Cat Operating Manual Bucyrus Shield Support 2700/6000-2x5278-1750 (7420 084 000 BA) - PDF DOWNLOAD

Operating manual Shield support 2700/6000-2x5278-1750 Doc. No.: 7420 084 000 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 as a result of technical development without prior 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

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

2.5

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

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

2.5 2.5

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

2.6

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

3. About storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

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

Storing 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.4 4.5

Requirements for the face hydraulic system . . . . . . .

4.5

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6

To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

4.6 4.7

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

4.8

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

5.3

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

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

5.3 5.6

Operation of the shieldsupport . . . . . . . . . . . . . . . . . . .

5.9

Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Doc. No.: 7420 084 000 BA 00

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

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

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

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

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

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

5.15 5.17 5.28 5.29 5.31 5.32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

5.35 5.36 5.36 5.37 5.37 5.38 5.38 5.41 5.41 5.42 5.42 5.42

6. Technical Data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

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

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

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

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

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

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

6.4 6.5 6.7 6.8 6.8 6.9 6.11

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.13 6.19

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21 6.22 6.25

Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 Electrohydraulic control units . . . . . . . . . . . . . . . . . . . . . . . .

PANZERMATIC® PM4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.27 6.28

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.29

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

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

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

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

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

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

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

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38

Contents Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.30 6.33

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.35

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7. For your information

Doc. No.: 7420 084 000 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 directives . . . . . . . .

7.7 7.7

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Contents

Shield support 2700/6000-2x5278-1750

1

About this manual

Before starting work

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

Before starting work applicable operating manual

product type

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

Ensure that the data on the shield agrees with the data given in the operating manual.

This operating manual is designed for: Shield support 2700/6000-2x5278-1750* ID No.: 7420 084 000 00 00 It should be used only for shields of this type!

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

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

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

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

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

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

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

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

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1.3

Before starting work Purpose of this operating manual efficiency

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

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

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

service

Should you have any questions, please contact our service department. Our service address can be found in Chapter 7, “For your information”.

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

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.

. Points in the text marked in this way describe individual work

steps. Follow this manual step-by-step. It will help you carry out your work faster and, more importantly, more safely.

1.4

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Try to memorize the symbols and their meanings.

E

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 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 constitute a part of this training.

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

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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 (control systems, signaling devices, etc.), J the hydraulic system,

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

2.4

Shield support 2700/6000-2x5278-1750

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

Use the shield only as intended!

Intended uses are: J propping the roof against the floor.

J ensuring an adequate travel way.

J the following shield operations:

– lowering, – pulling up, – aligning and – setting.

J the following conveyor operations: E

– advancing, Bucyrus DBT Europe GmbH, Lünen 2008

– retracting.

J forming a thrust bearing for:

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

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

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

shield,

J setting of the canopy in roof falls.

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

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

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

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

EMERGENCY STOP

support lock-out switch

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

- Only applicable for shields provided with electrohydraulic shield control systems Actuate the support lockout 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 safety equipment

Maintain the lighting systems in working condition.

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lighting system

Safety instructions automatic mode

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

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

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

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

Ensure that the transport safety devices have been correctly installed. In particular, ensure that the following are secured for transport: J side seal J flipper J relay bar (face and gobsides)

transporting

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

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

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

Only use transport straps for attaching round components, such as cylinders and props, which are not provided with lifting points.

Never use chains or steel cables for this purpose.

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

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

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

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2.7

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

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

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

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

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

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Fig. 1:

transport safety 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 safety device of the side seals. Use the hydraulic control system to adjust the seal cylinders such that the locking pins either drop down or can be pulled out without the use of physical force.

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

travel way

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

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

2.8

Shield support 2700/6000-2x5278-1750

Safety instructions Operation shield control

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

Check to determine whether all safety equipment on the shield are present and functional. See also Chapter 6.

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

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

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

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

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

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

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

Keep the floor as clean as possible. Keep the 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 neighboring the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. And it reduces the risk of the relay bar assembly jamming between the bases.

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

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

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

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2.9

Safety instructions shield alignment

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

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

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

roof falls

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

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

exceeded,

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

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

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

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

retracting the conveyor

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 all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the points of attachment intended for that purpose.

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

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

Check the setting pressure again. Under no circumstances should you disengage the canopy from the roof. It must always be in full contact over the entire length.

2.10

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tion,

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

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

J the points of attachment provided for the purpose.

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

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

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

Afterwards, check the setting pressure once again.

Maintenance Make sure that all safety and safety equipment of the shield units 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.

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

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

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

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

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

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

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2.11

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

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

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

or is done outside the required safety area.

J relieve the load on the components which are under hydraulic

pressure or mechanical stress.

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

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

Hydraulic system handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

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

protective devices hydraulic system

When removing protective devices which include hydraulic components, keep in mind that these hydraulic 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 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 protective caps. Replace defective protective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: J the hoses are not pinched.

J the hoses have no bubbles or blisters.

J the hoses or the outer sheaths of the hoses are not abnormally-

rigid or hard.

J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

2.12

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

E

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 hydraulics system during repair work.

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

Before removing staples to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Make sure the line is depressurized.

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

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

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

Use only hydraulic hose lines 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, identification 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 hydraulic hose that is thrashing about. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

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

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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 minimum

1.5 x nominal diameter),

Fig. 5:

Installing hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

Installing 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.

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

When installing the hydraulic hoses, 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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Storage and transport

Storage

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

Observance of the instructions and tips will increase the service life of the shields. In addition, you will be instructed how 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 coated with temporary corrosion protection. If stored properly, the equipment parts will be protected for a period of six months, starting from the date of delivery.

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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 water spraying system 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 systems 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 device for the purpose of proper storage.

*

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

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3.3

3.4

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

It is highly recommended that the equipment not be stored outdoors. It should be stored in a dry, well-ventilated room. If this is not possible for the entire shield unit, for example, then the hydraulic and electronic components might have to be dismantled and stored separately.

storage outdoors

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

electrical equipment, rubber and plastic parts

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

natural aging

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

moisture and dirt

All hydraulic elements must be appropriately protected against the penetration of dirt and moisture during storage. The connection surfaces of the 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 since they are constantly subjected to unilateral loads due to the weight of the parts. This can render the sealing element useless or reduce its service life considerably. This effect is mainly influenced by the size and duration of the acting force and the temperature at the time.

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

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

random sample inspection

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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long-term storage

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Storage

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 Operating Manual.

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

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

If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor (e.g.

HYDROCOR® CV 50). If this is not done, then the hydraulics components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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corrosion protection

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3.5

Transport Transport Warning!

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

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

Use only suitable load handling devices.

points of attachment

Where technically possible, the load units have suitable, fixed lifting 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 figures 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 medium originally used and it is to be made sure that the media are sufficiently mixed.

