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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2.15

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Safety instructions

2.16

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3

Storage and transport

Storage

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

Observance of the instructions and tips will increase the service life of the shield. In addition, you will be directed to perform the tasks involved with transport safely and efficiently.

Reading this chapter carefully will help you to simplify your day-today work.

Storage Storage of new equipment corrosion protection

The surfaces of the equipment are provided 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.

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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 used metallic materials from corrosion. It contains a color indicator which reacts when the pH value drops. The color of the medium changes from “red” to “yellow” here. The yellow coloration indicates that the anticorrosion protection is no longer sufficient.

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 spraying device of a shield, must be completely emptied or might have to be filled with an antifreeze medium. short term storage

During short term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. They do however still need to be protected, particularly against environmental influences, also against high temperatures, e.g. through the use of suitable protective covers and/or sheathings for the control units and through 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 projected 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 separately stored. *

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

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3.3

Storage

3.4

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 “Short term storage”

natural ageing

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

moisture and dirt

All hydraulics elements must be protected appropriately against penetration by dirt and moisture during storage. The connection surfaces of the hydraulics 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 as they are permanently 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

Random sample inspections must be carried out after a storage period of approximately two years. 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.

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

Bucyrus DBT Europe GmbH, Lünen 2008

storage outdoors

Storage 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. Supplementary information can also be found in the section “Permissible media” in this manual.

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

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

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

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corrosion protection

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3.5

Transport Transport Warning!

Use only load handling devices complying 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.

points of attachment

Where technically possible, the load units have suitable, fixed attachment points for transport and installation. Otherwise, corresponding thread bores or other fastening options are to be 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 drawings for transport subassemblies 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 frost-sensitive 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 originally used medium 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, the external forces are only to be applied to the attachment points and retainer surfaces as specified in special drawings, if available.

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 max. 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 are protected against harmful environmental influences by suitable packaging.

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

Shield support 1920/4420-2/2x5665/1414-1825

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In agreement with the customer, the transport units were defined taking the special local circumstances into account as follows: - The shield units are transported as a complete unit.

Bucyrus DBT Europe GmbH, Lünen 2008

transport units

Transport Transport units

A shield can be transported as a completely assembled unit or divided into transport units. If it is necessary to disassemble it into transport units, this is planned and laid down in close co-operation with the customer.

Tab. 2: Transport units

Transport safety devices

Designation

Transport position

Complete shield unit

As for normal use

Remarks

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

Tab. 3: transport safety devices Part

Transport securing device

Quantity

Flipper

Pin and retaining clip

1

Side seal, movable

Pin and retaining clip

4

Face side

Transport rod

1

Gob side

Chain

1

Hydraulic connections not used are protected by protective caps or plugs

-

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Relay bar

Hydraulic system

Caution!

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

Caution!

During transport, the canopy must always be in a horizontal position (parallel to the base). Under certain conditions, if the canopy is bent, hydraulic components could be seriously damaged.

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Transport Fig. 8:

Transport of the shield support as a complete unit b X4 X3

X4 S0

H S1

SY

S2

X1 X2 Sx L

S1 Load ring, 2 x on the coal face side in the base, capacity: 15000 kg S2 Load ring, 2 x gobside on the caving shield, capacity: 15000 kg X1, X2 Transport securing device to fix the relay bar during transport, face side and gob side X3 Transport securing device to fix the flipper

Important!

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

Tab. 4: Shield support 7420 188 000 00 01, dimensions and weights Variant

Device number

Length in mm

01 7420 188 000 00 01

9272

Width in mm 1750

Height in mm

Sx/Sy in mm

1920 1444/1109

Weight in kg 41714

Transport securing devices Fig. 9:

Relay bar assembly (face side)

a b

a b

3.8

Transport rod Spring clips 2x

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X4 Transport securing device to fix the moveable side seals So Center of gravity

Transport Fig. 10: Relay bar assembly (gob side)

a

c

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b

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a Chain 6x42 b Hex. head screw M 12x45-8.8 c Hex. nut M 12-8 Fig. 11: Flipper

b

a

a b

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3.9

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Transport

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4

Installation

Pre-assembly of the shield units

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

Warning!

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

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

Caution!

Before the hydraulic lines are connected with one another, the coupling sleeves and nipples of the plug-O connections must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068, see chapter 6, section “Lubricating greases and pastes”.

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Caution!

Before putting the transport units of the steel structure together, all slide surfaces must be treated with the molybdenum disulphide-free B3 lubricating paste in accordance with EWN 7068, see chapter 6, section “Lubricating greases and pastes”.

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

Installation of the shield units Caution!

For transport underground only the attachment detailed in chapter 3 “Transport” may be used. Further information about this can be found in chapter 3 “Transport”. Failure to comply can lead to personal injury and damage to property. installation plan

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

Important!

When installing the shields in the face, be sure to observe the shield numbers. Since some shield units may be provided with different functions, their set-up on the face is not arbitrary.

identification for installation in the face

In order to identify the shield units or their transport units more easily for the purpose of assembling and installing in the face, they should be labeled with a sequential number. 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 shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the right base of the shield.

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4.3

Installation of the shield units

Tab. 5: Allocation of the shield numbers

4.4

Shield number

Order number

G1 to G8

7420 188 000 00 01 End shield

Application

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Fig. 12: Shield number on the base, example

Installation of the shield units Supply connections Danger!

When moving the shield using the auxiliary supply, make absolutely sure that the HP ball valve of the return line (33b) is open. Hydraulic components can be seriously damaged. Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others can be seriously injured or even killed!

During installation, pressure can be applied to the individual shield using the so-called auxiliary supply and operated. The auxiliary supply must be connected to connections a and b (Fig. 13).

Fig. 13: View of the auxiliary supply line

P X 33a

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c a

P 33b b

33a HP ball valve, interrupts the pressure supply line of the auxiliary supply 33b HP ball valve, interrupts the return line of the auxiliary supply a Pressure line of the auxiliary supply

c

b Return line of the auxiliary supply c Vented cap screw, relieves residual pressure in the auxiliary supply X Auxiliary supply

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

The connections for the auxiliary supply are on the front of the shield, on the left next to the right prop (see Fig. 13 and the hydraulic circuit diagram, Fig. 28, in Chapter 5).

For utilization of the auxiliary supply, the connections P, R and W (see Fig. 16) on the supply block must with blocked with the hoses that will later be responsible for the connection with the neighboring shield (this corresponds as a rule to the status at the time of delivery). Should the blocking of the supply hoses not be possible in this way, then the connections must be sealed with corresponding plugs.

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4.5

Installation of the shield units Proceed as follows to join the shields to one another:

. Close the HP ball valves, items 23, 33a and 33b (see Fig. 13, 16 and the hydraulic circuit diagram, Fig. 28, in chapter 5).

. Remove the plugs from the connections of the auxiliary supply. . Connect the auxiliary supply to the pressure and return lines of the pump.

. Open the HP ball valves, item 33a and 33b (see Fig. 13 and the hydraulic circuit diagram, Fig. 28, in chapter 5).

The HP ball valves, items 21d, 21e, 22a, 22b, 33a and 33b (see chapter 5, page 5.27, Fig. 37 and 38) must be open: The shield can now be moved via the external control.

. Move the shield to the desired position. . Briefly actuate the “Bankpush” function until the pressure hose

. Open the pressure relief screws (c) (see Fig. 13) to relieve the connections of the auxiliary supply.

. Disconnect the connection lines of the auxiliary supply close ball valves 33a and 33b and seal the connections with the plugs.

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

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Warning!

Pressure may build up in the return line due to incorrect operation. This must be relieved via the bleeder fitting (item 30, see Fig. 14) 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.

E

is depressurized (shield support is not yet connected with the conveyor).

Installation of the shield units Fig. 14: Bleeder fitting DN 10 with pressure relief screw

30

E

a Bucyrus DBT Europe GmbH, Lünen 2008

30 Bleeder fitting DN 10 with pressure relief

a Vented cap screw

Fig. 15: Arrangement of the supply hoses during transport and commissioning via the auxiliary supply

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4.7

Installation of the shield units Fig. 16: Lateral view from the rear of the supply block

31c

21b

23 16 W

P

32

32 HP ball valve, interrupts the water supply P Pressure supply line DN 40SS R Return line, DN 50 W Water line, DN 50

Fig. 17: View of the dual filter

20

35 20 Dual filter, can be backflushed 35 In line filter DN 25

4.8

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16 Supply block 21b HP ball valve, interrupts the pressure supply to the baselift cylinder 23 HP ball valve, interrupts the pressure supply to the shield 31c HP ball valve, interrupts the nozzle rinsing line

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R

Installation of the shield units Fig. 18: Supply block, configuration P1

R2

P3

W1

P2 W2

P5 R1 P4 P7 P6 W4

R5

R4

R3 W3

R6

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R7 R1 Return line, DN 50, shield to shield connection R2 Return line DN 25, for the electro-hydraulic control unit R3 Return line, DN 20, for the auxiliary supply R4 Return line DN 10, retainer for PRV, 80 bar R5 Return line, DN 10, for bleeder fitting R6 Return line, DN 20, (sealed) R7 Return line, DN 20, (sealed)

P1 Pressure line, DN 40SS, connection from shield to shield P2 Main pressure line to the shield, DN 25, leads to dual filter P3 Pressure line, DN 10 (sealed) P4 Pressure line, DN 20 (sealed) P5 Pressure line, DN 12 (sealed)

P6 Pressure line, DN 10 (sealed) P7 Pressure line, DN 12, (sealed) W1 Water line, DN 50, connection from shield to shield W2 Water line, DN 20, to the water valve W3 Water line, DN 20, (sealed) W4 Water line, DN 10, leads to the spray hose

Coupling 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

The supply block for supplying the shield hydraulics is located between the two props. The supply block of the neighboring shield is connected using three hose lines: a pressure line (DN 40SS), a return line (DN 50) and a water line (DN 50). See also the hydraulic circuit diagrams in Chapter 6 of this manual.

control unit

The shield units are equipped with an electronic control unit of the type PMC®-R. The control unit and the electro-hydraulic control unit are connected via a solenoid driver board. The connection cables required for this are included in the delivery of the PMC®-R control.

