Cat Bucyrus Shield support 550 1650-2X1414-1500 Manual BI622820 - PDF DOWNLOAD

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Wereservetherighttointroducemodificationsasaresultoftechnical developmentwithoutpriornotice.

BucyrusEuropeGmbH,Lünen2009E

5.Operation

Aboutthismanual

Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Itprovidesyouwithinformationaboutthe structureofthemanualandthesymbolsusedinit.

Beforestartingwork

Usinganoperatingmanualthatisnotwrittenfortheshieldsupport athandcanresultinasafetyhazardforyourselfandothers.Ensurethatthedataontheshieldagreeswiththedatagiveninthe operatingmanual.

Thisoperatingmanualbelongstothe: shieldsupport 550/1650-2X1414-1500* IDno.:74201640000001/02

andisonlypermittedtobeusedforshieldsofthistype!

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththeshield.

Thereshould,ifpossible,alwaysbeanoperatingmanualforthe shieldavailableattheplaceofoperation.

Sendforanewoperatingmanualimmediatelyifthepresentoperatingmanualisnolongercompleteorhasbecomeillegible.

Personsforwhomtheoperatingmanualisintended

Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.

Allpersonsworkingontheface,attheedgeofthefaceoratthe entrymustreadthisoperatingmanual.

Thisincludespersonswho: J areinchargeoftransport, J preparetheriseheading, J performinstallation/removalwork, J operatetheshields, J correctmalfunctions, J performdailyroutineworkontheface, J monitor/lookafterforthehydraulicsystem, J performmaintenancework, J performrepairwork.

Supervisorypersonnelwho:

J initiatetheactivitiesnamedaboveand/or J supervisetheactivitiesnamedabove.

* Theshieldsupportisreferredtoastheshieldinthefollowingtext.

applicableoperatingmanual shieldtype newoperatingmanual

Purposeofthisoperatingmanual

Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtotheshieldsupport.

Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontothesafetyinstructions.

Trytomemorizetheappearanceandmeaningofthesafetyandinstructionsymbols.

Shouldyouhaveanyquestions,pleasecontactourServiceDepartment.Ourserviceaddresscanbefoundinchapter7“Foryourinformation”.

Payspecialattentiontochapter2,“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.

Observethisinformationandfollowtheproceduralinstructions.

Charactersandsymbolsused

Thefollowingsignsandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

Danger!

Pointsinthetextmarkedwiththissymbolpointoutimmediatelyimpendingdanger.Possibleconsequencesareveryseriousinjuryorevendeath.

Warning!

Thesepointscontaininformationonhazardoussituations. Possibleconsequencesareveryseriousinjuryorevendeath.

Caution

Thissymboldrawsattentiontodangeroussituations.Possible consequencesarelighttominorinjuriesanddamagetomachinery.

Notice!

Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesaredamagetothe shieldordamageinitsimmediatevicinity.

Important!

Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.

J Itemsinlistsaremarkedwithbullets.

–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.

. Textpassagesindicatedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Itwillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.

2 Yoursafety

Yoursafety

Thischapterprovidesimportantinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.

Theshieldsupporthasbeenmanufacturedusingstate-of-the-art technologyandinaccordancewiththegenerallyrecognizedsafety standardsandregulations.

Youandotherscanneverthelessbeexposedtodangeroussituations,e.g.,asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.

Donotmakeanymodificationsorcarryoutconversionswhich couldimpairthesafetyoftheshieldsupport.Allmodificationsand conversionsmustbeapprovedbyBucyrus.

UseonlyoriginalreplacementpartsfromBucyrus.Notethatuseof partsfromothermanufacturerswillvoidtheguarantee.

Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsforaccidentpreventionin yourcountry.

Observethesafetyandaccidentpreventionregulations: J ofthemine, J oftheminesinspectorateand J ofminingsupervisoryauthorities.

Pleasealsoreadtheoperatingmanualsofthecomponentsrequiredforoperation,e.g.gearboxes,E-motors,etc.carefullyand thoroughly.Clarifyanyquestions before startingwork.

Personnel Operation

Theshieldsupportmaybeoperatedonlybytrainedpersonnel.

Theshieldsupportmayonlybeoperatedbyqualifiedpersonnel whocanprovideproofofhavingbeentrainedonthecontrol system installed.

Readingoftheoperatingmanual,especiallythechapteronsafety, mustconstituteapartofthistraining.

Theymustpossessandfurnishproofofadequatefamiliaritywith the J mechanical system, J hydraulicsystem,and J controltechnology.

state-of-the-arttechnology additionaloperatingmanuals

Installationandrepairs

Asafundamentalrule,installationandrepairworkmayonlybecarriedoutbypersonnelwhohavebeentrainedadequatelyforthese particularrequirements.

Installationandrepairworkon:

J safetycomponents(pressurereliefvalves,extinguishers,etc.),

J electricalsystems(controlsystems,signalingdevices,etc.)

J thehydraulicsystem, mayonlybecarriedoutbyBucyrusserviceengineersorbyspeciallytrainedpersonneloftheminingcompany.

Operatingconditions Intendeduse

Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasashieldunitforlongwalls.

Usetheshieldonlyasintended.

Intendedusesare:

J proppingtheroofagainsttheminefloor,

J ensuringanadequatetravelway

J thefollowingshieldoperations: –lowering

–pullingup

–aligning

–setting

J thefollowingconveyoroperations: –advancing

–retracting

J formingathrustbearingfor:

–theconveyorandminingequipment

–conveyorsteeringdevices

–devicesforraisingtheconveyor –conveyorsteeringcylinders

Unauthorizeduse

Alluseswhicharenotexpresslyincludedinthelistof“intended uses”areconsideredtobeunauthorizedusesandarenotpermissiblewiththeshield.

Unauthorizeduseincludes:

J pushingtheshieldrearintothecavingarea

J raisingtheconveyorbymeansofthehydraulicforceofthe shield

J settingofthecanopyinrooffalls. Furtherinformationaboutthiscanbefoundinthe“Operation” sectionofthischapterandinchapter5inthe“Operationofthe shieldsupport”section.

Bucyrusdoesnotacceptanyliabilityfordamageresultingfromany suchunauthorizeduse.

lightingsystem signalingsystemsand safetyequipment EMERGENCYSTOP

supportlock-outswitch

Safetyinstructions

Basicprinciples

Alwaysworkwithutmostconcentration. Familiarizeyourselfwithyourworkingenvironment.

Alwayswearpersonalprotectiveequipment.

Informyourcolleaguesof: J yourexactlocation, J theworkyouareperforming, J thetimewhichyouwillprobablyrequire. Employonlyshieldswhichareinatechnicallyflawlesscondition. Alwayskeepoutofanyshieldwhichisnotset.

Maintainthelightingsystemsinafunctionalcondition.

Maintainthesignalingsystemsandsafety equipmentinworking condition.

Observetheacousticandvisualstart-upwarnings.Payspecialattentiontothestart-upwarningsfortheconveyorandforthemining equipment.

Presstheemergencystopswitchimmediatelyintheeventofmalfunctionsorirregularitiesinoperation.Notifyyoursupervisorofany peculiarity,sothatnecessaryactioncanbetakenimmediately.

-Onlyappliesforversionwiththeelectrohydraulicshieldcontrol system:

Actuatethesupportlock-outswitch(repairswitch)before: J maintenancework, J inspectionwork, J repairwork, J andduringprolongedpresenceintheshield.

movingparts

Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe: J basesandrelaybarassemblies, J canopies, J lemniscaticlinks, J sideseals, J frontcantilevers, J hydraulicpropsandcylinders, J steeringdevices.

automaticmode

Inautomaticmode,theshieldunitsofalongwallfacearecontrolled byanautomaticprogramwithoutanyhumanintervention.When travelingthefaceyoushouldthereforealwayskeepinmindthatthe shieldunitsmaymoveautomatically.Thereforeitisvitalthatyou observethewarningsatthefaceentriesaswellasthevisualand acousticsignalssentbytheelectroniccontrolunitintheshieldcurrentlyoperated.

Storageandtransport

Forthispurpose,thoroughlyreadchapter3,“Storageandtransport”.

Neverstandunderunsecuredorsuspendedloads.

Observethespecifiedstorageperiodsandthestorageinstructions. Neverstorematerialsofanykindinthetravelwayorinyourworkingarea.

Defectivecomponentsshouldimmediatelybetransportedaway fromtheface,inordertoavoidhinderingthefacecrew.Moreover, thismeasurepreventsinadvertentreinstallationofthesecomponentselsewhere.

Informthepersonsconcernedabouttheintendedtransportroute andtheprobabledurationofthetransport.

Makesurethetransportsafetydeviceshavebeeninstalledproperly.Inparticular,ensurethatthefollowingaresecuredfortransport:

J sideseals, J flippers, J relaybars(bothfacesideandgobside).

Connectthemeansofattachmentonlyattheliftingpointsprovided forthispurpose.Observethedifferentloadlimitsofthelifting points.Alsoobservetheinstructionsfortransportgivenonthereplacementpartdrawingswhichareincludedinthereplacement partscatalog.Non-standardtransportunitsareshowninspecial drawings,whichareincludedintheappendixoftheoperating manual,ifrequired.

Donotdamagethepolishedsurfacesofthecylindersandthe props.Damageofthiskindnecessitateselaborateandexpensive repairwork.

Forroundcomponents,suchascylindersandprops,whicharenot providedwithliftingpoints,onlyusetransportstraps.Neveruse chainsorsteelcablesforthispurpose.

Onlyusemeansofattachmentwhichareingoodconditionand havebeendesignedfortheloadsinvolved.

Firmlysecureallcomponentswhichmightstartmovingontheir own.

Observethepositionofthecenterofgravity,especiallyduring transportwithfloorconveyingdevices.Thecenterofgravitymust beaslowaspossible,inordertopreventtippingofthetransport unit.

transportsafetydevices

Safetyinstructions

Installation

Onlyuseappropriateloadingequipmentforthesafetransferofthe transportunits.

Priortocommencinganyworkontheshield,makesurethatthe shieldissecuredtopreventitfromretractingautomatically.

Mechanicallysecurethecavingshieldagainstinvoluntarylowering during:

J installationofthepropsandcylinders

J installationofthecanopies

J workontheopenhydraulic system.

Theshieldcanbesecured,forinstance,byplacinghardwood wedgesbetweenthepairsoflemniscaticlinks.

Iftheshieldisprovidedwithmovablesidesealsthesearepretensionedbyspringforce!Thereforedonotuseforcetoremovethe transportsafetydeviceofthesideseals.Usethehydrauliccontrol systemtoadjustthesealcylinderssuchthatthelockingpinseither dropdownorcanbepulledoutwithouttheuseofexcessiveforce.

Whenremovingthetransportsafetydeviceoftheflipperensure thatnobodyispresentintheswivelingareaofthelatterastheflippermayswingdownward.

Makesurethattheminimumdimensionsspecifiedforthetravel waywiththeshieldaremaintainedatalltimes.Theminimumdimensionsare:

J width:600mm

J height:400mm.

Anydevicesaddedtotheshieldlater,suchassteeringdevices, mustnotreducetheminimumtravelway.Itmaybenecessaryto installadditionaldeviceslimitingtheloweringheightinordertoensurethattheminimumtravelwayismaintained.

Fig.1:Self-blockinghardwoodwedgesbetweenthelemniscaticlinks stabilizethepositionofthecavingshield

transportsafetydevices

travelway

Operation

Inautomaticmode,theshieldunitsofalongwallfacearecontrolled byanautomaticprogramwithoutanyhumanintervention.When travelingthefaceyoushouldthereforealwayskeepinmindthatthe shieldunitsmaymoveautomatically.Therefore,itisvitalthatyou observethewarningsatthefaceentriesaswellasthevisualand acousticwarningsignalssentbythecontrolunitintheshieldunit currentlyoperated.

Checkwhetherallprotectivedevicesarepresentontheshieldand capableoffunctioning,seealsochapter6“Technicaldata”.

Youmayonlyoperatetheshieldcontrol systemifyouhaveextensiveknowledgeofthecontrolelementsandtheirfunctions.You musthavebeentrainedontherespectivecontrolandknowthe contentsoftherespectiveoperatingmanualforthatcontrol.

Youshouldnotbeinthesameshieldastheoneyouwishtooperate.Onlyoperatetheshieldfromaneighboringshield.

Makesurethatnopersonsarepresentintheareaoftheshieldbeingactuated.

Duringmanualoperation,theoperatormustalwayskeepaneyeon themovementrangeofthesupportunitbeforeandwhilethesupportisbeingmoved,andpreventanyhazardsbyactingwithcaution.

Alwayssettheshielduntilthefullsettingpressurehasbeen reached,sincegoodroofsupportcanonlybeensuredinthismanner.

Extendtheflippertowardsthecoalfaceasfaraspossibletopreventcoalorsurroundingrockfromfallingintothetravelway.

Cleantheoperatingcontrolsofthecontrolunitsregularly.Ensure thattheoperatingsymbolsareclearlyvisible.Thismeasureavoids operatingerrorsandaccidentswhichwouldresultfromthis.

Keepthefloorascleanaspossible.Keeptheminefloorfreeof debris.Thiswayyouwillbeabletoextendtherelaybarassembly withoutobstaclesandtoadvancetheconveyorwithoutproblems. Ensurethatthewatersprayingsystemrespondsduringadvancement.

Onaninclinedface,theconveyormustbeanchoredoppositethe support,ifnecessary.Thisway,youcanpreventtheconveyorfrom shiftingtothesidewithrespecttothesupport.Anditreducesthe riskoftherelaybarassemblyjammingbetweenthebases.

Hydraulicanchoragesmustalwaysbechargedtothespecified workingpressuresincethisistheonlywaysufficientanchorage betweenthesupportandconveyorisensured.

Whenadvancingtheshields,alwaysobservethespecifiedsequenceofstepstopreventtheshieldsfromcollidingwiththeanchoragecylinders.

Oninclinedfaces,alwaysadvancetheshieldsfromthebottomto thetop.Alwaysoperatetheshieldtobeadvancedfromwithinthe higherneighboringshield.Thisreducesyourriskofinjurybyfalling rocksandalsogivesyouabetterviewoftheadvancingoperation.

shieldcontrol

inclinedfaces

Safetyinstructions

Theshieldsmustbealignedatrightangleswithrespecttotheconveyorandparallelwithrespecttoeachother.Usethealigning devicesorthesidesealsforaligningtheshields.

Aligntheshieldsasearlyaspossible.Usethealigningdevicesor thesidesealsforaligningtheshields.

Earlyalignmentprevents:

J gettingunderthecanopyoftheadjacentshield,

J cantingoftheshields,

J slippingoftheshields,

J delaysinsupportingthenewlyminedroof.

Preventrooffallsbysupportingthenewlyminedroofasearlyas possible.

Neversetthetipofthecanopyintoarooffallsothat

J themaximumadmissibleangleofinclinationofthecanopyis exceeded,

J thestabilizingcylinderlocks,

J thecanopywillbeloadedexcessivelyinthelongitudinaldirection,

asthismaycausedamageduetoexcessivestressandstrainon thecomponents.

Duringthetemporarysupportofarooffall,ensurethatthesloping canopydoesnotgetinthewayofpassingminingequipment.

Ensurethatsufficientresidualstrokeisstillpresentinthepropsas theseamheightdecreases.Thispreventstheshieldsfromjamming betweentheroofandfloor.

Ifpossible,pulltheconveyorbackbyoperatingtherespectivefunctionsoftheelectronicshieldcontrolsystem.Ifthisisn'tpossible,do asspecifiedintheapplicableworkinstructionsofthemine.

Secureallminingequipmentagainstunauthorizedstarting.

Blockyourworkingareasothatnounauthorizedpersonsmayenter thisarea.

Checktodeterminewhethertheshieldsaresetsufficientlytightly betweentheroofandfloor.

Secureyourworkingareaagainstfallingrock.Thismeasureisespeciallyimportantiftheconveyormustbeliftedonthecoalface side.

Onlyusethepointsofattachmentintendedforthatpurpose.

Neverattachloadstohydrauliccylindersortotheirpointsofattachment.