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

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically. Here, external forces are only to be applied to the lifting points and mounting device surfaces as specified in special figures, 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 maximum 25 km/h for truck transport.

electrical and electronic components

3.6

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors or outdoor storage of the equipment during winter.

Unless these components or the complete equipment is protected against harmful environmental influences by suitable packaging.

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

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

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transport units

Transport transport units

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

Tab. 1: Transport units

transport safety devices

Designation

Transport position

Complete shield unit

General purpose

Remarks

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

Tab. 2: Transport safety devices Component

Transport safety devices

Quantity

Flipper

Bolts and securing devices

1

Side seal, movable

Pin and securing device

4

Face side

Transport rod

1

Gobside

Chain

1

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

Caution!

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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3.7

Transport Fig. 8:

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

Y

H

S0 X4

SY

X1 S3

X2 Sx

S4 L

bore, 2x faceside at the base, capacity: 15,000 kg bore, 2x gobside at the base, capacity: 15,000 kg transport safety device for relay bar, face side and gobside

X3 X4 Y

transport safety device for the flipper transport safety device for moveable side seals transport securing device “Canopy - base”, not included in scope of delive

So

center of gravity

Tab. 3: Shield support 7420 084 000 00 ... , Dimensions and weights of the variants Variant

3.8

Device No.

Length in mm

Width in mm

Height in mm

01 7420 084 000 00 01

7917

1610

2700

Sx/Sy in mm 1897/1460

Weight in kg 39850

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S3 S4 X1, X2

4

Installation

Pre-assembly of the shield units

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

Warning!

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

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

Caution!

Before the hydraulic lines are connected with one another, the sockets and nipples of the plug-O connections must be treated with the molybdenum disulfide-free B6 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 disulfide-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 preassembled. 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 property damage. installation plan

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

Important!

When installing the shields in the face, be sure to pay attention to the shield numbers. Since some shield units may be provided with different functions, their setup on the 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

Seq. No.

Device No.

Application

81 to 95

7420 084 000 00 01

Face shield

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Shield number, Example

Supply connections The shield is always supplied through the connections on the pipe distributor at the time of initial start up as well as during normal operation.

Fig. 10: View of the pipe distributor 25 15

P W 26a

26b

R

HP

23a 15 pipe distributor 23a HP ball valve, high-pressure feed to shield hydraulics (420 bar) 25 HP ball valve, pressure supply for shield hydraulics (320 bar)

26b HP ball valve, for spray hose R return line, DN 50, covered P pressure line, DN 40 W water, DN 25 HP high-pressure line DN 25

26a HP ball valve, supply line for water spraying system

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Fig. 9:

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

The pipe distributor for supplying the shield hydraulics is located between the two front lemniscatic links. The connection to the pipe distributor of the neighboring support is accomplished with the aid of four hose lines, one pressure line (DN40), one return line (DN50), one water line (DN 25) and the high-pressure line (DN 25).

See also the hydraulic circuit diagrams in Chapter 6 of this manual.

control unit

The shield units are equipped with a type PM4 electronic control device. The control device and the electrohydraulic control block are connected via a solenoid driver. The connection cables required for this are included in the delivery of the PM4 control system. For more details on how to connect the control device, please refer to the separate operating manual for the PM4 control system. An overview of the design of the control system is also given in Chapter 6 of this operating manual in the Section “Shield control”.

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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.

Contamination Class 18/14 pursuant to ISO 4406.

pressure, permissible

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 risk of malfunctions occurring in the electrohydraulic control system.

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

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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4.5

Commissioning Commissioning 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 underground 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 safety devices required for transport have been removed. See Chapter 3, Section “Transport”.

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

Please observe the following items:

. Make sure that all transport safety 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, particularly on the articulations.

Danger!

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

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

Make sure that hydraulic hoses 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. . Check the support function of the props (note pressure display on the pressure gauge).

1) maximum possible plugging.

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J mechanics:

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

J EMERGENCY STOP systems

. Check that all EMERGENCY STOP systems function properly.

J mining and conveying

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

Warning!

Bent support canopies may not project into the mining area.

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

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

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

Warning!

Shutoff 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.

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

. Check all functions of the shield control unit.

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

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4.7

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

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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 testing and anticorrosion medium used 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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Operation

Requirements

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

Danger!

You are only allowed to operate the shield control system if you have extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control system and have consolidated your knowledge during a corresponding training session on the object. Should this not be the case, you are not allowed to operate the control system! Inform your superior immediately and request the required training.

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Warning!

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

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

Requirements Operating conditions face crew

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

The face 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 the case of accumulations of debris.

face equipment

The face must be sufficiently illuminated.

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

The face conveyor must be equipped with a start-up warning system and a shutdown and lock-out device.

conveyor overload

Large layers of coal and rock cannot be broken up unless the face conveyor and the mining equipment are at a standstill. They must be broken up to such an extent that the free passage of crude ore under the shield canopies is ensured. Compressed-air picks have to be kept on hand for this purpose.

In the event that this breaking up cannot be accomplished to the extent required, then the layers of coal and rock may not be transported until it is has been ensured that nobody will endangered as a result. 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 at all times.

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

600 mm,

Height: 400 mm.

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

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

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

roof support work

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

work in the mining area

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

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

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

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

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

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

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.

5.4

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

E

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

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 appropriate measures to prevent the pressure from being reactivated by unauthorized personnel.

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

conveyor steering device

On an inclined face, the conveyor must be anchored neighboring the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. This allows you to reduce the risk that the relay bar assembly will get stuck in the base frame.

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

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

Doc. No.: 7420 084 000 BA 00

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5.5

Requirements Safety requirements automatic mode

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

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

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

operating the shield unit

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

Never stand in a shield unit which 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 setting pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as abutments for conveyor steering device.

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

5.6

Shield support 2700/6000-2x5278-1750

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 support is being moved, and prevent any hazards by acting with caution.

E

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

Requirements Fig. 11: W r o n g, support advanced too late

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 12: R i g h t, support advanced in time

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

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

When advancing the support, make sure that the shield canopy doesn’t get under the side seal of a neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged. hydraulic system, controls

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

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

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

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

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5.7

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

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

To make sure the return lines can’t be closed, safety valves must be installed in the return line (see hydraulic layout, if prepared by Bucyrus). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

5.8

Shield support 2700/6000-2x5278-1750

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

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

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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shield canopy position

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

Caution!

Never exceed the permissible angle of inclination of the canopy.

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

Fig. 13: 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 shieldsupport Caution!

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

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm.

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

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

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

Fig. 14: Shield support with extremely inclined shield canopy

α1

s1

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

5.10

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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M

Operation of the shieldsupport Caution!

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

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

Caution!

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

Since angle changes in the ends of the shield canopies or 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 roof falls.