For more details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control.

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

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4.9

Requirements for the face hydraulic system additional equipment

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

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

Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulics components included in the Bucyrus scope of delivery: Pressure fluid according to list of approved products. See section “Operating media” in chapter 6 of the operating manual.

nominal pressure

320 bar

admissible tolerance

¦ 10% of nominal pressure

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 danger of malfunctions occurring in the electro-hydraulic control.

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

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.

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permissible pressure

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Contamination Class 18/14 in accordance with ISO 4406.

Start-up Start-up Warning!

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

Notice!

Make sure that all transport securing devices required for transport have been removed. See chapter 3, section “Transport”.

To be observed prior to start-up Start-up 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 start-up 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 securing devices have been removed.

. Check all mechanical connections on the shield units. . Check the plugs of 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).

J Hydraulic system:

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

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

Danger!

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

As a result, you or others can be seriously injured or even killed!

Make sure that hydraulic hoses can’t be damaged by movements of the support.

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

. Check the hydraulic supply pressure.

1) Maximum possible plug-ins

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4.11

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

J Signaling and lighting systems, information plates

Important!

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

. Check all signaling systems. . Make sure that the face lighting is sufficient.

J Emergency stop systems.

. Check that all EMERGENCY STOP systems function properly.

J Mining and conveying

. Before start-up, 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.

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 shield 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.

Warning!

Shut-off valves may 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.

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Bucyrus DBT Europe GmbH, Lünen 2008

ciently signed. It is imperative that you observe the regulations of the responsible mining inspectorate.

E

. Check whether the face area, especially the travel way, is suffi-

Corrosion protection of hydraulic . 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 defects have been eliminated and the support has been found to be in complete working order.

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

Bucyrus DBT Europe GmbH, Lünen 2008

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When these components are put into operation, no special measures have to be taken with regard to corrosion protection since the used testing and anticorrosion medium is completely compatible with the approved operation fluids of the group HFA. See section “Permissible media” in chapter 6 of this operating manual.

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4.13

Bucyrus DBT Europe GmbH, Lünen 2008

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Corrosion protection of hydraulic

4.14

Shield support 1920/4420-2/2x5665/1414-1825

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 of or addition to hands-on training. It is recommended that you read this chapter in addition to the training, but it in no way releases the operator from participating in the training.

Danger!

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

Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

Bucyrus DBT Europe GmbH, Lünen 2008

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Warning!

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

The regulations about safe working of your mine must be followed strictly. Apply the following instructions analogously in addition and in accordance with the individual safety regulations of the mine.

Requirements Conditions for operation face crew

The face crew must be informed about possible danger situations.

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

The face crew must be instructed to stop the face conveyor immediately in case large layers of coal and rock have fallen onto the conveyor. This also applies in case of accumulations of debris.

face equipment

The face must be illuminated sufficiently.

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

The face conveyor must be equipped with a pre-start warning system and a shut-down and lock-out device.

conveyor overload

Large layers of coal and rock must be broken up to prevent spillage and jamming under shield canopies. Compressed-air picks have to be kept on hand for this purpose. The face conveyor and the mining machine must be at a standstill during the process of breaking up the layers of rock and coal.

In case large layers of rock and coal cannot be broken up as required they may only be transported when it is ensured that nobody will be put in danger. Any work on the face must be stopped until the transport of the rock and coal layers has been completed.

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5.3

Requirements travel way

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

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

600 mm,

Height: 400 mm.

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

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

If crawl pans are used whose length is adjustable, care has to be taken that a safe travel way of adequate width remains.

roof supporting work

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

work in the mining area

Work in the mining area may only be carried out from a safe position. The face conveyor and the mining machine must be at a standstill and locked-out to prevent restarting.

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 the best done by using flippers.

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

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

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 fall of rock and falling coal layers.

In faces of the inclined face, 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.

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Bucyrus DBT Europe GmbH, Lünen 2008

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

E

If the height of the travel way is restricted by the use of additional equipment, e.g. for conveyor alignment, care has to be taken hat a safe travel way of adequate height remains.

Requirements 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 suitable 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 only be continued outside of the safety zone required for safely carrying out repair work.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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Protective equipment increases the safety and may only be removed if it is required for carrying out work. After completion of work, the protective equipment should immediately be installed. water spraying system

The water spraying system is used to actively combat dust. Often, several nozzles are provided on the shield support and water can be sprayed through them if required. 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 machine 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 adjacent to the support, if necessary. This way you can prevent the conveyor from shifting to the side with respect to the support. With this, you lower the risk that the shifting system will get stuck in the base.

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.

When pulling up the shields, you must always observe the sequence of steps specified. 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 that is working in automatic mode. Make sure you observe the warnings at the face entry and the respective safety regulations of the mine.

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

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

shield unit operation

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 are persons in the vicinity of the shield unit or in the shield unit.

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

Advancing should be started in the lower section in faces with an inclined face. 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 prop of the shield units must always be set until the set 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 device.

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

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Bucyrus DBT Europe GmbH, Lünen 2008

During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the shield 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, base and the floor, the base and relay bar assembly or between the side seals of neighboring shield units.

Requirements Fig. 19: W r o n g , support advanced too late

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 20: 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 the 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, caving shield and lemniscate links must be mechanically secured to prevent unintentional movement when performing any work or maintenance on the prop (leg cylinders), stabilizing (canopy) cylinders, prop check valves, stabilizing cylinder twin check valves or to any components such as hoses, yield valves, etc. which are attached to the check valves or directly to the cylinders.

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

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

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

The valves should be set to 25 bar and spray in the atmosphere. damage, replacement parts

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

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

5.8

Shield support 1920/4420-2/2x5665/1414-1825

Operation of the shield Operation of the shield 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 electro-hydraulic control unit, it is imperative that the operator be familiar with the separate operating manual for this control.

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 anchorages.

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.

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canopy adjustment

The shield units should always be set so that the shield canopy and base are aligned as parallel to each other as possible. Within the framework of the maximum inclination and swivel angles named 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 the geological or operational conditions require this.

Caution!

Never exceed the permissible angle of inclination of the canopy.

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

Fig. 21: Shield support in normal position

α=0 M

M = Height of the set shield support α = Angle of inclination of the canopy

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5.9

Operation of the shield Caution!

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

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm!

The same applies analogously for 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. 22: Shield support with extremely inclined shield canopy.

α1

M

s

2

α

2

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. For this reason, move the support in such or similar cases without automatic positive set.

5.10

Shield support 1920/4420-2/2x5665/1414-1825

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s1

Operation of the shield Caution!

Avoid the canopy 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 Chapter 6, section “Technical data” of this manual, is exceeded, this could lead to damage to props, hydrocylinders and their fastening elements, as well as to the part hinges.

Since angle changes in 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 floor and roof, or fill break outs in the roof.

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Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in break outs (see Fig. 23), 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. 23: 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. 24) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

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5.11

Operation of the shield Fig. 24: R i g h t , fill out roof falls

RIGHT

shield support range of adjustment/changing seam 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 this is already in the lowest end position.

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

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

Before advancing a shield unit, the floor should be free of rough debris so that the entire forward movement can be done without obstacles and the following return operation isn’t hindered for the conveyor. Also, aligning operations can be carried out easier.

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 withdrawn for the purpose of dismantling, it must be secured against tipping over.

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Accumulation on the shield canopies can be avoided by 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 operation on inclined faces

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

Since in inclined workings shield unit advance usually begins in the lower lying part of the face, it is important that the face end shields are well aligned. Usually, hydraulic end supports, as well as alignment devices are used on the shield canopies and bases or between the bases and shield canopies.

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

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

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On an inclined face, the conveyor must be anchored with respect to the support. This way you can prevent the conveyor from shifting to the side with respect to the support. This way you lessen the danger of jamming the ram system in the basic frame, which would hinder the shield advancing.

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

In the case of unfavorable floor conditions, the base of the shield unit can sink into the floor. Then the base 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, it is lifted out by actuating a valve, or automatically during advancing.

For shield units without a lifting device, the procedure is different, depending on the type: 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.

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5.13

Safe working Safe working 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.

Warning!

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

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

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 person may be in the area between the operator and the moved shield.

Follow these steps if a shield 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 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.

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

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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.

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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 electro-hydraulic neighboring control. Always observe the instructions in the control unit’s separate operating manual.

Location of hydraulic components on the support The following table lists the hydraulic components of the shield support.

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Tab. 6: Hydraulic components Pos. 01

Pcs. 1

Designation Electrohydraulic control unit

02

1

03

1

04

1

CV, NG 20 can be unblocked hydraulically CV, NG 20 compact can be unblocked hydraulically Water valve unit

05

1

06

2

CV, can be unblocked hydraulically Pressure relief valve, 450 bar

07

2

Pressure relief valve, 450 bar

On the left base behind the left hand rear prop In the middle, underneath the caving shield a) On the right hand rear prop b) On the left hand rear prop a+b) On the stabilizing cylinder

08 09

1 1

CV, NW 25 Twin CV NG 10

On the supply block Flipper cylinder

11 12 13 14 15 16

1 4 1 1 1 1

Twin CV Glycerine pressure gauge Hose lines Water spraying system Brackets and accessories Supply block

on the stabilizing cylinder Each on prop CV

17 18

1 7

Accumulator PRV, 380 bar

19

1

CV, NW 20

20 21

1 5

Dual filter, can be backflushed HP ball valve, red handle

Arrangement In the center between the rear props On the right hand rear prop

Remarks On a holder on the bracket

On the left hand rear prop

with compensating valve for stabilizing cylinder On a holder on the bracket

without compensating valve

for shifting rams high flow-through rate for piston space side and annular space side in the return line For flipper cylinders for stabilizing cylinders Subassembly group Subassembly group Subassembly group

In the center between the rear props on the electro-hydraulic control unit a) On the CV (item 5) a) For shifting rams b) On the seal cylinder b) For seal cylinders c) 2x on the flipper cylinder c) For flipper cylinders piston space side and annular space side d) In the middle between the rear d) For baselift cylinder for props piston space e) On the front right hand props f) On the front left hand props In the center between the rear In the water feed line props To the right on the lemniscatic link Manually actuated a) On the side seal a) For seal cylinders b) In the center between the rear b) For lift cylinders props c) On the left hand rear prop c) For stabilizing cylinders d) On the front left hand prop d) In the pressure line for the front prop e) On the front right hand prop e) In the pressure line for the front prop