Resetallshieldsintheareawheretheconveyoristoberaised. Checkthesettingpressureagain.Donotunderanycircumstances loosenthecanopyfromtheroof;itmustbeinplacetheentire length.

shieldalignment

roof falls

residualstroke

retractingtheconveyor

raisingtheconveyor

Ifyouraisetheconveyorintheareaofseveralshields,theshields towhichliftinggearisattachedmustnotbelocatednexttooneanother.

Forraisingtheconveyor,useonly: J high-strength,undamagedchainslings, J theliftingpointsprovidedforthepurpose. Checkthatthepointsofattachmentareundamagedbeforeattachingaload.

J liftingtackleofadequateload-carryingcapacity.

Maintenance

Makesurethatallsafetyandprotectiveequipmentoftheshield supportunitsarecompleteandfunctional.IfthesafetyandprotectiveequipmentisincludedintheBucyrusscopeofdelivery,referto chapter6,“Technicaldata”,foritslocation.

Besuretoobservetheintervalsspecifiedformaintenanceandinspection.Seechapter5,section“Maintenance”.

Checktheshieldatleastonceeveryshiftforexternallyvisibledamage.

Informthesupervisorypersonnelandthefacecrewaboutmaintenanceandrepairwork.Providethemwithinformationontheintendedworkanditsprobableduration.

Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.

Immediatelyreplacedamagedcomponentsaffectingsafety.Stop andlockouttherespectiveshieldimmediatelyifcomponentdamagecreatesahazardandimmediaterepairisnotpossible.Ifthere isasafetyhazard,securethisareaandnotifytheentirefacecrew andresponsibleforemanwithoutdelay.

Useonlyreplacementpartswhichconformtothespecifiedtechnicalrequirements.ThisisbestensuredbyusingoriginalBucyrus replacementparts.

Pleaserefertothereplacementpartscatalogprovidedforthe equipmentfortheordernos.fortherequiredreplacementparts.

Donotmakemodificationsorcarryoutconversionswhichmightimpairthesafetyoftheshield.Bucyrusmustbeinformedofallconversionsandmodificationstocheckwhethertheyhaveanyeffect ontheapprovalorwhetheritisnecessarytoapplyforarevisedapproval.

Anymodificationscarriedoutwithoutauthorizationinvalidatethe Bucyrusdeclarationofconformityandanewconformitytestwillbe required.

Duringworkontherelaybarassembly,isolatetheworkingareafor theminingequipment.

Safetyinstructions

Youmayonlycarryoutworkintheminingareaif:

J theroofhasbeensecuredagainstfallingrock,

J thecoalfacehasbeensecuredagainstcollapsingand

J theminingequipmentandconveyorhavebeenshutdownand securedagainstrestartingorifyouhaveotherwiseensuredthat thecontinuationoftheminingworkdoesnotaffectthesafeperformanceoftherepairwork.

Beforedisconnectingtheshieldfromtheconveyor,youmust:

J arrangethattheminingoperationiseitherstoppedcompletely orisdoneoutsidetherequiredsafetyarea,

J relievetheloadonthecomponentswhichareunderhydraulic pressureormechanicalstress.

Immediatelydiscontinueanyworkontheshieldifconveyingand crushingoperationsareinprogressinyourworkingarea.

Thesupportmustbemechanicallysecuredforallworkwherethere isadangerofthesupportretractingautomatically.

Oninclinedfacessecurethecomponentstobereplacedagainst slippingbyusingchainsorliftingtackle,forexample.

Immediatelyaftercompletionofwork,reinstallanyprotectiveplates orsimilaritemswhichhavebeenremoved,andcheckthemforcorrectfunction.

Hydraulicsystem

handlinghydraulicfluids protectivedevices -hydraulicsystem

Avoiddirectcontactbetweenyourskinandhydraulicfluids. Hydraulicfluidcanpenetratetheskinandcauseseriousinfections. Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids poseaveryseriousdangertohealth.

maintenance,repair

pressurerelief valves

Notethatwhendismantlingprotectivedevicesthatincludehydrauliccomponents,thosecomponentsmaybepressurized.You couldbeseriouslyinjuredbyhydraulicfluidsquirtingoutinanuncontrolledmanner.Therefore,itisimperativethatyoudepressurize thehydrauliccomponentsbeforeremovingtheprotectivedevices. Onlypersonswhohaveandcandemonstratespecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.

Takecaretoensurethatpressurereliefvalvesarealwaysequippedwithprotectivecaps.Replaceanydefectiveprotectivecaps withoutdelay.

Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Check,inparticular,that:

J thehosesarenotpinched,

J thehoseshavenobubblesorblisters,

J thehosesortheoutersheathsofthehosesarenotabnormallyrigidorhard,

J theoutersheathingofthehoseisnotdamaged,

J theconnectorsaresecurelyinsertedintothecouplingsockets,

J theconnectionsareleak-tight.

permissiblehoses

Safetyinstructions

Makesurenodirtentersthehydraulicssystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamagetothewhole system.Backflushthehydrauliclinesthoroughlybeforeinstalling them.

Beforeremovingthestaplesfordisconnectingthehydraulichoses, turnthehoseatthecouplingsockettocheckwhetherthelineis pressurized.Thelineisstillunderpressureifthehoseisdifficultto turnordoesnotturnatall.Makesurethelineisdepressurized. Securetheplugconnectorsofthehydraulicelementswiththe properstaplesonly.Alwaysfastenthestaplescompletelywithboth sides.

Neverusenails,wireorsimilarmaterialstosecuretheconnectors. Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystem again.

Useonlyhydraulichosesapprovedfortheprevailingpressures.

Donotuseanyhydraulichoseswithdamagedconnectorsorworn O-rings.

Replacehydraulichosesonlywithhydraulichosesofthesameor higherquality.

Observethedateofmanufacturestampedonthehosefittingofthe hydraulichose.Neverusehydraulichoseswhicharemorethan 2yearsold,eveniftheyshownovisiblesignsofdamage.

Nevertrytoholdahydraulichosethatisthrashingabout.Immediatelydepressurizethesectioninconcern.

Nevertrytorepairdamagedhydraulichoses.

Replacehydraulichosesatthefirstsuspicionofdamage.

Fig.2:Examplehydraulichose,identification

Safetyinstructions

layinghydraulichoses

Laythehydraulichosescorrectlybehindthebracketsandclips providedforthem.

Alwayslayhydraulichosessothatthey: J alwayshavealittleslack,

Fig.3:Layinghydraulichoses,slack RIGHT

J arenottwisted, Fig.4:Layingahydraulichose,twisted

RIGHT

J arenotbentdirectlybehindtheconnectors(distanceminimum 1.5xnominaldiameter),

Fig.5:Layinghydraulichoses,bending RIGHT WRONG

J cannotchafe,

Fig.6:Layinghydraulichoses,crossing RIGHT

J arenotkinked,

J donothavetowithstandtensileloads,

J areprotectedagainstthermalradiation,

J areaccessibleatalltimes.

Inserthydraulichosesintothesocketsonlybyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagetheconnections.

Wheninstallingthehydraulichoses,makesuretheycannotbe:

J tornout

J kinked,

J crushed,

J drivenover

J twisted(Fig.:7).

Fig.7:Layinghydraulichoses,connectionsonmovingparts RIGHT WRONG

3 Storageandtransport

Storageandtransport

Thischaptercontainsimportantinformationoncorrectstorageand securetransportoftheshields.

Followingtheinstructionsandthemanualswillincreasetheservice lifeoftheshield.Youwillbeabletocarryouttransportworkmore safelyandquickly.

Payingcarefulattentiontothepointsinthischapterwillalsohelp youtosimplifyyourday-to-daywork.

Storage

Storageoftheequipment

Componentswithatemporaryanticorrosioncoatingareprotected foraboutsixmonths.

Protecttheequipmentfromdirectexposuretosunlight.

Onlystoretheelectricalequipment,electroniccomponents,replacementpartsmadeoutofrubberorplasticsuchassealsand hosesaswellashydraulicfluidsinclosedroomsat15Cto25C. Protectallpartsoftheequipmentstoredoutdoorsagainstmoisture anddirt,forexamplewithtarpaulins.

Themountingsurfacesofhydrauliccomponentsmustbeprotected againstcorrosionandsealedwithblindplates.Protectthehydraulic plug-typeconnectorsandtheelectricalconnectorswiththeappropriatecapsandplugs.

Duringshorttermstorage(approx.4weeks)ofequipmentoutdoors,butattemperatures above freezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirtandmoisture.

Duringlong-termstorage(morethan4weeks),theequipmentmust notbestoredoutdoors.Itneedstobestoredinadry,well-ventilatedroom.

Aninspectionmustbeconductedtodeterminewhetherthemeasurestakenandthemethodofstoragehavepreventeddamageafter astorageperiodofapproximatelytwoyears.

ThisinspectioncanbecarriedoutbyBucyrusuponrequest.

Evenwithproperstorage,sealsandhoselinesaresubjecttonaturalaging.Donotusethesecomponentsiftheyhavebeenstored formorethantwoyears.

Important!

Ensureduringstoragethatanynewsuppliesarestoredseparatelyfromexistingstocksinsuchawaythatonremoval,old stocksarealwaystakenfirst.

Storingusedequipment

Thepointslistedabove,withtheexceptionoftheoneconcerning anticorrosionprotection,canbeappliedanalogouslyforthestorage ofhydrauliccomponentsthathavealreadybeeninuse.

Ifthehydraulicssystemistobetemporarilyputoutof operation, theentirehydraulicsystemmustbethoroughlyflushedoutinadvanceandthenfilledwithasuitablecorrosioninhibitor(e.g. HYDROCOR® CV50*).Ifthisisnotdone,thenthehydraulics componentsmaysufferconsiderabledamagewithinashorttime, becausethepropertiesofthemediumusedcanundergovery rapid,verynegativechanges,e.g.duetomicrobialinfestation.

Water-bearingparts,suchasthepartsforthewaterspraying systemofashield,mustbecompletelyemptied,andpossiblyalso filledwithanantifreezefluidifrequired.

*HYDROCOR® CV50isacommercialtrademarkusedbyTheunissen ChemischeFabrikenGmbH,Wuppertal,Germany

Transport Loadunits;dimensionsandweights

Itisimperativethatyouobservethetransportsheets.Itincludesinformationon:

J dimensions,

J weight,

J liftingpointsand

J centersofgravity.

Theloadunitsareprovidedwithsuitableliftingpointsfortransport andinstallationasfarastechnicallypossible.

Warning!

Useonlyloadhandlingdeviceswhichcomplywiththetechnicalandlegalregulationsfortransportingloads.

Fallingcomponentscancauseseriousinjuryanddeath. Useonlysuitableloadhandlingdevices.

Beforetransport

Beforetransportingtheequipmentattemperaturesbelowfreezing, allhydrauliccomponentsoperatedwithbyemulsion(HFAEand HFAS)mustbecompletelydrainedandfilledwithacorrosioninhibitor(e.g.CV50).

Itisonlypermittedtotransportequipmentattemperaturesof-21

C to-40Cifcertainrequirementsfortheseconditionshavebeen takenintoaccountduringthedesignandproductionoftheequipment.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbesubjectedtosuddenimpactloadsatsuchlow temperaturesandmayonlybeloadedstaticallyorquasi-statically.

Duringtransportofthisequipmentwithfloorconveyingdevicesat suchlowtemperatures,measuresmustalsobetakentoensure thatthepartsanddevicesarenotsubjectedtosuddenimpact loads.

Atverylowtemperaturesandonpoorroads,thetransportvehicle speedmustthereforebelimitedtomaximum25km/hfortruck transport.

Electricalandelectroniccomponentsmustberemovedforoverseastransportorprolongedstorageoutdoorsoroutdoorstorageof theequipmentduringwinter,unlessthesecomponentsorthecompleteequipmentisprotectedagainstharmfulenvironmentalinfluencesbysuitablepackaging.

Theelectricalcablesremainintheequipment.Theymustbeprotectedcarefullyagainsttransportdamageandtheconnectorsmust beprotectedagainstdirt.

Ashieldunitcanbetransportedasacompletelyassembledunitor brokendownintosubassemblies.Ifitisnecessarytodisassemble itintotransportunits,thisisplannedandagreeduponinclosecooperationwiththecustomer. Tab.1:Transportunits

Forthepurposeofsafetransport,inadditiontothestandardtransportsafetydevicese.g.onsidesealsandflipper,themovableparts ofeverytransportunitarefastenedsothattheirpositionscannot shiftinadvertently.Specifically,thefollowinglistedtransportsafety devicesareprovidedonthetransportunits. Tab.2:Transportsafetydevices

Caution

Transportsafetydevicesmaygetdamagedduringtransportto themine,forexamplewhenloadingandunloadingthetransportunits.Therefore,checkalltransportsafetydevicesfor damageandreplacedamagedonesbeforeallowingtheunitsto betransportedintothemineshaft.Damagedtransportsafety devicesmaybethecauseofseriousdamagetothetransport unitortothetransportshaftifloadunitsaretransportedsuspendedunderthecagewithdamagedorinadequatetransport safetydevices.

Caution

Iftheassembledshieldunitistobetransported,thenthecanopyandbasemustfirstbemechanicallyconnectedtoeach otherusinganadditionaltransportsafetydevicesothatthey cannotmoveapart.Awoodenblockistobeplacedbetween therearlemniscaticlinkandthecavingshieldinordertoensurethatthetransportheightisattained.

Fig.8:Transportingtheroofsupportasacompleteunit S1 slottedhole,2xatthefrontonthecanopy,loadcapacity:8000kg S2 transportring,2xonthecavingshield,loadcapacity:5000kg X1 transportsafetydeviceforrelaybar,faceside X2 blockofwood(limitstheheightofretraction) So centerofgravity

Notice!

Fortransporting,usethefourliftingeyesS1andS2.

Tab.3:Modelspecificationforshield550/1650-2X1414-1500

Tab.4:Shieldsupport74201640000001and74201640000002, Dimensionsandweights

Therelaybarassemblyisequippedfacesidewithatransport safetydevicewhichfastensthebasesandtherelaybarassembly together.Thetransportsafetydeviceisconnectedtothecanopyby meansof2chains.

Transportsafetydevice,relaybarassembly

Fig.9:Transportsafetydevice,relaybarassembly(faceside)

116transportsafetydevice 117chain10x65 118shackle

Thetransportsafetydevicepinsaretobesecuredwiththe staples(5).

Fig.10:Transportsafetydevice,relaybarassembly

1transportsafetydevice 2pin

5staple aloadring,3000kg

Thefollowingtransportsafetydeviceisonlyusedforfaceshields, onwhosebasesthe

conveyorsteeringdevice74200730000000

isattached(seeseparateoperatingmanualfortheconveyorsteeringdevice).

Fig.11:Transportsafetydevice,relaybarassembly

1transportsafetydevice 2pin 5staple aloadring,3000kg

Fig.12:Relaybarassembly(gobside)withouttransportsafetydevice

4 Installation

Preassemblyoftheshieldunits

Installation

Inthischapter,youwillgetinformationaboutinstallingtheshield units.Pleasepayspecialattentiontothewarningsandtips.

Warning!

Inadditiontothesafetyinstructionsgiveninthismanual,also makesureyouobservethespecialsafetyinstructionsandoperationinstructionswhichapplytotheoperationofthemine. Failuretodosocanleadtoextremelyseriousaccidentswhich maybefatal.

Caution

Beforethehydraulicconnectionsarejoinedwithoneanother, thecouplingsocketsandnipplesoftheplug-inconnections mustbetreatedwiththemolybdenumdisulfide-freeB3lubricatingpasteinaccordancewithEWN7068.Seechapter6,section“Lubricatinggreasesandpastes”.

Caution

Alloftheslidesurfacesmustbetreatedwiththemolybdenum disulfide-freeB6lubricatingpasteinaccordancewith EWN7068beforethetransportsubassembliesofthesteel structureareconnectedwithoneanother.Seechapter6,section“Lubricatinggreasesandpastes”.

Preassemblyoftheshieldunits

Theshieldunitsaredeliveredcompletelypreassembled.Accordingly,nofurtherpreassemblyisrequiredonthemechanicalandhydrauliccomponentsoftheshieldunits.

