CAT DBT-Shield 1321/3048-2X5655-1860 Operating Manual - PDF DOWNLOAD

Operating Manual DBT-Shield 1321/3048-2X5655-1860 Doc. No.: 7420 145 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 Email: infodbt@dbt.de Telefax: +49 (0) 23 06 / 709 - 1421 Internet: www.dbt.de

Amendments and alterations to this publication are not subject to notification. DBT GmbH (DBT) reserves all rights to this publication.

Its content is protected by copyright laws, both domestic and international. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of the DBT. DBT declines all liability for direct or indirect consequences of printing errors.

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

DBT GmbH, Lünen 2005 E

Contents

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

1.3

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

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

1.4 1.4

2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Conditions of operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Use in conformance with specifications . . . . . . . . . . . . . . .

Use contrary to specifications . . . . . . . . . . . . . . . . . . . . . . .

2.5 2.5

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

2.6

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Overview of the safety instructions . . . . . . . . . . . . . . . 2.15 DBT GmbH, Lünen 2005

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

3.3

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

Used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.5

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

3.5

4. Installation

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

4.3

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

4.3

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

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

4.4 4.8

Requirements to the face hydraulic system . . . . . . . .

4.8

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

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

Start-up of the shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.9 4.10 4.10

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Contents 5. Operation Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

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

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

5.3 5.6

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

5.9

Safe working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.15 Location of hydraulic components at the shield . . . . . . . . .

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

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

5.15 5.27 5.29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Weekly inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To be done every six months . . . . . . . . . . . . . . . . . . . . . . . .

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

5.33 5.34 5.34 5.35 5.35 5.36 5.36 5.39 5.39 5.40 5.40 5.40

6. Technical data Shield variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

Base with lemniscatic links and central shifting unit . . . . .

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

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

Technical data of the shield, steel structure . . . . . . . . . . . .

6.4 6.6 6.8 6.10 6.11

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Double-telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic cylinder, double and single acting . . . . . . . . . . . .

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

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

Technical data of hydraulic cylinders . . . . . . . . . . . . . . . . . .

6.17 6.18 6.19 6.20 6.20 6.21

Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.25 Electrohydraulic control units . . . . . . . . . . . . . . . . . . . . . . . .

Electronic shield control PMC®-R . . . . . . . . . . . . . . . . . . . .

6.25 6.25

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.27

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Fault finding on shield hydraulic system . . . . . . . . . . . . . . .

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

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

Pilot-operated check valves . . . . . . . . . . . . . . . . . . . . . . . . .

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

Faulty pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36

Contents Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.28 6.31

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.33 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.33

7. For your information 7.3

Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Identification of shields . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5

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

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

7.5 7.5

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Our service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

DBT-Shield 1321/3048-2x5655-1860

1

About this manual

Before starting work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols used.

Before starting work applicable operating manual

Take care to ensure that the operating manual available to you is applicable for the shield support used. Compare the data given below with the data on the type plate of the shield. Where to find the type plate on the shield is described in chapter 7 of this operating manual.

This operating manual is designed for: DBT-Shield 1321/3048-2x5655-1860 and is only permitted to be used for shields of this type. Only use the operating manual applicable to the respective shield. If you don’t you will endanger yourself and others.

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Tab. 1: Type specification for DBT-shield 1321/3048-2x5655x1860 Identification no.

Prop force Year of Application construction 7420 145 000 00 01 2 x 5655 kN 2005 face endshield availability of operating manual

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

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

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

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

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

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

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1.3

Before starting work Purpose of this operating manual operating manual

This operating manual contains general information on the safe and economical handling of shield supports and provides you with important instructions on the work performed directly on or with the shields.

Therefore, read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

questions

Should you have any questions, please contact our service department. Contact details are given in chapter 7 of this operating manual.

safety

Read the chapter ”For your safety” with special attention. This chapter contains important information indicating possible hazards.

Observe the information given and follow the procedural instructions.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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

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

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

1.4

J

Items in lists are marked with black squares.

–

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

.

The symbol of the hand asks you to do something. Several successive paragraphs marked with the symbol of the hand represent a string of actions which must be executed in the order specified.

Follow the respective instructions step-by-step to perform the work safely and efficiently.

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DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

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Try to memorize the symbols and their meanings.

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety.

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

supplementary regulations

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

However, a certain risk remains which might get you into hazardous situations when working with or on the shields. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

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

Observe the safety and accident prevention regulations: J of the mining company, J of the mining authority, and

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J of the miners’ accident insurance association.

DBT GmbH, Lünen 2005

Personnel Persons employed in the operation, repair, and overhaul of hydraulic and/or electrohydraulic shield supports must have special qualifications. In addition to having received training in mining skills the following minimum requirements shall be met.

Operation and maintenance Operation and maintenance of the shields is only allowed to be performed by trained personnel. qualification

The training shall be matched to the type of shield actually used.

The electrohydraulic and hydraulic control systems shall be operated only by personnel who have been adequately trained to operate the present control system. The content of the operating manual, especially the chapter on safety, shall constitute a part of this training.

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

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2.3

Personnel Repair In general, repair work shall be performed only by persons who have the respective knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment. Repair work on and overhaul of J safety devices,as e.g. pressure relief valves J hydraulic props and cylinders J control blocks, valves, and filters

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shall be performed only by DBT service technicians or by specially trained personnel of the mining company.

2.4

DBT-Shield 1321/3048-2x5655-1860

Conditions of operation Conditions of operation Use in conformance with specifications The shield has been designed and manufactured exclusively for use as a support unit for longwall faces.

Use the shield only in conformance with specifications!

Use in conformance with specifications includes: J propping the roof against the floor; J ensuring an adequate travelway; J the following shield operations:

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

– advancing, DBT GmbH, Lünen 2005

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– retracting; J forming an abutment for:

– the conveyor and the mining machine, – conveyor steering devices, – devices for raising the conveyor, – conveyor steering cylinders;

Use contrary to specifications Uses which are not expressly stated as conforming with specifications are contrary to specifications and are not permissible with the shield.

Uses contrary to specifications include, among others: J pushing the shield back into the caving area, J raising of the conveyor by means of the hydraulic force of the

shield, J setting of the canopy in areas of roof fracture. Further informa-

tion in this respect is given in the section ”Operation” of this chapter and in chapter 5 of this manual in the section ”Operation of the shield”.

DBT assumes no liability for damages which result from use contrary to specifications.

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2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

lighting signalling systems and protective devices

Maintain the lighting systems in a functional condition.

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

support lock-out switch

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

Only applicable for shields provided with electrohydraulic control systems.

Actuate the support lock-out switch (repair switch) before performing.

J maintenance work, J inspection work, J repair work, and before J prolonged presence in the shield.

moving parts

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

automatic mode

2.6

In automatic mode, the support units of a longwall face are controlled by an automatic programme without any human interference.

When travelling the face you should therefore always keep in mind that the support units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the support currently operated.

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DBT GmbH, Lünen 2005

EMERGENCY STOP

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

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

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

Defective components should be immediately transported away from the face, in order to avoid interference with the face crew.

Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

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

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

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J the flipper, J the advancing beam (face and gobsides). transporting

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

Non-standard transport assemblies are shown on special drawings which are added in the annex to the manual, if required.

Do not damage the polished surfaces of the cylinders and props.

Damage of this kind necessitates elaborate and expensive repair work.

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

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

Firmly secure all components which might start moving.

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

Installation Employ appropriate loading equipment for safe transfer of the transport units.

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

Mechanically secure the caving shield against lowering during: J installation of the props and cylinders,

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2.7

Safety instructions J installation of the canopy, J work on the open hydraulic system,

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

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

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

travelway

Make sure that the minimum dimensions specified for the travelway within the shield are maintained under any circumstances. The minimum dimensions are: J width: 600 mm J height: 400 mm

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

Operation shield control

Check to determine whether all protective devices on the shield are present and functional. In automatic mode, the support units of a longwall face are controlled by an automatic programme without any human interference. When travelling the face you should therefore always keep in mind that the support units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the support currently operated.

Check to determine whether all protective devices on the shield are present and functional.

2.8

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transport securing devices

Securing by means of hardwood wedges

DBT GmbH, Lünen 2005

Fig. 1:

Safety instructions Operate the shield control system only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective control system and know the contents of the respective operating manual.

Carefully read the instructions for operating the control system used.

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

Always operate the shield only from the adjacent shield.

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

When operating the shield manually the operator has to watch the shield movement area constantly before and while operating the shield in order to avoid potential hazards by cautious behavior.

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

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

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Clean the control elements of the control units regularly. Clean the control equipment at regular intervals. Ensure that the operating symbols are clearly recognizable. This measure avoids faulty operation and resulting accidents.

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

This way you will be able to extend the shifting unit without hindrance and to advance the conveyor without problems.

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

Secure the conveyor by anchorages. This measure is required to prevent displacement of the conveyor with respect to the shield and the shifting unit jamming in the base skid. On inclined faces it may be necessary to anchor the conveyor with respect to the support.

This measure helps to prevent lateral displacement between the conveyor and the shield. And it reduces the risk of the shifting unit jamming between the skids.

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

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

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

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2.9

Safety instructions shield alignment

Set the shields in such a way that the canopies and the base skids are parallel with those of the adjacent shield. The shields must be aligned at right angles with respect to the conveyor and parallel with respect to each other. Use the steering devices or the side seals for aligning the shields.

Align the shields as soon as possible. Alignment in due time prevents: J getting under the canopy of the adjacent shield, J canting of the shields, J slipping of the shields, J and ensures an early support of the newly mined roof

roof falls

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

Never set the tip of the canopy into a roof fall-out such that J the max. admissible angle of inclination of the canopy is

exceeded J the stabilizing cylinder locks

During temporary support of a roof fall-out ensure that the drooping canopy does not get in the way of the passing mining machine. residual stroke

Ensure that sufficient residual stroke is still present in the props when the seam thickness decreases. This prevents the props from going solid between the roof and floor.

pulling back the conveyor

If possible, pull the conveyor back by operating the respective functions of the electronic shield control unit. If this is not possible, do as specified in the respective operating instructions of the mine.

Secure the entire mining machine against unauthorized starting.

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

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

raising of conveyor

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

Only use the points of attachment intended for that purpose. Never attach loads to hydraulic cylinders or their fastening points.

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

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

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

For raising the conveyor, only use:

2.10

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

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J the canopy will be loaded excessively in longitudinal direction

Safety instructions J high-strength undamaged round link steel chains, J the fastening points provided for the purpose. Check that the

fastening points are undamaged before attaching a load, J lifting gear with sufficient permissible load-bearing capacity.

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

Examine the shield at least once per shift for externally visible damage. See chapter 5, section ”Maintenance”.

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

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

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Replace damaged components affecting safety immediately.

Immediately shut down the shield concerned, if immediate repair is not possible. Stop and lockout the respective shield immediately if the component damage entails a hazard and an immediate repair is not possible. Secure this area and notify the entire coal face crew and the responsible foremen without delay, if there is a safety hazard.

Use only spare parts which conform with the specified technical requirements. This is best ensured by the use of original spare parts from DBT. As to the order numbers for the required spare parts please refer to the spare parts catalog provided for the equipment.

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

Any modifications carried out without authorization result in the certificate of conformity of DBT becoming invalid and require a new conformity test.

During work on the shifting unit, isolate the working area for the mining machine.

Working in the winning track is permissible only if J the roof has been secured against rock fall, J the coal face has been secured against sloping down, and J the mining machine and conveyor have been shut down and

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

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

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

pressure or mechanical stress.

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2.11

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

When performing any work which might entail the risk of the support retracting automatically secure the shield mechanically to prevent it lowering by itself.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid penetrating the skin can cause serious infections.

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

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

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective equipment -hydraulic

When removing protective equipment which includes hydraulic components keep in mind that these components may be pressurized. You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

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

maintenance, repair

pressure relief valves

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

Make sure that pressure relief valves are always provided with protection caps. Replace defective caps without delay.

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

J the hoses have no bubbles or blisters.

J the hoses or the outer sheathes of the hoses are not abnor-

mally rigid or hard.

J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurised. Be sure to depressurise the line before disconnecting couplers.

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

Never use nails, wire or similar materials for securing.