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

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5.15

Operation of the shield hydraulics Designation HP ball valve, red handle

Arrangement a) On the left hand rear prop b) On the right hand rear prop

23 24

1 1

HP ball valve, red handle In line filter

On the supply block At the front beneath the bracket

25

2

Screw-in socket

26

1

Pressure relief valve, 80 bar

On the prop head, rear prop, respectively On the supply block

27 28 29

1 1 2

Distributor Distributor, DN 10 Pressure gauge connection

30

1

Bleeder fitting

31

3

32 33

Remarks a) In the pressure line for the prop b) In the pressure line for the prop In the main pressure line On the pressure line of the auxiliary supply Ring space connection In the return line

On the left beneath the canopy On the left beneath the canopy On the prop CV, rear props, respectively On the supply block

In the seal cylinder circuit In the seal cylinder circuit

HP ball valve, blue handle

a) To the right under the canopy b) At the front beneath the bracket c) In the middle between the props

a) For lemniscate spraying b) For spray hose c) For nozzle rinsing

1

HP ball valve, blue handle

For water supply

2

HP ball valve with pressure relief, red handle

In the right center between the props a) At the front beneath the bracket b) At the front beneath the bracket

34 35

1 2

In line filter Screw-in nipple NW 8/10

36

2

CV, NG 13 compact

37

1

In line filter

Z1 Z2 Z3 Z4 Z5 Z6 Z7

2 1 1 4 1 1 2

Rear prop Shifting ram Stabilizing cylinder Seal cylinder Baselift cylinder Flipper cylinder Front prop

On the supply block On the prop head, front prop, respectively a) On the left front prop b) On the right front prop On the double filter, to the right on the lemniscatic link

In the return line

a) For the pressure line of the auxiliary supply b) For the return of the auxiliary supply (when the shield is moved over the auxiliary supply, the HP ball valve must be open) For water circulation

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

5.16

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Pcs. 2

Bucyrus DBT Europe GmbH, Lünen 2008

Pos. 22

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 21a, 21b, 21c, 21d, 21e, 22a, 22b, 23, 31a, 32

The following ball valves are closed during normal operation.: J 33b, 31c, 31b, 33a Tab. 7: HP ball valves Color red

Designation HP ball valve

Function Used for blocking the ring chambers of the seal cylinder

21b

red

HP ball valve

Used for blocking the pressure supply to the baselift cylinder

21c

red

HP ball valve

21D

red

HP ball valve

21e

red

HP ball valve

22a

red

HP ball valve

22b

red

HP ball valve

23

red

HP ball valve

31a

blue

HP ball valve

31b 31c

blue blue

HP ball valve HP ball valve

Interrupts the connection of the stabilizing cylinder/compensation valve Used for blocking the pressure supply to the piston space of the front prop Used for blocking the pressure supply to the piston space of the front prop Used for blocking the pressure supply to the piston space of the left hand rear prop Used for blocking the pressure supply to the piston space of the right hand rear prop Used for blocking the pressure supply line to the shield Used for blocking the water supply for the lemniscatic link spraying Used for blocking the spray pipe Used for blocking the nozzle rinsing line

32

blue

HP ball valve

Used for blocking the water supply

33a

red

HP ball valve

Pressure supply during start-up and for auxiliary devices

33b

red

HP ball valve

Used for blocking the return line

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Pos. 21a

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Utilization 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 In order to deactivate the compensating function of the stabilizing cylinder During maintenance work on the prop and any possible disassembly During maintenance work on the prop and any possible disassembly During maintenance work on the prop and any possible disassembly During maintenance work on the prop and any possible disassembly During maintenance and repair work on the shield in order to deactivate the function of the lemniscatic link spraying system For cleaning soiled components Rinses through the spraying system to remove contamination in the lines and on the nozzles In order to deactivate the function of the water spraying system For moving the shield during start-up and for connecting hydraulically operated auxiliary devices Must be open when moving using the auxiliary supply

5.17

Operation of the shield hydraulics Fig. 25: HP ball valve, shown opened and closed

Open

Closed

Through-flow for medium enabled

Through-flow for medium stopped

Shield hydraulics Fig. 26: Shield hydraulics, arrangement Image caption: see Table 6 35 25

6a 29 22a 21c 12

12

21d

3

18e 36a 12 18f 21e 36b

6b 29 12 2 22b

20

5.18

18a

37

5

13

16 23

8

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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35 25

Operation of the shield hydraulics Fig. 27: Shield hydraulics, arrangement Image caption: see Table 6

18c

26

9

14

30

17 33a

31b

24

Bucyrus DBT Europe GmbH, Lünen 2008

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33b

21b 18d 34

1

32

31c 19 4 15

31a 28 27 21a 7a 7b 11

18b

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5.19

Operation of the shield hydraulics Fig. 28: Shield hydraulics, Image caption: see Table 6 14 Z6

18c

Z4

9

18e

18f

12

12 4

21e 36b

17

21d

1

36a

Z7

Z7 19 31c 13

29

29

22b

22a

12

24

3

2

33a 33b

6b 31b 5 21c

18d Z5

Z1

6a

23

32

8 16

25

18a 25

27

30

31a

26

28

21a

11

7a

Z4

Z2 7b

Z1

Z3 37

Z4

20 Z4 18b

5.20

Shield support 1920/4420-2/2x5665/1414-1825

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12

35

21b 34

Bucyrus DBT Europe GmbH, Lünen 2008

35

Operation of the shield hydraulics Fig. 29: Functions of the electro-hydraulic control unit, symbol plates

Bucyrus DBT Europe GmbH, Lünen 2008

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12 Functions

Tab. 8: Electrohydraulic control units with 12 functions, allocation of functions Function, designation

Function no. for

Advance shield

1

Set prop

2

Advance conveyor

3

Retractprop

4

Extend front legs

5

Retract front leg

6

Extend seal cylinder (canopy)

7

Extend seal cylinder (caving shield)

8

Extend flipper cylinder

9

Retract flipper cylinder

10

Retract seal cylinder

11

Extend baselift cylinder

12

Fig. 30: Functions of the water valve unit, symbol plate Water spray canopy

1 2 Water curtain

Tab. 9: Water valve unit with 2 functions, allocation of functions Function, designation

Doc. No.: 7420 188 000 BA 00

Function no.

canopy water spray system

1

Water curtain

2

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5.21

Operation of the shield hydraulics Fig. 31: Hydraulic lines, sheet 1/2 Image caption: see Table 6 18c

9 Z6

Z4

35 35 36b

18f

Z7

36a

Z7

12

18e

Z5

21D

21e

25

18D

Z1

4

25

Z1

12

21b

3 12

2 12

29 29

22b 28

22a 27 18a Z4 21a 5 31a Z4

Z3 Z2

13 11 7a 7b Z4 18b

5.22

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

1 a

a

21c

E

6a 6b

Operation of the shield hydraulics Fig. 32: Hydraulic lines, sheet 2/2 Image caption: see Table 6

31b 24 31c

33a

19 34 32

33b 16

23

8

50x2600 50x2600 R3

Bucyrus DBT Europe GmbH, Lünen 2008

E

R2

40SS-Ox2700

30 26 20 37

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5.23

Operation of the shield hydraulics Fig. 33: Lateral view from the rear of the supply block

31c

21b

23 16 W

P

32

32 HP ball valve, interrupts the water supply P Pressure supply line DN 40SS R Return line, DN 50 W Water line, DN 50

Fig. 34: View of the dual filter

20

37

20 Dual filter, can be backflushed 37 In line filter DN 25

5.24

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

16 Supply block 21b HP ball valve, interrupts the pressure supply to the baselift cylinder 23 HP ball valve interrupts the pressure supply to the shield 31c HP ball valve, interrupts the nozzle rinsing line

E

R

Operation of the shield hydraulics Bracket for PMC®-R and control unit 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.

Fig. 35: Bracket for PMC®-R control unit and control unit

A

Bucyrus DBT Europe GmbH, Lünen 2008

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B

13 4

16

14 8

1

9

2

5

3

15 10 11 11

6 7

12 1 Bracket 2 Bracket for control unit 3 Locking clip 4 Bracket for PMC®-R 5 Pipe, Ø30x5 6 Stud bolt, M 10 7 Hex nut, M 10-A 2-70 8 Hex. head screw, M 6x10-A 2-70 9 Washer 10 Hex. head screw, M 16x55-A 2-70

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12

17

17

11 Hex. head screw, M 10x25-A 2-70 12 Hex nut, M 10-A 2-80 13 Cyl. head screw , M 10x20-A 2-70 14 Instruction plate, 12x 15 Instruction plate, double 16 Hex. head screw, M 10x20-A 2-70 17 Spring cotter A Protective plate, closed B Protective plate, open

5.25

Operation of the shield hydraulics Fig. 36: Holder for PMC®-R control unit and electro-hydraulic control unit

A d a e

B c

b

A Holder for PMC®-R B Holder for electrohydraulic control unit a PMC®-R control unit b Electrohydraulic control unit

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c Symbol plate d Emergency stop e Shield support blocked button

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

E

B

Operation of the shield hydraulics Fig. 37: Left prop, view from the gob side,

6a 22a

21c

a

12

b

Bucyrus DBT Europe GmbH, Lünen 2008

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3

3 Prop control valve 6a Pressure relief valve 12 Pressure gauge 21c HP ball valve interrupts the line to the stabilizing cylinder - compensating valve 22a HP ball valve, is used for interrupting the pressure supply to the pis-

ton space of the prop, opened, as shown a Compensating valve for stabilizing cylinder b Connection for testing device/ pressure gauge

Fig. 38: Right prop, view from the gob side,

22b 6b

12

a

2 2 Prop control valve 6b Pressure relief valve 12 Pressure gauge

the pressure supply to the piston space of the prop, opened, as shown a Connection for testing device/ pressure gauge

22b HP ball valve, used for interrupting

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5.27

Operation of the shield hydraulics Fig. 39: Right front prop, view from the gob side,

12

21e

18f

36b Prop control valve

Fig. 40: Left front prop, view from the gob side,

12

21D

18e

36a

12 Pressure gauge 18e Pressure relief valve 380 bar 21d HP ball valve, used for interrupting the pressure supply to the piston space of the prop, opened, as shown

5.28

36a Prop control valve

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

12 Pressure gauge 18f Pressure relief valve 380 bar 21e HP ball valve, used for interrupting the pressure supply to the piston space of the prop, opened, as shown

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36b

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

Do not put the filter into operation before making sure that all connections have been made properly. 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 both filters regularly once per shift Warning!