Installationoftheshieldunits

Caution

Forundergroundtransportation,onlythoseliftingpointsmay beusedwhicharedescribedindetailinchapter3“Transport”. Furtherinformationaboutthiscanbefoundinchapter3 “Transport”.Failuretocomplycanleadtopersonalinjuryand propertydamage.

Theshieldunitsareinstalledinthefaceaccordingtotheinstallationplanofthemine.

Important!

Wheninstallingtheshieldsintheface,besuretopayattention totheshieldnumbers.Sincesomeshieldunitsmaybe providedwithdifferentfunctions,theirsetuponthefaceisnot arbitrary.

Inordertoidentifytheshieldunitsortheirtransportunitsmoreeasilyforthepurposeofassemblingandinstallingintheface,they shouldbelabeledwithasequentialnumber.Thisnumbershould correspondtotheorderinwhichtheshieldunitsaretobearranged intheface,forexample.Thenumbersshouldbewrittenincolorso thattheyareclearlyvisibleonthesurfaceoftheparts.

installationplan

identificationfor installationintheface

shieldnumber

Theshieldnumberservesasanidentificationfeature.Allshields arenumberedsequentially.Firmlyattachedtagswiththerespective shieldnumberareontheleft-handbaseontheshield.

Fig.13:Shieldnumberonthebase,example

Tab.5:Allocationoftheshieldnumbers

Theshieldunitscanbeutilizedinanumberofdifferentheightpositionsatvariousprevailingairpressurelevels. Theelectroniccontrolunitsareequippedwithaventscrewinorder toenablepressureequalizationbetweentheinternalandexternal pressureofthecontrolunithousing.

. Unscrewtheventscrew(hexsocket4mmkeywidth)onthe controlbyseveralturns.

Pressureequalizationisindicatedbyanaudiblehissing.

Caution

Makesurethattheventscrewforpressureequalizationonthe controlsystemisreleased.Thefoildisplaysmaybecomedamagedifnopressureequalizationisestablished.

b

. Afterwards,rotatetheventscrewuntilitisonceagainhandtight.

Caution

Takecaretoensurethattheventscrewistightenedhand-tight againafterpressureequalizationonthecontrol.Ifthisisnot done,thendirtandmoisturecouldpenetratethecontrolunit andfiredampprotectionisnolongerensured.

Pressureequalizationoftheelectroniccontrolunit

Fig.14:Exampleofaventscrewonanelectroniccontrolunit

Supplyconnections

Duringinstallation,pressurecanbeappliedtotheindividualshield usingtheso-calledauxiliarysupplyandoperated.Theauxiliary supplymustbeconnectedtoconnectionsaandb(Fig.15).

Notice!

Connectionsa,boftheauxiliarysupplymustbe sealedwith plugscduringnormaloperation.

Fig.15: Viewof thesupplyblockandtheauxiliaryconnections(supplylinesarebypassedfortransport)

Foroperatingtheshieldwiththehelpoftheauxiliarysupply,the shieldfunctionsmustbeactivatedviaanadditionalexternal PMC®-Rcontrolunit.ThisisconnectedtotheinternalPMC®-R controlunitviaacorrespondingcable(seeseparateoperating manualforthePMC®-Rcontrolunit).

Theconnectionsfortheauxiliarysupplyarelocatedtotheright nexttothesupplyblock(seeFig.15andinchapter5,thehydraulicsschematics,Fig.26).

Forutilizationoftheauxiliarysupply,theconnectionsP,R,W1and W2(seeFig.15)onthesupplyblockwiththehosesthatwilllater beresponsiblefortheconnectiontotheneighboringshieldmustbe blockedandbypassed-asarule,thiscorrespondstostatusatthe timeofdelivery.Ifthesupplyhosescannotbeconnectedupinthis way,thentheconnectionsmustbesealedwithcorresponding plugs.

Proceedasfollowstojointheshieldstooneanother:

. ClosetheHPballvalvesatItems32and34(seeFig.15).

. Removetheplugscfromconnectionsaandb(seeFig.15)of theauxiliarysupply.

. Connecttheauxiliarysupplytothepressureandreturnlineof thepump.

. Afterwards,reopentheHPballvalvesatItems32and34. Theshieldisnowmovableviatheexternalcontrolunits.

. Movetheshieldtothedesiredposition.

Torelievepressureonthepressurehose,

. BypasstheHPballvalve,Item32,andactivatethefunction “Advanceconveyor”brieflyuntilthepressurehoseisrelieved (supportisnotyetconnectedtotheconveyor).

12PRV(80bar)inthereturnline 13supplyblock

16plugDN10withpressurerelief aventedcapscrew

Fig.16:Plugcaponsupplyblock,atrear

Warning!

Pressuremaybuildupinthereturnlineduetoincorrectoperation(forexample:closedreturnline).Thismustbereducedvia thepressurereliefvalve(seeFig.16,Item16)byscrewingin theventedcapscrew.Afterrelievingthepressure,thisscrew mustbescrewedallthewayoutagain. Makesurethatallhoselinesarefreeofpressurebeforeyou undotheconnectionlinesatthesupplyblock!

. Relievetheconnectionsoftheauxiliarysupply(seealsochapter5,Fig.39).

. Disconnecttheconnectionlinesoftheauxiliarysupplyandseal theconnectionswiththeplugs.

. LoosenthefourconnectionlinesP,R,W1andW2onthesupplyblockandconnectthemwiththeneighboringshield.

Establishalinkbetweentheconnections

ThehydraulicconnectionsontheshieldunitsaredesignedasplugtypeconnectionsinaccordancewithDIN20043,whichisstandard forGermanmining.

Thesupplyblockforsupplyingtheshieldhydraulicsislocatedto therightunderneaththecanopyinfrontoftheright-handprop.The connectiontothesupplyblockoftheneighboringsupportismade usingfourhoselines:onepressureline(DN25),onereturnline (DN32)onewaterline(DN50),onewaterline(DN50)andawater line(DN25).SeealsoFig.15aswellasthehydraulicsschematics inchapter6ofthismanual.

EverythirdshieldunitisequippedwithaModelPMC®-Relectronic controlunit.Thecontrolunitandtheelectrohydrauliccontrolunit areconnectedviaasolenoiddrivermodule.Theconnectingcables requiredforthisareincludedinthedeliveryofthePMC®-Rcontrol. Formoredetailsonhowtoconnectthecontrolunit,pleasereferto theseparateoperatingmanualforthePMC®-Rcontrol.Anoverviewofthedesignofthecontrolisalsogiveninchapter6ofthis operatingmanualinthesection“Shieldcontrol system”.

Theshieldunitsaredesignedtoaccommodatetheinstallationof additionalequipmentwhichisnotincludedintheBucyrusscopeof delivery.Forexample:

J lightingsystem,

J two-wayintercomsystem.

Theinformationrequiredfortheinstallationofadditionalequipment canbefoundinthecorrespondingoperatingmanualfromtherespectivemanufacturer.

hydraulicsystem

additionalequipment

Requirementsforthefacehydraulicsystem

ThehydraulicmediummustmeetthefollowingconditionsforallhydraulicscomponentsincludedintheBucyrusscopeofdelivery: ContaminationClass18/14pursuanttoISO4406.

Pressurefluidsinaccordancewiththesection“Permissiblemedia” inchapter6ofthisoperatingmanual.

Nominalpressure:320bar

Tolerancerange: ± 10%ofnominalpressure

Ifthefacehydraulicsystemisdesignedsuchthatitisunstableor tooweak,therecouldbeatemporarypressuredropduringoperation.

Intheeventthatthepressurefallsto180barorless,thereisarisk ofmalfunctionsoccurringintheelectrohydrauliccontrolsystem. Valvefunctionsmightnotbeexecuted.Itmayevenresultinvalves startingtovibratewhichcouldleadtovalvedamage.

Caution

Ifthereisapressuredrop,dangeroussituationsmayarise, leadingtoaccidentsinvolvingdamagetopropertyand/orinjuriestopersonnel.

Makesurethatthesystempressurecanneverfallbelow 180baranywhereinthefacehydraulicsystem.

Commissioning

Warning!

Theinitialstart-upandthetestrunmayonlybecarriedoutby awell-trainedandexperiencedcrewfamiliarwiththespecial conditionsinundergroundmining,especiallywiththesafety requirements.Thecrewmustalsobewell-practicedinhandlingtheequipmentandbefamiliarwiththecontentofthe associatedoperatingmanuals.

Notice!

Makesurethatalltransportsafetydevicesrequiredfortransporthavebeenremoved. Seechapter3,section“Transport”.

Tobeobservedpriortostart-up

Commissioningmayonlybecarriedoutbytrainedandqualified personnel.Ifthesupportisbeingusedforthefirsttime,itisabsolutelyimperativethatthecommissioningbecarriedoutunderthe directionoftheBucyrusinstallationservice.

Pleaseobservethefollowingitems:

J Mechanical:

. Makesurethatalltransportsafetydeviceshavebeenremoved.

. Positionthesymbolbaronthebracketsoftheelectrohydraulic controlunitsothatthesymbolsareclearlylegible.

. Checkallmechanicalconnectionsontheshieldunits.

. Checktheplug-inconnectionsontherelaybarassembly. Whentherelaybarassemblyisdesignedwithaplug-incrawl pan,itmustbemadesurethatitispluggedincorrectly.Under nocircumstancesmaythecrawlpanbepluggedinfornormal operationinthe“loweringposition” 1) .

J Hydraulicsystem:

. Checktheentirehydraulicsystemforleaks.Sealanyleaky connectionsimmediately.

. Especiallycheckwhetherhingesandhosescanbedamaged duetomovementsofthesupport.

Danger!

Damagedhosescanburstandhydraulicfluidcanescapeunderhighpressure.

Asaresult,youorotherscouldbeseriouslyinjuredoreven killed.

Makesurethathydraulichosescan'tbedamagedbymovementsofthesupport.

Laythehydraulichosescorrectlybehindthebracketsprovided forthem.

1)Maximumpossibleplugging.

. Checkthehydraulicsupplypressure.

. Checktheload-carryingfunctionoftheprops.Thecurrent pressureunderthepistonofapropcanbequeriedonthe PMC®-Rcontrolunit.Here,youcanquerythepressurefora neighboringsupportorthesupportinwhichyouarecurrently located.Thepressuregaugeonthepropcontrolvalveofthe propindicatesthepressuredirectly.

. Checkalloperationelementstomakesuretheyareworking properly.Testwhetherthefunctioniscorrectlyexecutedwhen thecorrespondingoperatingelementisactivated.

J Signalingandlightingsystems,informationplates:

Important!

Forfurtherinformation,pleaseseethecorrespondingseparate operatingmanualfromtherespectivemanufacturer.

. Checkallsignalingsystems.

. Makesurethatthefacelightingissufficient.

. Checkwhetherthefacearea,especiallythetravelway,issufficientlymarkedwithsigns.Itisimperativethatyouobservethe regulationsoftheresponsibleminesinspectorate.

J EMERGENCYSTOPsystems:

. CheckthatallEMERGENCYSTOPsystemsfunctionproperly.

J Miningandconveying:

. Beforecommissioning,checkallfunctionsofthefacesystem.

. Testtomakesuretheentirefacesystem(mining equipment, conveyingsystem,supports)isworkingtogetherperfectly.

Warning!

Bentsupportcanopiesmaynotprojectintotheminingarea.

Anticorrosionprotectionofhydrauliccomponents

Howtoputthesupportintooperation

Movetheshieldunitstotheiroriginalpositions,i.e.:

J shieldsandconveyorsarealignedinastraightline, J theshieldsarealignedatrightanglestotheconveyor, J theshieldcanopiesarealignedparalleltothefloor.

Checkthesupportforanyinstallationerrorsorothersourcesof error:

. Checkalllineconnectionsmadeduringtheinstallationofthe shields,especiallyallsupplylinesoftheshieldhydraulics, forcompletenessandcorrectness.

Warning!

Shut-offvalvesmustnotbeinstalledintothereturnlinesfor theshieldhydraulicsasotherwiseadangerouslyhighpressuremaybuildupwhichcould,forexample,causehoselines toburst.

Thismayresultinpersonsbeingseriouslyinjuredoreven killed.

. Checkthefunctionofthehydraulicandwatersupplyforthe face.

. Checkallfunctionsoftheshieldcontrolunit.

Donotallowthesupporttobeoperateduntilalldeficiencieshave beeneliminatedandthesupporthasbeenfoundtobeinperfect workingorder.

Anticorrosionprotectionofhydraulic components

TheBucyrushydrauliccomponentsaretestedbeforedeliverywith ananticorrosionmedium.

Whenthesecomponentsareputintooperation,nospecialmeasureshavetobetakenwithregardtoanticorrosionprotectionsince thetestingandanticorrosionmediumusediscompletelycompatiblewiththeapprovedoperationfluidsofthegroupHFA.Seesection“Permissiblemedia”inchapter6ofthisoperatingmanual.

Operation

Thischapterprovidesgeneralinformationontheoperationand maintenanceoftheshields.Thisinformationistoberegardedas preparationfororadditiontohands-ontraining.Itisrecommended thatyoureadthischapterasasupplementtothetraining,butthis innowayreleasestheoperatorfromparticipatinginthetraining.

Danger!

Youareonlyallowedtooperatetheshieldcontrolsystemif youhaveextensiveknowledgeofthecontrolelementsandof thewaythecontrolworks.Youmusthavehadinstructionon theactualcontrolandhaveconsolidatedyourknowledgeduringacorrespondinghands-ontraining session.Shouldthisnot bethecase,youarenotallowedtooperatethecontrol!Inform yoursuperiorimmediatelyandrequesttherequiredtraining.

Warning!

Ignoringthesafetyregulationswillcause accidentsandmay resultinseriousbodilyinjuriesordeath.

Theregulationsconcerningthesafeoperationofyourmine mustbestrictlyfollowed.Applythefollowinginstructionsin additiontoandinaccordancewiththeindividualsafetyregulationsofthemine.

Requirements Operatingconditions

Thefacecrewmustbeinformedaboutpossiblehazards.The safetymeasurestobetakenmustbelaiddowninwritingandmust bemadeknowntothefacecrew.

Thefacecrewmustbeinstructedtostopthefaceconveyorimmediatelyifdangeroussituationscouldariseduetolargelayersof coalandrockhavingfallenontotheconveyor.Thisalsoappliesin thecaseofaccumulationsofdebris.

Thefacemustbesufficientlyilluminated.

Towarnthefacecrewandforcrewcommunication,intercommunicationsystemsmustbeprovided.

Thefaceconveyormustbeequippedwithastart-upwarning systemandashutdownandlock-outdevice.

Largelayersofcoalandrockmustnotbebrokenupunlessthe faceconveyorandtheminingequipmentareatastandstill.They mustbebrokenuptosuchanextentthatthefreepassageofcrude oreundertheshieldcanopiesisensured.Compressed-airpicks havetobekeptonhandforthispurpose.

Intheeventthatthisbreakingupcannotbeaccomplishedtothe extentrequired,thelayersofcoalandrockmaynotbetransported untilitishasbeenensuredthatnobodywillendangeredasaresult. Anyworkonthefacemustbestoppeduntilthetransportofthe rockandcoallayershasbeencompleted.

BucyrusEuropeGmbH,Lünen2009

facecrew

faceequipment

conveyoroverload

Theminimumdimensionsforthetravelwayspecifiedmustbe maintainedatalltimes.

IntheFederalRepublicofGermany,thefollowingvaluesapplywith respecttotheminimumdimensionsofthetravelway:

Width:600mm

Height:400mm

IfthesupportisusedincountriesotherthantheFederalRepublic ofGermany,therespectiveregulationsapplicableinthosecountriesmustbeobserved.

Debrisorobjectslyinginthetravelwaymustberemovedimmediately.Thisappliesparticularlyforlowseamheights.

Ifvariable-lengthcrawlpansareused,carehastobetakenthata safetravelwayofadequatewidthismaintained.

Iftheheightofthetravelwayisrestrictedbytheuseofadditional equipment,e.g.forconveyorsteeringdevices,carehastobetaken thatasafetravelwayofadequateheightismaintained.