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

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handling of hydraulic fluids

E

Hydraulics

Safety instructions permissable hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 2:

Example: 4SP hydraulic hose, designation 3 2 1

6

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

DBT GmbH, Lünen 2005

E

1 manufacturer 2 hose type 3 date of manufacture, 1st quarter 2002

5

Never try to hold a pulsing hydraulic hose. Depressurise the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying hydraulic hoses, twisting RIGHT

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WRONG

2.13

Safety instructions J are not bent directly behind the connections

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

Laying hydraulic hoses, bending WRONG

RIGHT

J cannot chafe, Fig. 6:

Laying hydraulic hoses, crossing WRONG

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

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

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

Fig. 7:

Laying hydraulic hoses, connections on moving parts RIGHT

2.14

WRONG

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RIGHT

Overview of the safety instructions Overview of the safety instructions This is a summary of all safety instructions given in the individual chapters of this operating manual. As these safety instructions are cited out of their context the meaning is not always obvious.

Chapter 3: Storage and transport WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices.

CAUTION! Transport safety devices may get damaged during transport to the mine, for example when loading and unloading the transport units.

Therefore, check all transport safety devices for damage and replace damaged ones before allowing transport of the units in the mine shaft. Damaged transport safety devices may be the cause of serious damage to the transport unit or to the transport shaft if load units are transported suspended under the cage with damaged or inadequate transport safety devices.

DBT GmbH, Lünen 2005

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If the points of attachment on the caving shield are to be used for transporting the assembled support unit, canopy and base skid must be connected mechanically by means of an additional transport safety device to prevent them moving apart.

Chapter 4: Installation DANGER! Damaged hoses might burst and hydraulic fluid could escape under high pressure. This could severely injure or even kill you or others.

Make sure that the movements of the shield do not cause any damage to the hose lines.

Lay the hose lines correctly behind the retainers provided for that purpose.

WARNING! When performing any work, observe the safety instructions given in this manual and also the special safety instructions and operating manuals provided by the mine management. Failure to comply can lead to most serious accidents which might even result in death.

Incorrect operation can cause pressure to build up in the return line. Such pressure has to be relieved via the relief valve (item 23, see fig. 13) by turning in the vented cap screw. After pressure has been relieved turn the screw back as far as it will go.

Take care to make sure that all hoses are depressurized before you start loosening the connecting lines at the manifold block!

The first start-up and the test run should only be performed by a well-trained and experienced crew who are familiar with the special conditions prevailing in underground mines, particularly with the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

Canopies must not be sloping downwards and reach into the track for the mining machine.

Do not install shut-off valves into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could e.g. cause hose lines to burst. This may result in serious injuries to persons or even death.

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2.15

Overview of the safety instructions CAUTION! Prior to assembly, sockets and nipples of the plug-type connectors must be treated with lubricating paste B3 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

NOTICE! Take care to ensure that all transport safety devices required for transport have been removed. See chapter 3, section ”Transport”.

IMPORTANT! When installing the shields in the face, be sure to observe the shield numbers. Since the individual shields might be provided with different functions they must be arranged in the specified order.

For details, please refer to the respective separate operating manual of the manufacturer.

Chapter 5: Operation and maintenance DANGER! You are only allowed to operate the shield control if you have a profound knowledge of the control elements and of the way the control system works. You must have been task-trained on the present control system and should have practiced to deepen your knowledge. Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or death to the operator.

Therefore, never fix the push buttons and take care to ensure that damaged pilot valves are always replaced without delay.

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

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

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Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

E

For transport underground only the attachment points detailed in chapter 3 ”Transport” are allowed to be used. Further information is given in chapter 3 ”Transport”. Failure to comply may lead to personal injury and damage to property.

Overview of the safety instructions Always stay clear of a shield which is being moved. Circumstances which are not always obvious may lead to unexpected movements of the shield unit which could result in severe injuries or even death.

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

During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. Pay attention to the separate manual of the electronic control system.

Do not put the filter into operation, prior making sure that all connections have been made properly.

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

DBT GmbH, Lünen 2005

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The control elements on the control valve block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose. They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries.

During normal operating mode, the shield is operated exclusively by means of the electronic control. In this respect it is imperative that you observe the separate operating manual of the control unit.

If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

You are only allowed to operate the controls of the control valve block when you know exactly which effects the functions have with respect to the shield. Therefore you should have received adequate training. If not, there is a risk of operating errors involved which might cause severe injuries to persons, possibly resulting in death.

The manual operation of a push button on one of the pilot valves causes the direct execution of the respective function. In this case, dependencies between the individual functions will not be considered. This could lead to dangerous situations if, for example, functional sequences are initiated in the wrong order. For example, the function ”advance shield” can be activated without the functions ”retract side seal” and ”actively lower shield” having been actuated before. This could cause hazardous situations resulting in very severe injuries.

When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior.

Trouble shooting on hydraulic systems entails an increased accident hazard. Particularly by malfunctions of the hydraulic system and hydraulic medium escaping at high pressure severe injuries could be caused.

Therefore you are required to be very cautious and wear the specified protective equipment. Failure to comply with these instructions could cause severe injuries.

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2.17

Overview of the safety instructions CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of a tendency to roof fall-outs and/or extremely soft floor.

Take care not to damage the push-buttons of the pilot valves.

Jammed push-buttons will cause malfunctions of the valves which may result in accidents.

Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

NOTICE! It is important that the control symbols are legible to avoid the risk of operating errors and resultant accidents.

IMPORTANT! Both cases require knowledge of the flow plan and skilled personnel. The safety guidelines contained in this manual must strictly be observed.

Chapter 6: Technical data WARNING! Risk of getting squeezed between moving parts of the shifting unit and the shield.

Keep away from advancing shield units or such which are going to be advanced.

During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

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Do not exceed the angles of inclination of the canopy (angle between shield canopy and caving shield) specified in chapter 6 ”Technical data”. If the angles are exceeded, this will cause damage to props and hydraulic cylinders, their arresting elements as well as the articulations of the components.

E

Avoid an excessive inclination of the canopy by filling roof fall-outs or by supporting minor fall-outs with the shield in horizontal position.

At this point, we explicitly emphasize again that any damage caused by the non-compliance with these instructions is possibly not covered by the guarantee.

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

Never close the lowering ports of double-acting props pressuretight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

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

Never close the lowering ports of double-acting props pressuretight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

DBT GmbH, Lünen 2005

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CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy - caving shield) will not be exceeded.

Do not change the pressure setting of pressure relief valves! Only use pressure relief valves which have been factory-set to the required value and are provided with the relevant color code.

Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

Always replace pressure relief valves with valves which are as new and have the same properties. Refer to the hydraulic flow plan in this respect. Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

If the max. angles stated are exceeded, damage will be caused to the props and cylinders as well as to their arresting elements and to the articulations.

NOTICE! The technical data of the cylinders are given in the section “Technical data” of the shield used.

Always fit new seals when replacing a pressure relief valve. Failure to comply may result in leakages at the plug-type connection and impair the operational safety of the hydraulic system.

How to operate the electronic shield control unit type is not subject of this manual. See separate operating instructions.

Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

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2.19

Overview of the safety instructions The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

DBT GmbH, Lünen 2005

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The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

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3

Storage and transport

Storage

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

Observance of the instructions and tips will increase the service life of the shields. You will also be able to carry out the transport work quicker and more safely.

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

Storage Storage of new equipment corrosion protection

The surfaces of the equipment are provided with a temporary corrosion protection. If stored properly, the equipment parts will be protected for six months referred to the date of delivery.

DBT GmbH, Lünen 2005

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Prior to delivery the hydraulically operated equipment will be tested and operated at the DBT site using the anti corrosive and anti freezing fluid HYDROCOR® CV50*. This fluid remains in the hydraulic system for transport and a following short-time storage period.

HYDROCOR ® CV50 is freeze-proof down to - 40 degrees Celsius and protects inside metallic materials against corrosion.

It is equipped with a color indicator, which is responsive on the pHvalue of the fluid. The color of the fluid will change from ”red” to ”yellow” in case the pH-value drops down. A yellow colored fluid indicates insufficient corrosion protection.

For further particulars on the properties of HYDROCOR® CV50 please refer to the respective data sheet of the manufacturer.

Water-bearing parts of the equipment such as for example the components belonging to the water spraying system of a shield should be completely emptied or, if required, be filled with an anti freezing fluid. short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must, however, be particularly protected against environmental influences, including high temperatures, for example by suitable covers or sheathings for the controls and by additionally covering the equipment. If the equipment is to be stored for more than four weeks additional special measures may have to be taken, depending on the environmental conditions. It may, for example, be necessary to remove the electronic control unit in order to store it adequately.

long-term storage

If the equipment is to be stored for more than 6 months, the cavities in the hydraulic components must be completely filled with a preserving fluid such as e.g. HYDROCOR® CV 50. This fluid must have corrosion-protection properties and should be frost-proof within the respective temperature range of the application. All ports must be sealed with durable and suitable plugs.

It is highly recommended not to store the equipment outdoors but in a well ventilated room. If it is not possible to store the complete equipment indoors, remove the hydraulic and electronic components and store them separately. *

Doc. No.: 7420 145 000 BA 00

HYDROCOR ® CV50 is a trade name of Theunissen, Chemische Fabriken GmbH, Wuppertal / Germany

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3.3

Storage storage outdoors

Equipment parts stored outdoors must be protected against direct sunlight, precipitation and dirt - for example by using tarpaulins.

These parts have to be stored such that fluid will not be allowed to collect in cavities. Fluids entering any cavities during transport or loading/unloading must be able to flow off freely.

electrical equipment, rubber and plastic parts

As a general rule, electrical equipment, electronic components, spare parts made of rubber or plastic - such as seals and hoses as well as pressure fluids have to be stored in closed rooms at 15 °C. to 25 °C. protected against direct sunlight. Exceptions: see ”Short-term storage”.

natural ageing

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

moisture and dirt

Equipment parts stored outdoors for a longer period of time must be protected against direct sunlight, precipitation, and dirt, for example by using tarpaulins.

When storing assemblies - such as props and cylinders - containing contacting joints, sealing elements may suffer plastic deformation as they are constantly subjected to static unilateral loads due to the weight of the components. This may render the seals useless or reduce the life of the sealing element. This effect is greatly influenced by the size and duration of the load and the prevailing temperature.

Therefore, props, cylinders and similar components should only be stored in an upright position. This especially applies if the components are to be stored for a longer period of time.

If you intend to store a machine containing any of the above-mentioned components you may have to dismantle such components in order to store them adequately.

random sample inspection

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

On request, the inspection can be carried out by DBT. The cost will be borne by the mine.

HFA fluids

With respect to the storage of HFA fluids or concentrates for the production of HFA fluids in any case the regulations of the manufacturer or supplier of those media have to be observed first. Supplementary information is given in the section ”Hydraulic fluids” in this manual.

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the ”first in, first out” principle. Mark the containers accordingly.

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plastic deformation

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Protect all hydraulic elements during storage in a suitable manner against the ingress of dirt and moisture. The connecting surfaces of the hydraulic components must be protected against corrosion and closed with blind plates. Hydraulic plug-type connections and the connectors of the electric cables must be closed with suitable caps or plugs.

Transport Used equipment If there is any need to store hydraulic equipment that has been in use before the items specified above apply analogously, with the exception of the item corrosion protection. corrosion protection

In case the hydraulic system is to be put out of operation temporarily the complete system has to be flushed thoroughly and filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50). If this is not done, considerable damage to the hydraulic components may be caused within a short time since the properties of the medium used may change very fast and negatively, e.g. due to microbial attack.

Transport

DBT GmbH, Lünen 2005

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WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices. transport units

In consultation with the customer and taking into consideration the local conditions prevailing at the site transport units were specified as follows: The shields are delivered as completely pre-assembled units.

points of attachment

As far as technically possible, the load units are provided with suitable and fixed points of attachment for transport and assembly. If not, adequate threaded holes or other provisions are available for the temporary attachment of parts. Details on the arrangement and load-carrying capacity of the attachment points are given in the spare parts catalog or on the special drawings for transport assemblies which are added in the annex to this manual, if required.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with a medium sensitive to frost, for example, an oil-in-water emulsion (HFAE) have to be completely drained and then filled with a frost-proof preserving fluid, e.g.

HYDROCOR® CV 50. If, for technical reasons, the fluid cannot be drained completely choose a preserving fluid which can be mixed with the medium originally used and ensure that the media are adequately mixed.

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

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and are only loaded statically or quasi-statically. External forces are only allowed to be introduced via the points of attachment and absorption surfaces indicated on separate drawings, if any.