Never put both levers into backflush position simultaneously, because the emulsion flow will be completely shut off and backflushing will be impossible.

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.

Bucyrus DBT Europe GmbH, Lünen 2008

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

Fig. 41: View of the dual filter

b

20

a

b

a

20 Dual filter, can be backflushed A Normal operation: both levers in position “A”

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B Backflushing: One of the levers in position “B”

5.29

Operation of the shield hydraulics Repair and emergency operation

Fig. 42: Layout of the PMC®-R control unit b

c a d 2

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

c Emergency stop d Shield support blocked button

Fig. 42 shows the layout of the PMC®-R control unit and the electrohydraulic control unit on the support.

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

5.30

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

Warning!

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

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

E

This section contains information on the functions and operation of the hydraulic control, 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 is not described here, but in a separate operating manual. If the control device is included in the Bucyrus scope of delivery, the respective operating manual will be included in the Bucyrus documentation provided for the installation.

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

It has also been 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. 43: Control valve block (12 functions)

17

b

e

c 1

a

d

Bucyrus DBT Europe GmbH, Lünen 2008

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1 Electrohydraulic control unit 17 Accumulator a Button b Pilot valve

c Connecting cable d Solenoid driver e Symbol plate

Important!

Note that - depending on the marking on the connecting cable the end with the shorter distance is to be connected to the pilot valve. See also the separate operating instructions for the control unit.

Fig. 44: Symbol plate for electrohyd. control unit with 12 functions

Fig. 45: Symbol plate for water valve unit Water spray canopy

1 2 Water curtain

The symbol plates are located on the control valve block above the pilot valves. The symbols correspond to the various functions which are initiated by actuating the respective button. The meaning of the symbols and functions are described below.

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5.31

Operation of the shield hydraulics Operation and functions of the control valve block 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 control valve block when you know exactly which 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 incorrect operation. This could result in serious injury and even fatal accidents.

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

The function stops as soon as you release the button.

Danger!

Jammed or locked buttons can cause uncontrolled movements of the shield, seriously injuring or even killing you.

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

Warning!

Manual actuation of a button on one of the pilot valves initiates direct execution of the corresponding function. Dependencies between the individual functions are not taken into account.

Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”.

This can cause dangerous situations which can result in very serious injury.

5.32

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

There are two push-buttons on the cover of each individual pilot valve. When you actuate a button, the corresponding work valve is operated immediately.

E

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

Operation of the shield hydraulics Shield functions (12 functions) 1

Advance shield Before executing this function, the side seal of the shield unit must be released and the function “lower prop” 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 ring space of the shifting ram, is opened automatically.

2

Set both props

Bucyrus DBT Europe GmbH, Lünen 2008

E

Before this function is actuated, the shield canopy must be correctly aligned. The baselift cylinder retracts automatically. 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.

While the props are being set, a canopy, which has too steep a setting angle, aligns itself automatically to the roof as long as the function of the compensating valve for the stabilizing cylinder is not blocked.

The compensating valve a (see Fig. 37) and the associated shut-off valve (Fig. 37, item 21c) are on the left prop when looking at the coal face. When the shut-off valve is open (lever in the direction of flow), the compensating valve is activated. When the shut-off valve is closed (lever perpendicular to direction of flow), the compensating valve has no function. While the props are being set, the compensating valve limits the pressure of the stabilizing cylinder to 200 bar as long as the pressure under the piston of the prop 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 it automatically.

3

Advance 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

Retract both props Before initiating this function, it must be made sure that the neighboring shield is completely set.

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

5

Extend front props Caution!

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

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5.33

Operation of the shield hydraulics 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 the force is equalized or until the end position has been reached.

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

6

Retract front props Caution!

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

Before initiating this function, it must be made sure that the neighboring shield is 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.

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

The seal cylinders continue to extend out 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.

8

Extend seal cylinder (caving shield) The function serves to align the shield unit to the adjacent support.

The seal cylinders continue to extend out 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.

9

Extend flipper 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.

10

Retract flipper 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.

11

Retract seal cylinder The seal cylinders continue to retract as long as the button is held down 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.

12

Extend baselift 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.

5.34

Shield support 1920/4420-2/2x5665/1414-1825

E

Extend seal cylinder (canopy) Bucyrus DBT Europe GmbH, Lünen 2008

7

Operation of the shield hydraulics Functions of the water valve unit Fig. 46: Functions of the water valve unit, symbol plates Water spray canopy

Water curtain

Water spray canopy W1

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

W2

Water curtain

Bucyrus DBT Europe GmbH, Lünen 2008

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

Doc. No.: 7420 188 000 BA 00

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5.35

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

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

hydraulic control

Special measures

After extensive work on the hydraulics system or after the start-up of a new face, there is an increased risk of dirt having found its way into the hydraulic 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 control valve of the shield control system serve to 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 preparation of the medium there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation. For example, the filters described above should be spot checked regularly for contamination. If necessary the filter cartridges must be replaced regularly as a precautionary measure.

pressure relief valves

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

Pressure relief valves which are pre-tensioned with gas pressure must be additionally spot checked at regular intervals to ensure their correct function. We recommend such spot checks at 3-monthly intervals.

5.36

Shield support 1920/4420-2/2x5665/1414-1825

E

At the latest 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 shows 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

one week after start-up

Maintenance high-pressure hydraulic hoses

All high-pressure hydraulic hoses 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.

dual filter, can be backflushed

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

Daily inspection hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid: – Hose lines, – Control valve blocks, – Valves,

Bucyrus DBT Europe GmbH, Lünen 2008

E

– Props, – Shifting and lifting cylinders, – Link, steering and flipper cylinders.

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

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

Weekly maintenance control unit

. Check each control unit for correct function. . Replace defective control units or individual components immediately.

. Clean the control units, especially the control panel.

Notice!

It is important that the control symbols are easily legible. This prevents the risk of incorrect operation 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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5.37

Maintenance Fig. 47: Lubricating nipples on the hydraulic props

b

a

b Grease escaping at dirt stripper

Carry out 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 damage determined. The records should be evaluated regularly, for example every month, and combined in a damage report. This will enable you to detect frequently occurring damage and take preventative action. This will heighten system availability and lower operating costs accordingly.

5.38

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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a Lubricating nipples on the guide bushing

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 circuit and hose diagrams for the shield hydraulics.

Also refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

Functional errors can in principle occur in all components. The majority of faults on hydraulic valves is, however, cause by hydraulic bypass flows. These are normally audible to the operator.

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

Bucyrus DBT Europe GmbH, Lünen 2008

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Warning!

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

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

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

Fault localization failure to lower the shield

Doc. No.: 7420 188 000 BA 00

Possible cause

Check/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 ring 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 approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked prop hose lines.

Replace the hoses, if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

VEVT / 01

5.39

failure to advance the shield

Possible cause

Check/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 ring 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.

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 approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked prop hose lines.

Replace the hoses, 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

Check/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 canopy.

Step on roof or floor preventing ad- Lower canopy sufficiently to clear the step or vance. lift the base.

5.40

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 pilot-operated check valve does not work.

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

The check valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked shifting ram hose lines. Replace the hoses, if necessary.

Make sure hoses are laid properly.

Shifting ram is defective.

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

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

failure to set the shield

E

Troubleshooting

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

canopy cannot be positioned

canopy cannot be lowered

Doc. No.: 7420 188 000 BA 00

Possible cause

Check/measure required

Prop control valve is defective.

Replace prop control valve. Continue trouble shooting in the pressure continues to drop.

Props are damaged.

Check prop for damage and replace, if necessary.

Remove hose from prop lower connection and check whether pressure fluid is escapes without large prop movement. 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 applicable: Replace the pressure relief valve and retest the function.

Possible cause

Check/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.

Pilot-operated check valve isn’t working.

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

Check/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.

Pilot-operated check valve isn’t working.

Check whether the pressure for controlling the valve is sufficient. Minimum is about 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.

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5.41

Troubleshooting 3/2-way or pilot valve The valve is jammed or a by-pass has formed due to internal leakages. 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 valve can therefore be faulty. valve sticks

. Try to solve the problem by initiating the function several times on the electrohydraulic control unit or the control valve block.

internal leakage

. Locate the faulty valve by initiating the functions individually

. Close the main shut-off valve in the pressure feed line at the pipe distributor.

. Then operate the functions manually to depressurize the system.

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

Pilot-controlled check valves The formation of a by-pass is shown by a drop in pressure.

. Try to solve the problem by initiating the function several times on the electrohydraulic control unit or the control valve block.

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

. Check the valve and replace if defective Checking the prop check valves To check the prop check valves please proceed as follows:

. Set the prop until the set pressure has been reached. . Remove the hose line ”Set props” at the pilot-operated check valve If fluid escapes at the connection of the piloted check valve, it is defective.

5.42

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

valve replacement

E

one by one.

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.

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 set 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 ring space connections (located on the prop head and prop pipe) and apply pressure to the control connection (extend prop) of the pilotoperated check valve.

. Activate the function “Set prop”.

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.

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

Pressure relief valve defective Bucyrus DBT Europe GmbH, Lünen 2008

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

In the hydraulic circuit of a shield unit, various types of pressure relief valves are used. For example, pressure relief valves are used on the props which have a high flow rate. 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 spare parts catalog.

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

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

. Check the filters in the hydraulic system.

Backflush filters can be cleaned by backflushing. On fine-mesh filters such as on the control valve block, the filter elements must be replaced.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

5.43

Bucyrus DBT Europe GmbH, Lünen 2008

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Troubleshooting

5.44

Shield support 1920/4420-2/2x5665/1414-1825

6

Technical data

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.