Iftheareabehindthefrontpropsistobeusedasatravelway, e.g.incasesofthickseams,inthepresenceofsteeplyinclined facesoriftheshieldsupportcanbeadvanceduptotheconveyor, thentravelwaymustbemarkedattheendsofalongwallbyasign.

Roofsupportworkmustbecarriedoutsothatthefillingsectionof thefaceconveyorremainsunobstructed.Thismeansthatthe shieldcanopiesoftheshieldunitsmustbesetagainsttheroofimmediatelyaftertheshieldunithasbeenloweredandadvanced.

Workintheminingareamustnotbecarriedoutunlessthemining equipmentandthefaceconveyorhavefirstbeenlocked-outand securedtopreventrestarting.Workintheminingareamayonlybe carriedoutfromasafeposition.

Theconveyorandthespaceabovetheconveyormayonlybe enterediftheroofhasbeensecuredagainstfallingrock. Inthickseams,thecoalfacemustalsobeprotectedagainstslabbingintheseplaces.Onfacesequippedwithshieldsupports,this isbestdonebyusingflippers.

Caremustbetakenthattheflippersarealwaysextendedtowards thecoalfacefarenoughtoachievethedesiredprotection.This doesnotapplywhenshieldunitsareadvancing.

Iftheshieldunitsarenotequippedwithaflipper,someotherkind ofprotectionmustbeappliedtoshieldtheminingareafromtherest oftheface,e.g.extra-highspillplates,wiremesh,netsorthelike.

Workwhichhastobeperformedintheimmediatevicinityofthe faceconveyoratorabovethespillplatesmayalsoonlybecarried outaftertheplaceofworkhasbeensecuredagainstfallingrock andcoallayers.

Withinclinedfaces,additionalbarricades,suchasaircushions, mustbesetupabovetheworkareaintheconveyortoprotect againstthefollowingmaterial.Thedesignandamountofrequired safetyequipmentdependsonthelocalconditions.

travelway

roof supportwork

workintheminingarea

Beforeyoustartworkonthehydraulicsystem,youmustalways firstmakesurethattherespectivesectionofthesystemhas been depressurized.Also,takeappropriatemeasurestopreventthe pressurefrombeingreactivatedbyunauthorizedpersonnel.

Iftheshieldunitsaretobedetachedfromtheconveyor,mining musteitherbecompletelystoppedoritmustbeotherwiseensured thatminingcanbecontinuedonlyoutsideofthesafetyzonerequiredforsafelycarryingoutrepairwork.

Partswhichareundermechanicalorhydraulicpretensionmustbe relievedbeforetheycanbereleasedordismantled.Thepretension canberelieved,forexample,byaligning,lifting,orlowering.

If,inexceptionalcases,thepretensioncannotberelievedcompletely,itmustbereducedasfaraspossible,andtherespective partmustbesecuredbysuitablemeans,suchaschainsorlocking elements,sothatthetensioncanbesafelyabsorbedasitisreleased.Allworkinthisareamayonlybecarriedoutfromasafeposition.

Safetyequipmentincreasessecurityandmayonlyberemovedifit isrequiredforcarryingoutwork.Thesafetyequipmentshouldbe reinstalledimmediatelyfollowingcompletionofthework.

Thewatersprayingsystemservestoactivelycounteractdust.Usuallyseveralnozzlesareattachedtotheshieldsupport,through whichwatercanbesprayedasneeded.Thewaterspraying system isactivatedonlytemporarily,dependingontheoperatingstateof thesystem,forexample,whenpushingtheshieldandwhenthe miningequipmentpassesthesupport.Thesprayingvalvesare controlledbytheprogramoftheelectronicshieldcontrolsystemor directlybymeansofthehydraulicshieldcontrol system.

Onaninclinedface,theconveyormustbeanchoredoppositethe support,ifnecessary.Thisway,youcanpreventtheconveyorfrom shiftingtothesidewithrespecttothesupport.Thisallowsyouto reducetheriskthattherelaybarassemblywillgetstuckinthe baseframe.

Theintendedworkingpressuremustalwaysbeappliedtothehydraulicconveyorsteeringdevice.Thisistheonlywaytoguarantee thattherewillbesufficientbracingbetweenthesupportandconveyor.

Whenadvancingtheshields,youmustalwayscomplywiththespecifiedsequenceofsteps.Otherwise,theconveyorsteeringdevice canbecomedamagedandunfitforuse.

watersprayingsystem

conveyorsteeringdevice

Safetyrequirements

Exercisespecialcareandcautionwhentravelingafaceworkingin automaticmode.Makesureyouobservethewarningsattheface entryandtherespectivesafetyregulationsofthemine.

Youmustalwaysbeawarethattheshieldwhichyouareiniscontrolledbytheautomaticsystem.Forthisreason,makesureyouobservetheacousticandvisualwarningsfromtheelectroniccontrol unitofthecurrentlycontrolledshield.

Pressthe“Supportlock-out”switchifyouhavetobeintheshield foralongerperiodoftime.

Theshieldunitmustalwaysbeoperatedfromasafepositionand fromaneighboringshieldunit.

Neverstandinashieldunitwhichhasn'tbeenset.

Neverallowbodypartstogetbetweenthecanopyandtheroof, basesandthefloor,thebaseandrelaybarassemblyorbetween thesidesealsofneighboringshieldunits!

Duringmanualoperation,theoperatormustalwayskeepaneyeon themovementrangeoftheshieldunitbeforeandwhilethesupport isbeingmoved,andpreventanyhazardsbyactingwithcaution.

Noonemaybeinashieldunitwhileitisbeingadvanced.

Youmaynotloweroradvanceashieldunitifthereisanypersonin thevicinityoftheshieldunitorintheshieldunit.

Youmustnotloweroradvanceashieldunitmanuallyifthemining equipmentisdirectlyinfrontoforintherangeofactionofthesupport.

Advancingshouldbestartedinthelowersectioninthecaseofinclinedfaces.Theneighboringcontrolofferstheoperatorinthe above-lyingshieldunitprotectionandallowstheshieldunitbeing pulleduptobemonitored.

Thepropsoftheshieldunitsmustalwaysbesetuntilthesetting pressureisreachedinordertoachievegoodroofsupportandto ensuresufficientbracingbetweentheroofandthefloorforshield unitswithspecialfunctions,suchasthrustbearingsforconveyor steeringdevices.

Thesupportsmustbeadvancedassoonaspossibletopreventthe potentialdangerofrooffalls.

operatingtheshieldunit

Whentakingdownastepintheroof,ashieldcanopywhichis angleddownwardsmustnotgetinthewayofminingequipment passingby.

Beforeashieldunitcanbepulledup,theflippermustbecompletelyfoldedin.Undernocircumstancesmaythesupportbeadvancedagainstthecoalfacewiththeflipperextended.Failureto observethiscanleadtoseriousdamage,especiallytotheflipper cylindersandtheflippersuspension.

Whenadvancingthesupport,makesurethattheshieldcanopy doesn'tgetunderthesidesealofaneighboringshield.Theside sealoftheneighboringshieldcanotherwisebeseriouslydamaged. Takecaretoavoidincorrectoperationoftheshieldcontrol system. Thesymbolplatesonthecontrolunitsindicatethefunctionsofthe shieldcontrolsystem.Theyshouldbelegibleatalltimesandmay notberemovedordamaged.

Hosesmustremainfreetomove.Theymaynotbesqueezedor overstretched.Makesurethehoselinesarebundledproperly.

Damagedhydraulichosesandhoseconnectionsmustbereplaced immediately.Thisworkmayonlybecarriedoutbyskilledpersonnel.

Fig.17: Wrong,supportadvancedtoolate

Fig.18: Right,supportadvancedintime

control,hydraulicsystem

damage,replacementparts

Theshieldcanopyandcavingshieldmustbemechanicallysecured againstfallingwhenreplacinghoselinesbetweenpilotedcheck valvesandpropsorotherhydrauliccylinderslyingintheflowof force,suchasstabilizingcylindersoradjustingcylinders.Analogously,thisalsoappliesforworkonthehingesoftheshieldunit. Shutoffvalvesmustnotbeinstalledinthereturnlines.

Tomakesurethereturnlinescan'tbeclampedshut,safetyvalves mustbeinstalledinthereturnline(seehydrauliclayout,ifprepared byBucyrus).Ifthelayoutwaspreparedbytheoperator,werecommendsafetyvalvesbeinstalledat50mintervalsinthereturnline. Thevalvesshouldbesetto25barsprayedintheatmosphere.

Specialincidents,especiallyanyfounddeficienciesanddamage, mustbereportedimmediately.

Machineandhydraulicpartsmayonlybereplacedwithoriginal parts.

Operationoftheshieldsupport

Well-trainedoperatingpersonnel,knowledgeandcompliancewith thesafetyregulations,aswellastheoperatinginstructionslisted belowlargelypreventdangeroussituationsfromarising,andare goodpreconditionsforthefail-safeinteractionofthesupportand miningwithinthefacesystem.

Ifthesupportisequippedwithanelectrohydrauliccontrolunit,itis imperativethattheoperatorbefamiliarwiththeseparateoperating manualforthatcontrol.

Theshieldunitsmustalwaysbesetuntilthesettingpressurehas beenreachedinordertoachievegoodroofsupportandtoensure sufficientbracingbetweentheroofandthefloorforshieldunitswith specialfunctions,suchasthrustbearingsforanchoringdevices.

Ingeneral,thesupportsshouldbeadvancedtosupporttheexposedroofsurfaceasquicklyaspossible.

Theshieldunitsmustbealignedatrightanglestotheconveyor.

Theshieldunitsshouldalwaysbesetsothattheshieldcanopyand baseframearealignedasparalleltoeachotheraspossible.Within theframeworkofthemaximuminclinationandswivelanglesspecifiedonthetechnicaldatasheet,however,stepsontheroofcan beunderpinnedandstepsonthefloorcanbeovercomebybending theshieldcanopyaccordingly,ifrequiredbygeologicaloroperationalconditions.

Caution

Neverexceedthepermissibleangleofinclinationofthecanopy.

Exceedingthepermissibleangleofinclinationofthecanopy specifiedinthe“Technicaldata”sectionofchapter6canlead tothesupportbecomingdamaged.Thisespeciallyappliesfor stabilizingcylinders,whosefasteningelementsandfulcrum pointsareontheshieldcanopyandthe cavingshield.

Fig.19:Shieldsupportinnormalposition

Operationoftheshieldsupport

Caution

Neverextendorretractthestabilizingcylindersoftheshield supportcompletely!

Stabilizingcylindersmustalwayshavesufficientresidual stroke.

Guidevalue: atleast20mm.

Thesameappliestotheadjustingcylinderofthefrontcantilever.

Thisistheonlywaythatanypotential,suddenlyoccurringload surgescanbe“cushioned”bythehydraulicsafeguardofthestabilizingcylinders.

Ifthereisn'tsufficientresidualstrokeavailable,thiscouldresultin seriousdamagetothesupportunderunfavorableconditions-high forceandunfavorableleverratio.

Fig.20:Shieldsupportwithextremelyinclinedshieldcanopy.

M 

1 s 1

M

2

2

M=heightofthesetshieldsupport

 =angleofinclinationofthecanopy

Caution

BucyrusEuropeGmbH,Lünen2009 E BI622820

Thisisespeciallytrueiftheshieldcontrolsystemis equippedwith an automaticpositivesettingfunction.Thenthereisadangerthat underunfavorableconditions,forexampleasoftfloorandpossibly anadditionalinclinationtowardrooffalls,theautomaticpositivesettingfunctioncouldleadtothestabilizingcylindersnothaving enoughresidualstrokeorthattheyevenarecompletelyextended. Therefore,insuchorsimilarcases,movethesupportwithout automaticpositivesetting.

Caution

Keepthecanopyfrombeing excessivelyinclinedbyfillingout therooffalls,forexample,orby underpinningsmallerroof fallswithahorizontallypositionedshield. Atthispoint,weagainexplicitlyemphasizethatanydamage causedbynotcomplyingwiththeseinstructionsisnot coveredbythewarranty.

Caution

Ifthepermissibleangleofinclinationofthecanopy(angle betweentheshieldcanopyand cavingshield),whichisspecifiedinchapter6,section“Technicaldata”,isexceeded,this couldleadtodamagetoprops,hydrauliccylindersandtheir fasteningelements,aswellastotheparthinges.

Sinceanglechangesintheendsoftheshieldcanopiesorbase endsinvolvemajorheightchanges,thenecessityoftakingappropriatecountermeasurescanberecognizedatanearlystage,even withoutameasuringinstrument.Forinstance,itmaybenecessary toripandleveloffstepsintheminefloorandroof,orfillrooffalls. Shieldcanopiesoftwo-propshieldswithstabilizingcylindersmay never besetwiththetipofthecanopyinbreakouts(seeFig.21), whenthestabilizingcylinderiscompletelyextended.Theremustalwaysbeenoughresidualstrokeavailablesothatdynamicloads fromtheroofcanbeabsorbedbythehydraulicallysecuredstabilizingcylinder.

stabilizingcylinderisextended.

Rooffallscanbeovercomebyfillingthem(seeFig.22)orbysettingtheshieldcanopieshorizontally.Thiswillunderpintheroofin thenextstep.

Fig.21: Wrong:donotsetthetipofthecanopyintherooffallwhenthe

rangeofadjustmentofthe support/ changingfacethickness

Whenunderpinningastepintheroof,ensurethatashieldcanopy angleddownwarddoesn'tgetinthewayoftheminingequipment passingby.

Accumulationontheshieldcanopycanbeavoidedbygrinding whileadvancingthecanopyalongtheroof.Insomecases,the pilescanalsobeguidedintotheconveyorbybrieflyloweringthetip ofthecanopy.

Theretractedheightoftheshieldunitsmustbesuitableforthelowestseamheight.

Thesupportmustbeoperatedsothatthereisalwayssufficientresidualstrokeremainingforloweringtheshieldunit.Otherwise,the shieldunitcangetstuckbetweentheroofandfloorandbeseriouslydamagedbysuddenlyoccurringloadsurges,causedbya rockburst,forexample.Loadsurgescannotbehydraulicallycushionedifthereisnotsufficienthydraulicfluidunderthepistonofthe proporifitisalreadyinthelowerendposition.

Theminimumresidualstrokerequiredforloweringtheshieldunit canbemaintainedby:

J keepingthelongwallopeningsufficientlylargeusingthemining equipment,

J avoidingtheaccumulationofdebrisandfinecoalonthefloor,

J removingaccumulatedpilesofrockontheshieldcanopies.

Beforeadvancingashieldunit,thefloorshouldbefreeofrough debrissothattheentireforwardmovementcanbedonewithout obstaclesandthesubsequentreturnoperationisn'thinderedforthe conveyor.Also,aligningoperationscanbecarriedoutmoreeasily.

Iftheseamheightincreasesconsiderablyandthehydraulicstroke isnotsufficient,thepropsmustbeextendedintimeorreplacedby propswithgreaterstroke.Here,onlyapprovedpartscanbeused.

Whenthepropsareextendedorshortened,theshieldcanopymust besecurelysupported.Beforeapropcanbeloweredforthepurposeofdismantling,itmustbesecuredagainsttippingover.

Fig.22: Right:filloutrooffalls

Especiallywhenoperatingoninclines,theshieldunitsmustbepreventedfromslippingandjammingbycorrectingtheiralignmentin timebyusingsidesealsandaligningdevices.Thispreventsa shieldcanopyfromunderpinningitsneighboringunit,oftencausing considerabledamage.

Since,inoperationswherethereareinclines,theshieldunitadvanceusuallybeginsinthelower-lyingpartoftheface,itisimportantthatthefaceendshieldsarewell-aligned.Usuallyhydraulicend supportsandaligningdevicesareusedontheshieldcanopiesand thebaseframeorbetweenthebaseframeandshieldcanopies.

Automaticcontrolscanbeusedforthesidesealswhichpreventa loweredshieldunitfromtippingoverduringtheadvancingoperation.Otheraligningoperationswhichmightbenecessaryareonly possibleusingmanualcontrol,however.

Thesidesealofthecavingshieldmustonlybeusedforaligning withrespecttotheneighboringshieldwhenthatshieldhasbeen alignedtothesameextent.