The equipment is not allowed to be transported at temperatures below -40 °C. During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

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

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3.5

Transport electrical and electronic components

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

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

transport units

A shield can be transported as a completely assembled unit or divided into transport units. If dismantling into transport units is necessary, this is planned and laid down in close cooperation with the costumer.

Tab. 2: Transport units Transport position

support unit complete

as for normal use

sideflipper

hydraulic cylinders on top

Remarks

For the purpose of ensuring safety during transport, the movable parts of each transport unit must be fastened such as to prevent their changing their position inadvertently, if required in addition to the standard securing devices, e.g. on side seals and flipper. The following transport safety devices are provided on the transport units: E

Tab. 3: Transport safety devices Part

Transport safety device

relay bar, faceside

transport rod

1

relay bar, gobside

chain

1

hydraulics

hydraulic ports not used are closed with protection caps or plugs

-

Quant.

CAUTION! Transport safety devices may get damaged during transport to the mine, for example when loading and unloading the transport units. Therefore, check all transport safety devices for damage and replace damaged ones before allowing transport of the units in the mine shaft. Damaged transport safety devices may be the cause of serious damage to the transport unit or to the transport shaft if load units are transported suspended under the cage with damaged or inadequate transport safety devices.

CAUTION! If the points of attachment on the caving shield are to be used for transporting the assembled support unit, canopy and base skid must be connected mechanically by means of an additional transport safety device to prevent them moving apart.

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transport safety devices

Designation

Transport Fig. 8:

Transport of shields as complete unit S1 S0

820

943

Sy

H

S2 X1 X2 Sx L

S2

B

990

S1

4956

DBT GmbH, Lünen 2005

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S1

S1 lifting eye, 2 on the caving shield, load-bearing capacity: 15000 kg S2 lifting eye, 2 on the base frame, load-bearing capacity: 15000 kg X1, X2 securing elements to fix the relay bar during transport, faceside and gobside So center of gravity

For transportation use the four lifting eyes S1 and S2 Tab. 4: Shield support 7420 145 000 00 01, dimensions and weight Variant

Order no.

01 7420 145 000 00 01

1)

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Length in mm 7840

Width in mm 1800

Height in mm

Sx/Sy in mm

Weight approx. in kg

1321 1510 / 774

31035

Sideflipper and protective wall detached.

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3.7

Transport

Fig. 9:

Securing elements to fix the relay bar, transport rod (faceside)

1

2

Fig. 10: Additional securing elements to fix the relay bar, chain (faceside)

1

2 3

1 chain 13x39 2 hex. head screwe M 16x50-8.8 3 hex. nu M 16-8

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1 spring clip 2x 2 transport rod

4

Installation

Pre-assembly of the shield units

Installation This chapter contains information on the installation of the shield units. Please pay particular attention to the warnings and tips.

WARNING! When performing any work, observe the safety instructions given in this manual and also the special safety instructions and operating manuals provided by the mine management.

Failure to comply can lead to most serious accidents which might even result in death.

CAUTION! Prior to assembly, sockets and nipples of the plug-type connectors must be treated with lubricating paste B3 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

DBT GmbH, Lünen 2005

E

CAUTION! Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

Pre-assembly of the shield units The shields are delivered as completely pre-assembled units.

Hence, no further pre-assembly is required for the mechanical and hydraulic systems of the shields.

Installation of the shield units CAUTION! For transport underground only the attachment points detailed in chapter 3 ”Transport” are allowed to be used. Further information is given in chapter 3 ”Transport”. Failure to comply may lead to personal injury and damage to property. installation plan

The shields are installed in the longwall face in correspondence with the installation plan of the mine.

IMPORTANT! When installing the shields in the face, be sure to observe the shield numbers. Since the individual shields might be provided with different functions they must be arranged in the specified order.

identification for installation in the face

shield number

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To facilitate identification for assembly and installation in the face the shields or the transport units should be provided with consecutive numbers. This numbering should, for example, correspond to the order in which the shields are to be arranged in the face. The numbers should be written on the surface of the components with a clearly visible color.

The shield number is an identification feature. All shields are numbered consecutively. Firmly attached plaques showing the respective shield number are provided at the base skid.

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4.3

Installation of the shield units

E

Shield number at the base, example

Tab. 5: Allocation of shield numbers shield no.

order no

application

G1 to G8

7420 145 000 00 01

face endshield

Supply connections During installation, the individual shields can be supplied with pressure and operated using the socalled auxiliary supply line. The auxiliary supply line must be connected to ports a and b (fig. 12) Fig. 12: View on the auxiliary ports of the face shield

a

a pressure line

b

b return line

When using the auxiliary supply line, the shield functions must be operated via an additional external PMC®-R control unit connected to the internal PMC®-R control unit by a cable (see separate operating manual for the PMC®-R control unit).

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Fig. 11:

Installation of the shield units The ports for the auxiliary supply line are located at the L.H. side under the canopy (see fig. 12 and in chapter 5, Hydraulic flow plan, fig. 23).

When using the auxiliary supply line, ports P, R, and W (see fig. 13) of the manifold block must be closed by connecting the hoses which later provide the connection with the adjacent shield (as a rule, this is the as-supplied condition). Should it not be possible to connect the hoses to these ports the latter must be closed by plugs.

To interconnect the shields please proceed as follows:

. Close the high-pressure ball valves items 31, 29a, and 29d (see fig. 13 and in chapter 5, Hydraulic flow plan, fig. 23)

. Remove all sealing plugs from ports a and b (see fig.12 of the auxiliary supply line.

. Connect the auxiliary supply line with the pressure and return lines of the pump.

. Open the high-pressure ball valves, items 31 and 10.

(After the valves have been opened the hydraulic pump pressure will be available at the electrohydraulic control) DBT GmbH, Lünen 2005

E

. The high-pressure ball valves item 9 (see chapter 5, page 5.24 figs. 30 and 31) at the prop check valves must be open. (the shield can now be operated via the external control unit)

. Move the shield to the desired position. . Close the high-pressure ball valve item 31 to interrupt any further pressure supply.

. Operate the function ”lower props” for a short time until the pressure hose is depressurized.

WARNING! Incorrect operation can cause pressure to build up in the return line. Such pressure has to be relieved via the relief valve (item 23, see fig. 13) by turning in the vented cap screw. After pressure has been relieved turn the screw back as far as it will go.

Take care to make sure that all hoses are depressurized before you start loosening the connecting lines at the manifold block!

. Detach the three connecting lines P, R, and W from the manifold block and connect them with the adjacent shields.

. Pressure-relieve the ports of the auxiliary supply line. . Remove the connecting lines of the auxiliary supply line and close the ports with the sealing plugs.

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4.5

Installation of the shield units Fig. 13: View on the manifold block of the face endshield

8 29d

a b

23

P R

29a 30

10

31

W

4.6

30 high-pressure ball valve (water supply line) 31 high-pressure ball valve (auxillary high pressure line) a PMC®-R control unit b water hose R return line DN 50 P pressure line, DN 40SS W water line, DN 50

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

8 dual filter, back flush type 10 high-pressure ball valve (pressure line) 19 manifold block 23 plug-in socket with relief 29a high-pressure ball valve (auxillary high pressure line, water) 29d high-pressure ball valve (shut of water hose)

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19

Installation of the shield units Fig. 14: View of the dual filter of the face endshield

8

10

10 high-pressure ball valve (pressure line)

DBT GmbH, Lünen 2005

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8 dual filter, back flush type

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4.7

Requirements to the face hydraulic system Coupling between the connections The hydraulic connectors are plug-type connectors according to DIN 20043. hydraulic system

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each shield unit. This pipe provides the hydraulic supply to the individual shield unit. The manifold pipes of adjacent shield units are connected with the use of three hose lines: A pressure line (DN 40), a return line (DN 50) and a water line (DN 50). See the hydraulic block diagram in chapter 6.

control unit

The shield units are equipped with an electronic control unit of type PMC®-R. The connection between the control unit and the electrohydraulic control block is provided by a solenoid driver module.

The connecting cables required for this purpose are included in the scope of supply of the PMC®-R control system. How to connect the control unit is described in the separate operating manual for the PMC®-R control system. An overview of the design of the control is also given in chapter 6 of this operating manual in the section titled ”shield control”.

additional equipment

Provision is made on the shield units to allow the attachment of additional equipment which is not included in DBT’s scope of supply, as for example: J two-way intercom system

For information on the installation of the additional equipment, please refer to the pertinent operating manual of the respective manufacturer.

Requirements to the face hydraulic system hydraulic medium

For all hydraulic components included in the scope of supply of DBT, the hydraulic medium must meet the following requirements: Purity class 18 / 14 to ISO 4406 Pressure fluid according to list of approved products, see section ”Permissible media” in chapter 6 of this manual. nominal pressure

320 bar

admissible tolerance

10 % of nominal pressure

CAUTION! Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

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J lighting system

Start-up Start-up WARNING! The first start-up and the test run should only be performed by a well-trained and experienced crew who are familiar with the special conditions prevailing in underground mines, particularly with the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

NOTICE! Take care to ensure that all transport safety devices required for transport have been removed. See chapter 3, section ”Transport”.

To be observed prior to start-up Start-up must be performed by trained and qualified personnel. If the mine uses the shield support for the first time, it is imperative that the DBT field service is present during start-up.

Please observe the following items: J Mechanics

. Check to make sure that all transport safety devices have been E

removed.

DBT GmbH, Lünen 2005

. Check all mechanical connections on the shields . Check attachment of the shifting unit.

On shifting units with adjustable crawl pan make sure that the crawl pan has been attached properly. Never use the last slot for connection.

J Hydraulic system

. Test the entire hydraulic system for leaks. Seal any connections that are leaking.

. Check whether shield movements, particularly in the links, could cause damage to hoses.

DANGER! Damaged hoses might burst and hydraulic fluid could escape under high pressure. This could severely injure or even kill you or others.

Make sure that the movements of the shield do not cause any damage to the hose lines.

Lay the hose lines correctly behind the retainers provided for that purpose.

. Check the hydraulic supply pressure. . Check supporting power of the props. (observe pressure gauge reading)The actual pressure under the piston of a prop can be read off the PMC®-R control unit. You can either read off the pressure of an adjacent support or of the support where you are currently located. The pressure gauge at the prop check valve indicates the pressure direct.

. Check all operating elements to make sure that the correct function is executed when actuating the respective operating element.

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4.9

Start-up J Signalling and lighting systems, information signs

IMPORTANT! For details, please refer to the respective separate operating manual of the manufacturer.

. Check all signalling systems. . Check that the face is illuminated sufficiently. . Check that the face area, especially the travelway, is provided

with all signs required. It is imperative that you observe the regulations of the responsible mining authority.

J Emergency stop systems

. Check that all emergency stop systems function properly.

J Mining and conveying

. Check all functions of the longwall system before start-up. . Check correct interaction of the complete longwall system (mining machine, conveyor system, shields).

WARNING! Canopies must not be sloping downwards and reach into the track for the mining machine.

Bring the shields into initial position, which means: J shields and conveyor are aligned in a straight line, J the shields are aligned at right angles with respect to the conveyor, J the shield canopies are parallel to the floor.

Check the shields for any installation errors or any other sources of errors.

. Check all line connections made during the installation of the

shields, particularly the supply lines for the hydraulic system of the shields, to make sure they are complete and correct.

WARNING! Do not install shut-off valves into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could e.g. cause hose lines to burst. This may result in serious injuries to persons or even death.

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

. Check all functions of the shield control system.

Do not allow the shield to be operated until all defects have been eliminated and the shield is fully functional.

Corrosion protection of hydraulic components Before delivery, DBT hydraulic components are provided with a corrosion preventing medium for testing purposes.

There are no special measures required to remove remnants of the testing fluid before putting the hydraulic components into operation.

The testing fluid is fully compatible with the permissible media listed in the section “Hydraulic Fluids” in chapter 6.

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Start-up of the shields

5

Operation

Basic requirements

Operation This chapter provides general information on the operation and maintenance of the shields. This information is to be regarded as preparation of or addition to hands-on training. Reading of this chapter is recommended in addition to the training measures, but it in no way release the operator from participating in the training.

DANGER! You are only allowed to operate the shield control if you have a profound knowledge of the control elements and of the way the control system works. You must have been task-trained on the present control system and should have practiced to deepen your knowledge. Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

DBT GmbH, Lünen 2005

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

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

Basic requirements Conditions for operation face crew

The face crew must be informed about possible danger situations.