Description Type

1920/4420-2/2x5655/1414-1825

The four-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, movable on the right side, J Hydraulic prop,

Bucyrus DBT Europe GmbH, Lünen 2008

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J Hydraulic equipment with hose lines and control.

Tab. 10: Variants of the shield Variant

Application

Device number

01

End shield

7420 188 000 00 01 8244x1750x4420 9272x1750x1920

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

Weight approx. in kg 41714

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

The caving shield is a one-piece steel construction, it is flexibly connected with the canopy and also to the base by means of the so-called lemniscatic link.

The 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 resistance and range of vertical adjustment of the supports.

The multi-stage hydraulic props have the same capacity at all stages and act on both sides.

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

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

3)

Doc. No.: 7420 188 000 BA 00

Side flap completely folded out

VEVT / 01

6.3

Description Main subassemblies Fig. 48: Dimensions of the shield

L1 L3

b

L2

HA H HE

L6

L5

B1

L4

L

B2

L1

L2

L3

L4

L5

L6

H

HA

HE

b

B1

B2

9272

6355

1355

5000

4330

1755

175

3200

4420

1920

1750

1680

370

Fig. 49: Main subassemblies

21 51

31 11

42

41

1 61 1 Base 11 Canopy 21 Side seal 31 Caving shield

6.4

41 Rear prop 42 Front prop 51 Stabilizing cylinder 61 Electrohydraulic shield control system

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 11: Shield variants, dimensions

Description Tab. 12: End shield 7420 188 000 00 01, subassemblies used Item

Description

Order no.

Approxi- Remarks mate weight in kg

0001

Base / base skid

7420.188.300.00.01

13078 Shifting ram Lifting cylinder Relay bar assembly

8241.334.000.00.00 8241.280.000.00.00 7420.188.330.00.01

0011

Canopy

7420.188.400.00.01

12946 Flipper

7420.173.420.00.00

0021

Side seal

7420.188.700.00.01

2153

0031

Caving shield

7420.188.800.00.01

6708

0041

Hydraulic prop (rear prop)

8250.134.000.00.00

2172

0042

Hydraulic prop (front prop)

8250.136.000.00.00

474

0051

Stabilizing cylinder

8241.333.000.00.00

261

0061

Shield control system - 12 functions -

8112.274.000.00.00

8154.120.000.00.00 8112.274.010.00.00 8112.274.020.00.00 8112.274.030.00.00

Bucyrus DBT Europe GmbH, Lünen 2008

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Electrohydr. control unit Lines Water spraying system Brackets

Doc. No.: 7420 188 000 BA 00

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6.5

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 simply supported 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 with a pin connection.

Characteristic for the base 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 is used to advance the shield. Correspondingly, the conveyor is pushed with the smaller force, which is generated via the ring 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.

Fig. 50: Base

1690

31

55

67

33

565

1755

800

370

66 40 17 18

1680

980

4330 64

20

2 32 19 10 27 56 29 67

65

30 33

41

30

1

66 13

42 6

16

115

12 60

15

11

1 Baselift cylinder ZE-225/140-1130 2 Shifting ram ZE-150/90-300 6 Relay bar assembly 10 Securing device 11 Base 12 Lemniscatic link, front right 13 Lemniscatic link, front 15 Lemniscatic link, back right 16 Lemniscatic link, back left 17 Prop retainer, right 18 Prop retainer, left

6.6

19 Cylinder bearing 20 Running board 27 Pin, Ø70x312 28 Securing device 29 Pin, 30/20x191 30 Locking plate 31 Pin, 60/50-120 32 Pin, Ø 16x117 33 Pin, 35/29x62 40 Lemniscatic link pin, 213.5x607 41 Lemniscatic link pin, 193.5x607

42 Prop retainer 55 Hex. head screw M 16x120-A-80 56 Staple 64 Hex. head screw M 20x65-A 4-80 65 Hex. nut, M 20 66 Locking clip 5.6 67 Locking clip 4 71 Hex. nut, M 16

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

240

325

815

1050 720 420 232

E

71

Description RELAY BAR ASSEMBLY The relay bar assembly is located in the middle of the base.

It mainly consists of the relay bar, shifting ram, baselift cylinder and the required fastening elements. It serves to advance the conveyor and shield.

The shifting ram is reverse mounted with the force of the cylinder is transmitted 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 can be lifted from the floor during pulling up.

The baselift cylinder is located in the middle of the base. The force of the baselift cylinder acts on the floor via the relay bar.

Tab. 13: Relay bar assembly Relay bar assembly,

Dimensions

Device number

L1

H1

7420 188 330 00 01

4297

295

1 H1

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 51: Relay bar assembly

L1 2

1 Relay bar 2 Clevis assembly for conveyor

Doc. No.: 7420 188 000 BA 00

VEVT / 01

Other fastening elements: see spare parts catalog

6.7

Description Functional 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, this lifts up the bases from 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 support, the baselift cylinder retracts again automatically.

Bucyrus DBT Europe GmbH, Lünen 2008

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4. Advancing the conveyor The shifting ram is retracted.

6.8

Shield support 1920/4420-2/2x5665/1414-1825

Description Shield canopy The canopy transfers the supporting force of the prop to the roof. It is articulated and is connected with 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 is equipped with a movable side seal on the right side and a fixed one on the left side, and also has a flipper.

Tab. 14: Shield canopy Canopy

Features

Device number

(125)

Fig. 52: Canopy A-A

980

1600

1730

a

17 20 a 21

12

13

21

23 18

11

250

15

10

22

730

0

16

1200

1

2520

19

6200

23

240

14 2 7700

Bucyrus DBT Europe GmbH, Lünen 2008

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7420 188 400 00 01 Total length: 6450 mm 1)

1 Canopy, subassembly 2 Flipper 10 Plug, left 11 Securing device 12 Pegs Ø73x134 13 Pin, Ø20x160

14 Joint pin, Ø154,3x598

19 Pin, Ø20x135

15 Peg Ø65x132

20 Locking element with connector

16 Pin, Ø16x160

21 Spring clip, 5x32

17 Pin, Ø65x215

22 Locking clip 2.5

18 Pin, Ø 12x120

23 Spring cotter

1) with the flipper folded back to the canopy

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.9

Description Prop head Important!

Before installing the prop head, put the pegs of the prop head fixture into the bores of the retainer. Secure the pegs with the securing device (pins, spring clips) in the second groove.

After installing the prop head, push the pegs in the bores of the prop head. Secure the pegs using the securing device in the first groove.

Fig. 53: Prop head attachment

c

b a Pin, Ø20x160 b Peg, 73x134

c Spring clip, 5x32

Fig. 54: Prop head attachment

c

a

b

a Pin, Ø20x160 b Peg, 73x134

6.10

c Spring clip, 5x32

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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a

Description Flipper

Fig. 55: Flipper 29 30 31

32 33

28 1540

18

1

14

24

38

36

35

34

25

21 22 185

Bucyrus DBT Europe GmbH, Lünen 2008

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23

1300 3

15

17

13

12

11

37

19

16

2

27 26

1485

1 Hydraulic cylinder ZE-125/90-535 2 Flap 3 Extension 11 Catch 12 Pin, 35/28.5x145 13 Pin, Ø28.5x145 14 Pin, 25/16x150 15 Rubber mat 16 Rubber mat 17 Strip 18 Damper

Doc. No.: 7420 188 000 BA 00

19 Damper 21 Fork 22 Lemniscatic link 23 Lemniscatic link 24 Securing device 25 Pin, Ø44.5x304 26 Pin, Ø44.5x250 27 Pin, Ø44.5x184 28 Pin, 45/30.5x115 29 Pin, 55/43.5x159 30 Cyl.head screw, M 10x60 A 2-70

VEVT / 01

31 Hex.nut M 10-8 32 Hex. head screw M 16x50 A 2-70 33 Hex.nut M 16-8 34 Countersunk screw, M 12x35 A 2-70 35 Locking clip 4 36 Locking clip 3.2 37 Spring clips, 6x42 38 Washer Other fastening elements: see spare parts catalog

6.11

Description Side seal The side seals seal the gap between adjacent shield units. They are also used to align a shield unit to the adjacent shield units.

The left side (viewed in the shifting direction) of the side seal is locked using the shield canopy and tightly fastened with the caving shield. The right 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.

Tab. 15: Side seals used for all shield varieties Description Side seal

Order no.

7420 188 700 00 01

Length L in mm

Approximat e weight in kg

4395

2153

Notice!

If the side seal on the other side is movable, the seal cylinders and their respective guiding pins are to be installed symmetrically.

Warning!

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

Notice!

When putting the side seals into operation, remove the transport safety devices items 20*, 25* and 26*, 44* on the movable side.

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

6.12

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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Caution!

Before putting the support unit into operation, the transport safety devices (see Fig. 56 marked with a *) of the side seal must be removed.

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

Description Fig. 56: Side seal 10 40 42 22 31 26

29

50

1

44

31

40

26

44

29

50 1 26

30

26

45

30

1 31

505

1750+ 150 stroke

22

22

35

10

43

41

48

32

48 32

44*

26*

32

48

48

32

32

48 44*

26*

54

57 53 32

42

12

41

13

4395 54

47

5

34

47

34

49 32

49

32

59 56 32 49 56

Bucyrus DBT Europe GmbH, Lünen 2008

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33 51

7

58

25* 20* 34 47

55 33 34 47 20*

1 Hydraulic cylinder ZE-63/50-215 5 Side seal, canopy, right 7 Side seal, caving shield, right 10 Guiding pin 12 Guiding pin 13 Guiding pin 20 Transport safety device 22 Pin, Ø 28x93 25 Staple DN 12 26 Staple DN 25 29 Screw pin M10x25 30 Screw pin, M10x12-45 H 31 Splint pin, 6,3x40

Doc. No.: 7420 188 000 BA 00

32 Locking clip 4 33 Locking clip 2,5 34 Hex. head screw M 12x20-A 4-80 35 Cylinder liner, 103x105 40 Compression spring 18x130x800 41 Compression spring 12x79x560 42 Guiding pin 133x1370 43 Guiding pin 103x1120 44 Pin 40/34x343 45 Pin, 40/34x64 46 Pin, 15/12x120 47 Spring washer 48 Pin, Ø28x242

VEVT / 01

46 25*

33

46

49 Pin, Ø28x212 50 Cylinder liner Ø133x105 51 Pin, Ø 12x120 53 Securing device 54 Cover plate for canopy 55 Cover plate for canopy 56 Securing device 57 Plug, right 58 Plug, 215 59 Plug, 235

For other fastening and securing elements, see also the spare parts catalog

6.13

Description Caving shield The caving shield protects the face area toward the gob. It is connected to the shield canopy and with the base 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 of the side seal.