Onaninclinedface,theconveyormustbeanchoredagainstthe support.Thisway,youcanpreventtheconveyorfromshiftingto thesidewithrespecttothesupport.Thiswayyoulessenthedangerofjammingtherelaybarassemblyinthebaseframe,which wouldhindertheshieldadvancing.

Whenadvancingtheshields,youmustalwayscomplywiththespecifiedsequenceofsteps.Otherwise,theconveyorsteeringdevice canbecomedamagedandunfitforuse.Furtherinformationcanbe foundinchapter6,inthe“Accessories”section,orintheoperating manualfortheconveyorsteeringdevice.

Inthecaseofunfavorablefloorconditions,thebaseframeofthe shieldunitcansinkintothefloor.Thenthebaseframemustbeliftedwhentheshieldispulledupsothatthesystemfollowsthe courseoftheseamanddoesn'tsinkintothefloor.

Forshieldunitswhichareequippedwithaspecialhydrauliclifting device,thebaseframeisliftedoutbyactuatingavalve,orautomaticallyduringadvancing.

Forshieldunitswithoutaliftingdevice,theprocedureisdifferent, dependingonthedesignmodel:

J Individualbasesontwo-propshieldscanusuallybeliftedhydraulicallybyactivelyretractingaprop

J Shieldunitswithundividedbaseframesmustbeliftedandsupportedusingstandardminingmethods.

Important!

Familiaritywiththecircuitdiagramandskilledpersonnelare requiredforbothprocedures.Makesurethatyouobservethe safetyregulationsunderallcircumstances.

Worksafety

Forthepurposeofsafeoperation,thesupportsareequippedwitha neighboringcontrol.Thismeansthatthesupportfunctionsareoperatedusingthecontrolunitontherightorleftneighboringsupport orwiththeautomaticsequentialphasecontrol system.

Warning!

Neverbeonasupportwhichiscurrentlybeingmoved.Circumstanceswhicharenotalwaysapparentmayleadtounexpected movementsintheshieldunit.Thiscouldresultinseriousinjuryorevendeath.

Forexample,theshieldcanopymayjerkfreeduringloweringif itwasstuckbetweenthecanopiesoftheneighboringshields.

Caution

Takecarenottodamagethepilotvalvebuttons.Stickingbuttonsmightleadtomalfunctionsandcauseanaccident.

Observethefollowingsafetyregulations:

Makesurethatyourbodyiscompletelyunderasetshield.Keep awayfromshieldswhichareintheprocessofbeingmovedor whicharetobemovedsoon.

Ifgroupsofshieldsareautomaticallyadvanced,noonemaybein theareabetweentheoperatorandthemovedshield.

Observethefollowinginstructionsifasupporthasfailedtoadvance:

1.Determinethecause.Checkthefollowingpossibilities: J malfunctionoftheelectroniccontrols, J externalobstructions:

–Shieldiswedgedinbetweentheneighboringshields.

–Tipofthecanopyisstuckintheroof.

–Floorstepordebrisisblockingthebase.

2.Iftheautomaticfunctionoftheelectroniccontrolsystemisnot workingproperly,thesupportcanbemanuallycontrolledfromthe electroniccontrolunitofaneighboringshield,usingtheindividual control.Seetheseparateoperatingmanualfortheelectroniccontrolsystem.

3.Ifthecauseisanexternalobstruction,trytogettheshieldfree bymanuallymovingtheneighboringshields.

Operationoftheshieldhydraulics

Warning!

Duringnormaloperation,thesupportmayonlybemovedby meansofthecontrolunitoftheelectrohydraulicneighboring controlsystem.Alwaysobservetheinstructionsinthecontrol unit'sseparateoperatingmanual.

Arrangementofhydrauliccomponentsonthesupport Thefollowingtableindicatesthehydrauliccomponentsforthesupport.

opyonthesprayingvalve(19)

hydrauliccontrolunit,behindthe HPballvalve(34)

Tab.6:Hydrauliccomponents

Operationoftheshieldhydraulics

FunctionsoftheHPballvalves

Thefollowingballvalvesareopenduringnormaloperation: J 30,34

Thefollowingballvalvesareclosedduringnormaloperation: J 32

30 Blue HPballvalveDN10

32 Red HPballvalveDN12

34 Red HPballvalveDN25

Interruptsthewaterfeedto thewatersprayingsystem

Pressuresupplyduring start-upandforauxiliary devices

Isusedforblockingthe pressuresupplylinetothe shield

Preventsthewaterfeedtothewatersprayingsystem

Formovingtheshieldduringstartupandforconnectinghydraulicallyoperatedauxiliarydevices

Duringmaintenanceandrepair workontheshield

Shieldsupport550/1650-2X1414-1500

Tab.7:HPballvalves

Fig.23:HPballvalve,shownopenedandclosed open closed

Through-flowformediumenabled

Through-flowformediumstopped

Fig.25:Functionsof theelectrohydrauliccontrolunit,symbolplates

Operationoftheshieldhydraulics

9*protectivehoseDN25-1600

10*protectivehoseDN32-1500,gr.

11*protectivehoseDN50-1500

Shieldsupport550/1650-2X1414-1500

Fig.27:Hydrauliclines

Shieldcomponents

Fig.28:Shield,sideview

1electrohydrauliccontrolunit

12PRV(80bar)inthereturnline

13supplyblock

16plugDN10withpressurerelief

30HPballvalveDN10,forwater sprayingsystem

32HPballvalveDN12,forauxiliary supply

34HPballvalveDN25,inthepressuresupplyline

apressureline,auxiliarysupply breturnline,auxiliarysupply cplugonchainforauxiliarysupply dsolenoiddrivermodule eiconbar

Ppressureline,DN25

Rreturnline,DN32

W1waterline,DN50

W2waterline,DN20

Fig.30: Viewof thesupplyblockandtheauxiliaryconnections (supplylinesshort-circuitedfortransport)

Checkvalve,pilotedforstabilizingcylinder

Fig.32:ViewofthepilotedCVforstabilizingcylinder

Controlunits

Forevery3faceshields,onePMC®-Rcontroldeviceand2support lock-outswitchesareprovided.ThePMC®-Risplacedonthe middleshieldhere.Thetwoneighboringshieldsofthisgrouphave asupportlock-outswitch.

Important!

EverythirdshieldisequippedwithaPMC®-Rcontrolunit.The othertwoshieldsaregivenasupportlock-outswitch.

Fig.34:ControldevicePMC®-Rinthemiddleshieldofagroup

Fig.35:Supportlock-outswitches,eachinoutershieldofagroup

Fig.36:Viewoftheelectrohydrauliccontrolunit

Fig.37:Left-handprop,viewfromthefaceside

Fig.38:Right-handprop,viewfromthefaceside

Operationoftheshieldhydraulics

Plugwithpressurerelief

Viaapressurereliefvalve,theenclosedpressurecanberelieved by screwingin theventedcapscrew. Afterrelievingthepressure,thisscrewmustbescrewedalltheway outagain.

Openpressurerelief: screwinscrew

Closepressurerelief: screwoutscrew

Important!

Checktheporosityofthesealingring(13)regularly.Justto makesure,youcancovertheringwitharagtopreventhydraulicfluidfromsprayingout.

TheshieldisequippedwithaplugDN10withventedcapscrew.

Theplug(a)withpressurerelieflocatedonthesupplyblockisfor reducinganypressurethatmayariseinthereturnline.Thiscanbe necessary,e.g.whenthesupplylineconnectionshavebeenclosed offfortransportandincreasedpressurehasbuiltupinthereturn lineduringinstallation.

Fig.40:Viewofthesupplyblock

22supplyblock aplugDN10withpressurerelief

Repairandemergencyoperation

Thissectioncontainsinformationonthefunctionsandoperationof thehydrauliccontrolsystem,whichmayonlybeusedinexceptionalcasessuchasforrepairandemergencies.

Inthefollowing,itisassumedthattheshieldhasalreadybeencorrectlyinstalled.Itisalsoassumedthatallshutoffvalvesareopen asduringnormaloperation.

Operationofthecontrolunitoftheelectroniccontrolsystemis not describedhere,butinaseparateoperatingmanualforthecontrol unit.

Furthermore,itisassumedthatthereaderisfamiliarwiththefundamentalprinciplesofthehydraulicshieldsupportandtheoperationofthecontrolunit.

Warning!

Theactuatorsontheelectrohydrauliccontrolunitshouldonly beusedinanemergencyandforrepairworkandonlyinaccordancewiththespecialoperatinginstructionsofthemining company.Duringnormaloperationtheyshouldnotbeused. Otherwise,dangeroussituationscouldarisewhichcouldresult inveryseriousinjury.

Caution

Theshieldsupportisoperatedinnormaloperation exclusively bymeansoftheelectroniccontrolsystem.Itisimperativethat youobservetheinstructionsinthecontrolunit'sseparateoperatingmanual.

Fig.34aboveshowsthelayoutofthePMC®-Rcontroldeviceand theelectrohydrauliccontrolunitonthesupport.

OperationofthePMC®-Rcontrolunitisnotdescribedinthisoperatingmanual.Forinformationonthis,pleaserefertotheseparate operatingmanualforthePMC®-Rcontrolunit.

Symbolplate

Thesymbolplateislocatedabovethepilotvalvesontheelectrohydrauliccontrolunit.Thesymbolscorrespondtothevariousfunctionswhichareinitiatedbyactuatingtherespectivebutton.The meaningofthesymbolsandfunctionsaredescribedbelow.

Fig.41:Symbolplateforelectrohydrauliccontrolunitwith8functions

Operationandfunctionsoftheelectrohydraulic controlunit

Thissectionprovidesinformationonthefunctionsoftheelectrohydrauliccontrolunit.Alwaysobservetheinstructionscontainedin theoperatingmanualsoftheelectrohydrauliccontrolunitandthe electroniccontrolunit.

Warning!

Youareonlyallowedtooperatethecontrolsoftheelectrohydrauliccontrolunitwhenyouknowexactlywhateffectsthe functionshavewithrespecttotheshieldsupport.Youmust haveattendedaspecialtrainingcoursetothispurpose.Otherwise,thereisariskofoperatingerrors.Thiscouldresultin seriousinjuryandevenfatalaccidents.

Controllingtheshieldsduringrepairoperationisespeciallydangerousbecauseyouarethenoperatingtheshielddirectlyandimmediatelyunderwhereyouarestanding.Itisthereforeextremelyimportantthatyouknowandunderstandtheinterrelationships betweenthefunctionsandmovementsoftheshield.

Whileactuatingtheshieldusingrepairmode,nootherpersonsmay standintheshield'sareaofmovement.

Therearetwopushbuttonsonthecoverofeachindividualpilot solenoidvalve.Whenyoupressabutton,thecorrespondingwork valveisoperatedimmediately.

Thefunctionstopsassoonasyoureleasethebutton.

Danger!

Jammedorlockedbuttonscancauseuncontrolledmovements oftheshield.Thiscouldseriouslyinjureorkillyou. Forthisreasonneverlockthebuttonsandensurethatdamagedpilotvalvesarereplacedimmediately.

Warning!

Manualactuationofabuttonononeofthepilotvalvesinitiates thedirectexecutionofthecorrespondingfunction.Dependenciesbetweentheindividualfunctionsarenottakenintoaccount.Dangeroussituationscouldariseiffunctionalsequencesareinitiatedinanincorrectorder.Forexample,the function “advanceshield” canbeactivatedwithoutpreviously activatingthefunctions “retractsideseal” and “activelylower support”.Thiscancausedangeroussituationswhichcanresultinveryseriousinjuries.

Advanceshield

Beforethisfunctioncanbeperformed,function3“Prop,retracton theright”andfunction4“Prop,retractontheleft”mustbecarried out.

Thefunctionisexecutedaslongasthebuttonispresseduntil thereisabalanceofforcesoruntiltheendpositionisreached. Aslongasthefunctionisactivated,thepilotedcheckvalve(14), whichhydraulicallyshutsofftheannularspaceoftheshiftingram, isopenedautomatically.

Setprops

Beforethisfunctionisactuated,theshieldcanopymustbecorrectlyaligned.Thefunctionisexecutedaslongasthebuttonis presseduntilthereisabalanceofforcesoruntiltheendpositionis reached.

Prop,retractontheright

Beforeinitiatingthisfunction,itmustbemadesurethattheneighboringshieldsarecompletelyset.

Thefunctionisexecutedaslongasthebuttonispressedoruntil theendpositionisreached.

Prop,retractontheleft

Beforeinitiatingthisfunction,itmustbemadesurethattheneighboringshieldsarecompletelyset.

Thefunctionisexecutedaslongasthebuttonispressedoruntil theendpositionisreached.

Important!

Formoredetailedinstructionsconcerningthefunctions “Lowerprops”and“Setprops”,consultthe“Conveyorsteeringdevice”operatinginstructions.

Advanceconveyor

Beforeinitiatingthisfunction,ensurethattheshieldunitiscompletelyset.

Thefunctionisexecutedaslongasthebuttonispresseduntil thereisabalanceofforcesoruntiltheendpositionisreached.

Extendstabilizingcylinder

Thefunctionliftsthetipofthecanopyandisforaligningthecanopy.Itisexecutedaslongasthebuttonispresseduntilthereisa balanceofforcesoruntiltheendpositionisreached.

Afterthecanopyhasbeencorrectlyaligned,thepropsmustbereset.

Caution

Donotexceedthepermissibleinclination!

Observethevalueforminimumresidualstroke.

Activatewatersprayingsystem

Thefunctionisexecutedaslongasthebuttonremainspressed.

Retractstabilizingcylinder

Beforeinitiatingthisfunction,itmustbemadesurethattheneighboringshieldsarecompletelyset.

Thefunctionlowersthetipofthecanopyandisforaligningthe canopy.Itisexecutedaslongasthebuttonispressedoruntilthe endpositionisreached.

Afterthecanopyhasbeencorrectlyaligned,thepropsmustbereset.

Caution

Donotexceedthepermissibleinclination! Observethevalueforminimumresidualstroke.

electroniccontrolsystem

hydrauliccontrolsystem

oneweekafterstart-up

Maintenance Warning!

Ifoperationalsafetyisendangered,damagedcomponents mustbereplacedimmediately.Ifthisisnotpossible,youmust immediatelyshutdowntheshieldandsecureit.Immediately notifytheentirefacecrewandyoursuperiors.

RefertotheseparateoriginaloperatingmanualforthePMC®-R controlunit.

Specialmeasures

Nolaterthanoneweekafterstart-up,thefiltercartridgesonthe electrohydrauliccontrolunitsoftheshieldcontrolsystemintheentirefacemustbespotcheckedforcontamination.Ifinspectionindicatesthattheprobabilityofmalfunctionscausedbycontaminated filterelementsishigh,allfiltercartridgesalongthefacemustbereplaced.

Afterextensiveworkonthehydraulicssystemorafterthestart-up ofanewface,thereisanincreasedriskofdirthavingfounditsway intothehydraulicssystem.Dependingonthedegreeofcontamination,thiscancausethefiltercartridgesinthe systemtobecome clogged.Asaresult,itispossiblethatfunctionsrunslowlyoreven cannolongerbecarriedout.Wethereforerecommendthatthe measuresoutlinedabovebetakeninordertoavoidmalfunctionsin theoperationoftheshieldhydraulics.

filtercartridges

Thefiltercartridgesonthesupplyblockandontheelectrohydraulic controlunitoftheshieldcontrolsystemprotectthedownstreamhydrauliccomponentsagainstdamagecausedbycontaminantsinthe hydraulicmedium.Theseonlyhavetoberegularlyreplacedifthe filteringsystemofthefacesupplyunitisinadequate.

Therefore,itisveryimportanttoensuretherequiredhydraulicmediumquality.

Ifproblemsoccurinthepreparationofthehydraulicmedium,there willbeanincreasedriskoffailuresduetocloggedfilters.Additional measuresmaybenecessarytoensurereliableandsafeoperation. Forexample,thefiltersdescribedaboveshouldbespot-checked regularlyforcontamination.Ifnecessarythefiltercartridgesmust bereplacedregularlyasaprecautionarymeasure.

replacingfilters

Thetimeintervalsbetweenmandatoryfilterreplacementsdepends onthedegreeofcontaminationinthewaterand/oroftheemulsion (HFAfluid)usedandmustthereforebedeterminedonacase-bycasebasis.Cloggedfiltersmaybethereasonthatfunctionsstartto slowdownorevenreachapointwheretheycannolongerbecarriedout.