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

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

face equipment

The face must be illuminated sufficiently.

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

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

conveyor overload

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

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

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5.3

Basic requirements travel way

The minimum dimensions for the travelway specified must be maintained.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travelway: Width: 600 mm Height: 400 mm If the support is used in countries other than the Federal Republic of Germany the respective regulations applicable in those countries must be observed.

Debris or objects lying in the travelway must be removed immediately. This does especially apply for low seam heights.

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

roof supporting work

Care must be taken that the filling section of the face conveyor remains unobstructed. This means that the canopies of the shields must be set against the roof immediately after the shields have been lowered and advanced.

work in the mining track

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

The conveyor and the space above the conveyor may only be entered if there is a protection against fall of rock from the roof.

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

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

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

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

On inclined faces the conveyor must additionally be provided with barriers, for example air cushions, which have to be fitted above the place where the work has to be carried out. Their number and type depends on the gradient and other local conditions.

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DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

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

E

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

Basic requirements repair work

Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been depressurized. In addition, you should take adequate measures to prevent any unauthorized persons from restoring pressure.

If support units are to be detached from the conveyor, stop the mining operation completely or ensure by other means that the mining work continues only outside the safety zone required to safely perform the repair work.

Components which are subject to mechanical stress or hydraulic tension are only allowed to be loosened or removed after they have been relieved of their tension or stress, for example by aligning, lifting or lowering.

If, in exceptional cases, the tension or stress cannot be relieved completely, it should be reduced as far as possible and the respective component be secured by suitable means such as for example chains or locking elements to permit the tensions to be absorbed safely when they occur. Any work in this area is only allowed to be performed from a safe position.

DBT GmbH, Lünen 2005

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Protection equipment increases safety; it is only allowed to be removed if this is required for performing the work. After completion of the work, the protection equipment should immediately be installed again properly. water spraying system

The water spraying system is designed for the active suppression of dust. The shield support is equipped with several nozzles which spray water as and if required. Depending on the operating mode of the installation, the spraying system will be activated from time to time, for example when advancing the support and when the mining machine passes the support. Operation of the spraying valves is program-controlled via the electronic shield control or direct by the hydraulic shield control system.

conveyor steering devices

On inclined faces, the conveyor has to be secured by anchorages, if required. This measure is required to prevent the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid.

Hydraulic anchorages must always be supplied with the specified working pressure. Only thus is a sufficient anchorage between support and conveyor ensured.

When pulling up the shields, always observe the specified sequence of steps. If not, the anchorage device might be damaged and become unfit for use.

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5.5

Basic requirements Safety requirements automatic mode

Exercise special care and caution when travelling a face that is operated automatically. Be sure to observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be prepared for the shield which you are in being addressed by the automatic system. Therefore it is vital that you observe the acoustic and optical warning signals sent by the control unit of a shield which is just being operated.

Operate the ”support lock-out switch” when you have to stay in a shield for a longer period of time.

shield operation

A shield must always be operated from a safe position and from within an adjacent shield.

Never ever stay under a shield which has not been set.

Take care that no part of your body ever gets between the canopy and the roof, the base and the floor, skid and shifting unit or between the side seals of adjacent shields.

You are not allowed to lower or advance a shield as long as a person is in the immediate vicinity of the support unit or in the support unit.

You are not allowed to lower or advance a shield manually when the mining machine is before or in the range of action of the support unit.

On inclined faces, shield advance should be started in the lower section. Since the shields are to be operated by adjacent control, the operator can operate and observe the unit to be advanced from a safe position within the adjacent shield.

The props of the shields must always be set until the setting pressure has been reached to ensure good roof support and in case of shields with special functions, e.g. shields serving as abutments for conveyor alignment systems, sufficient anchoring between roof and floor.

The shields must be advanced as soon as possible to prevent the potential danger of roof fall-outs.

5.6

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

Nobody is allowed to stay in a shield which is being advanced.

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When operating the shield manually the operator has to always watch the area of movement of the shield before and while operating the shield in order to prevent potential hazards by cautious behavior.

Basic requirements Fig. 15: W r o n g , shields have not been advanced in the right time

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Fig. 16: C o r r e c t, shields have been advanced in time

A canopy which is sloping downwards at a step in the roof must not obstruct the passing of the mining machine.

The flipper must be folded back completely prior to advancing the shield unit. Never advance a shield against the coal face with a folded-out flipper. Otherwise the flipper cylinders and the link joints of the flipper will be damaged seriously.

While advancing a shield unit special care must be taken that the shield canopy does not get under the side seal of an adjacent shield. Otherwise the side seal of the adjacent shield will be damaged seriously. hydraulics, controls

Take care to avoid misoperation of the shield control.

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

Hoses must remain free to move. They must not be squeezed or overstretched. Care must be taken that they are properly bundled.

Damaged hydraulic hoses and hose connections must be replaced at once. This work must only be carried out by trained persons.

Hose lines between pilot-operated check valves and props or cylinders, which have a load-accepting function, e.g. stabilizing cylinders or swivel canopy cylinders, may only be replaced after the canopy and the caving shield have been secured in position mechanically. This also applies to the work on the articulations.

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5.7

Basic requirements Shut-off valves must not be installed in the return line.

To prevent damage in case the return line is closed safety valves of nominal diameter 32 relieving to atmosphere should be installed additionally into the return line, spaced about 40 m apart. Relief pressure 25 bar. damages, spare parts

Special observations, in particular concerning defects or damage, have to be reported immediately.

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Machine parts and hydraulic elements may only be replaced by genuine spare parts.

5.8

DBT-Shield 1321/3048-2x5655-1860

Operation of the shield Operation of the shield A good training of the operating personnel, knowledge and observance of the safety regulations and of the operating instructions listed afterwards largely help to prevent the occurrence of hazardous situations. Moreover, they are good prerequisites for a reliable interaction of shield and mining machine within the longwall system.

If the shield is equipped with an electrohydraulic control system, a profound knowledge of the separate operating manual for this control system is absolutely necessary for shield operation.

The shields must be set until the setting pressure has been reached to ensure good roof support and, in case of shields with special functions, e.g. shields serving as abutments for anchorages, sufficient anchoring between roof and floor.

It is a general rule that the shields should be advanced as soon as possible to achieve an early support of the newly mined roof.

The support units must be aligned at right angles with respect to the conveyor.

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canopy adjustment

The shields must always be set in such a way that the canopies and the bases are as parallel as possible. Within the maximum angles given in the technical data sheet it is possible, however, to adapt the canopy to steps in the roof and to overcome steps in the floor, if required by geological or operational conditions.

CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

Fig. 17: Shield in the normal position

α=0 M

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

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5.9

Operation of the shield CAUTION! Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

This is the only way of cushioning high peak loads, which may occur suddenly, by the hydraulic securing action of the stabilizing cylinders. If the residual stroke is not sufficient, this may result in serious damage to the shield under unfavorable leverage conditions.

Fig. 18: Shield with extremely inclined canopy

s1

α1

α2

s2

M

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

CAUTION! Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of a tendency to roof fall-outs and/or extremely soft floor.

This applies especially if the shield control unit is equipped with an automatic positive setting function. Under unfavorable conditions for example, soft floor and in addition, perhaps a tendency to roof fall-outs - the automatic positive setting function could lead to the stabilizing cylinders not having sufficient residual stroke or being extended or retracted completely. Therefore, operate the shield in such or similar cases without automatic positive set.

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M

Operation of the shield CAUTION! Avoid an excessive inclination of the canopy by filling roof fallouts or by supporting minor fall-outs with the shield in horizontal position.

At this point, we explicitly emphasize again that any damage caused by the non-compliance with these instructions is possibly not covered by the guarantee.

CAUTION! Do not exceed the angles of inclination of the canopy (angle between shield canopy and caving shield) specified in chapter 6 ”Technical data”. If the angles are exceeded, this will cause damage to props and hydraulic cylinders, their arresting elements as well as the articulations of the components.

Since changes in the angles result in considerable changes in height at the ends of the canopy or skids, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the floor and roof, or fill cavities the roof.

DBT GmbH, Lünen 2005

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Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 19) if the stabilizing cylinder is fully extended. There must always be sufficient stroke available for decreasing dynamic loads from the roof by the hydraulically protected stabilizing cylinder.

Fig. 19: W r o n g, by no means must the tip of the canopy be set in a cavity, if the stabilizing cylinder is fully extended.

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 20) or by leveling off the canopy.

By these measures the roof will be caught during the next step.

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5.11

Operation of the shield Fig. 20: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

Care must be taken that a canopy which is sloping downwards at a step in the roof does not obstruct the pass of the mining machine.

The closed height of the shields must be suitable for the lowest seam height.

The shield must be operated such as to ensure that there is always sufficient residual stroke available for lowering. If not, the shield might get jammed between the roof and the floor and may be heavily damaged by sudden load peaks - for example caused by a mountain bump. Load peaks cannot be cushioned hydraulically when there is not enough hydraulic fluid under the piston of the prop or the piston already has reached its bottom dead center position.

The minimum residual stroke required for lowering the shield can be maintained by J keeping the seam opening sufficiently large by means of the

mining machine J avoiding the accumulation of debris and fine coal on the floor J removing accumulated dirt from the canopies

Before the shields are advanced, the floor must be clear of coarse debris so that the shields can be advanced by the full length of the stroke without obstruction and subsequent advance of the conveyor is not impeded. Besides, a clean floor facilitates corrections in the attitude of the shields.

If the seam height increases considerably and the hydraulic stroke is not sufficient the props have to be extended in time or replaced by props with a larger stroke. You are only allowed to use approved components.

When extending the props or retracting the extensions, the canopy must be secured in position. Make sure that the prop which has been separated from the canopy cannot turn over.

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range of adjustment / changing seam thickness

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Accumulation of dirt on the canopies can be avoided by advancing the shields under roof contact. In some cases it is possible to let the dirt fall onto the conveyor or to clear it away after lowering the tips of the canopies for a short time.

Operation of the shield inclined faces

Particularly in inclined workings sliding and canting of the shields must be avoided by correcting their attitude in time by means of the side seals and steering devices. This is to prevent a shield from getting under the canopy of its adjacent shield, often causing considerable damage.

Since in inclined workings shield advance starts as a rule in the lower section of the face, a correct attitude of the end shields is of importance. For correcting the attitude, hydraulically operated guide beam assemblies and steering devices at the canopy and the base or between canopy and base are used.

The side seals can be used with automatic controls to prevent tilting of a lowered shield during advance. Any corrections in the attitude becoming necessary can be carried out by means of manual control only.

The side seal of the caving shield is only allowed to be used for alignment with respect to the adjacent shield if the two shields have been advanced to the same extent.

On inclined faces, the conveyor has to be secured with anchorages. This measure prevents the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid which would make shield advance difficult.

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When pulling up the shields, always observe the specified sequence of steps. If not, the conveyor anchorage device might be damaged and become unfit for use. Further information, if any, is given in chapter 6, section ”Accessories” and in the operating manual for the conveyor anchorage device. unfavorable floor conditions

With unfavorable floor conditions, the base frame of the support unit might sink into the floor. In this event, the base frame must be raised during shield advance to make sure that the installation follows the seam line and does not sink into the floor.

Shields which are equipped with a hydraulic base lifting device are raised out of the floor by operating a valve or automatically during shield advance.

Shields without base-lifting device require different procedures, depending on their design: J Individual skids of two-leg shields can, as a rule, be lifted

hydraulically by retracting a prop.

J shields with solid bases must be lifted and underlaid by means

usually applied in mines.

IMPORTANT! Both cases require knowledge of the flow plan and skilled personnel. The safety guidelines contained in this manual must strictly be observed.

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5.13

Safe working Safe working For safety of the operator the shields are provided with adjacent controls; i.e. each shield is operated using the controls located in the shield to the left or to the right of the unit to be advanced, or by automated remote batch control.

WARNING! Always stay clear of a shield which is being moved. Circumstances which are not always obvious may lead to unexpected movements of the shield unit which could result in severe injuries or even death.

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

CAUTION! Take care not to damage the push-buttons of the pilot valves.

Jammed push-buttons will cause malfunctions of the valves which may result in accidents.