Fig. 57: Caving shield 1730 1175

330

1130

11 10

3281

2720

1

Bucyrus DBT Europe GmbH, Lünen 2008

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65

9

4

520

2 5 3

7

8

6 980

1 Caving shield, subassembly 2 Plug, 235 3 Plug, 215 4 Lemniscatic link pin Ø213,5x550 5 Lemniscatic link pin Ø193,5x550 6 Locking plate 7 Pin, 15/12x120 8 Locking clip 2,5 9 Pin, Ø65x215 10 Locking element 11 Spring cotter 5 S1 Lifting eye, capacity: 3000 kg S2 Lifting eye, capacity: 15000 kg

S1

S1 S2

S2

Notice!

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

6.14

Shield support 1920/4420-2/2x5665/1414-1825

Description Technical data, steel structure End shield

Bucyrus DBT Europe GmbH, Lünen 2008

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Securing from tipping, permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . Degrees

Support force with four props

Support force with two props

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

1920

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

4420

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

2500

Advance stroke, . . . . . . . . . . . . . . . . . . . . mm Shifting ram stroke . . . . . . . . . . . . . . . . . . mm

1062 1130

Distance of prop centers (inclination) . . mm

980

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

3680/5000

Forepole of canopy with hydraulic forepole . . . . . . . . . . . . . . . mm

-

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

1355

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

1750

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

6355

Caving shield inclination, Support retracted . . . . . . . . . . . . . . . . . . . Degrees Support extended . . . . . . . . . . . . . . . . . . . Degrees

10.7 83.5

Width of caving shield with side seal . . . mm

1750

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

1680

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

38767

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

1800

Support force for an average seam thickness of . . . . . . . . . . . . . . . . . . . mm a) at 310 bar setting pressure . . . . . . . . . kN b) at 450 bar nominal pressure . . . . . . . . kN

3200 9276 13465

Support force for an average seam thickness of . . . . . . . . . . . . . . . . . . . mm a) at 310 bar setting pressure . . . . . . . . . kN b) at 450 bar nominal pressure . . . . . . . . kN

3200 7406 10751

Support resistance per m2 Roof surface for an average seam thickness of . . . . . mm a) at 310 bar setting pressure . . . . . . . . . kN/m2 b) at 450 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

Doc. No.: 7420 188 000 BA 00

15

VEVT / 01

3200 750 942/1089

6.15

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. You can find additional information in the spare parts catalog of the shield support.

Tab. 16: Elecrohydraulic shield controlsystem Description

normal and exceptional operation

Order no.

Shield control system

8112.274.000.00.00

Electrohydraulic control unit, 12 Functions

8154 120 000 00 00

Hose lines

8112 274 010 00 00

Water spraying system

8112 274 020 00 00

Brackets

8112 274 030 00 00

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

6.16

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

Warning!

During normal operation the buttons on the pilot valves of the control valve blocks 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.

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The pilot valves of the electro-hydraulic control unit are equipped with buttons, which allow the shield functions to be operated manually. A symbol plate shows the function/button allocation.

Hydraulic system Shield hydraulics The following table lists the hydraulic components of the shield support.

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 17: Hydraulic components Pos. 01

Pcs. 1

Designation Electrohydraulic control unit

02

1

03

1

04

1

CV, NG 20 can be unblocked hydraulically CV, NG 20 compact can be unblocked hydraulically Water valve unit

05

1

06

2

CV, can be unblocked hydraulically Pressure relief valve, 450 bar

07

2

Pressure relief valve, 450 bar

On the left base behind the left hand rear prop In the middle, underneath the caving shield a) On the right hand rear prop b) On the left hand rear prop a+b) On the stabilizing cylinder

08 09

1 1

CV, NW 25 Twin CV NG 10

On the supply block Flipper cylinder

11 12 13 14 15 16

1 4 1 1 1 1

Twin CV Glycerine pressure gauge Hose lines Water spraying system Brackets and accessories Supply block

on the stabilizing cylinder Each on prop CV

17 18

1 7

Accumulator PRV, 380 bar

19

1

CV, NW 20

20 21

1 5

Dual filter, can be backflushed HP ball valve, red handle

22

2

HP ball valve, red handle

23 24

1 1

HP ball valve, red handle In line filter

25

2

Screw-in socket

Arrangement In the center between the rear props On the right hand rear prop

Remarks On a holder on the bracket

On the left hand rear prop

with compensating valve for stabilizing cylinder On a holder on the bracket

without compensating valve

for shifting rams high flow-through rate for piston space side and annular space side in the return line For flipper cylinders for stabilizing cylinders Subassembly group Subassembly group Subassembly group

In the center between the rear props on the electro-hydraulic control unit a) On the CV (item 5) a) For shifting rams b) On the seal cylinder b) For seal cylinders c) 2x on the flipper cylinder c) For flipper cylinders piston space side and annular space side d) In the middle between the rear d) For baselift cylinder for props piston space e) On the front right hand props f) On the front left hand props In the center between the rear In the water feed line props To the right on the lemniscatic link Manually actuated a) On the side seal a) For seal cylinders b) In the center between the rear b) For lift cylinders props c) On the left hand rear prop c) For stabilizing cylinders d) On the front left hand prop d) In the pressure line for the front prop e) On the front right hand prop e) In the pressure line for the front prop a) On the left hand rear prop a) In the pressure line for the prop b) On the right hand rear prop b) In the pressure line for the prop On the supply block In the main pressure line At the front beneath the bracket On the pressure line of the auxiliary supply On the prop head, rear prop, reRing space connection spectively

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.17

Hydraulic system Pos. 26

Pcs. 1

Designation Pressure relief valve, 80 bar

Arrangement On the supply block

Remarks In the return line

27 28 29

1 1 2

Distributor Distributor, DN 10 Pressure gauge connection

In the seal cylinder circuit In the seal cylinder circuit

30

1

Bleeder fitting

On the left beneath the canopy On the left beneath the canopy On the prop CV, rear props, respectively On the supply block

31

3

HP ball valve, blue handle

a) To the right under the canopy b) At the front beneath the bracket c) In the middle between the props

a) For lemniscate spraying b) For spray hose c) For nozzle rinsing

32

1

HP ball valve, blue handle

For water supply

33

2

HP ball valve with pressure relief, red handle

In the right center between the props a) At the front beneath the bracket

1 2

In line filter Screw-in nipple NW 8/10

36

2

CV, NG 13 compact

37

1

In line filter

Z1 Z2 Z3 Z4 Z5 Z6 Z7

2 1 1 4 1 1 2

Rear prop Shifting ram Stabilizing cylinder Seal cylinder Baselift cylinder Flipper cylinder Front prop

On the supply block On the prop head, front prop, respectively a) On the left front prop b) On the right front prop On the double filter, to the right on the lemniscatic link

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

6.18

Shield support 1920/4420-2/2x5665/1414-1825

E

34 35

a) For the pressure line of the auxiliary supply b) For the return of the auxiliary supply (when the shield is moved over the auxiliary supply, the HP ball valve must be open) For water circulation

Bucyrus DBT Europe GmbH, Lünen 2008

b) At the front beneath the bracket

In the return line

Hydraulic system Shield hydraulics Fig. 58: Shield hydraulics, arrangement Image caption: see Table 17 35 25

35 25

6a 29 22a 21c 12

12

21D

3

18e 36a 12 Bucyrus DBT Europe GmbH, Lünen 2008

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18f 21e 36b

6b 29 12 2 22b

20

Doc. No.: 7420 188 000 BA 00

18a

VEVT / 01

37

5

13

16 23

8

6.19

Hydraulic system Fig. 59: Shield hydraulics, arrangement Image caption: see Table 17

18c

26

9

14

30

17 33a

31b

24

21b 18d 34

1

32

31c 19 4 15

31a 28 27 21a 7a 7b 11

18b

6.20

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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33b

Hydraulic system Fig. 60: Shield hydraulics, Image caption: see Table 17 14 Z6

18c

Z4

9

18e

18f

12

12 4

21e 36b

17

21d

1

36a

Z7

Z7 19 31c 13 35

E Bucyrus DBT Europe GmbH, Lünen 2008

12

35

21b 34

29

29

22b

22a

12

24

3

2

33a 33b

6b 31b 5 21c

18D Z5

Z1

6a

23

32

8 16

25

18a 25

27

30

31a

26

28

21a

11

7a

Z4

Z2 7b

Z1

Z3 37

Z4

20 Z4 18b

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.21

Hydraulic system Fig. 61: Functions of the electro-hydraulic control unit, symbol plates

Tab. 18: Electrohydraulic control units with 12 functions, allocation of functions Function, designation

Function no. for

Advance shield

1

Set prop

2

Advance conveyor

3

Retract prop

4

Extend front leg

5

Retract front leg

6

Extend seal cylinder (canopy)

7

Extend seal cylinder (caving shield)

8

Extend flipper cylinder

9

Retract flipper cylinder

10

Retract seal cylinder

11

Extend baselift cylinder

12

Fig. 62: Functions of the water valve unit, instruction plate Water spray canopy

1 2 Water curtain

Tab. 19: Water valve unit with 2 functions, allocation of functions Function, designation

6.22

Function no.

Canopy water spray system

1

Water curtain

2

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

E

12 Functions

Hydraulic system Double-telescopic prop The prop described is a double-telescopic prop with equal loadbearing capacity at both stages. Equal load-bearing capacity of the two stages is ensured by a piloted check valve which is installed in the piston pipe.

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

The head is fastened using two pegs each that are inserted into the bore holes in the mounting device before the prop head is installed.