Werecommend:

waterfilters

doublefilter, canbebackflushed

J Replacethewaterfiltersdirectly.

J Backflush doublefilters(bothfilters)regularlyoncepershift.

Thepistonrodsofcylinders,whichareusuallyonlyrarelyextended andretractedcompletely,forexamplepropsandstabilizingcylinders,mustbethoroughlycleanedevery6monthsandthentreated withasuitablecorrosioninhibitoronallshieldswhichareequipped withawatersprayingsystem.

Allpressurereliefvalvesmustbesubjectedtoafunctionaltest atthelatestafteroneyearofoperation,orwhentheequipmentis movedtoanotherface.Ifitisnotpossibletokeepthisdeadlinebecausetheendofthesectionplannedtobeminedwillonlybe reachedshortlyafterthedeadline,thepressurereliefvalvescan, asanexception,becheckedaftertherespectivesectionhasbeen completed.

Pressurereliefvalveswhicharepretensionedwithgaspressure mustbeadditionallyspotcheckedatregularintervalstoensure theircorrectfunction.Werecommendsuchrandomsampleinspectionsatquarterlyintervals.

Allhigh-pressurehydraulichoselinesmustbereplacedirrespective ofanyvisibledamageatthelatestaftertwoyearsofoperationfor safetyreasonsandtoensurecorrectfunctionofthesystem.Ifthis deadlinecannotbemetbecausetheendthesectionplannedtobe minedwillonlybereachedshortlyafterthisdeadline,anditisimpossibletoreplacethehoselinesintheface,thenanexception canbemadeandthereplacementofthesehoselinescanwaituntil aftertherespectivesectionhasbeencompleted.

Dailymaintenance

. Checkallshieldsbyvisuallyinspectingthemforescaping hydraulicfluidatthefollowingpoints: –hoselines, –electrohydrauliccontrolunit, –valves, –props, –shiftingramandbaseliftcylinders(lifting), –hinge,alignmentandflippercylinders.

. Checkthepressuregaugesonthepropsforvisibledamage andcorrectfunction.

. Checkallshieldsbyvisuallyinspectingthemfordamagetothe steelstructure,forinstance: –ontherelaybarassembly, –onpinconnectionsandretainingdevices, –onthesideseal, –onbrackets,etc.

pistonrods

pressurerelief valves

highpressure hydraulichoses

hydraulicsystem

steelstructure

Weeklymaintenance

. Checkeachcontrolsystemforcorrectfunctioning.

. Replacedefectivecontrolsystemsorindividualcomponents immediately.

. Cleanthecontrolsystems,especiallythe operatingpanel.

Notice!

Itisimportantthatthecontrolsystemsymbolsbeeasily legible.Thispreventstheriskofoperationalerrorsandany resultingaccidents.

Everysixmonths

. Applyapreservativetothepistonrodsofthehydrauliccylinders.Furtherdetailsarecontainedinthischapterinthesection “Specialmeasures”.

Regular,scheduleddamageassessment

Werecommendkeepingarecordofanydamagefound.Therecordsshouldbeevaluatedregularly,forexampleeverymonth,and summarizedinadamagereport.Thiswillenableyoutodetectfrequentlyoccurringdamageandtakepreventativeaction.Thiswill heightensystemavailabilityandloweroperatingcostsaccordingly.

Troubleshooting

Instructionsfortroubleshooting

Theshieldhydraulicsofashieldunitconsistsofamultitudeofindividualcomponents.Thelinkingofthecomponentswitheachother isshowninthecircuitandhosediagramsfortheshieldhydraulics. Alsorefertothesection“Operatingtheshieldhydraulics”inthis chapterorthereplacementpartscatalog.

Functionalerrorscan,inprinciple,occurinallcomponents.Most faultsonhydraulicvalves,however,arecausedbyhydraulic bypassflows.Thesearenormallyaudibletotheoperator.

Thefollowinginformationisprovidedtoassistyouinthedetection andeliminationoffaults.

Warning!

Thereisaheightenedriskofaccidentswhenperforming troubleshootingworkonhydraulic systemsinparticular,malfunctionsinthehydraulicsystemandhydraulicmediumescapingathighpressurecancauseseriousinjury.

Therefore,takespecialcareandalwayswearthespecifiedprotectiveclothingandequipment.

Failuretocomplywiththeseinstructionscanresultinserious injury.

Faultlocalization

Possiblecause

Theshut-offvalvefortheshield supplyonthesupplyblockis closed.

Measurerequired

Opentheshutoffvalve!

Valvescanonlybeswitchedwhenthesupply lineisopen.

Theshieldcanopyisstuck betweentheneighboringsupports. Findthecause.Ifrequired,lowerneighboring supportsandaligntheminordertofreethe canopy.

Controlpistononthepropcontrol valveisn'tworking.

Checkwhetherthepressureissufficientto controlthevalve.Minimumapproximately 80bar.

Thepropcontrolvalvemaybedefective.

Damagedortrappedhoselines. Checkfordamagedorkinkedprophoselines. Replacethehoselinesifnecessary.Make surehosesarelaidproperly.

Propisdefective.

Checkthepropfordamageandleakage. Replacetheprop,ifnecessary.

Possiblecause

Theshut-offvalvefortheshield supplyonthesupplyblockis closed.

Theshieldcanopyisstuck betweentheneighboringsupports.

Thepressureofthehydraulicsupplyistoolow.

Controlpistononthepropcontrol valveisn'tworking.

Measurerequired

Opentheshutoffvalve!

Valvescanonlybeswitchedwhenthesupply lineisopen.

Findthecause.Ifrequired,lowerneighboring supportsandaligntheminordertofreethe canopy.

Checkwhether -thehydraulicsupplyisworkingproperly, -allshutoffvalvesareopen, -thesystempressureissufficient.

Checkwhetherthepressureissufficientto controlthevalve.Minimumapproximately 80bar.

Thepropcontrolvalvemaybedefective.

Damagedortrappedhoselines. Checkfordamagedorkinkedprophoselines. Replacethehoselinesifnecessary.Make surehosesarelaidproperly.

Propisdefective.

Checkthepropfordamageandleakage. Replacetheprop,ifnecessary.

Possiblecause

Theshut-offvalvefortheshield supplyonthesupplyblockis closed.

Thesupportisstuckbetweenthe neighboringsupports.

Steponrooforfloorblockingthe support.

Thepressureofthehydraulicsupplyistoolow.

Thecontrolpistononthepilot-operatedcheckvalvedoesnotwork.

Measurerequired

Opentheshutoffvalve!

Valvescanonlybeswitchedwhenthesupply lineisopen.

Findthecause.Ifrequired,lowerneighboring supportsandaligntheminordertofreethe support.

Lowercanopysufficientlytoclearthestepor liftthebase.

Checkwhether -thehydraulicsupplyisworkingproperly, -allshutoffvalvesareopen, -thesystempressureissufficient.

Checkwhetherthepressureissufficientto controlthevalve.Minimumapproximately 80bar.

Thepropcontrolvalvemaybedefective.

Damagedortrappedhoselines. Checkfordamagedorkinkedshiftingram hoselines.Replacethehoselinesifnecessary.Makesurehosesarelaidproperly. Shiftingramisdefective. Checkwhetherthe -shiftingramisdamaged

-thepilotedcheckvalveisworkingproperly Removehosefromtheconnectiononthepistonsideandexecutethe“Advanceconveyor” function.Ifpressurefluidescapes,replacethe shiftingram.

setpressureisnotreached / proppressuredropsagain aftersetting

Possiblecause

Measurerequired

Propcontrolvalveisdefective. Replacepropcontrolvalve.Continue troubleshootingifthepressurecontinuesto drop.

Propsaredamaged. Checkpropsfordamageandreplace,ifnecessary. Removehosefromproploweringconnection andcheckwhetherpressurefluidisescaping eventhoughthepropisnolongerbeingextended.Ifapplicable:pistonpackingdefective, replaceprop.

Pressurereliefvalvedefective. Monitorpressuredroponthepressuregauge. Ispressurefluidleakingfromthepressurereliefvalve?Ifso: Replacethepressurereliefvalveandretest thefunction.

canopycannot bepositioned

Possiblecause

Theshut-offvalvefortheshield supplyonthesupplyblockis closed.

Measurerequired

Opentheshutoffvalve!

Valvescanonlybeswitchedwhenthesupply lineisopen.

Theshieldcanopyisstuck betweentheneighboringsupports. Findthecause.Ifrequired,lowerneighboring supportsandaligntheminordertofreethe canopy.

Thepressureofthehydraulicsupplyistoolow.

Checkwhether -thehydraulicsupplyisworkingproperly, -allshutoffvalvesareopen, -thesystempressureissufficient.

Pilotedcheckvalveisn'tworking. Checkwhetherthepressureforcontrollingthe valveissufficient.Minimumisabout80bar. Thecheckvalvemaybedefective.

Damagedortrappedhoselines. Checkfordamagedorkinkedprophoselines. Stabilizingcylinderisdefective. Checkstabilizingcylinderfordamageandexchange,ifnecessary.

canopycannotbelowered

Possiblecause

Theshut-offvalvefortheshield supplyonthesupplyblockis closed.

Measurerequired

Opentheshutoffvalve!

Valvescanonlybeswitchedwhenthesupply lineisopen.

Theshieldcanopyisstuck betweentheneighboringsupports. Findthecause.Ifrequired,lowerneighboring supportsandaligntheminordertofreethe canopy.

Thepressureofthehydraulicsupplyistoolow. Checkwhether -thehydraulicsupplyisworkingproperly, -allshutoffvalvesareopen, -thesystempressureissufficient.

Pilotedcheckvalveisn'tworking. Checkwhetherthepressureforcontrollingthe valveissufficient.Minimumisabout80bar. Thecheckvalvemaybedefective.

Damagedortrappedhoselines. Checkhoselinesforcontrollingtheprop/ stabilizingcylinder.

Stabilizingcylinderisdefective. Checkstabilizingcylinderfordamageandexchange,ifnecessary.

3/2-wayorpilotvalve

Thevalveisjammedorabypasshasformedduetointernalleakage.Thelattercannormallybedetectedontheworkvalvesofthe electrohydrauliccontrolunitbyaneasilyaudiblehissingnoise.

Pilotorcontrolvalveswithasignificantlylowervolumeflowwillbecomenoticeablywarmerduetotheconstantlyflowingmedium.

Defectivepilotvalvesaredifficulttodetectasnomediumisdischargedonthevalveterminal.Thereisthereforenoobviousindicationoffaults,suchasdischargedfluid,forexample.

The3/2-wayvalveorthepilotsolenoidvalvecanthereforebe faulty.

. Trytosolvetheproblembyactivatingthefunctionseveral timesontheelectrohydrauliccontrolunitorelectroniccontrol unit.

. Locatethefaultyvalvebyactuatingthefunctionsindividuallyin sequence. Ifthenoisestopswhileafunctionisactuated,thatvalveis faulty.

Youmayhavetopressthebuttonforthefaultyfunctionfor severalsecondsbeforethenoiseceases.

. Closethemainshut-offvalveinthepressurefeedlineatthe pipedistributor.

. Thenoperatethefunctionsmanuallytodepressurizethe system.

. Replacethe3/2-wayvalveorpilotvalve.

Pilotedcheckvalves

Theformationofabypassisshownbyadropinpressure.

. Trytosolvetheproblembyactivatingthefunctionseveral timesontheelectrohydrauliccontrolunitorelectroniccontrol unit.

Iftheproblemoccursoncemore,thevalvemaybedefective.

. Checkthevalveandreplaceifdefective

Checkingthecheckvalvesontheprops

Tocheckthepropcheckvalvespleaseproceedasfollows:

. Setthepropuntilthesettingpressurehasbeenreached.

. Removethe“Setprop”hoselineonthepilotedcheckvalve. Iffluidescapesfromtheconnectionofthepilotedcheckvalve,itis defective.

Internalby-passinprops

Ifaninternalby-passinthepropissuspected,thisprocedure shouldbefollowed:

. Setthepropuntilthesettingpressurehasbeenreached.

. Makesurethattheannularspaceofthepropisdepressurized.

. Releasethehoseofthepropannularspaceconnectionatthe prop.

. Actuatethe“Setprop”functionfromtheneighboringsupport.

Ifthereisaninternalbypassintheprop,forexample,duetodamagedpistonpacking,fluidwillflowoutoftheproploweringconnection.Ifthishappens,thepropmustbereplaced.Iffluidescapes fromthedetachedhoselines,thepilotedcheckvalveisdefective.

Pressurereliefvalvedefective

Leakingpressurereliefvalvescannormallybedetectedbythedischargeoffluid,orapressuredropisdisplayedonthepressure gauge.Iffluidisalreadydischargedatworkingpressure,thepressurereliefvalveisdefectiveorthedischargepressuresettingof thevalveusedistoolow.

Inthehydrauliccircuitofashieldunit,variousmodelsofpressure reliefvalvesareused.Forexample,pressurereliefvalveswitha highflowrateareusedontheprops.Whilethepressurerelief valvesforsecuringshiftingrams,stabilizingcylindersetc.aredesignedforalowerflow.

Pressurereliefvalvesfordifferentcylindersofforthepistonand ringsidesofacylindercanbesettodifferentmaximumpressure values.Pleaserefertotheinformationinthehydrauliccircuitdiagramsorthereplacementpartscatalog.

Defectiveorblockedfilter

Operationoftheshieldisslowalthoughthe systempressureliesin thenormalrange.

Itisalsopossiblethatthehydraulicsystemhas beencontaminated,forexampleduringrepairworkonthehydraulic system.

. Checkthefiltersinthehydraulicsystem.

Backflushfilterscanbecleanedbybackflushing.Thefilterelementsmustbereplacedonfine-meshfilters,suchasontheelectrohydrauliccontrolunit.

Technicaldata

Thischaptercontainsthetechnicaldescriptionofthesupportand itsmainsubassembliesaswellasthetechnicaldataforthedescribed

Description

Model 550/1650-2x1414-1500

Thetwo-propshieldmainlyconsistsofthefollowinglistedmain subassemblies:

J baseframewithlemniscaticlinksandrelaybarassembly, J canopy, J cavingshield, J hydraulicprops, J hydraulicequipmentwithhoselinesandcontrol.

Tab.9:Shieldsupport(1)

ApplicationDeviceno.

Tab.10:Shieldsupport(2)

Application

Thetwo-propshieldisequippedwithatwo-partbaseframe.Itconsistsoftwosinglebasesthatareconnectedonthegobsidethrough theyokeoftherelaybarassembly.Therelaybarassemblyiscentrallylocatedbetweenthebases.Theshiftingramfunctionsdirectly. Thecavingshieldisaone-piecesteelconstructionconnectedby meansofthelemniscaticlinkstothebaseframe.

Theshieldcanopytransmitsthesupportloadofthepropsintothe roof.Theconnectiontothecavingshieldisflexiblebymeansofpin connections.Thehingeisreinforcedbythestabilizingcylinder.

Programmedmethodsofcalculationensurethebestpossiblesupport.Thisensuresthatthesupportresistanceandrangeofvertical adjustmentisoptimallycoordinated.Themultistagehydraulicprops havethesameloadcapacityatanystageandactonbothsides.

Thelemniscaticlinksystemhastheeffectthatthedistance betweenthetipofthecanopyandthecoalfaceisnearlyconstant overtheentireadjustingrangeoftheshield.

Theshieldunitsareequippedwithallcomponentsrequiredforrealizinganelectrohydraulicneighboringcontrolwiththeelectronic PMC®-Rcontrolsystem.

Fig.42:Shield,sideview

Tab.11:Shield74201640000001/02,mainsubassemblies

Fig.43:Faceshield,dimensions

Tab.12:Shieldvariants,dimensions

Baseframewithlemniscaticlinksandrelaybar assembly

Thebearingstrengthofthehydraulicpropsistransmittedtothe floorthroughbothbases.Thepropsarehingedintheballsockets inthebasesandareheldonbothsidesbypropretainers.