Bucyrus DBT Europe GmbH, Lünen 2008

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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. 15), 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. 15: 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. 16) 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 shieldsupport Fig. 16: R i g h t, fill out roof falls

RIGHT

supportrangeofadjustment/changing face thickness

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

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

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

equipment,

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

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

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

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

5.12

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

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

Operation of the shieldsupport operating in inclines

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

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

Automatic controls can be used for the side seals which prevent a lowered shield unit from tipping over during the 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.

Bucyrus DBT Europe GmbH, Lünen 2008

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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. And this way you lessen the danger of jamming the relay bar assembly in the base frame, which would hinder the shield advancing.

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

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

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

For shield units without a lifting device, the procedure is different, depending on the design model: J individual 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

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

Warning!

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

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

Caution!

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

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

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

– shield is wedged in between the neighboring shields.

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the base.

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

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

5.14

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

Observe the following safety regulations:

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

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

Arrangement of hydraulic components on the support The following table indicates the hydraulic components for the support.

Tab. 4: Hydraulic components Designation

Configuration

Remarks

1

Quantity 1

Electrohydraulic control unit

Between the two front lemniscatic links, fastened to the support

On a support

2

2

CV, NG 20

On every prop

3

1

CV, can be unblocked hydraulically

Right-hand, front lemniscatic link, inner side

Blocks the annular space side of the shifting ram

4

4

CV, can be unblocked hydraulically

Underneath the canopy, between the props

Blocks the annular space and/or the piston space side of the flipper cylinder

5

8

PRV, 420 bar

a) 1x on the check valve (Pos. 3) b) 2x on the check valve (Pos. 4) c) 2x on the check valve (Pos. 4)

a) for shifting rams b) for flipper cylinders c) for flipper extension cylinders d) for seal cylinders

Bucyrus DBT Europe GmbH, Lünen 2008

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Item

d) 2x on the HP ball valve (Pos. 23b+c) e) 1x on the HP ball valve (Pos. 23d)

e) for lift cylinders

6

2

PRV, 440 bar

On every prop

7

1

CV, NW 25

On the pipe distributor,return

8

1

Double filter, can be backflushed

On the right-hand front lemniscatic link

9

1

Spraying valve

On the right-hand front lemniscatic link

10

1

Twin CV

On the stabilizing cylinder

11

1

Accumulator cartridge

On the electrohydraulic control unit

12

1

Hose lines

Subassembly group

13

1

Water spraying system

Subassembly group

14

1

Brackets and accessories

Subassembly group

15

1

Pipe distributor

16

1

CV, hydraulically piloted

17

2

CV, DN10

On every prop

19

2

PRV, 420 bar

On the stabilizing cylinder

20

2

Pressure gauge

On the prop CV of every prop

22

1

Block ball valve

On the left-hand front lemniscatic link

Manually actuated

Between the front lemniscatic links

Retract/extend pusher cylinder

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

Doc. No.: 7420 084 000 BA 00

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5.15

Operation of the shield hydraulics Item 23

Quantity 4

Designation

Configuration

Remarks

HP ball valve

a) on the pipe distributor

a) in the high-pressure supply line, blocks the supply line to the shield hydraulics b) in the supply line to the annular space of the seal cylinders c) in the supply line to the annular space of the seal cylinders e) in the supply line to the annular space of the lifting cylinder

b) on the distributor strip underneath the caving shield c) on the distributor strip underneath the caving shield e) on the lifting cylinder

2

HP ball valve

a) on the left prop CV b) on the right prop CV

Blocks supply line to the piston space of the prop

25

1

HP ball valve

On the pipe distributor

In the pressure supply line, blocks the supply line to the shield hydraulics

26

2

HP ball valve

a) on the pipe distributor b) on the pipe distributor

a) in the feed line for the water spraying system b) for spray line

On the pipe distributor

In the water feed line

1

Water filter

Z1

2

Prop

Z2

1

Shifting ram

Z3

1

Stabilizing cylinder

Z4

4

Seal cylinder

Z5

1

Baselift cylinder

Z6

2

Flipper extension cylinder

Z7

1

Flipper cylinder

Z8

1

Pusher cylinder

5.16

Bucyrus DBT Europe GmbH, Lünen 2008

27

E

24

Shield support 2700/6000-2x5278-1750

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 23a, 23b, 23c, 23d, 24a, 24b, 25, 26a

The following ball valves are closed during normal operation: J 26b

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 5: HP ball valves Item

Color

Designation

Function

Use

23a

Red

HP ball valve

Is used for shutting off the high-pressure supply line to the shield

During maintenance and repair work on the shield

23b

Red

HP ball valve

Used for blocking the annular spaces of the seal cylinder

Close when transporting the shield, so that the side seal doesn’t extend and the mechanical interlock can be installed

23c

Red

HP ball valve

Used for blocking the annular spaces of the seal cylinder

Close when transporting the shield, so that the side seal doesn’t extend and the mechanical interlock can be installed

23d

Red

HP ball valve

Used for blocking the annular spaces of the lifting cylinder

During maintenance and repair work on the shield

24a

Red

HP ball valve

Is used for blocking the pressure supply to the piston space of the leftprop

During maintenance work on the prop and any possible disassembly

24b

Red

HP ball valve

Is used for blocking the pressure supply to the piston space of the right prop

During maintenance work on the prop and any possible disassembly

25

Red

HP ball valve

Is used for blocking the pressure supply line to the shield

During maintenance and repair work on the shield

26a

Blue

HP ball valve

Used for shutting-off the water supply

In order to deactivate the function of the water spraying system

26b

Blue

HP ball valve

Used for blocking the spray pipe

For cleaning soiled components

Fig. 17: HP ball valve, shown opened and closed

open

closed

Through-flow for medium enabled

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Through-flow for medium stopped

5.17

Operation of the shield hydraulics Shield hydraulics Fig. 18: Shield hydraulics, arrangement Image caption: see Table 4

Bucyrus DBT Europe GmbH, Lünen 2008

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13

5

4

19

10

5

23b+c

5.18

Shield support 2700/6000-2x5278-1750

Operation of the shield hydraulics Fig. 19: Shield hydraulics, arrangement Image caption: see Table 4

9

16 8 22 3 25 Bucyrus DBT Europe GmbH, Lünen 2008

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15 26a

7 26b

23a 14

24b

2

17b

24a

5a

17a 1, 11 20 27

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5.19

Operation of the shield hydraulics Fig. 20: Hydraulics schematics, overview Image caption: see Table 4

Z4 19

Z3 10

Z4 19

Z1

Z2 2

24b Z1

5a

24a

2 3

17

23d

Z7 5e 12

5b

5b

13 5c 9

4

17

6

Z4

Z4

Z8

4

4

Z6

20

E

Z5

20

22

5d

23c

5d

Z6 5c

23b

4

1

16

11

23a 27

26a

7 15 26b

5.20

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6

Operation of the shield hydraulics

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 21: Functions of the electrohydraulic control unit, symbol plates

16 functions

Tab. 6: Electrohydraulic control units with 16 functions, allocation of functions Function, designation

Doc. No.: 7420 084 000 BA 00

Function No.