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

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

Fig. 63: Double-telescopic prop, Type SD-5650-400-1620/3940

Bucyrus DBT Europe GmbH, Lünen 2008

E

b2 Detail X

X 21

2 e 5 b1 1 e d

a

e c

1 Prop base 2 Piston pipe 5 Pressure relief valve, 520 bar 21 Piston rod a Valve connection plate

Doc. No.: 7420 188 000 BA 00

VEVT / 01

b1 Ring space connection Lower stage b2 Ring space connection Upper stage c Cam d Lubricating nipple e Load ring 3000 kg

6.23

Hydraulic system Fig. 64: Double-telescopic prop, TypeSD-1410-200-1555/3910 B2 7

2 5 B1 e

1

c 1 Prop base 2 Piston pipe 5 Pressure relief valve, 520 bar 7 Piston rod a Valve connection plate b1 Ring space connection Lower stage

Bucyrus DBT Europe GmbH, Lünen 2008

E

a

b2 Ring space connection Upper stage c Cam e Load ring 3000 kg

Tab. 20: Telescopic prop Length in mm

Stroke in mm

ID no.

Telescopic prop

retracted

extended

upper stage

lower stage

8250 134 000 00 00

1620

3940

1125

1195

8250 136 000 00 00

1555

3910

1160

1195

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 pressure-tight. Otherwise, pressure might build up in the ring space when extending the prop which is several times more than the set pressure.

6.24

Shield support 1920/4420-2/2x5665/1414-1825

Hydraulic system Function prop setting

Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the ring 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.

Hereby, the pressure fluid is supplied via the check valve in the floor of the piston pipe.

prop loading

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 floor of the piston rod to the floor 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.

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 on the pressure relief valve is exceeded, the pressure fluid flows from the prop and the prop is pushed in under the nominal prop force.

Bucyrus DBT Europe GmbH, Lünen 2008

E

b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure fluid, which is blocked by the pressure relief valve in the floor of the piston pipe.

The further course of the force flow up to the setting of the piston pipe is as described under a). props lowering

The pressure fluid is connected to the return under the middle prop via the control valve.

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 tube is “set”, the check valve is opened by a tappet, whereby the pressure fluid acts like a spring lifting the piston pipe to close the valve again. When lowering along the entire stroke, the procedure repeats itself at the same force absorption.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.25

Hydraulic cylinder Hydraulic cylinder Design 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. 65: Hydraulic cylinder, typical example Type a)

2 1

3

5

4

1

4

6

2 1 Outer cylinder 2 Cylinder bottom 3 Piston rod

3

4 Guide bushing 5 Connection 6 Connection

Notice!

The technical data for the cylinders can be found in section “Technical data, hydraulic cylinders” of the used shield unit.

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 ports of double-acting props pressure-tight.

Otherwise, when extending the prop, a pressure can build up in the ring 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 either fed through the connections at 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 ring space connection must be protected against the penetration of dirt with a filter screw. If the cylinder is used without the ring space seals, the seal grooves are to be filled with grease.

6.26

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

E

Type b)

Hydraulic cylinder Stabilizing cylinder Fig. 66: Hydraulic cylinder ZE-220/140-493

70

70 L d

a

b

11

c

E

1 Bucyrus DBT Europe GmbH, Lünen 2008

1 Cylinder tube 11 Piston rod a Valve connection plate b Pressure relief valve connection, ring space

c Pressure relief valve connection, piston space d Load ring 3000 kg L Retracted 920 - extended 1413 Stroke: 493

Baselift cylinder

365

Fig. 67: Hydraulic cylinder ZE-150/90-300

2

a

b 1 L

3 1 Cylinder tube 2 Piston rod 3 Wearing bottom a Piston space connection

Doc. No.: 7420 188 000 BA 00

VEVT / 01

b Ring space connection L Retracted 588 - extended 888 Stroke: 300

6.27

Hydraulic cylinder Shifting ram Fig. 68: Shifting ram type ZE-225/140-1130,

72

72 L

a b

d

c

11

2

Alignment cylinder (seal cylinder) Fig. 69: Hydraulic cylinder ZE-63/50-215

30 L a 2

b

1

1 Cylinder tube 2 Piston rod a Piston space connection

6.28

b Ring space connection L Retracted 440 - extended 655 Stroke: 215

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

b Piston space connection c Ram system adapter d Load ring 3000 kg L Retracted 1660 - extended 2790 Stroke: 1130

1 Cylinder tube 2 Reed-switch rod 11 Piston rod 14 screw fitting a Ring space connection

E

1

14

Hydraulic cylinder Flipper cylinder Fig. 70: Hydraulic cylinder ZE-125/90-535

32 70 L 4 2 7 a d 1 Bucyrus DBT Europe GmbH, Lünen 2008

E

b 1 Cylinder tube 2 Reed-switch rod 4 Piston rod 7 screw fitting a Valve connection plate

Doc. No.: 7420 188 000 BA 00

VEVT / 01

b Reed-switch rod connection adapter d Load ring 1000 kg L Retracted 822 - extended 1357 Stroke: 535

6.29

Hydraulic cylinder Technical data, hydraulic cylinder double telescopic prop, double-acting, 2-stage

Type SD-5650-400-1620/3940, device no. 8250 134 000 00 00 Prop height

6.30

1620

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

3940

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

2320

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

400/285

Piston rod diameter . . . . . . . . . . . . . . . . . mm

370/265

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

1256.6 / 638

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

181.4 / 86.4

Prop force setting pressure, 310 bar . . . kN

3896

Set pressure, 450 bar . . . . . . . . . . . . . . . kN

5655

Retracting force at 310 bar . . . . . . . . . . . kN

562 E

Type SD-1410-200-1555/3910, device no. 8250 136 000 00 00 Prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1555

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

3910

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

2355

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

200/140

Piston rod diameter . . . . . . . . . . . . . . . . . mm

185/130

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

314.2 / 154

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

45.4 / 21.2

Prop force setting pressure, 310 bar . . . kN

974

Set pressure, 450 bar . . . . . . . . . . . . . . . kN

1414

Retracting force at 310 bar . . . . . . . . . . . kN

140,7

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

double telescopic prop, double-acting, 2-stage

a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

Hydraulic cylinder stabilizing cylinder, double-acting

Bucyrus DBT Europe GmbH, Lünen 2008

E

baselift cylinder, double-acting

shifting ram double-acting, el.connection, reeved arrangement with counter pressure

alignment cylinder, double-acting

Doc. No.: 7420 188 000 BA 00

Type ZE-220/140-493, device no. 8241 333 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

493

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

220

Piston rod diameter . . . . . . . . . . . . . . . . . mm

140

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

380.1

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

226.2

Thrust at 310 / 450 bar . . . . . . . . . . . . . . kN

1178 / 1710

Pulling force at 310 / 450 bar . . . . . . . . . kN

701 / 1018

Type ZE-150/90-300, device no. 8241 280 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

150

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

176.7

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

113.1

Thrust at 310 / 380 bar . . . . . . . . . . . . . . kN

548 / 671

Pulling force at 315 / --- bar . . . . . . . . . . kN

351 /---

Type ZE-225/140-1130, device no. 8241 334 000 00 00, version with reed-switch rod Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

225

Piston rod diameter . . . . . . . . . . . . . . . . . mm

140

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

154

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

243.6

Thrust at 310 bar . . . . . . . . . . . . . . . . . . . kN

477

Pulling force at 310 / 380 bar . . . . . . . . . kN

755 / 926

Type 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

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

11.5

Thrust at 315 / --- bar . . . . . . . . . . . . . . . kN

98.3 / ---

Pulling force at 315 / 380 bar . . . . . . . . . kN

36.2 / 43.7

VEVT / 01

6.31

Hydraulic cylinder Type ZE-125/90-535, device no. 8241 336 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

535

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

125

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

122.7

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

59.1

Thrust at 310 / 380 . . . . . . . . . . . . . . . . . . kN

380 / 466.3

Pulling force at 310 / 380 bar . . . . . . . . . kN

183.2 / 224.6

Bucyrus DBT Europe GmbH, Lünen 2008

E

flipper cylinder, double-acting

6.32

Shield support 1920/4420-2/2x5665/1414-1825

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 set 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 spare parts catalog.

Tab. 21: Pressure relief valves, use of the various types Application

Type

Set pressure in bar

Order No.

General application, for props and stabilizing cylinders

Spring-loaded

380

7337 486 380 00 00

Only for stabilizing cylinders

Spring-loaded

450

8220 027 450 00 00

Only for props

Spring-loaded

450

7337 611 450 00 00

Return line

Spring-loaded

80

8220 042 080 00 00

Only for props

Spring-loaded

520

8220 061 520 00 00

Bucyrus DBT Europe GmbH, Lünen 2008

E

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.

Non-compliance 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. Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Defective seals lead to leaky plug connections and impair the operational safety of the hydraulics.

Always fit new seals when replacing a pressure relief valve. code system

Pressure relief valves are color coded according to DIN 21557.

The letter code includes the following information: J Set pressure, target value J Week setting was made J Year setting was made J Last setting made by Tab. 22: Typical letter code 420 or 42 1)

09

03

xy

Set pressure

Week

Year

Made by last

Color coding is with either one or two colors. It indicates the range within which the set pressure is located. The following Fig. 71 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.33

Pressure relief valves Fig. 71: Pressure relief valve, example

b

a

a Color code b Protective cap

The following table shows the relationship between the color code and the pressure range.

1)

6.34

Pressure range (bar)

black

0 - 49

black / white

50 - 99

brown

100 - 149

brown / white

150 - 199

green

200 - 249

green / white

250 - 299

blue

300 - 349

blue / white

350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow / white

550 - 599

orange

600 - 649

orange / white

650 - 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” equals 420 bar, “08” equals 80 bar

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

Color

E

Tab. 23: Color codes for pressure relief valves, overview

Shield control system Shield control system Electrohydraulic control units Fig. 72: Electrohydraulic control unit, 12 functions

1

a

4

3

2

Bucyrus DBT Europe GmbH, Lünen 2008

E

a Connection (DN 20) for storage cartridge 1 Distribution block 2 Pilot valves with electromagnetic operation

3 Button for manual operation 4 Plug contact for connecting the electronic control unit

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.