Always observe these safety rules :

Follow these steps if a shield has failed to advance : 1. Determine reason for failure to advance, there may be: J Malfunctioning of electronic controls J External obstructions:

– shield wedged in between adjacent shields – canopy has tip lodged in roof – floor step or excessive debris in front of base tip 2. In case of malfunction of the automated batch cycles, advance the shield manually in single step mode by use of the control unit of the adjacent shield unit. See separate manual of the electronic control.

3. In case of external obstructions utilize adjacent manual control to overcome the obstruction(s).

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When groups of shields are advanced automatically, nobody is allowed to stay in the area between the operator and the shield to be moved.

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Keep all parts of your body under the canopy of a set shield and away from the shield in motion or about to be advanced.

Operation of the shield hydraulics Operation of the shield hydraulics WARNING! During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. Pay attention to the separate manual of the electronic control system.

Location of hydraulic components at the shield Tab. 6: Hydraulic components Item 1

Qty. 1

3 4 5 6 7 8 9

1 1 1 2

check valve, NW 25 in-line-filter, NW 20 dual filter, back flush type high-pressure ball valve

manifold block under the canopy, L.H. under the canopy, R.H. on each prop check valve

tank line water supply manual operated, at holder red handle

10

1

high-pressure ball valve

12

2

high-pressure ball valve

13

1

pressure relief valve, 80 bar

red handle in the pressure line a) red handle, compensating valve b)red handle, for lifting cylinder connected to return line

14 16

2 2

pressure relief valve, 440 bar pressure relief valve, 420 bar

17

2

pressure relief valve, 420 bar

18

1

water spray valve

19 20 21 22 23

1 1 1 1 1

manifold block hose lines water spray system retainers and accessories plug DN 10

under the canopy close to dual filter a) prop check valve, R.H. b) under the canopy behind prop L.H. under the canopy close to manifold block on each leg gobside a) shifting ram valve b) piston line of lifting cylinder at stabilizing cylinder, for pisten and rod a) under the canopy behind leg L.H. b) 2x under the canopy in front of leg L.H. unter the canopy between legs

24 25 28 29

4 4 2 5

prop check valve NG 20 prop check valve NG 20 pressure gauge connection high-pressure ball valve

30 31

1 1

high-pressure ball valve high-pressure ball valve

35 S1 Z1 Z2

2 1 2 1

pressure gauge pressure sensor prop shifting ram

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Location centric under the canopy

1 1 1

Description electrohydraulic control unit 10 functions accumulator cartridge shifting ram check valve twin check valve

Remark at holder

electrohydraulic control unit under the canopy, R.H. mounted to stabilizing cylinder

under the canopy close to the manifold block prop, front L.H. prop, front R.H on each prop check valve a) auxillary high pressure line, to flush canopy water sprays b) to separate canopy water sprays and lemniscate water sprays c) 2x to separate the front and middle water sprays of the water curtain d) shut off water hose water inlet line under canopy L.H. auxillary high pressure line, under the canopy L.H. on each prop check valve at prop check valve, only R.H.

for piston chamber and annulus

at holder subassembly subassembly subassembly in the return line

test and pressure reliev port a) water circuit, blue handle

blue handle red handle

1) deviating quantity for end shield variants with pusher cylinder and / or side flipper

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5.15

Operation of the shield hydraulics Qty. 1 1

Description stabilizing cylinder lift cylinder

Location

Remark

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Item Z3 Z4

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Operation of the shield hydraulics Shield hydraulics Fig. 21: Shield hydraulics, arrangement, Z-Nr. 8112 210 000 00 00 key, see table 6 13 6

29a 31 23 18 30

29c

8

20

7

12

3

1

22

16 29b

4 16 21

17

5

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14

35

10 9 35

12 9

28

28

24 19

25

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5.17

Operation of the shield hydraulics

Fig. 22: Functions of electrohydraulic control unit, symbol plates shield variant 01 .

DBT GmbH, Lünen 2005

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Switch board diagram

Instruction plate 10 functions

Tab. 7: Electrohydraulic control units with 10 functions, allocation of functions

Function

5.18

Function no.

advance shield

1

set both props

2

advance conveyor

3

lift cylinder, extend

4

stabilizing cylinder, extend

5

stabilizing cylinder, retract

6

not used

7

not used

8

water sprays lemniscate and canopy

9

lower both props actively

10

DBT-Shield 1321/3048-2x5655-1860

Operation of the shield hydraulics Fig. 23: Shield hydraulics, Z-Nr.: 8112 210 000 00 00, Blatt 2/2 key, see table 6

3

19

31

29a 23

10 8 1

6

29d 30

13

DBT GmbH, Lünen 2005

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7

18

29b

Z4 21

12 16 14 35 28 9

S1

35 28

12

9

Z2

4

14

24

17

25

16

20

Z3 5

Z1

Z1

17

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5.19

Operation of the shield hydraulics Fig. 24: Hydraulic lines, overview, Z-Nr.: 8112 210 010 00 00 key, see table 6

5 17

29b 12b 16b

DBT GmbH, Lünen 2005

* *

B PB PA A A

4

E

16a

24 28 35

A PB PB PA AAA

25 28 35

R K

ZA PB PB PA AAA

S1

9

9

14

14

1, 3 18 8

7 30 19

6

10 29c

5.20

12x800 12x700

23

31

29a

13

DBT-Shield 1321/3048-2x5655-1860

Operation of the shield hydraulics Fig. 25: Shield 7420 145 000 00 01

a 8

19

3

19 manifold a PMC®-R control unit

DBT GmbH, Lünen 2005

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3 control valve block 8 dual filter

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5.21

Operation of the shield hydraulics

Fig. 26: View on the manifold block of the face endshield 29d

8

a b

23

P R 10

29a 30

W

31

19 a PMC®-R control unit

water) 29d high-pressure ball valve (shut of water hose) 30 high-pressure ball valve (water line)

b water hose

P pressure line, DN 40SS 31 high-pressure ball valve (auxiliary high pressure line)

W water line, DN 50

Fig. 27: View on the dual filter of the face endshield

8

10

8 dual filter, back flush type

5.22

10 high-pressure ball valve (pressure line)

DBT-Shield 1321/3048-2x5655-1860

E

R return line DN 50 DBT GmbH, Lünen 2005

8 dual filter, back flash type 10 high-pressure ball valve (pressure line) 19 manifold block 23 plug-in socket with relief 29a high-pressure ball valve (auxiliary high pressure line,

Operation of the shield hydraulics Fig. 28: PMC®-R control unit, under the canopy L.H.

a b

c

d a PMC® -R control unit b holder for PMC® -R control unit

c Emergency-Stop button d Local-Lockout button

Fig. 29: View on the props with proctective cover for prop check valve

DBT GmbH, Lünen 2005

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1

1 protectiv cover Fig. 30: Prop L-H., face side, shown without protective cover

28

35

9

24 S1

9 high-pressure ball valve, serves to isolate the prop piston chamber from pressure supply, closed as shown 24 prop check valve

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28 pressure gauge connection (test and pressure reliev port) 35 pressure gauge S1 pressure sensor

5.23

Operation of the shield hydraulics Fig. 31: Prop R-H., face side, shown without protective cover

28 35

9

12a 25

5.24

28 pressure gauge connection (test and pressure reliev port) 35 pressure gauge

DBT-Shield 1321/3048-2x5655-1860

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25 prop check valve

DBT GmbH, Lünen 2005

9 high-pressure ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown 12a high-pressure ball valve, shown closed open enables auto aligning function of the canopy, if open

Operation of the shield hydraulics Fig. 32: View under the canopy, back L.H.

12b 16b

29b

a

DBT GmbH, Lünen 2005

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12b high-pressure ball valve, for lifting cylinder 16b pressure relief valve, piston line of lifting cylinder

29b high-pressure ball valve, to separate canopy water sprays and lemniscate water sprays a lemniscate nozzle

Fig. 33: view under the canopy, back R.H.

4

a 16a

4 check valve for shifting ram 16a pressure relief valve for shifting ram

a lemniscate nozzle

Operation of the dual backflush filter

Doc. No.: 7420 145 000 BA 00

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5.25

Operation of the shield hydraulics WARNING! Do not put the filter into operation, prior making sure that all connections have been made properly. operation

The filter works, if both backflush levers are in parallel position. The filter needs to be backflushed after contamination accumulates to the point of increased pressure drop and restricted flow.

flushing

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

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

Only one filter element must be backflushed at a time by simply turning the lever 90 degrees for about two seconds and then returning the lever to the working position. Repeat procedure for the other filter element.

Effective backflushing requires flow in excess of 70 I/min (19 GPM).

DBT GmbH, Lünen 2005

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Fig. 34: View on the dual filter

8

B

A

8 dual filter, back flush type A normal operation: both levers in position “A”

5.26

B

A

B back-flushing: one of the levers in position “B”

DBT-Shield 1321/3048-2x5655-1860

Operation of the shield hydraulics Repair and emergency operation This section contains information on the functions and the operation of the hydraulic control which may only be used in exceptional situations, i.e. during repairs and emergencies. It is assumed here that the shield has been previously installed correctly and that all the shut-off valves are open as for normal operation.

The operation of the control unit of the electronic control system is not described here but in a separate operating manual. If the control unit is part of the DBT scope of supply you will find the corresponding operating manual in the DBT documentation on the system.

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

It has also been assumed that the reader is familiar with the fundamental principles of the hydraulic shield-type support and the operation of the control unit.

DBT GmbH, Lünen 2005

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WARNING! The control elements on the control valve block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose. They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries. During normal operating mode, the shield is operated exclusively by means of the electronic control. In this respect it is imperative that you observe the separate operating manual of the control unit. If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

Fig. 35: Arrangement control unit PMC®-R

a

b c

a control unit PMC® -R b Emergency Stop button

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c Local-Lockout button

5.27

Operation of the shield hydraulics Figure 35 above shows the arrangement of the PMC®-R control unit and the control valve block.

How to use the PMC®-R control unit is not described in this manual.

See separate manual for the PMC®-R control unit.

Fig. 36: Electrohydraulic control (10 functions), centric under the canopy

c

3 b a d

1 electrohydraulic control 3 accumulator cartridge a push button

b pilot valve c connecting cable d symbol plate

Fig. 37: Symbol plate for 10 function control valve block

The symbol plate is located at the control valve block underneath the pilot control valves. The symbols on the plate correspond directly to the functions activated by the respective push buttons.

The meaning of the symbols and the functions is described in the following.

5.28

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

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1

Operation of the shield hydraulics Operation and functions of the control valve block This section contains information on the functions of the control valve block. Please be sure also to observe the operating instructions for the hydraulic control valve block and the electronic control unit.

WARNING! You are only allowed to operate the controls of the control valve block when you know exactly which effects the functions have with respect to the shield. Therefore you should have received adequate training. If not, there is a risk of operating errors involved which might cause severe injuries to persons, possibly resulting in death.

Control of the shield is particularly dangerous during repair operation as you then operate the shield under which you are standing direct. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

No other persons are allowed to remain in the movement area of the shield as long as you are operating the shield using the repair mode.

DBT GmbH, Lünen 2005

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There are two push-buttons on the cover of every single pilot control valve. When you press a button, the corresponding working valve is operated directly.

The function stops as soon as you release the push-button.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or death to the operator.

Therefore, never fix the push buttons and take care to ensure that damaged pilot valves are always replaced without delay.

WARNING! The manual operation of a push button on one of the pilot valves causes the direct execution of the respective function.

In this case, dependencies between the individual functions will not be considered. This could lead to dangerous situations if, for example, functional sequences are initiated in the wrong order. For example, the function ”advance shield” can be activated without the functions ”retract side seal” and ”actively lower shield” having been actuated before. This could cause hazardous situations resulting in very severe injuries.

Doc. No.: 7420 145 000 BA 00

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5.29

Operation of the shield hydraulics 1

Advance shield Before this function is initiated, the side seal of the shield must be released and the function ”lower prop” must have been executed for both props.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

As long as the function is activated, the pilot-operated check valve sealing off the annulus of the shifting ram is automatically held open.

2

Set both props Before this function is initiated the canopy should be aligned properly.

While this function is performed the lift cylinder will be retracted actively and the dust suppression system will be activated.

This function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

During setting of the props, a canopy bar of the shield which is set at too steep an angle will adjust itself automatically to the roof as long as the function of the compensating valve is not barred.

The canopy bar may then have to be aligned again.