Extending stabilizing cylinder

1

Retracting stabilizing cylinder

2

Extending prop

3

Extending seal cylinder (caving shield)

4

Retracting props

5

Setting high pressure

6

Advancing shield

7

Bankpush

8

Retracting seal cylinder

9

Extending seal cylinders (canopy)

10

Retracting flipper cylinders

11

Extending flipper cylinders

12

Retracting flipper extension cylinders

13

Extending flipper extension cylinders

14

Extending baselift cylinders

15

Water spraying system, face side

16

VTVT / 02

5.21

Operation of the shield hydraulics Fig. 22: Hydraulics schematics, Overview 1 Image caption: see Table 4

Z5 5e

23d

Z1

Z1

24b 2

2

24a

17b 20

Z2

20

Bucyrus DBT Europe GmbH, Lünen 2008

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17a

1

5a

3 Z8 26a 26b

22 25

8

16 9

5.22

Shield support 2700/6000-2x5278-1750

Operation of the shield hydraulics Fig. 23: Hydraulics schematics, Overview 2 Image caption: see Table 4 Z7 13 Z6

Z6

Z4

Z1

Z1

5c

5c

4

Bucyrus DBT Europe GmbH, Lünen 2008

E

4

5b

4

4

5b

Z4

5d 5d

23b

23c

Z4

10 Z3 19

Z4

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5.23

Operation of the shield hydraulics Fig. 24: View of the pipe distributor 25 15

P W 26a

26b

R

HP

23a HP ball valve, high-pressure feed to shield hydraulics (420 bar) 25 HP ball valve, pressure supply for shield hydraulics (320 bar)

26b HP ball valve, for spray hose R return line, DN 50, covered P pressure line, DN 40 W water, DN 25 HP high-pressure line DN 25

26a HP ball valve, supply line for water spraying system Fig. 25: Electrohydraulic control unit b c

e

a

d

a pilot valve b solenoid driver module c connecting cable

5.24

d symbol plate e button

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

15 pipe distributor

E

23a

Operation of the shield hydraulics Fig. 26: PM4 control device mounted on adjustable support

a

b

Bucyrus DBT Europe GmbH, Lünen 2008

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a PM4 control device b support for PM4 control device Fig. 27: Adjustable support for PM4 control device

2

(5)

6,8 B 6

a

1

A 7,9

8

A mounting, pivotable B mounting, pivotable 1 bracket 2 cover plate 5 cylinder head screw M12x55-A 2-70 6 hex. head screws M16x45 - 8.8, tightening torque 195 Nm 7 hex. head screws M16x50 - 8.8, tightening torque 195 Nm 8 washer 9 hex. nut M16-8

Before you put the shield support into operation, adjust the support in such a way that you can operate the PM4 control unit easily.

Set the inclination of the bracket (1) at hinge (A).

. Secure the bracket against knocking over.

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5.25

Operation of the shield hydraulics . Loosen hex. head screws (7) at the base of the bracket. . Swivel the bracket into the desired position and fasten it temporarily.

. Tighten the hex. head screws (7) at the hinges (A) on the base of the bracket with the prescribed tightening torque.

. Remove temporary fastening.

Set the inclination of the cover plate (2) with respect to the bracket at hinge (B).

. Secure the cover plate against knocking over. . Loosen hex. head screws (6) at the cover plate. . Swivel the cover plate into the desired position and fasten it temporarily.

. Tighten the hex. head screws (6) at the hinges (B) with the prescribed tightening torque.

Fig. 28: View of the left-hand front lemniscatic links, block ball valves for actuation of the pusher cylinder

A 22

B

22 block ball valve ...

A retracting pusher cylinder

5.26

B extending pusher cylinder

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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. Remove temporary fastening.

Operation of the shield hydraulics Fig. 29: Prop, view from the gobside

2 2 24b

24a

17b 17a 20 20

6b

Bucyrus DBT Europe GmbH, Lünen 2008

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6a

2 prop control valve 6a/b pressure relief valve 440 bar 17a/b check valve DN 10

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20 pressure gauge 24a/b HP ball valve, blocks the pressure supply to the piston space of the prop

5.27

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 properly established. 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 routinely once per shift.

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

Fig. 30: View of the double filter

8

A

A

B B

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

5.28

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

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

Warning!

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

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

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

Operation of the control device for the electronic control system is not described here, but in a separate operating manual for the control device instead. If the control device is included in the Bucyrus scope of delivery, you will find the corresponding Operating Manual in the documentation of the system.

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 device.

Bucyrus DBT Europe GmbH, Lünen 2008

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Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special 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 system. It is imperative that you observe the instructions in the control device’s separate operating manual.

The illustration Fig. 31 shows the arrangement of the PM4 control device on the support. Operation of the PM4 control device is not described in this operating manual. For information on this, please refer to the separate operating manual for the PM4 control device.

Fig. 31: Cover for control block

b a c

a PM4 control device c EMERGENCY STOP

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b shield support blocked button

5.29

Operation of the shield hydraulics Fig. 32: Electrohydraulic control unit e d

a

c

b

E

d connecting cable e solenoid driver module

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 device.

Fig. 33: Symbol plate for the control block with 16 functions

The symbol plate is arranged on the control block underneath the pilot valves. The symbols correspond to the various functions which are initiated by actuating the respective button. The meaning of the symbols and functions are described below.

5.30

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

a button b symbol plate c pilot valve

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

Warning!

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

The function stops as soon as you release the button.

Danger!

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

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

Warning!

Manual actuation of a button on one of the pilot solenoid valves initiates the direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the function “Pull shield” can be activated without previously activating the functions “Retract side seal” and “Actively lower support”. This can cause dangerous situations which can result in very serious injuries.

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5.31

Operation of the shield hydraulics Shield functions (16 functions) Extending stabilizing cylinder

1

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

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

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

Retracting stabilizing cylinder

2

Setting both props

3

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.

Extending seal cylinders, caving shield 4

5

5.32

The function serves to align the shield unit to the neighboring 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.

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

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

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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

E

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

Operation of the shield hydraulics Setting high pressure 6

The “Extend prop” function must have been executed before this function can be executed. The enablement for “Set high pressure” is not announced electrically until after the setting pressure has been reached. The props are set with an even higher pressure with this function.

Advancing shield

7

Bucyrus DBT Europe GmbH, Lünen 2008

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8

Before executing this function, the side seal of the shield unit must be released and the function “Retract 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 piloted check valve, which hydraulically blocks the annular space of the shifting ram, is opened automatically.

Bankpush Before initiating this function, ensure that the support 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.

Retracting seal cylinders

9

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.

Extending seal cylinders, canopy

10

The function serves to align the shield unit to the neighboring 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.