PMC®-R control unit Notice!

Please observe the separate operating manual for the PMC®-R control unit.

Fig. 73: Control unit PMC®-R, input allocation Front view

Rear view

Doc. No.: 7420 188 000 BA 00

A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

VEVT / 01

PMC®-R inputs A1 = left hand, adjacent unit A2 = not used B1 = not used B2 = not used C1 = pressure sensor P1 C2 = pressure sensor P2 D1 = shifting ram sensor D2 = flipper cylinder sensor E1 = not used E2 = not used F1 = right hand, adjacent unit F2 = solenoid driver module of unit

6.35

Shield control system Fig. 74: PMC®-R for end shield, schematic diagram Rear view A2 B2 C2 D2 E2 F2

Front view

1

A1 B1 C1 D 1 E1 F1 Left-hand neighbor

Right-hand neighbor

F1

A1

P1

P2 4

5b

5a

*

*

*

*

b

1 single control unit (SCU) 4 Solenoid driver 5a Pressure sensor, left 5b Pressure sensor, right

6.36

a Reed-switch rod, shifting ram b Reed-switch rod cylinder, flipper cylinder * Marking for connection on valve block other components: see spare parts catalog

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

E

a

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 canopy and caving shield.

Fig. 75: Angles α1 / α2

α1 α2

Bucyrus DBT Europe GmbH, Lünen 2008

E

M

Tab. 24: Angles α1 / α2 at height M Inclination α at height M

Shield Ident no.

α1 in °

α2 in °

M in mm

7420 188 000 00 01

10

10

1920 to 2200

15

15

2200 to 4420

Caution!

Exceeding the permissible angles given can lead to damage to the props and cylinders and their fasten 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.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.37

Accessory Accessory Anti topple system The Anti topple system, drawing number 7427 037 000 00 01 can be used for the shield variants in the following list : Tab. 25: Anti topple system, device no. 7427 037 000 00 01, suitable shield variants Shield use

Device no.

End shield

7420 188 000 00 01

6.38

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

Caution!

When using the Anti topple system there is a risk that the alignment cylinders will collide with the prop. Here both the alignment cylinders and the prop can be damaged.

Make sure when advancing the shield support that there is sufficient space between the sAnti topple device and the prop.

E

Before aligning, the shield which is to be aligned should be lowered. The neighboring shield on to which the alignment cylinder is attached must be set.

By actuating (pushing or pulling) the lever “X” (Fig. 77) the corresponding alignment cylinder is retracted and the shield is aligned.

It may be necessary to also use the corresponding side seal to align more precisely.

Accessory Fig. 76: Anti topple device Shield 2

Shield 1

S

Shield 3

L

Bucyrus DBT Europe GmbH, Lünen 2008

E

H

L

23

22

71, 70

49

45 56

62

21

16

1 Hydraulic cylinder 5 Shackle 10 Pin 40x125 15 Universal joint 16 Universal joint 21 Pin 49,8x200 22 Pin

5

72

1

63, 48, 10 15

23 Pin 143x190 45 Bracket 48 Washer 49 Hex. head screw M 24x90 56 Hex.nut M 24-8 62, 63 Locking clip 70, 71 Spring dowel pin

a L Shield center distance = 1750 H Offset = 300 S Step = 1000 a Hydraulic cylinder retracted: 910 mm extended: 1510 mm

Warning!

Make sure that the offset between shield 1 and shield 2 does not exceed the maximum permissible size.

Otherwise the alignment cylinders or their brackets can be seriously damaged. You could be seriously injured or even killed by falling parts.

The offset may never exceed 300 mm!

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.39

Accessory Fig. 77: Hydraulic control for Anti topple device

a

b 14

5, 7, 8 14

R 5, 7, 8

P 13

4, 7

3, 7

R

3, 7

5, 7, 8

R 5, 7, 8

14 15

6.40

X 1 Hydraulic control unit 3, 4 Screw-in socket 5 Plug-in reducing piece 7, 8 Staple 10 Hex. head screw M 10x20 13-15 Hose

a Piston surface b Ring surface X Lever to actuate the Anti topple device

Shield support 1920/4420-2/2x5665/1414-1825

E

1, 10

Bucyrus DBT Europe GmbH, Lünen 2008

13

Permissible media Permissible media Hydraulic fluids Operating media Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is the danger of serious damage to the hydraulic equipment and 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, for example, to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by Bucyrus on request.

Suitability test Before the certificate of Bucyrus is issued 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: J stability, J sealing materials, J corrosion.

In addition, 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 required.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive the respective Bucyrus certificate.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.41

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 respectively 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. 78: Typical certificate

6.42

Shield support 1920/4420-2/2x5665/1414-1825

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

– Target value: ≤ 105 Kol/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible max. 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 The quality of the water used for the preparation of 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.

The following table 26 lists limit values for the essential properties and components of the water.

If the limit values shown are maintained, it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not met 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 also lead to the loss of the certificate, even if they are within the limit values mentioned.

Doc. No.: 7420 188 000 BA 00

VEVT / 01

6.43

Permissible media Tab. 26: Properties of the process water, limit values Test criteria

Limit value

Appearance, color, smell

No peculiarities permissible, e.g.turbidity, bad smell etc.

Electrical conductivity

< 1800 µS/cm

pH - value

6.5 ..... 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

< 750 mg/l CaCO3 - equivalent (≤ 42° dH)

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 Kol/ml

Ratio of solid foreign matter at 1.2 µm -filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

- / 18 / 14

Important!

The lubricants to be used are specified in the respective chapters, e. g.: Installation, Maintenance.

Lubricating greases general properties

Base:

lithium soap

NLGI class:2 Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presenceof water:

practically non-soluble in water

Application temperature range: -20 to +120°C ≧ 200°C

Flash point : 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).

Tab. 27: Lubricating greases for general application

lubricating grease A2

Flash point 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 Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*)

6.44

Flash point in °C

Supplier

EWN = Bucyrus works standard

Shield support 1920/4420-2/2x5665/1414-1825

Bucyrus DBT Europe GmbH, Lünen 2008

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Lubricating greases and pastes

Permissible media 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. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 29: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

Lubricating molybdenum

Gleitmo 805 *)

Li

NLGI class

Flash point in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 is used in accordance with the Bucyrus standard EWN 7068: Lubricating molybdenum “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 cylinders, of pin connections and similar connection elements at the shield support.

Behavior in the presenceof water:

non-soluble in water

Application temperature range: -34 to +120°C When the equipment is treated at our works 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 (flash point 132 °C) Important!

The instructions for mixing lubricating greases also naturally apply to the lubricating pastes.

*)

Doc. No.: 7420 188 000 BA 00

The products listed in table 27 are suitable lubricating greases for filling of adjacent cavities.

VEVT / 01

6.45

Tightening torques Tightening torques Screws with ISO metric thread Tab. 30: Recommended tightening torques at µtotal = 0.14 Tightening torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

1) 2) 3) 4)

6.46

The dimensions listed in brackets are used in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

Only for expansion screws having a reduced shaft cross-section of 24.2 mm.

The tightening torques comply with the works standard (EWN 6003).

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(mm)

Bucyrus DBT Europe GmbH, Lünen 2008

Thread 1)

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 Tel: Fax: Email:

Great Britain

+49 / 23 06 70 9 - 0 +49 / 23 06 70 9 - 1421 info@de.bucyrus.com

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 Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: Fax: Email:

+7 / 49 56 23 - 5396 +7 / 49 59 24 - 8363 viktor.sobolev@ru.bucyrus.com

OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: Fax: Email:

Doc. No.: 7420 188 000 BA 00

VEVT / 01

+7 / 38 43 35 - 3441 +7 / 38 43 35 - 3442 evgeniya.belousova@ru.bucyrus.com

7.3

Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: Fax: Email:

+1 / 72 47 43 - 1200 +1 / 72 47 43 - 1201 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: Fax: Email:

7.4

+ 27 / 11 82 5 - 8212 + 27 / 11 82 5 - 7389 hetta.fuller@za.bucyrus.com

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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: Fax: Email:

+86 / 10 65 88 - 2998 +86 / 10 65 88 - 6570 Info.beijing@cn.bucyrus.com

Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: Fax: Email:

+ 86 / 31 66 08 6 - 840 (& 841, 842, 843) + 86 / 31 66 08 6 - 845 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: Fax: Email:

Doc. No.: 7420 188 000 BA 00

VEVT / 01

+86 / 31 53 20 - 3117 (& 3445, 3404) +86 / 31 53 20 - 3438 Info.tangshan@cn.bucyrus.com

7.5

Identification of the shields Identification of the shields Type plate The main subassemblies of the shields are identified by a type plate.

Fig. 79: Type plate, example

3

12345 01/08

678

7420 188 000 00 01 6

7

4

4 5

5665 kN

1 Manufacturer 2 SAP/order no.

3 Date of manufacture 4 Serial no.

5 Device number 6 Number of props 7 Prop set load

Shield number The shields are numbered consecutively. Tags with the respective shield number are on the right base of the shield.

Fig. 80: Shield number on the base, example

Tab. 31: Allocation of the shield numbers

7.6

Application

Shield number

Device number

G1 to G8

7420 188 000 00 01 End shield

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2

Bucyrus DBT Europe GmbH

Bucyrus DBT Europe GmbH, Lünen 2008

1

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 32: National standards and guidelines, extract

Designation

Title

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation System Plug connectors for hydraulic system Fire-resistant hydraulic fluids Maintenance and inspection for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulphate ash Tensioning force, tightening torques and surface pressure for bolts T-head-bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

Bucyrus DBT Europe GmbH, Lünen 2008

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EWN 6003 1) 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 guidelines Tab. 33: European standards and guidelines, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on the approximation of the laws of the Member States relating 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 - Part0: General requirements DIN EN 60445 Basic and safety principles for man-machine interface 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 potentially DIN EN 1710 explosive atmospheres in underground mines Mobile extracting machines at the face - safety DIN EN 1552 requirements for shear loaders and plough systems Directive 98/37/EEC

1)

Doc. No.: 7420 188 000 BA 00

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

VEVT / 01

7.7

Bucyrus DBT Europe GmbH, Lünen 2008

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Standards and guidelines

7.8

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