Bothpairsoflemniscaticlinksarehingedtothebaseframewitha pinconnection.

Therelaybarassemblyislocatedbetweenthetwobasesinthe center.Theyokeconnectsthetwobasestoeachotheronthegobsideandtotherelaybarassembly.Thebasesarenotconnectedto eachotheronthefaceside.Theshiftingramfunctionsdirectly.

Thatmeansthattheforcegeneratedbythepistonsurfacesisused toadvancetheconveyor.Thelesserforceoftheannularsurfaceis usedtoadvanceorpulluptheshield.Theshiftingramcanbe equippedwithareedrodformeasuringforwardmovement.

Therelaybarassemblyisfastenedtotheconveyorusingtheclevis assemblyonthecrawlpan.Thehemisphericalshellinthefront areaofthecrawlpanisthethrustbearingforthehydrauliccylinder oftheoutriggersteering systemthatstabilizesthehingebetween thecrawlpanandtheconveyor.

Important!

Observetheinstallationmarkingswheninstallingthefront lemniscaticlinks.Themarkingsmustpointupwardsandthe marking“K”mustfacethebaseframe(base)(seeFig.45).

Fig.44:Base,dimensions

1035 745

Description

31lemniscaticlinkpin80/74x105

32lemniscaticlinkpinØ64.3x340

33pin30/23x35

35pinØ60x115

41hex.headscrewM12x140-A4-80

Notice! ApplylubricantB6EWN7068toallconnectingpointsandslide surfaces.

1shiftingram,ZE-105/60-700 5relaybarassembly 11base,left 12base,right 13lemnisaticlink,rear 14beam 15propretainer,right 16propretainer,left 20lockingplate

Fig.45:Base(baseframe)forfaceandtransitionshield,items

Relaybarassembly

Therelaybarassemblyunitisusedtopushtheconveyorandadvancetheshield.Todothis,itistelescopicallyextendedorretractedusingtheshiftingram.Theshiftingramfunctionsdirectly.This meansthatthegreaterforcethatisgeneratedbythepistonsurface isusedtoadvancetheconveyor.

15hoseprotection

20hex.headscrewM20x40-A2-70

21hex.headscrewM10x140-A2-70

22roundheadscrewM20x85

23hex.nutM20-10

24capnutM10-A2-70

11pin60/50x85

12pinØ23x119

13pin30/23x95

Notice!

ApplylubricantB6EWN7068toallconnectingpointsandslide surfaces.

Fig.46:Relaybarassemblyforfaceandtransitionshield

Therelaybarassemblyislocatedinthemiddleofthebase.Itprimarilyconsistsofthegobsidecylinderbearing(2),theyoke(1), thecylinderseatwiththeguidingrods(10)andthecrawlpan(3), theshiftingramandtherequiredconnectingelements.

Thegobsidepartoftherelaybarassembly,thecylinderseat(2),is attachedtothebasesofthebaseframebytheyoke(1).Thepiston rodoftheshiftingramaffectsthecylinderseatatthecrawlpan(3).

Theguidingrods(10)canbereplaced.Theyareattachedtothe crawlpan(3)withpinsandareguidedlongitudinallyintothegobsidecylinderbearing(2).

Fig.47:Relaybarassemblywithcrawlpan

Description

Functionsoftherelaybar assembly

Warning!

Bodypartswhichgetbetweenmovingpartsoftherelaybar assemblyandsupportcanbecrushed. Forthisreason,makesurethatyoukeepadistancefrom shieldswhicharebeingadvancedoraretobeadvancedsoon.

Theshieldisusedasthethrustbearing,meaningthattheshield mustbeset.Thegobsidepartoftherelaybarassembly,thecylinderbearing(2),supportsitselfwiththeyoke(1)onthesetshield. Thefacesidepartoftherelaybarassemblymovesinthedirection ofthefacewhentheshiftingramisextended.Theconveyorisadvanced.Thepowerrequiredforadvancingtheconveyorisgeneratedbythepistonsurfaceoftheshiftingram.

Theconveyorisusedasthethrustbearing,meaningthattheshield mustbelowered.Thefacesidepartoftherelaybarassembly,the crawlpan(3),supportsitselfattheconveyor.Thegobsidepartof therelaybarassemblymovesinthedirectionofthefacewhenthe shiftingramisretracted.Theconveyorispulledup.Thepowerrequiredforpullinguptheshieldisgeneratedbytheannularsurface oftheshiftingram.

Fig.48:Relaybarassemblywithconveyor,basicdiagram

aconveyor bshield

cconveyorsteeringdevice dcrawlpanontherelaybar assembly

bankpush

advanceshield

Canopy

Thecanopytransfersthesupportingforceofthepropstotheroof. Itisarticulatedandisconnectedwiththecavingshieldbymeansof pinconnections.Thehingebetweenthecanopyandthecaving shieldisstabilizedbythestabilizingcylinder.Theheadsofthe propsarefastenedtothecanopyandcanberotated.

Caution

Toavoidoverloadingthestabilizingcylinders,youmustmake surethatthesettingangleoftheshieldcanopydoesn't exceed themaximumpermissiblevalue,e.g.whenthecanopyissetin anareaoffracture.

Fig.49:Canopyforvariant01and02,dimensions

Notice!

ApplylubricantB6EWN7068toallconnectingpointsandslide surfaces.

Prophead

Important!

Beforeinstallingtheprophead,putthepegsoftheprophead fixtureintotheboreholesofthemountingdevice.Securethe pegswiththesecuringdevices(pins,lockingclips)inthe secondgroove.

Afterinstallingtheprophead,pushthepegsintheboreholes oftheprophead.Securethepegsinthefirstgroovebyusing thesecuringdevices.

Fig.50:Canopyforthefaceshield,items

Fig.51:Mountingtheprophead

1cavingshield

Cavingshield

Thecavingshieldprotectsthefaceareatowardthecavingarea. Itisconnectedtotheshieldcanopyandwiththebaseframeviathe frontandrearlemniscaticlinks.Astabilizingcylinderstabilizesthe hingebetweenthecavingshieldandtheshieldcanopy.

Thecavingshieldhasretainersforthecylindersandguidingpins forthesideseal.

BucyrusEuropeGmbH,Lünen2009 E BI622820

510 270 750 1 6

S1

7,21 1610 15,17

S1 S2 S2

5lemniscaticlinkpinØ64.3x340

6lemniscaticlinkpinØ74.3x113

7pin30/25x77.5

10lockingplate

16hex.headscrewM12x45-A2-70

17capnutM12-A4-80

20springcotter5

Notice!

S1loadring, loadcapacity:3000kg S2loadring, loadcapacity:5000kg 1229

20 5

ApplylubricantB6accordingtoEWN7068toallconnecting pointsandslidesurfaces.

Fig.52:Cavingshieldforfaceandtransitionshield

15hex.headscrewM12x55-A4-80

Technicaldata,steelstructure

Faceshield,devicenumber74201640000001/02

Securingfromtipping permissibleinclination, omnidirectionaluptodegrees15

Hydraulicsystem

Thefollowingsectionprovidesanoverviewofthepartsofthe shieldhydraulics.Supplementalinformationcanbefoundinthereplacementpartscatalogfortheshieldsupportorthehydrauliccomponentslistedinchapter5.

Duringnormaloperation,theshieldfunctionsmayonlybeoperated viathePMC®-Rcontrolunit.

Shieldcontrolsystem

Electrohydrauliccontrolunit

Theelectrohydrauliccontrolunithas8functionsandisthesame withfaceandtransitionsshields.

Thepilotvalvesoftheelectrohydrauliccontrolunitareequipped withbuttonswhichallowtheshieldfunctionstobeactuatedmanually.Asymbolplateshowsthefunction/buttonallocation.

1distributorblock8functions

2double3/2-waymagneticpilot solenoidvalve

4controlvalvecartridgeNG13

5screwconnection

Warning!

6filtercartridge apushbutton bconnectingsocketsfor controlunit cconnectionsocketonthe rearside

Duringnormaloperationthebuttonsonthepilotvalvesofthe electrohydrauliccontrolunitshouldnotbeusedtoactivate functions.Failuretoobservethiswarningcanresultinunexpectedandhazardoussituations,for exampleifinterlocking functionsaredeactivatedasaresult.

Thebuttonsonthepilotvalvesshouldonlybeusedinspecial exceptionalcases,forexampleforrepairandmaintenance work.Insuchcasesitisimperativetoobservetheapplicable specialsafetyregulations.

Fig.53:Electrohydrauliccontrolunit,8functions

PMC®-Rcontrolunit

Notice!

PleaseobservetheinstructionsinthePMC®-Rcontrolunit's separateoperatingmanual.

ControldevicePMC®-R,inputallocation; Faceshielddevicenumber74201640000001/02

Fig.54:ControldevicePMC®-R,inputallocation

Frontview

PMC®-Rinputs

A1=neighboringshield, left(PMC®-Rleft)

A2=notassigned

B1=notassigned

B2=notassigned

C1=sensor,shiftingram

C2=pressuresensor

D1=notassigned

D2=notassigned

E1=sensor,rightneighboringshield

E2=sensor,leftneighboringshield

F1=neighboringshield, right(PMC®-Rleft)

F2=solenoiddrivermodule

Rearview A2B2C2D2E2F2 A1W1C1D1E1F1

Fig.55:ControldevicePMC®-R,schematicrepresentation

Two-stagetelescopicprop

Thetwo-stagetelescopicpropisdoubleactingandisdesignedfor equalload-bearingcapacityonbothstages.Equalload-carryingcapacityisensuredbyapilotedcheckvalvewhichisinstalledinthe pistonpipe.

Thebottomandtopoftheproparedesignedasaglobejoint.This allowstheproptobejoinedtothesupportviaarotatablefastening. Theheadisfastenedusingtwopegseachthatareinsertedintothe boreholesintheretainerbeforethepropheadisinstalled.The pegsaresecuredinthesecondgroovebyapinandspringclip. Afterthepropheadisinstalled,thepegsarepushedintothebore holesofthepropheadandsecuredinthefirstgroovewithapin andspringclip.

Thetechnicaldatacanbefoundinthesection“Technicaldata, hydrauliccylinders”.

1propbase 2pistonpipe 6pistonrod

Fig.56:Double-telescopicprop,modelSD-1410-200-675/1525

Tab.14:Telescopicprop

setprops

Warning!

Riskofseriousbodilyinjuriesduetopressurefluidsuddenly escapingathighpressureandburstinghydrauliclinescaused bydangerousoverpressure.

Neverclosetheloweringconnectionsondoubleactingprops sothattheyarepressure-tight.Otherwise,pressuremight buildupintheannularspacewhenextendingtheprop,which isseveraltimesmorethanthesetpressure.

Function

Pressurefluidisadmittedunderthepistonpipeviathepiston spaceconnection.Thepistonpipefirstextends,wherebythepressurefluidintheannularspaceisconductedawayintothereturn line.Ifthepistonofthepistonpipemovesagainstthestopbefore theshieldcanopyhasreachedtheroof,thepistonrodextends.The pressurefluidissuppliedatthesametimeviathecheckvalvein thebottomofthepistonpipe.

loadingprops

a) Pistonpipeextendedonly:

Theforceistransferredmechanicallyfromtheshieldcanopyvia thepropheadtothepistonrodandagainviathebottomofthepistonrodtothebottomofthepistonpipe.Furthertransmissionofthe forceishydraulicallyviathepressurefluidunderthepistonpipein thepropbaseandfromthere,mechanicallyintothebaseframe (base).

Thehydraulicpressureunderthepistonpipeisregulatedbyapressurereliefvalvewhichisinstalledintheassociatedcontrolvalve.If thepressuresetonthepressurereliefvalveisexceeded,thepressurefluidflowsoutofthepropandthepropispushedinunderthe nominalpropforce.

b) Pistonpipeandpistonrodextended:

Theforceismechanicallytransferredfromtheshieldcanopyvia thepropheadtothepistonrod.

Thepistonrodsupportsitselfonthepressurefluid,whichis blockedbythecheckvalveinthebottomofthepistonpipe.

Furthertransmissionofforceuptothesettingofthepistonpipeis asdescribedundera).

loweringprops

Thepressurefluidisconnectedtothereturnunderthepistonpipe viathecontrolvalvefortheprop.

Bothstagesofthepropcanbeactivelylowered.Oncethepiston rodhascompletelyretracted,thecheckvalveinthebottomofthe pistonpipeisopenedbythetappet,allowingthepistonpipetothen retract.

Afewmillimetersbeforethepistonpipeis“fullyretracted”,the checkvalveisopenedbyatappet,wherebythepressurefluidunderneaththepistonpipeactslikeaspringliftingthepistonpipeto closethevalveagain.Whenloweringalongtheentirestroke,the procedurerepeatsitself.

Hydrauliccylinder Design

Thehydrauliccylindersusedmainlydifferinthearrangementof theirconnections.Theycanberoughlydividedintotwogroups: Typea)Connectionsarrangedontheoutercylinder Typeb)Connectionsarrangedattheendofthepistonrod.

Notice!

Thetechnicaldataforthecylinderscanbefoundinthe“Technicaldata,hydrauliccylinders”sectionfortheshieldunit used.

Warning!

Riskofseriousbodilyinjuriesduetopressurefluidsuddenly escapingathighpressureandburstinghydrauliclinescaused bydangerousoverpressure.

Neversealtheloweringconnectionsofdouble-actinghydraulic cylinderssothattheyarepressure-tight!

Otherwise,pressurethatisseveraltimeshigherthanthesettingpressurecanbuildupintheannularspacewhenextendingthecylinder.

Theendofthepistonrodeitherhasitsownfasteningoptionoris madesothatafasteningoption,e.g.rodheadorforkhead,canbe screwedonandcanbesecuredagainstworkinglooseusing clampingscrewsoraclampingsleeveconnection.

Thepressurefluidisfedthroughtheconnectionseitheronthe outercylinder(Typea)oronthepistonrod(Typeb).

Ifadoubleactingcylinderisonlytobeoperatedasasingle-acting cylinder,theannularspaceconnectionmustbeprotectedagainst thepenetrationofdirtwithafilterscrew.Ifthecylinderisused withouttheannularspaceseals,thesealgroovesaretobefilled withgrease.

Fig.57:Hydrauliccylinders,typicalexamples

Fig.58:HydrauliccylindermodelZE-105/60-700

Fig.59:HydrauliccylinderZE-63/40-280

telescopicprop, double-acting,2-stage

Technicaldata,hydrauliccylinder

ModelSD-1410-200-675/1525-CR,DeviceNo.82501250000000

shiftingram, double-acting,drivendirectly

stabilizingcylinder, double-acting

Pressurereliefvalves

Pressurereliefvalvesprotectthehydrauliccomponents,suchas propsandcylinders,againstdamagecausedbyoverloads.When thesettingpressureisreached,thevalveopensandthefluidisdischarged.

Thepressurereliefvalvesinthefollowingtablecanbeusedinthe hydrauliccircuitoftheshieldsupport.Alsorefertothehydrauliccircuitdiagramandreplacementpartscatalog.

Tab.15:Pressurereliefvalves,useofthevariousmodels

Caution

Thesetpressureofpressurereliefvalvesshouldnotbechanged.Onlyusepressurereliefvalveswhichhavebeenfactorysettotherequiredvalueandwhichhaveacorrespondingcolor code.

Noncomplianceendangerstheoperationalsafetyofthehydraulicsystemandcancauseseriousandsometimesirreparabledamagetocomponents.

Caution

Alwaysreplacepressurereliefvalveswithnewvalveshaving thesameproperties.Alwayscomparewiththehydraulicsystem'scircuitdiagram.Noncomplianceendangerstheoperationalsafetyofthehydraulicsystemandcancauseserious andsometimesirreparabledamagetocomponents.

Notice!

Alwaysfitnewsealswhenreplacingapressurereliefvalve. Failuretocomplywiththeseinstructionscanleadtoleakyplug connectionsandimpairtheoperationalsafetyofthehydraulics.

Pressurereliefvalvesarecolor-codedandletter-codedpursuantto DIN21557.