Retracting flipper cylinder

11

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

Extending flipper cylinder

12

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

Retracting flipper extension cylinders

13

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

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5.33

Operation of the shield hydraulics Retracting flipper extension cylinders 14

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

Extending baselift cylinder

15

The props must already be lowered before this function is executed.

The piston space of the baselift cylinder is connected with the return line when the function is not activated.

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

The baselift cylinder is retracted again of its own accord because of the intrinsic weight of the support and/or during the setting of the props.

16

Water spraying system

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The function is executed as long as the button remains pressed.

5.34

Shield support 2700/6000-2x5278-1750

Maintenance Maintenance Warning!

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

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

hydraulic controlsystem

Special measures

one week after start-up

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

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

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

filter cartridges

The filter cartridges on the supply block and on the electrohydraulic control unit of the shield control system 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 hydraulic fluid, there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation.

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.

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5.35

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

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

double filter, can be backflushed

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

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid:

J electrohydraulic control unit J valves J props J shifting and lifting cylinders J link, steering and flipper cylinders

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

steel support cage

. Check all shields by visually inspecting them for damage to the steel structure, for instance:

J on the relay bar assembly J bolt connections and retaining devices J on the side seals J on brackets, etc.

Weekly maintenance control system

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

. Clean the control systems, especially the operating panel.

Notice!

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

5.36

Shield support 2700/6000-2x5278-1750

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J hose

Maintenance Carry out every six months

. Apply a corrosion inhibitor to the piston rods of the hydraulic

cylinders. More detailed information is contained in this chapter in the section “Special measures”.

Assessment of damage according to schedule

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

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5.37

Troubleshooting Troubleshooting Instructions for troubleshooting The shield hydraulics of a shield unit consists of a multitude of individual components. The linking of the components with each other is shown in the schematics and hose diagrams for the shield hydraulics. Also refer to the 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.

Fault localization support cannot be withdrawn

5.38

Possible cause

Measure required

The shutoff 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 shutoff valve in the supply line to the prop piston space is closed.

Open the shut-off valve!

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

The shield canopy is stuck between the neighboring supports.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

Warning!

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

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

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

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

Troubleshooting support cannot be set

Possible cause

Measure required

The shutoff 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 shutoff valve in the supply line to the prop piston space is closed.

Open the shutoff valve.

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

support cannot be advanced

Doc. No.: 7420 084 000 BA 00

The pressure of the hydraulic supply is too low.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Measure required

The shutoff valve for the shield supply on the supply block is closed.

Open the shut-off valve!

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

The support is stuck between the neighboring supports.

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

Step on roof or floor blocking the support.

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

The pressure of the hydraulic supply is too low.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

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

Shifting ram is defective.

Check whether the - shifting ram is damaged, - the piloted check valve is working properly.

Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressure fluid escapes, replace the shifting ram.

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5.39

canopy cannot be positioned

canopy cannot be lowered

5.40

Possible cause

Measure required

Prop control valve is defective.

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

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lower connection and check whether pressure fluid is escaping even though the prop is no longer being extended.

If applicable: piston packing defective, replace prop.

Pressure relief valve defective.

Monitor pressure drop on the pressure gauge.

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

Possible cause

Measure required

The shutoff 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 shutoff valves are open.

- the system pressure is sufficient.

Piloted check valve isn’t working.

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

The check valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and exchange, if necessary.

Possible cause

Measure required

The shutoff 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 shutoff valves are open, - the system pressure is sufficient.

Piloted check valve isn’t working.

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

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

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Troubleshooting

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

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

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

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

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

internal leakage

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.

E Bucyrus DBT Europe GmbH, Lünen 2008

. Locate the faulty valve by initiating the functions individually

replace valve

. 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 solenoid valve.

Piloted 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 device.

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

. Check the valve and replace if defective.

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

. Set the prop until the setting pressure has been reached. . Remove the hose line “Set props” at the pilot-operated check

valve.

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

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5.41

Troubleshooting Internal by-pass in props If an internal by-pass in the prop is suspected, this procedure should be followed:

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

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

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

In the hydraulic circuit of a shield unit, various models of pressure relief valves are used. For example, pressure relief valves 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. The filter elements must be replaced on fine-mesh filters, such as on the electrohydraulic control unit.

5.42

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

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Pressure relief valve defective

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 2700/6000-2x5278-1750 The two-prop shield mainly consists of the following listed main subassemblies: J base with lemniscatic links, shifting unit and baselift cylinder J canopy with flipper J caving shield J side seal, moveable on left side J hydraulic props J hydraulic equipment with hose lines and control system Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 7: Variants of the shield support Variant

Application

Device No.

01

Face shield

7420 084 000 00 01 6472x19001)x6000

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

Approximate weight in kg 39850

7920x1610x2700

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

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

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

All shield canopies are equipped with a flipper.

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

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

The shield units are equipped with all components required for implementing an electrohydraulic neighboring control with the electronic PM4 control system.

1)

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side seal fully extended

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6.3

Description Main subassemblies Fig. 34: Main assemblies face shield 11

21

51 61

41

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31

71 1 Tab. 8: Face shield 7420 084 000 00 01, applicable subassemblies Item

Designation

ID No.

01

Base frame / base

7420 084 300 00 01

Approxi- Remarks mate weight in kg

14942

Shifting ram Lifting cylinder

8241.176.000.00.00 8241.169.000.00.00

Pusher cylinder Relay bar assembly

8241 046 000 00 00 7420.084.330.00.01

11

Canopy

7420 084 400 00 00

9217 Flipper

21

Side seal

7420 084 700 00 00

3035

31

Caving shield

7420 084 800 00 00

6668

41

Hydraulic prop

8250 062 000 00 00

2690

51

Stabilizing cylinder

8241 294 000 00 00

320

61

Shield control system - 16 functions -

8112 111 000 00 00

71

Caving flap

7420 085 891 00 00

6.4

7420.084.420.00.00

Electrohydr. control unit Lines Water spraying system Brackets

8154.052.000.00.00 8112.111.010.00.00 8112.111.020.00.00 8112.111.030.00.00

55

Shield support 2700/6000-2x5278-1750

Description Base with lemniscatic links and relay bar assembly The solid base frame 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 of the shifting ram is used to advance the shield. Correspondingly, the conveyor is advanced forward with the smaller force which is generated via the annular surface.

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

With the help of the baselift cylinder, the shield can be lifted during shield advance when the floor is soft.

Fig. 35: Base frame 14

13

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1

26 22, 23 40, 41, 42 25 24 3

15

S1 31, 37, 38

4 6 1 shifting ram ZE-165/100-1130 3 baselift cylinder ZE-150/90-240 4 pusher cylinder ZE-135/120-300 6 relay bar assembly 11 base 13 lemniscatic link, front right 14 lemniscatic link, front left 15 lemniscatic link, rear 22 prop retainer, right 23 prop retainer, left 24 bearings for baselift cylinder

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11 25 running board box 26 walk way 31 lemniscatic link pin 37 securing device 38 washer 40 filler piece, front 41 filler piece, middle 42 filler piece, rear S1 load eyelet, load capacity: 15,000 kg For other fastening and securing elements, see the spare parts catalog.