While the props are being set, the pressure limit of the stabilizing cylinder will be reduced by the compensating valve to 200 bar as long as the pressure under the piston of the prop does not exceed 100 bar. This means that the stabilizing cylinder retracts if the canopy bar is inclined at too steep an angle. The canopy bar then presses only with the tip against the roof and automatically adjusts itself to the roof.

Fig. 38: R.H. prop, faceside view

12a

12a ball valve, closed as shown enables auto aligning function of the canopy, if open

5.30

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

The compensating valve and the related isolating valve are located at the R.H. prop as seen looking towards the coal face. See figure 38. When the isolating valve (12a), see figure 38, is open (lever aligned to the direction of flow), the compensating valve is active. If the isolating valve valve is closed (lever across the direction of flow), the compensating valve has no function.

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Compensating valve

Operation of the shield hydraulics 3

Advance conveyor Before initiating this function, ensure that the shield has been completely set to the roof.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

4

Extend base lift cylinder Before this function is executed the props must have been lowered.

The piston chamber of the baselift cylinder is connected to return when this function is not activated.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

The baselift cylinder retracts automatically due to the weight of the shield or when the props are being set.

The ball valve (12b), see figure 39, serves to enable / disable this function. .

Fig. 39: Ball valve L.H. under the canopy

DBT GmbH, Lünen 2005

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12b

12b ball valve, closed as shown shuts off the pressure supply to the lifting cylinder, piston chamber; enables automatic extension of the lift cylinder during shield advance, if open

5

Extend stabilizing cylinder CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

This function causes the canopy tip to raise and serves to correct the attitude of the canopy. It is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

After the attitude of the canopy has been corrected the props will have to be set again.

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5.31

Operation of the shield hydraulics 6

Retract stabilizing cylinder CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Before initiating this function ensure that the adjacent shields are completely set.

The function causes the canopy tip to lower and serves to correct the attitude of the canopy. It is performed as long as the button is held depressed or until the end position has been reached After the attitude of the canopy has been corrected the props will have to be set again.

9

not used

Lemniscate and canopy water sprays The function is performed as long as the button is held depressed.

10

Actively lower both props Before this function is initiated, ensure that the adjacent shields have been set completely.

This function is performed as long as the button is held depressed or until the end position has been reached.

5.32

DBT-Shield 1321/3048-2x5655-1860

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8

not used

DBT GmbH, Lünen 2005

7

Maintenance Maintenance WARNING! When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior. electronic control

. See separate original operating instructions for the PMC®-R control unit.

Special measures one week after start-up

When extensive work has been performed on the hydraulic system or after start-up of a new face there is an increased risk of dirt having entered the hydraulic system. Depending on the degree of contamination this may lead to the filter cartridges getting clogged. This results in the functions being operated slower or not at all. We therefore recommend that you take the measure described above in order to prevent failures occurring during operation of the shield hydraulics.

E DBT GmbH, Lünen 2005

One week after start-up, at the latest, the filter cartridges of the electrohydraulic control valve blocks of the shield control units on the complete longwall must be checked for dirt on a random basis.

If this inspection reveals that there is a high probability of failures due to dirty filters all filter cartridges on the face must be replaced.

piston rods

All shields equipped with a water spraying system require the piston rods of those cylinders which are usually only rarely extended or retracted completely, for example, props and and stabilizing cylinders, to be thoroughly cleaned approximately every 6 months. A suitable preservative should be applied afterwards.

filter cartridges

The filter cartridges of the manifold block and the control valve block of the shield control unit are designed to protect the downstream hydraulic components against damage due to dirt in the hydraulic medium. They have to be replaced regularly only if the filtration in the face supply line is insufficient.

Therefore, it is vital that you see to quality in the treatment of the hydraulic medium.

If problems occur in the preparation of the medium there will be an increased risk of failures due to clogged filters. To maintain operational reliability of the installation, additional measures may then be required. For example, the filters mentioned above should be regularly inspected for contaminations on a random basis. It may be necessary to replace the filter cartridges regularly as a precaution.

pressure relief valve

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

Pressure-relief valves with nitrogen filling must be inspected at regular intervals to check that they function correctly. We recommend to perform sample tests once every three months.

Doc. No.: 7420 145 000 BA 00

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5.33

Maintenance hydraulic high-pressure hoses

dual back flush filter

For reasons of safety and to maintain the installation operative all hydraulic high-pressure hoses must be replaced regularly at least after two years of operation, irrespective of whether they show any signs of damage. If this deadline cannot be met because the end of the section planned to be mined will only be reached shortly after the deadline, the hoses can by way of exception be replaced after the respective section has been completed.

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

Daily maintenance hydraulics

. Check all shield units by visual inspection for hydraulic fluid escaping on the: – hose lines, – control valve blocks, – valves – props,

. Check pressure gauges at the props for any visible signs of damage and correct functioning. steel structure

. Check all shield units by visual inspection for damage to the steel structure, for instance: – on the shifting unit, – bolt connections and retainers – on the side seals, – on holders, etc.

Weekly inspection control unit

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

. Clean the control units, especially the control panel.

NOTICE! It is important that the control symbols are legible to avoid the risk of operating errors and resultant accidents. hydraulic support prop

. Apply grease to the dirt strippers of both telescopic stages using the grease nipples. Use grease A2 according to EWN 7068, see chapter 6 section ”Lubricating greases and pastes”.

5.34

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

– stabilizing cylinder, seal and flipper cylinders.

E

– shifting ram and lift cylinder

Maintenance Fig. 40: Grease nipples at the prop

b

a

a grease nipple at the sleeve holder

b escaping grease at the dirt stripper

To be done every six months DBT GmbH, Lünen 2005

E

. Apply a preservative to the piston rods of the hydraulic cylinders. Details are given in this chapter under the heading ”special measures”.

Assessment of damage according to schedule We recommend to keep records of the damages found. These records should be evaluated regularly, say once a month, and summarized in a damage report. Frequently recurring failures can thus be detected early and the source of the failure eliminated. This will improve the availability of the installation and help to reduce operating cost.

Doc. No.: 7420 145 000 BA 00

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5.35

Trouble shooting Trouble shooting Fault finding on shield hydraulic system The hydraulic circuits of the shields contain a number of modules and components, identified in the schematic drawings. See ”operating the shield hydraulics” in this chapter or the spare parts catalog.

Faults can occur on any of the components. The main cause on hydraulic valves is a by-pass which in most cases is audible to the operator.

The following information will assist you in the detection and elimination of faults.

WARNING! Trouble shooting on hydraulic systems entails an increased accident hazard. Particularly by malfunctions of the hydraulic system and hydraulic medium escaping at high pressure severe injuries could be caused.

Therefore you are required to be very cautious and wear the specified protective equipment. Failure to comply with these instructions could cause severe injuries.

5.36

possible cause

check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shut-off valve in feed line to prop piston chamber is closed.

Open shut-off valve.

Lines to piston chamber and annulus of prop must be open.

Canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

Pilot piston in the prop check valve is not operating.

Check if there is enough pressure to operate the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit. Replace hoses if required.

Props are damaged.

Check prop for damage or leakage (if damaged, replace prop).

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

failure to lower the shield

E

Fault localization

Trouble shooting failure to set the shield

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shut-off valve in feed line to prop piston chamber is closed.

Open shut-off valve.

Lines to piston chamber and annulus of prop must be open.

Canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

DBT GmbH, Lünen 2005

E

Pilot piston in the prop check valve Check if there is enough pressure to operate is not operating. the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

failure to advance the shield

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit. Replace hoses if required.

Props are damaged.

Check prop for damage or leakage (if damaged, replace prop).

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

Step on roof or floor preventing ad- Lower canopy sufficiently to clear the step or vance. put baselift function to ”ON”.

Doc. No.: 7420 145 000 BA 00

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot piston in the pilot-operated check valve is not operating.

Check if there is enough pressure to operate the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in shifting ram circuit. Replace hoses if required.

Shifting ram is defective.

Check - shifting ram for damage - that POCV works correctly.

Disconnect hose on piston side and operate function ”advance panline”. If pressure fluid escapes replace shifting ram.

SSVR / 01

5.37

failure to operate the tip up function

failure to operate the tip down function

5.38

Possible cause

Check / measure required

Faulty prop check valve.

Check prop check valve replacing unit. Continue trouble shooting if pressure continues to drop.

Props are damaged.

Check props for damage (if damaged, replace prop).

Disconnect hose from prop lower port and check if pressure fluid escapes without large prop movement. If so: piston packing defective. Replace prop

Faulty pressure relief valve.

Check pressure gauge reading. Is pressure relief valve weeping?

If so, replace pressure relief valve and check functions.

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shield canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot-operated check valve is not operating.

Check if there is enough pressure to operate the valve (minimum 80 bar).

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

Check cylinder for damage (if damaged, replace cylinder).

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shield canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot-operated check valve is not operating.

Check if there is enough pressure to operate the valve (minimum 80 bar).

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop and/or stabilizing cylinder circuits.

Stabilizing cylinder is damaged.

Check cylinder for damage (if damaged, replace cylinder).

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

failure to maintain the prop pressure after setting the support

E

Trouble shooting

Trouble shooting 3/2-Way valve or pilot valve The valve sticks or a by-pass has formed due to internal leakages.

On the directional valves of the control valve block the latter mainly shows by a clearly audible hissing noise.

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

Defective pilot valves are difficult to recognize as there is no medium escaping at the valve bank. Therefore, there are no obvious signs of a defect, as e.g. fluid escaping.

The 3/2-way valve or the pilot valve may also be defective. valve sticks

. Try to eliminate the problem by operating the functions on the control unit or the control valve block several times.

internal leakage

. Try to locate the defective valve by operating the individual functions one after the other. If the noise stops while a function is operated the respective valve is faulty. You may be required to hold the push-button for the defective function for some seconds before the noise stops.

valve replacement

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

E

manifold pipe.

DBT GmbH, Lünen 2005

. Operate the functions manually to depressurize the system. . Replace the 3/2-way valve or the pilot valve.

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

. Try to eliminate the problem by operating the functions on the control unit or the control valve block several times.

If the problem still exists, the valve may be faulty.

. Check valve and replace, if defective.

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

. Set the props until setting pressure has been reached. . Detach the ”set props” hose line at the POCV. If fluid escapes at the POCV port the valve is defective.

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5.39

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

. Pump props up to roof at set pressure. . Isolate the annulus side of the prop to be checked. To this end, detach the hose line at the prop annulus ports (located at the prop head and the prop cylinder) temporarily and admit pressure to the control port (extend prop) of the POCV.

. Operate the ”set prop” function.

If there is an internal by-pass in the prop, for example due to damaged piston packings, fluid will flow out of the prop lower port. If this happens, the prop must be replaced. If fluid escapes from the detached hoses the POCV is defective.

If no fluid flows from the annulus side hoses or the POCV, the POCV is defective, too.

Pressure relief or pressure relief valves of various types are used in the hydraulic circuit of a shield. pressure relief valves used on props, for example, have a high flow rate while the pressure relief valves used on shifting rams, stabilizing cylinders etc. are designed for a lesser flow rate.

The pressure relief valves for different cylinders or for the piston and ring sides of a cylinder may have different max. value settings.

Please observe the information given in the hydraulic flow plans or in the spare parts catalog.

Defective or blocked filter Operation of the shield is slow although pressure is known to be normal operating pressure. Contamination is assumed to have occurred in the hydraulic system, e.g. after repair work.Check the filters in the hydraulic system. Backflush filters may be cleaned by backflushing. On fine-mesh filters which are, for example, used on the control valve blocks, the filter elements must be replaced.

5.40

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

A faulty pressure relief valve can usually be seen to be weeping or a check on the pressure gauge reveals it is not holding pressure. If pressure fluid still flows out at operating pressure, the pressure relief valve is defective or the discharging pressure setting of the valve used is too low.

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Faulty pressure relief valve

6

Technical data

Shield variants

Technical data This chapter contains important and useful information on the design and a technical description of the shield and its main components.

Shield variants Type 1321/3048-2x5655-1860 The two-leg shield units basically comprise the following main components: J base with lemniscatic links, shifting unit and baselift cylinder J canopy with flipper J caving shield J side seal, moveable at R.H. side only J hydraulic props J hydraulic equipment with hose lines and controls

Five different versions of the same type of shield will be supplied: DBT GmbH, Lünen 2005

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Tab. 8: Variants of the shield (1) Variant

Application

Order-no.