Thetextcodeincludesthefollowinginformation: J settingpressure,setpoint, J theweekthesettingwasmade, J theyearthesettingwasmade, J personwhomadelastchanges.

Tab.16:Lettercode,example

420or42 1) 09 03 xy

Settingpressure Week Year Lastpersonwho madechanges

Colorcodingiswitheitheroneortwocolors.Itindicatestherange withinwhichthesettingpressureislocated.ThefollowingFig.60 showsapressurereliefvalveprovidedwithablueandwhitecolor code.Thiscolorcodecorrespondstothepressurerangeof350to 399bar.

Fig.60:Pressurereliefvalve,example acolorcode bprotectivecap

Thefollowingtableshowstherelationshipbetweenthecolorcode andthepressurerange.

Tab.17:Colorcodesforpressurereliefvalves,overview ColorPressurerange(bar)

Orange

Orange/white

600-649

650-699

1) SettingpressureaccordingtoDIN21557:1/10xnominalpressureinbar,“42” equals420bar,“08”equals80bar

Anglesofinclinationofthecanopy

Theanglesofinclinationofthecanopyrelativetothefloorlevelare atleast15degreesunlesslimitedbytheretracted/extendedstate ofpropsorstabilizingcylindersorbythelimitedarticulationofthe hingedjointbetweenshieldcanopyandcavingshield.

Caution

Exceedingthepermissibleanglesspecifiedcanleadtodamagetothepropsandcylindersandtheirfasteningelementsas wellastotheparthinges.

Important!

Whenthesupportisextendedorretractedasfaraspossible, thecanopy/cavingshieldcrosspointmovescorrespondingly whenthecanopyisloweredoraligned/positioned.

Permissiblemedia

Hydraulicfluids

Permissiblehydraulicfluids

Notice!

Useonlyhydraulicfluidsforwhichyouhaveavalidcertificate issuedbyBucyrus.Otherwise,thereisadangerthatthehydraulicequipmentcanbeseriouslydamagedandcouldresult inthelossofwarrantyclaims.

Ingeneral,foroperatinghydrauliccomponentsfromBucyrus,only suchhydraulicfluidsareallowedtobeusedforwhichtherespectiveoperatorhasavalidcertificateinaccordancewithEWN8350or anexemptionpermitfromBucyrus.Bucyruswillnotacceptany claimsunderwarrantyforcomponentswhichhavebeenorareoperatedusingadifferenthydraulicfluid.

Inaddition,national–andsometimesalsoregional–regulations onhealthandsafetyatworkandanyenvironmentalregulations mustbeobservedforoperation.

Ifamineonlyusesindividualhydrauliccomponentswithoutusing Bucyrusshieldsupports,orifobtainingavalidcertificatewouldrequiretoomucheffort,thesamehydraulicfluidwhichisusedforthe existingshieldsupportmaybeusedfortheseindividualcomponents,subjecttoapprovalbyBucyrus.Thesameapplies,e.g.tohydraulicchaintensioners,hydraulicallytensionabledriveunits,etc. TherespectiveexemptionpermitwillbeissuedbyBucyrusonrequest.

Suitabilitytest

BeforeBucyruswillissueacertificateforahydraulicfluid,therespectivefluidhastobesubjectedtoasuitabilitytest.However,this suitabilitytestonlyreferstothetechnologicalpropertiesofthehydraulicfluid,anddoesnotallowanyconclusionstobedrawnwith respecttoitspropertiesregardinghealthandsafetyandenvironmentalprotection.

Originalsamplesoftheconcentrateandthewaterwhichwillbe usedlaterwhenpreparingthehydraulicfluidattheminearerequiredtoperformthesuitabilitytest.

Thesuitabilitytestwillbecarriedoutbyanindependenttesting instituteauthorizedbyBucyrus.Thecriteriaasspecifiedin EWN8350willbeappliedforthetest.Thesuitabilitytestmainly servestoclarifythepropertiesofthehydraulicfluidwithrespectto thefollowing:

J stability,

J sealingmaterials,

J corrosion.

Inadditionifrequiredachemical“fingerprint”oftheconcentratewill bepreparedinordertoexcludeorproveanypossiblechangesin thecompositionoftheconcentrate.

Ifthesuitabilitytestshowsthatthehydraulicfluidmeetsrequirements,theoperatorwillreceiveacorrespondingcertificatefrom Bucyrus.

Certificate

Thecustomerwillbegivenacertificateattestingthesuitabilityof thehydraulicfluidfortheoperationofBucyrushydraulic systems foreachproducttested.Certificatesshallbevalidforaperiodof oneyearand,afterasimplifiedtest,caneachbeextendedforan additionalyear.Thecertificatewillnolongerbevalidifoneorseveraloftherequirementsforobtainingthecertificatearenolonger fulfilled.Thisisthecase,forexample,ifthequalityofthewater haschangedsubstantiallyand/orthecompositionoftheconcentratehasbeenchanged,adifferentconcentrateisusedorthe concentrateandwatermixtureratiodoesnotcorrespondtothe datagivenonthecertificate.Forfurtherinformation,pleaserefer toEWN8350,Part1.

Thefollowingillustrationshowsatypicalcertificate.

Fig.62:Typicalcertificate

Hydraulicfluidmaintenance

Theconsistentgoodqualityofthehydraulicfluidisessentialforthe operationalreliabilityofhydraulic systems.Therefore,maintenance ofthehydraulicfluidmustnotbeneglected,butshouldbeperformedwithspecialcare.Themostimportantpropertiesofthehydraulicfluidshouldideallybemonitoredautomaticallyandrecorded inordertobeabletodirectlycounteranyharmfuleffects.These propertiesinclude:temperature,foaming,pH-value,concentrateratioandmicrobialload.

Theoperatoroftheequipmenthastoprepareahydraulicfluid maintenanceconceptforanyindividualapplication.Themaintenanceconceptshouldbepreparedinclosecooperationwiththe manufactureroftheconcentrateandhastobeappliedconsistently.

Ifitisnotpossibletomonitorthehydraulicfluidcontinuously,the propertieslistedinthefollowingshouldbecheckedatleastonce everyweek:

J pHvalue

–Targetvalue:7.5to9.5

J Concentrateratio

–Targetvalue:seecertificate

J Microbialload

–Setpoint:  105 col/ml.

Inaddition,theelectricalconductivity,foamingandtheoperating temperatureofthehydraulicfluidshouldbemonitoredregularly.

Thepermissiblemaximumtemperatureofthehydraulicfluidis 55°C.Duringnormaloperation,however,anoperatingtemperature of45°Cshouldnotbeexceeded.Ahigheroperatingtemperature willreducethestabilityoftheemulsionandshortenthelifeofthe sealingmaterial.

Qualityoftheprocesswater

Thequalityofthewaterusedtomakethehydraulicfluidhasan enormousinfluenceonthepropertiesofthehydraulicfluid.Accordingly,therequirementsformonitoringthewaterqualityarevery high.

IfthelimitsshownintheTable19aremaintained,itcanbeassumedthatthewaterisbasicallysuitable.

Ifoneorseveralofthelimitsmentionedarenotcompliedwiththis shouldbetakenintoconsiderationwhenselectingaconcentrate. Additionalwatertreatmentmayalsoberequired.

Thecustomershallinanycase,however,provideasampleofthe originalwatertopermitperformingthetestsrequiredfortheissue ofthecertificate.

Changesinthecompositionofthewaterwillleadtothelossofthe certificateeveniftheyarewithinthelimitvaluesmentioned.

Waterusedforthispurposemaynotcontainaggressivecomponentsanddirtparticles.Inordertoguaranteeperfectlong-termoperation,thewatermustbefilteredwithaprefilter,withaminimumof 100 m.Inordertoprotectthecomponents,thelimitvalueslisted inthetablemustnotbeexceeded.

usinghydraulicfluids

usingassprayingwater

Thefollowingtablelistslimitvaluesfortheessentialpropertiesof theprocesswater.

Caution

Usingwaterwhichisnotofthespecifiedqualitycancause seriousdamagetocomponentsurfacesandtheentirehydraulicsystem.Useonlywaterthatconformstothespecified limitvalues.

Tab.19:Propertiesoftheprocesswater,limitvalues

TestcriterionLimitvalue Appearance,color,smell

e.g.turbidity,badodor,etc.

Bacteriologicalrequirements

10mg/l 1) Contaminationclassaccordingto ISO4406:1999

Ratioofsolidforeignmatterat1.2 mfilteringinconformitywithDINEN12662

1)Thevalueslistedmustbeobservedduringtheproductionofhydraulicliquids. Theydonotapplywhenthewaterisusedexclusivelyassprayingwater.

Lubricatinggreasesandpastes

Important!

Thelubricantstobeusedarespecifiedintherespective chapters,e.g.installation,maintenance.

Lubricatinggreases

Greasebase:Lithiumsoap

NLGIclass:2 .....................

Workedpenetration:265to295(0.1mm)

Behaviorinthepresenceofwater:practicallyinsolubleinwater Temperatureofapplication:-20 oCto+120 oC .......

Flashpoint: ≧ 200 oC ......................

Lubricatinggreasesforgeneralapplicatione.g.forrollerbearings subjecttonormalload,forlabyrinths,andforinstallation(according toEWN *) 7068).

Tab.20:Lubricatinggreasesforgeneralapplication

Lubricatinggreasescontainingadditivesforhighpressureapplicationse.g.forrollerbearingsandbearinglocationssubjecttoextremeload.

Tab.21:Lubricatinggreaseswithadditives

Important!

Thegreaseslistedinthesametablecanbemixed.Other productsmayonlybeusedifthesuppliercanguaranteethat theyareequivalent.Differentlycomposedlubricatinggreases mustnotbemixedasthismaychangetheconsistency,i.e.the mixturecanbecomethinnersothatthelubricationeffectisnot sufficient.

Itmayalsobedangeroustouselubricatinggreasesthathave thesamesaponificationbasebutdifferentorigins.Ifindoubt, themanufacturerofthelubricatinggreasetobeusedshould becontactedtoconfirmthecompatibilityofthegreaseinquestion.

lubricatingpasteB3

Lubricatingpastes

Lubricatingpastesfreefrommolybdenumdisulfide,containingsolid lubricantsforlubricatingcenteringboresandconnectionsofsplined shaftsofsprocketdrumsandchainsprocketsduringinstallation.

Tab.22:Lubricatingpastesfreefrommolybdenumdisulfide SupplierType

Whentheequipmentis lubricatedatourfactoryforthefirst time,thelubricanttypeusedaslubricatingpasteB3inaccordance withtheworksstandardEWN7068is:

Gleitmolybdän“gleitmo805”

lubricatingpasteB6

Partingagentsandlubricantswithorganiclubricatingmediaona syntheticbasematerialforgreasingthreadedareasandfitting pointsonpropsandhydraulicprops,ofpinconnectionsandsimilar connectingelementsatthesupport.

Behaviorinthepresenceofwater:non-solubleinwater

Applicationtemperaturerange:-34 oCto+120 oC

Whentheequipmentis treatedatourfactoryforthefirsttime, thelubricanttypeusedaslubricatingpasteB6inaccordancewith theworksstandardEWN7068is:

Chestertonpartingandlubricatingmaterial785 (flashpoint132ºC)

Important!

Theinstructionsformixinglubricatinggreasesalsoapplyto thelubricatingpastes.

*)Theproductslistedintable20aresuitablelubricatinggreasesforfillingofadjacentcavities.

Tighteningtorques

Tighteningtorques

ScrewswithISOmetricthread

Tab.23:Tighteningtorquesfor total =0.14

Important!

Thetighteningtorquesstatedinthereplacementpartslists mustbeobservedduringinstallationandmaintenancework.

1)Thedimensionslistedinbracketsareusedinexceptionalcasesonly.

2)Accordingtoin-houseworksstandard(EWN6110,editionFebruary1985).

3)Onlyforexpansionboltshavingareducedshaftcross-sectionof24.2mm.

4)Thetighteningtorquescomplywiththeworksstandard(EWN6003).

Shieldsupport550/1650-2X1414-1500

Foryourinformation

Ifyourequiresparepartsortechnicalproblemsoccur,contactour after-salesservicepersonnelorcontactusdirectly(homepage: www.bucyrus.com).

Serviceaddresses

Europe

BucyrusEuropeGmbH

Industriestrasse1

D-44534Lünen,Germany

Tel:+49/2306709-0

Fax:+49/2306709-1421

E-mail:info@de.bucyrus.com

BucyrusUKLtd.

HallamFieldsRoad Ilkeston,DerbyshireDE74BS UK

Tel:+44/115951-2500

Fax:+44/115932-9683

E-mail:info@gb.bucyrus.com

BucyrusUKLtd.

2RenshawPlace

Holytown Motherwell,ML14UF

NorthLanarkshire

Scotland

Tel:+44/1698835-000

Fax:+44/1698835-038

BucyrusPolskaSp.z.o.o. ul.Fabryczna6, 41-404Myslowice

Tel:+48/323170-500

Fax:+48/323170-509

BucyrusEuropeGmbHOfficeMoscow

125009Moskau

ul.Tverskaja,dom9/17,str.7 office315

RussianFederation

Tel.:+7(495)9409209

Fax:+7(495)9407145

E-mail:viktor.sobolev@ru.bucyrus.com

OEBucyrusService

ul.Kirzavodskaja4/8

654004Novokuzneck

Russia

Tel.:+7(3843)991381

Fax:+7(3843)991384

E-mail:Andrey.Ravnyushkin@ru.bucyrus.com

BucyrusEuropeGmbH,Lünen2009

Germany

GreatBritain Poland Russia

SouthAfrica

NorthAmerica,Canada,SouthAmerica

BucyrusAmericaInc.

2045WestPikeStreet

Houston,PA15342-1010,USA

Tel:+1/724743-1200

Fax:+1/724743-1201

E-mail:info@us.bucyrus.com

BucyrusAmericaInc.

4041WurnoRoad

Pulaski,VA24301

Tel:+1/540980-4530

Fax:+1/540994-3889

Australia

BucyrusAustraliaUndergroundPty.Ltd.

CustomerService

20KillaraClose, Beresfield,NewSouthWales2322

Tel:+61/24914-7144

Fax:+61/24914-7169

BucyrusAustraliaUndergroundPty.Ltd.

14CommercialAvenuePaget

M.M.CBox5182

Mackay,Queensland4741

Tel:+61/74952-0000

Fax:+61/74952-0099

Africa

BucyrusAfricaUndergroundPty.Ltd.

CornerofGammaandZetaRoads IndustriesWest Germiston1401

Tel:+27/11825-8212

Fax:+27/11825-7389

E-mail:hetta.fuller@za.bucyrus.com

China

Asia

BucyrusEuropeGmbHBeijingRepresentativeOffice

Suite1112,TowerB

FullLinkPlaza

No.18ChaowaiStreet

Beijing100020

Tel:+86/106588-2998

Fax:+86/106588-6570

E-mail:Info.beijing@cn.bucyrus.com

Bucyrus(Langfang)MiningMachineryCo.Ltd.

Jinyua.Road

-LangfangEconomicandTechnicalDevelopmentZoneHebeiProvince065001

Tel:+86/3166086-840(&841,842,843)

Fax:+86/3166086-845

E-mail:Info.langfang@cn.bucyrus.com

Bucyrus(Tangshan)MiningMachineryCo.Ltd.

No.4GangyaoRoad

Tangshan063027

HebeiProvince

Tel:+86/315320-3117(&3445,3404)

Fax:+86/315320-3438

E-mail:Info.tangshan@cn.bucyrus.com

Identificationoftheshield

Identificationoftheshield

Nameplate

Themainsubassembliesoftheshieldsareidentifiedbyatype plate.

Fig.63:Nameplate,example

Shieldnumber

Theshieldnumberservesasanidentificationfeature.Allshields arenumberedsequentially.Firmlyattachedtagswiththerespective shieldnumberareontheleft-handbaseontheshield.

Fig.64:Shieldnumberonthebase,example

Tab.24:Allocationoftheshieldnumbers

Standardsanddirectives

Referencednationalstandardsandguidelines

Tab.25:Nationalstandardsanddirectives,extract

Tab.26:Europeanstandardsanddirectives,extract