6.5

Description Relay bar assembly The relay bar assembly is located in the middle of the base. It consists mainly of the relay bar, shifting ram, baselift cylinder and the required connection elements. It serves to advance the conveyor and the shield.

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

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

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

Fig. 36: Ram system 10, 17, 18 1 13 E

12, 14, 19

17

11, 15, 16 1 relay bar 2 beam 5 clevis assembly for conveyor 13 pin

17 staple Other mounting elements: see spare parts catalog

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, causing the bases to be lifted up off the floor.

Warning!

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

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

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

4. Bankpush The shifting ram is retracted.

6.6

Shield support 2700/6000-2x5278-1750

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5

2

Description Shield canopy The canopy transfers the supporting force of the props 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 left side and a fixed one on the right side, and also has a flipper.

Fig. 37: Canopy 2

8, 9, 10 11, 15

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1

14 S1

S2

1 canopy 2 flipper 5 pawl 6 pin, 28x170 7 spring clip 8 joint pin 9 securing device

S3 5, 6, 7

12, 13

10 pin, 12X120 11 spring clip 12 pin 60x185 13 retainer 14 spring clip 15 plug, right

S1 lifting eye, load capacity 15,000 kg S2 lifting eye, load capacity 8000 kg S3 lifting eye, load capacity 5000 kg

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6.7

Description Flipper Fig. 38: Flipper 4

2 3

1

5 11 1 flipper cylinder ZE-165/100-615 2 flipper extension cylinders ZE 115/80-285 3 flipper

5 fork control arm 11 lemniscatic link 12 fork For other fastening and securing elements, see the spare parts catalog.

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

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

The caving shield has retainers for the cylinders and guiding pins of the side seal.

Fig. 39: Caving shield 1

15 S1

6

1 caving shield, subassembly 5 lemniscatic link pin 6 pin 5 7 pin 10 locking plate 15 staple 16 locking clip S1 lifting eye, load capacity: 5000 kg S2 lifting eye, load capacity: 8000 kg

6.8

10

7 16 S2

S2

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

4 extension

12

Description Side seal The side seals seal the gaps between naighboring shield units.

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

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

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.

E

Warning!

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

Bucyrus DBT Europe GmbH, Lünen 2008

Notice!

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

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

Notice!

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

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.9

Description Fig. 40: Side seal 54 41

12

40 42 10

40

54

42

40 40 10

11

55 43 55 1 5

41

20, 25

13 20, 25

1 seal cylinder ZE 80/63-315 5 side seal, canopy, left 7 side seal, caving shield, left 10 ..13 guiding pin 20, 25 transport safety device 40, 41 compression spring

6.10

42, 43 guiding pin 54, 55 cover plate For other fastening and securing elements, see also the spare parts catalog

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

7

Description

Bucyrus DBT Europe GmbH, Lünen 2008

E

Technical data, steel structure Height, retracted . . . . . . . . . . . . . . . . . . . . mm

2700

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

6000

Height adjustment, hydraulic . . . . . . . . . . mm

3300

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

1000 1130

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

950

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

2900

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

1050

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

1600

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

4050

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

14 56.8

Width of caving shield with side seals . . mm

1600

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

1610

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

42536

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

1750

Support force for an average seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm a) at 320 bar setting pressure . . . . . . . . . kN b) at 440 bar nominal pressure . . . . . . . . kN

5000 7879 10833

Support resistance per m2 roof surface for an average seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm a) at 320 bar setting pressure . . . . . . . . . kN/m2 b) at 440 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

Doc. No.: 7420 084 000 BA 00

VTVT / 02

5000 849 983 / 1168

6.11

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. normal and exceptional operation

During normal operation, the shield functions may only be operated via the PM4 control device.

The pilot solenoid valves of the control block are equipped with buttons which allow the shield functions to be operated manually.

A symbol plate shows the function/button allocation.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Warning!

During normal operation, the buttons on the pilot solenoid valves of the control block 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 solenoid 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.

6.12

Shield support 2700/6000-2x5278-1750

Hydraulic system Shield hydraulics The following table indicates the hydraulic components for the support.

Tab. 9: Hydraulic components Designation

Configuration

Remarks

1

Quantity 1

Electrohydraulic control unit

Between the two front lemniscatic links, fastened to the support

On a support

2

2

CV, NG 20

On every prop

3

1

CV, can be unblocked hydraulically

Right-hand, front lemniscatic link, inner side

Blocks the annular space side of the shifting ram

4

4

CV, can be unblocked hydraulically

Underneath the canopy, between the props

Blocks the annular space and/or the piston space side of the flipper cylinder

5

8

PRV, 420 bar

a) 1x on the check valve (Pos. 3) b) 2x on the check valve (Pos. 4) c) 2x on the check valve (Pos. 4)

a) for shifting rams b) for flipper cylinders c) for flipper extension cylinders d) for seal cylinders

Item

Bucyrus DBT Europe GmbH, Lünen 2008

E

d) 2x on the HP ball valve (Pos. 23b+c) e) 1x on the HP ball valve (Pos. 23d)

e) for lift cylinders

6

2

PRV (pressure release valve), 440 bar

On every prop

7

1

CV, NW 25

On the pipe distributor,return

8

1

Double filter, can be backflushed

On the right-hand front lemniscatic link

9

1

Spraying valve

On the right-hand front lemniscatic link

10

1

Twin CV

On the stabilizing cylinder

11

1

Accumulator cartridge

On the electrohydraulic control unit

12

1

Hose lines

Subassembly group

13

1

Water spraying system

Subassembly group

14

1

Brackets and accessories

Subassembly group

15

1

Pipe distributor

16

1

CV, hydraulically piloted

17

2

CV, DN10

On every prop

19

2

PRV, 420 bar

On the stabilizing cylinder

20

2

Pressure gauge

On the prop CV of every prop

22

1

Block ball valve

On the left-hand front lemniscatic link

Manually actuated

Between the front lemniscatic links

Retracting/extending pusher cylinder

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

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.13

Hydraulic system Item 23

Quantity 4

Designation

Configuration

Remarks

HP ball valve

a) on the pipe distributor

a) in the high-pressure supply line, blocks the supply line to the shield hydraulics b) in the supply line to the annular space of the seal cylinders c) in the supply line to the annular space of the seal cylinders e) in the supply line to the annular space of the lifting cylinder

b) on the distributor strip underneath the caving shield c) on the distributor strip underneath the caving shield e) on the lifting cylinder