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

Weight approx. in kg

Shield no.

01

face endshield

7420 145 000 00 01

7840 x 1800 x 3048 7840 x 1800 x 1321

31035

G1 to G8

The shield is provided with a solid base which has the two interconnected skids separated by a tunnel.

The caving shield is a solid steel structure and connected to the base via the lemniscatic links.

The canopy transmits the support load of the two hydraulic props into the roof. Connection to the caving shield is via pins and a stabilizing cylinder.

Programmed methods of calculation ensure the best possible support resistance and range of vertical adjustment of the shields.

Props used are telescopic props with equal load acceptance in all stages. They are always double-acting..

The lemniscatic linkage is a mechanism which causes the articulation between the canopy and the caving shield to move on a nearstraight line path over the whole vertical range of the shield, keeping the canopy tip to face distance near-constant.

The shield units are equipped with all hydraulic components needed to perform electrohydraulic adjacent control using the PMC®-R electronic control unit.Main subassemblies

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.3

Shield variants Main subassemblies

3295

1510

130

1321 (52”) 1678 (66”)

820

3048 (120”)

Fig. 41: shield dimensions

3295

1724

1668

transport length 7840 (307”) 1800

370 1720

6.4

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

E

990

Shield variants Fig. 42: DBT-Shield 7420 145 000 00 00, main components 61

11

51 31

41

DBT GmbH, Lünen 2005

E

1

1 base of shield 11 canopy

41 prop 51 stabilizing cylinder 61 electrohydraulic shield control, shield variant 01

31 caving shield

Tab. 9: DBT-shield 7420 145 000 00 01 , variants, applicable components item

description

order no.

1

base

7420.145.300.00.01

10720 shifting ram, dia. 225 8241.279.000.00.00 lift cylinder 8241.280.000.00.00 shifting unit 3853 long 7420.145.330.00.00

11

canopy 5845 long

7420.145.400.00.01

11025

31

caving shield

7420.145.800.00.01

4720

41

prop

8250.113.000.00.00

1575

51

stabilizing cylinder

8241.282.000.00.00

250

61

shield control system - 10 functions -

8112.210.000.00.00

155 el.-hydr. control unit hose lines water spray system retainer & accessories

Doc. No.: 7420 145 000 BA 00

SSVR / 01

weight remarks approx approx. in kg

8154.118.000.00.00 8112.210.010.00.00 8112.210.020.00.00 8112.210.030.00.00

6.5

Shield variants Base with lemniscatic links and central shifting unit The solid base transmits the shield load of the hydraulic props into the floor. The props are supported in an articulated manner in ball sockets welded to the base and secured by bolted prop retainers.

The links of the lemniscate system are hinge-connected with the base by pins.

The type of base described is characterized by having the shifting unit and its guiding device arranged between the skids. The shifting unit is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reverse-mounted shifting unit, the force of the piston surface area is utilized to advance the shield and the smaller force of the ring surface area to advance the pan line. The connection to the conveyor is provided via a universal joint.

A baselift cylinder serves for raising the base out of a soft floor during shield advance.

DBT GmbH, Lünen 2005

E

Fig. 43: Base

1 shifting ram ZE-225/140-1000 2 base lift cylinderr ZE-150/90-300 4 base 5 shifting unit 11 front lemniscatic link 13 rear lemniscatic link 14 pin dia. 169,3x602 15 pin dia. 129,3x592

6.6

18 washer 19 hex. head screw M 30x45-8.8 20 base lift cylinder bearing 21 pin dia. Ø50x143 22 staple DN 40 23 pin dia. Ø16x117 26 pin dia.

27 staple DN 8/10

28 pin dia. Ø70x312 29 locking plate 30 pin 31 retaining clip 32 prop retainer, R.H 33 prop retainer, L.H. refer to the spare parts catalog too

DBT-Shield 1321/3048-2x5655-1860

Shield variants Shifting unit Fig. 44: shifting unit

2

1

1 relay bar 2 clevis assembly for conveyor others: fastening elements, see spare parts catalog

DBT GmbH, Lünen 2005

E

The conveyor shifting unit is arranged in the middle of the base frame. It consists mainly of the relay bar, the shifting ram, the baselift cylinder and the necessary fastening elements. It serves to advance conveyor and shield.

The shifting ram is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reversemounted shifting ram, the force of the piston surface area is utilized to advance the shield and the smaller force of the ring surface area to advance the pan line.

The base lifting device serves for raising the base out of a soft floor during shield advance.

The baselift cylinder is attached in the center of the base to a thrust piece. The component of force produced by the lifting cylinder is transmitted into the floor via the relay bar of the shifting unit.

Functional description 1. Initial position of shield The shifting cylinder of the support unit is retracted.

2. Advancing the shield During shield advance the lifting cylinder presses down on the relay bar of the shifting unit causing the base skid to lift.

WARNING! Risk of getting squeezed between moving parts of the shifting unit and the shield.

Keep away from advancing shield units or such which are going to be advanced.

3. Setting the shield After shield advance the props are to be set. The lifting cylinder yields during the process of setting.

4. Advancing the pan line The shifting cylinder is switched to ”retract”.

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.7

Shield variants Shield canopy The canopy of a shield has the hydraulic props connected in an articulated manner. It transmits the support load of the props into the roof. The canopy is connected with the caving shield by a locking hinge. Stability for the articulation is provided by a stabilizing cylinder.

CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy caving shield) will not be exceeded.

DBT GmbH, Lünen 2005

E

Fig. 45: Canopy

1 canopy, subassembly 2 canopy extension 5 prop head retainer 6 pin 7 retaining clip 8 pin dia. Ø148,5x598 9 locking plate 10 pin 11 retaining clip

6.8

12 pin dia. Ø65x215 13 stapler DN 40 14 pin 15 pin 16 retaining clip 17 pin 18 spring clip 19 spring clip

DBT-Shield 1321/3048-2x5655-1860

Shield variants Fig. 46: Prop head retention

7

6

5

DBT GmbH, Lünen 2005

E

5 prop head retainer 6 pin Ø28x170 7 retaining clip 6x42

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.9

Shield variants Caving shield The caving shield shields the face area towards the gob. It is connected to the canopy by a hinge link and to the base by the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the main canopy to provide stability for the articulation.

Provision is made on the caving shield for the attachment of the cylinders and guide pins of the side seal.

Fig. 47: Caving shield

S1

S2

S2

DBT GmbH, Lünen 2005

E

S1

1 caving shield, subassembly 2 lemniscatic pin dia.169,3x552 3 lemniscatic pin dia. 129,3x552 4 locking plate 5 pin dia.12x120/115 6 retaining clip

6.10

7 pin dia. 65x215 8 staple DN 40 9 retaining clip S1 lifting eye, load-carrying capacity: 15000 kg S2 lifting eye, load-carrying capacity: 15000 kg

DBT-Shield 1321/3048-2x5655-1860

Shield variants Technical data of the shield, steel structure

DBT GmbH, Lünen 2005

E

Endshield permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . deg

15

closed height . . . . . . . . . . . . . . . . . . . . . . . mm

1321

extended height . . . . . . . . . . . . . . . . . . . . mm

3048

height adjustment of shield . . . . . . . . . . . mm

1727

advance stroke . . . . . . . . . . . . . . . . . . . . . mm shifting ram stroke . . . . . . . . . . . . . . . . . . mm

914 1000

distance of prop centers (inclination) . . . mm

990

forepole of canopy . . . . . . . . . . . . . . . . . . mm

3595

rear projection of canopy . . . . . . . . . . . . . mm

4115

width of canopy . . . . . . . . . . . . . . . . . . . . mm

1800

length of canopy . . . . . . . . . . . . . . . . . . . . mm

4935 + 820 = 5755

inclination of caving shield, shield closed . . . . . . . . . . . . . . . . . . . . . . . deg. shield extended . . . . . . . . . . . . . . . . . . . . . deg.

6.13 51,8

width of caving shield . . . . . . . . . . . . . . . . mm

1790

width of base . . . . . . . . . . . . . . . . . . . . . . . mm

1720

total area of base . . . . . . . . . . . . . . . . . . . cm2

42794

shield center distance . . . . . . . . . . . . . . . mm

1850

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 320 bar setting pressure . . . . . . . . . kN b) at 440 bar yield pressure . . . . . . . . . . kN

1700 6488 9124

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 1700 a) at 320 bar setting pressure . . . . . . . . kN/m2 540 b) at 440 bar yield pressure (distance canopy tip to face low / high) . kN/m2 665 / 759

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.11

Hydraulic system Hydraulic system The following section gives an overview of the hydraulic system installed on the shield units. For additional information please refer to the spare parts catalog.

Tab. 10: Electrohydraulic(EH) shield control system and use description

normal and exceptional operation

order no.

EH-control unit, 10 functions

8154 118 000 00 00

hose lines

8112 210 010 00 00

water spray system

8112 210 020 00 00

retainers and accessories

8112 210 030 00 00

During normal operation the functions of the shield units are to be operated by use of the PMC® -R control unit only.

6.12

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

WARNING! During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

E

The individual pilot valves of the control valve block are equipped with facilities for manual operation. The functions of the directional control valves are shown on the symbol plate.

Hydraulic system Shield hydraulics

DBT GmbH, Lünen 2005

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Tab. 11: Hydraulic components Location centric under the canopy

1 1 1

Description electrohydraulic control unit 10 functions accumulator cartridge shifting ram check valve twin check valve

6 7 8 9

1 1 1 2

check valve, NW 25 in-line-filter, NW 20 dual filter, back flush type high-pressure ball valve

manifold block under the canopy, L.H. under the canopy, R.H. on each prop check valve

tank line water supply manual operated, at holder red handle

10

1

high-pressure ball valve

12

2

high-pressure ball valve

13

1

pressure relief valve, 80 bar

red handle in the pressure line a) red handle, compensating valve b)red handle, for lifting cylinder connected to return line

14 16

2 2

pressure relief valve, 440 bar pressure relief valve, 420 bar

17

2

pressure relief valve, 420 bar

18

1

water spray valve

19 20 21 22 23

1 1 1 1 1

manifold block hose lines water spray system retainers and accessories Steckverschluß DN 10

under the canopy close to dual filter a) prop check valve, R.H. b) under the canopy behind prop L.H. under the canopy close to manifold block on each leg gobside a) shifting ram valve b) piston line of lifting cylinder at stabilizing cylinder, for pistn and rod a) under the canopy behind leg L.H b) 2x under the canopy in front of leg L.H. unter the canopy between legs

24 25 28 29

4 4 2 5

prop check valve NG 20 prop check valve NG 20 pressure gauge connection high-pressure ball valve

30 31

1 1

high-pressure ball valve high-pressure ball valve

35 S1 Z1 Z2 Z3 Z4

2 1 2 1 1 1

pressure gauge pressure sensor prop shifting ram stabilizing cylinder lift cylinder

Item 1

Qty. 1

3 4 5

Remark at holder

electrohydraulic control unit under the canopy, R.H. mounted to stabilizing cylinder

under the canopy close to the manifold block prop, front L.H. prop, front R.H on each prop check valve a) auxillary high pressure line, to flush canopy water sprays b) to separate canopy water sprays and lemniscate water sprays c) shut off water hose water inlet line under canopy L.H. auxillary high pressure line, under the canopy L.H. on each prop check valve at prop check valve, only R.H.

for piston chamber and annulus

at holder subassembly subassembly subassembly in the return line

test and pressure reliev port a) water circuit, blue handle

blue handle red handle

RV = Rückschlagventil, DBV = Druckbegrenzungsventil, HD = Hochdruck

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.13

Hydraulic system Shield hydraulics Fig. 48: Shield hydraulics, arrangement, 8112 210 000 00 00 key, see table 11 13 6

29a 31 23 18 30

29c

8

20

7

12

3

1

22

16 29b

4 16 21

17

5

DBT GmbH, Lünen 2005

E

14

35

10 9 35

12 9

28

28

24

25

6.14

19

DBT-Shield 1321/3048-2x5655-1860

Hydraulic system

Fig. 49: Functions of Electrohydraulic control unit

DBT GmbH, Lünen 2005

E

Switch board diagram

Instruction plate 10 functions

Tab. 12: Electrohydraulic control units with 10 functions, allocation of functions function, description

Doc. No.: 7420 145 000 BA 00

function no.

advance shield

1

set both props

2

advance conveyor

3

lift cylinder, extend

4

stabilizing cylinder, extend

5

stabilizing cylinder, retract

6

not used

7

not used

8

water sprays lemniscate and canopy

9

lower both props actively

10

SSVR / 01

6.15

Hydraulic system Fig. 50: Shield hydraulics, shield variant 01 key, see table 11

3

19

31

29a 23

10 8 1

6

29d 30

13

18

29b

Z4 21

12 16 14 35 28 9

S1

35 28

12

9

Z2

4

14

24

17

25

16

20

Z3 5

Z1

Z1

17

6.16

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

E

7

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

Bottom and top end of the prop are designed as a globe joint. This allows to join the prop to the base and the canopy with angular articulation. The cams at the bottom end of the prop will be fixed at the base using bolted arresting devices.