2

HP ball valve

a) on the left prop CV b) on the right prop CV

Blocks supply line to the piston space of the prop

25

1

HP ball valve

On the pipe distributor

In the pressure supply line, blocks the supply line to the shield hydraulics

26

2

HP ball valve

a) on the pipe distributor b) on the pipe distributor

a) in the feed line for the water spraying system b) for spray line

On the pipe distributor

In the water feed line

1

Water filter

Z1

2

Prop

Z2

1

Shifting ram

Z3

1

Stabilizing cylinder

Z4

4

Seal cylinder

Z5

1

Baselift cylinder

Z6

2

Flipper extension cylinder

Z7

1

Flipper cylinder

Z8

1

Pusher cylinder

6.14

Bucyrus DBT Europe GmbH, Lünen 2008

27

E

24

Shield support 2700/6000-2x5278-1750

Hydraulic system Shield hydraulics Fig. 41: Shield hydraulics, arrangement Image caption: see Table 9

Bucyrus DBT Europe GmbH, Lünen 2008

E

13

4

5 19

10

5

23b+c

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.15

Hydraulic system Fig. 42: Shield hydraulics, arrangement Image caption: see Table 9

9

16 8 22 3 25 Bucyrus DBT Europe GmbH, Lünen 2008

26a

E

15 7 26b

23a 14

24b

2

17b

24a

5a

17a 1, 11 20 27

6.16

Shield support 2700/6000-2x5278-1750

Hydraulic system Fig. 43: Hydraulics schematics, overview Image caption: see Table 9

Z4 19

Z3 10

Z4 19

Z1

Z2

Z1

5a

24a

2

24b

2 3

6

Z5

20

17

23d

E

Z7 Bucyrus DBT Europe GmbH, Lünen 2008

5e 12

5b

5b

20

17

6

Z4

Z4

Z8

4

4

5d

22 Z6 13 5c 9

4

Z6 5c

5d

23c 23b

4

1

16

11

23a 27

26a

7 15 26b

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.17

Hydraulic system Fig. 44: Functions of the electrohydraulic control unit, symbol plates

Tab. 10: Electrohydraulic control units with 16 functions, allocation of functions Function, designation

6.18

Function No.

Extending stabilizing cylinders

1

Retracting stabilizing cylinders

2

Extending props

3

Extending seal cylinders (caving shield)

4

Retracting props

5

Setting high pressure

6

Advancing shield

7

Bankpush

8

Retracting seal cylinder

9

Extending seal cylinders (canopy)

10

Retracting flipper cylinders

11

Extending flipper cylinders

12

Retracting flipper extension cylinders

13

Extending flipper extension cylinders

14

Extending baselift cylinders

15

Water spraying system, face side

16

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

16 functions

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

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

The prop head is fastened by means of two clampable pawls on the canopy, which engage in the recesses on the prop head. The cams of the prop base are clamped with the so-called prop retainers on the base of the support.

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

Fig. 45: Double-telescopic prop, model SD 5280-400-2050/5210-BD 2050 5210

Stroke lower stage Stroke upper stage

1620 1540

Ball R240

Bucyrus DBT Europe GmbH, Lünen 2008

E

Retracted Extended

1 prop base 2 piston pipe 3 floor valve 21 piston rod Also see the spare parts catalog

Warning!

Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never close the lowering connections on double-acting props so that they’re pressure-tight. Otherwise, pressure might build up in the annular space when extending the prop, which is several times more than the set pressure.

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.19

Hydraulic system Function setting props

Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the annular space is conducted away into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressure fluid is supplied at the same time via the check valve in the bottom of the piston pipe.

Loading props a) piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. Further transmission of the force is hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the base.

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

The pressure fluid is connected to the return under the piston pipe via the control valve for the prop.

Both stages of the prop can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston rod can then retract.

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

6.20

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

E

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated control 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.

Hydraulic cylinder Hydraulic cylinder Construction The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod.

Fig. 46: Hydraulic cylinder, typical example Type a)

2 1

3

5

4

1

4

6

Bucyrus DBT Europe GmbH, Lünen 2008

E

Type b)

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 the “Technical Data, Hydraulic Cylinders” section for the shield unit used.

Warning!

Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic lines caused by dangerous overpressure.

Never seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, when extending the cylinder, pressure can build up in the annular space which is several times more than the set pressure!

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against working loose using clamping screws or a clamping sleeve connection.

The pressure fluid is either fed through the connections at the outer cylinder (Model a) or on the piston rod (Model b).

If a double-acting cylinder is only to be operated as a single-acting cylinder, the annular space connection must be protected against the penetration of dirt with a filter screw. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.21

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

Type SD 5280-400-2050/5210-BD, Device No. 8250 062 000 00 00 Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

2050

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

5210

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

3160

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

400/285

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

370/265

cm2

1256.6/638

Piston surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annular surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 181.4/86.4 4021.1

Setting pressure, 440 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kN

5529

Retracting force at 320 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . kN

580.5

shifting ram double-acting

6.22

Type ZE-165/100-1130-SC-W-CR, Device No. 8241 173 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

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

165

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

100

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

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 320 bar . . . . . . . . . . . . . . kN

684

Pulling force at 320/420 bar . . . . . . . . . . kN

433/568.3

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

E

Prop force with setting pressure, 320 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kN

Hydraulic cylinder stabilizing cylinder, double-acting

Bucyrus DBT Europe GmbH, Lünen 2008

E

baselift cylinder, double-acting

seal cylinder, double-acting

flipper cylinder, double-acting

Doc. No.: 7420 084 000 BA 00

Type ZE-200/125-690-EC-W-BD, Device No. 8241 294 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

690

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

220

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

125

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

380

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

257

Thrust force at 320/420 bar . . . . . . . . . . . kN

1216/1596

Pulling force at 320/420 bar . . . . . . . . . . kN

824/1079.4

Type ZE-150/90-240-LI-BD, Device No. 8241 169 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

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

150

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

90

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

176.7

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

113.1

Thrust force at 320/--- bar . . . . . . . . . . . . kN

565.4/---

Pulling force at 320/ --- bar . . . . . . . . . . . kN

361.9/---

Type ZE-80/63-315-RI-BD, Device No. 9571 170 100 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

315

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

80

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

63

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

50.3

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

19.1

Thrust force at 320/--- bar . . . . . . . . . . . . kN

160.9/---

Pulling force at 320/420 bar . . . . . . . . . . kN

62 / 80.2

Type ZE-165/100-615-KD-W-BD, Device No. 8241 175 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

600

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

165

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

100

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

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 320/420 bar . . . . . . . . . . . kN

684/898

Pulling force at 320/420 bar . . . . . . . . . . kN

433/568.3

VTVT / 02

6.23

Hydraulic cylinder

6.24

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

285

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

115

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

80

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

103.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

53.6

Thrust force at 320 bar . . . . . . . . . . . . . . kN

324

Pulling force at 320 bar . . . . . . . . . . . . . . kN

171.5

Type PU-135/120-300, Device No. 8241 046 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

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

135

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

120

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

143.1

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

30

Thrust force at 320 bar . . . . . . . . . . . . . . kN

458

Pulling force at 320 bar . . . . . . . . . . . . . . kN

96.1

Shield support 2700/6000-2x5278-1750

E

pusher cylinder, double-acting

Type ZE-115/80-285-KD-BD, Device No. 8241 174 000 00 00

Bucyrus DBT Europe GmbH, Lünen 2008

flipper extension cylinder, double-acting

Hydraulic cylinder Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalog.

Tab. 11: Pressure relief valves, use of the various models Application

Design model

Setting pressure in bar

Device No.

General application, not for props

Spring-loaded

420

7337 486 420 00 00

Only for props

Spring-loaded

440

8220 059 440 00 00

Bucyrus DBT Europe GmbH, Lünen 2008

E

Caution!

The setting pressure of pressure relief valves should not be changed. Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

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

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system’s circuit diagram. Noncompliance 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. marking

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The letter code includes the following information: J setting pressure, target value J week setting was made J year setting was made J last made by Tab. 12: Letter code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last changes made by

Color coding is with either one or two colors. It indicates the range within which the setting pressure is located. The following Fig. 47 shows a pressure relief valve provided with a blue/white color code.

This color code corresponds to the pressure range of 350 to 399 bar.

1)

Doc. No.: 7420 084 000 BA 00

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

VTVT / 02

6.25

Hydraulic cylinder Fig. 47: 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.

6.26

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

Shield support 2700/6000-2x5278-1750

Bucyrus DBT Europe GmbH, Lünen 2008

Color

E

Tab. 13: Color codes for pressure relief valves, overview

Shield control system Shield control system Electrohydraulic control units Fig. 48: Electrohydraulic control unit b c

e

a

Bucyrus DBT Europe GmbH, Lünen 2008

E

d

a pilot valve b solenoid driver module c connecting cable

d symbol plate e buttons

Warning!

During normal operation, the buttons on the pilot valves of the control block 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.

Doc. No.: 7420 084 000 BA 00

VTVT / 02

6.27

Shield control system PANZERMATIC® PM4 Notice!

Operation of the PANZERMATIC® control system is not described here, but in a separate operating manual.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 49: Panzermatic® PM4, schematic presentation

1 control device 3 solenoid driver module 9 pressure sensor 10 infrared receiver

6.28

22 EMERGENCY STOP SWITCH 27 warning lamp Other components: see spare parts catalog

Shield support 2700/6000-2x5278-1750

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

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α1 ~9.6° at M =2700 mm and limited articulation of the hinged joint between shield canopy and caving shield

Bucyrus DBT Europe GmbH, Lünen 2008

α2 ~ 13.7° a 6000 mm measured with retracted stabilizing cylinder

Caution!

Exceeding the specified permissible angles can lead to damage to the props and cylinders and their fastening elements, as well as to the part hinges.

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6.29

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, for operating hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

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 if required a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate.

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

6.30

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Bucyrus DBT Europe GmbH, Lünen 2008

If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies, e.g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc.

The respective exemption permit will be issued by Bucyrus on request.

E

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate 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

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Fig. 50: Typical certificate

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6.31

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 J concentrate ratio

J microbial load

– target value: ≤ 105 col/ml.

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

The permissible maximum temperature of the hydraulic fluid is 55°C. During normal operation, however, an operating temperature of 45°C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following table (Table 14) lists limit values for the essential properties and components of the water.

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

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will also lead to the loss of the certificate, even if they are within the limit values mentioned.

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– target value: see certificate

Permissible media Tab. 14: Properties of the process water, limit values Limit value

Appearance, color, smell

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

Electrical conductivity

< 1800 μS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

Ratio of solid foreign matter at 1.2 μmfiltering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

-/18/14

Lubricating greases and pastes

E Bucyrus DBT Europe GmbH, Lünen 2008

Test criterion

Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

lubricating grease A1

Base:

Lithium soap

NLGI Class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presence of water:

practically non-soluble in water

Temperature of application:

-20 to +120°C

Flash point:

≧ 200°C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN*)7068).

Tab. 15: Lubricating greases for general application

lubricating grease A2

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Flashpoint in °C

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 16: Lubricating greases with additives Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*)

Doc. No.: 7420 084 000 BA 00

Flash point in °C

EWN = Bucyrus works standard

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6.33

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.

Tab. 17: Lubricating pastes free of molybdenum disulfide Type

Base

Gleitmolybdän

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: Gleitmolybdän “gleitmo 805” lubricating paste B6

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support.

Behavior in the presence of 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.

*)

6.34

The products listed in Table 15 are suitable lubricating greases for filling of adjacent cavities.

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Supplier

Tightening torques Tightening torques Screws with ISO metric thread Tab. 18: Tightening torques at μtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Bucyrus DBT Europe GmbH, Lünen 2008

Tightening torque 4)

Pitch P Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

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

1) 2) 3) 4)

Doc. No.: 7420 084 000 BA 00

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).

VTVT / 02

6.35

Bucyrus DBT Europe GmbH, Lünen 2008

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Tightening torques

6.36

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7

For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestraße 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: 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: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

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Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd.

+61/24 91 4 - 7144 +61/24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

7.4

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Tel: Fax:

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Customer Service 20 Killara Close, Beresfield, New South Wales 2322

Service addresses Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

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7.5

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

The shields are numbered consecutively. The plaque with the shield number is located on the base.

Fig. 51: Type plate, example

1 2

Bucyrus DBT Europe GmbH 3

12345 01/08

678

7420 084 000 00 0x 7

2

5

5275 kN

1 manufacturer 2 SAP/Device No. 3 date of manufacture 4 serial No.

5 device number 6 number of props 7 prop force

Shield number Fig. 52: Shield number, example

7.6

Seq. No.

Device No.

Application

81 to 95

7420 084 000 00 01

Face shield

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6

4

Standards and Guidelines Standards and Guidelines Referenced national standards and guidelines Tab. 19: National standards and directives, 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 hydraulics Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Nonmetallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

Bucyrus DBT Europe GmbH, Lünen 2008

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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 directives Tab. 20: European standards and directives, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 98/37/EWG the approximation of the laws of the Member States 1998-06-22 relating to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and Directive 94/9/EC 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of Machinery 2004-04 DIN EN ISO 12100-2 Safety of Machinery 2004-04 Non-electrical equipment for potentially explosive DIN EN 13463-1 2002-04 atmospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 2004-12 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interface 2000-08 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water - Distillation method Equipment and components intended for use in potentially DIN EN 1710 2006-01 explosive atmospheres in underground mines Mobile extracting machines at the face - safety DIN EN 1552 2003-09 requirements for shear loaders and plow systems 1)

Doc. No.: 7420 084 000 BA 00

EWN = Bucyrus works standard

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Standards and Guidelines

7.8

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