The prop head is fastened to the canopy using special securing elements.

The technical data of the hydraulic prop are to be found in section “Technical data, hydraulic cylinders”.

Fig. 51: Double telescopic prop, type SD-5650-400-1145/2620-BN

X

21 e DBT GmbH, Lünen 2005

E

section X

b 2 b

42

d a

e

c

1

1 prop bottom end 2 piston pipe 21 piston rod 42 greace nipple a valve connection plate b piston pipe annulus ports c cam

d pressure relief valve port e load ring 3000 kg prop length: - retracted 1145 mm - extended 2620 mm stroke: - upper stage 760 mm - lower stage 715 mm

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

Never close the lowering ports of double-acting props pressure-tight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.17

Hydraulic system Function prop setting

Pressure fluid is admitted under the piston of the center prop through the piston chamber connection. The center prop will extend first and the pressure fluid displaced from the annulus is passed into the return line. If the piston of the center prop contacts the threaded bush before the canopy comes to rest against the roof, the inner prop will extend. Pressure fluid is admitted through the check valve.

Loading props a) Center prop extended only Load is transmitted mechanically from the canopy to the inner prop via the prop head and, then, to the valve housing installed in the inner prop. The further transmission of load is hydraulically via the pressure fluid under the center prop into the foot of the prop and from there mechanically into the base.

The hydraulic pressure under the center prop cannot exceed the pre-determined value as a pressure relief valve is installed in the respective control valve. When the preset pressure is exceeded, the pressure relief valve will open and permit fluid to escape and the prop yields with the rated prop resistance.

Load is transmitted mechanically from the canopy to the inner prop via the prop head. The inner prop bears on the pressure fluid under its piston. This fluid is trapped by the check valve. The further course of load transmission is as described under a). prop lowering

6.18

The pressure fluid under the center prop is connected to the return by means of the prop control valve.

Both stages of the prop can be power lowered. The inner prop will start to close when the center prop is closed completely and the check valve is opened by the tappet.

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

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b) Center Prop and Inner Prop Extended

Hydraulic system Hydraulic cylinder, double and single acting design

The following figure shows the main components of a hydraulic cylinder. The cylinders differ mainly by the arrangement of the connections. They can be roughly divided into two groups: Type a) arrangement of connections at the outer cylinder Type b) arrangement of connections at the piston rod Fig. 52:

Hydraulic cylinder, typical example

Typ a)

2

1

4

5

3

DBT GmbH, Lünen 2005

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Typ b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

1

4

6

4 guide bush 5 connection 6 connection

NOTICE! The technical data of the cylinders are given in the section “Technical data” of the shield used.

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

Never close the lowering ports of double-acting props pressure-tight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

The end of the piston rod can either be attached directly or it is designed in such a way that the means of attachment - e.g. rod head or fork head - can be screwed on and secured against working loose by clamping screws or a spring dowel sleeve.

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

If a double-acting cylinder is to be used as single-acting cylinder only, the annulus connection must be provided with a screw with filter element to avoid contamination by dirt. If the cylinder is used without the seals which seal off the annulus, the grooves for the seals have to be filled with lubricating grease.

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.19

Hydraulic system Stabilizing cylinder Fig. 53: Hydraulic cylinder, type ZE-220/140-453-EC-BN

10 a b d

70

70 L c

E

1

a valve connection plate

DBT GmbH, Lünen 2005

c pressure relief valve port, piston chamber d load ring 3000 kg L retracted 830 - extended 1233

1 cylinder tube 10 piston rod b pressure relief valve port, annulus

Baselift cylinder Fig. 54: Hydraulic cylinder ZE-150/90-300-LI-CR

2 a

b

365

1

L

3 1 cylinder tube 2 piston rod 3 wearing bottom

6.20

a piston chamber port b annulus port L retracted 588 - extended 888

DBT-Shield 1321/3048-2x5655-1860

Hydraulic system Shifting ram Fig. 55: Hydraulic cylinder type ZE-225/140-1000-SC-W-CR,

11 72

70 L d a

1

2 14

b c

DBT GmbH, Lünen 2005

E

1 cylinder tube 2 reed contact rod 11 piston rod 4 screw joint a piston chamber port

b annulus port c shifting unit adapter d load ring 3000 kg L retracted 1339 - extended 2339

Technical data of hydraulic cylinders double telescopic prop, double-acting - 2 stages

Doc. No.: 7420 145 000 BA 00

Type SD-5650-400-1145/2620-BN, Gerätenr. 8250 113 000 00 00 prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1145

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

2620

hydraulic stroke . . . . . . . . . . . . . . . . . . . . . mm

1475

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

400 / 285

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

370 / 265

piston surface area . . . . . . . . . . . . . . . . . . cm2

1256.6 / 638

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

181.4 / 86.4

prop force at 320 bar setting pressure . kN

4021.1

prop force at 440 bar yield pressure . . . kN

5655

retracting force at 320 bar . . . . . . . . . . . . kN

580.5

SSVR / 01

6.21

Hydraulic system stabilizing cylinder, double-acting

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

453

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

220

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

140

piston surface area . . . . . . . . . . . . . . . . . . cm2

380.1

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

226.2

thrust at 320 / 440 bar . . . . . . . . . . . . . . . kN

1216 / 1710

pulling force at 320 / 440 bar . . . . . . . . . kN

724 / 1018

Type ZE-225/140-1000-SC-W-CR, Gerätenr. 8241 279 000 00 00, stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1000

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

225

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

140

piston surface area . . . . . . . . . . . . . . . . . . cm2

154

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

243,6

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

493 / ---

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

780

baselift cylinder, double-acting

6.22

Type ZE-150/90-300-LI-CR, Gerätenr. 8241 280 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

150

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

90

piston surface area . . . . . . . . . . . . . . . . . . cm2

176,7

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

113,1

thrust at 320 / --- bar . . . . . . . . . . . . . . . . kN

565,5 / ---

pulling force at 320 / --- bar . . . . . . . . . . . kN relief valves

361,9 / ---Pressure

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

E

shifting ram double-acting, el. connection, reverse-mounted

Type ZE-220/140-453-EC-BN, Gerätenr. 8241 282 000 00 00

Hydraulic system Pressure relief valves Pressure relief valves protect the hydraulic equipment, such as props and cylinders, connected with them from overload. When the set pressure is reached, the valve opens and the pressure fluid is discharged to atmosphere.

For the type of valve used please see the following table, the hydraulic flow plan or the spare parts catalog.

Tab. 13: Pressure relief valves, use of different types application

type

set pressure in bar

order no.

general application, spring-loaded not for props and stabilizing cylinders

420

7337 486 420 00 00

only at stabilizing cylinder

spring-loaded

420

8220 027 420 00 00

only at props

gas-pressure operated

440

7337 611 440 00 00

for return line

spring-loaded

80

8220 042 080 00 00

DBT GmbH, Lünen 2005

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CAUTION! Do not change the pressure setting of pressure relief valves!

Only use pressure relief valves which have been factory-set to the required value and are provided with the relevant color code.

Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

CAUTION! Always replace pressure relief valves with valves which are as new and have the same properties. Refer to the hydraulic flow plan in this respect. Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

NOTICE! Always fit new seals when replacing a pressure relief valve.

Failure to comply may result in leakages at the plug-type connection and impair the operational safety of the hydraulic system. code system

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

The letter code includes the following details: J Set pressure, target value J Week setting was made J Year setting was made J Last setting made by Tab. 14: Typical letter code

1)

420 od. 42 1)

09

03

xy

set pressure

week

year

made by last

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

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.23

Hydraulic system The color code may consist of one or two colors. It characterizes the setting pressure range. The following figure 41 shows a pressure relief valve provided with a blue-white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 56: Typical pressure relief valve

a color code b protection cap b

a

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

6.24

pressure range (bar)

black

0 - 49

black / white

50 - 99

brown

100 - 149

brown / white

150 - 199

green

200 - 249

green / white

250 - 299

blue

300 - 349

blue / white

350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow /white

550 - 599

orange

600 - 649

orange / white

650 - 699

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

color

E

Tab. 15: Color codes for pressure relief valves, overview

Electrohydraulic control system Electrohydraulic control system Electrohydraulic control units Fig. 57: Electrohydraulic control, 10 functions

a

1 2

3

4

a connecting accumulator cartridge 1 control valve block

DBT GmbH, Lünen 2005

E

2 pilot control valve for electromag netic operation

3 push-button for manual operation 4 plug contact, electrical connection to the control unit

WARNING! During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

Electronic shield control PMC®-R NOTICE! How to operate the electronic shield control unit type is not subject of this manual. See separate operating instructions.

Fig. 58: Control unit type PMC®-R, input configuration front view

rear view

Doc. No.: 7420 145 000 BA 00

A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

SSVR / 01

PMC®-R inputs A1 = L.H. adjacent unit A2 = not used B1 = not used B2 = not used C1 = pressure sensor C2 = not used D1 = shifting ram sensor D2 = not used E1 = not used E2 = not used F1 = R.H. adjacent unit F2 = solenoid driver module of unit

6.25

Electrohydraulic control system

Fig. 59: Electronic shield control unit type PMC®-R, schematic diagram A2

B2

A1

B1

rear view C2 D2 E2

C1

D1

E1

F2

front view

1

F1 R.H. adjacent support, port A1

L.H. adjacent support, port F1

P1

4

5 *

*

*

* SHRINK--ON MARKS TO VALVE BLOCK

1 single control unit (SCU) 4 solenoid driver 5 pressure sensor

6.26

a reed rod, shifting ram other: see spare parts catalog

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

E

a

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

Fig. 60: Angles α 1 / α 2

α1 α2

DBT GmbH, Lünen 2005

E

M

Tab. 16: Angles α 1 / α 2 at height M Inclination α at height M

Shield Order-no.

7420 145 000 00 01

α1 in °

α2 in °

M in mm

6

10

1321 to 1500

10

15

1500 to 1700

15

15

1700 to 3048

CAUTION! If the max. angles stated are exceeded, damage will be caused to the props and cylinders as well as to their arresting elements and to the articulations.

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.27

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids NOTICE! Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

For the operation of hydraulic components of DBT GmbH generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWM 8350 or an exemption permit of DBT GmbH is available to the respective operator. DBT GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

Suitability test Before the certificate of DBT GmbH is issued for a hydraulic fluid the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by DBT GmbH. For the tests, the criteria as specified in EWN 8350 will be applied. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to J stability J sealing materials J corrosion

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

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

6.28

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

If a mine only uses individual hydraulic components without applying DBT shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid as is used for the existing shield support shall be allowed to be used for these individual components, subject to approval by DBT. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by DBT GmbH upon request.

E

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

Operating media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of hydraulic systems of DBT GmbH for each product tested. The respective certificate shall be valid for a period of one year and, after a simplified test, can be extended for an additional year each. The certificate shall become invalid if one or several of the prerequisites for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

The following illustration shows a typical certificate.

DBT GmbH, Lünen 2005

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Fig. 61: Typical certificate

Doc. No.: 7420 145 000 BA 00

SSVR / 01

6.29

Operating media Hydraulic fluid maintenance A consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

These properties include: temperature, foaming, pH-value, concentrate ratio, and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously the properties listed in the following should be checked at least once every week: J pH-value

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: see certificate – Target value: < 105 Kol/m In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

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

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

The following table 17 lists limit values for the essential properties and components of the water.

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

If one or several of the limit values mentioned are not met this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

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

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

6.30

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

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J Microbial load

Operating media Tab. 17: Properties of the process water, limit values Test criterium

Limit value

Appearance, color, smell

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

electrical conductivity

< 1800 µS/cm

pH-value

6,5 ..... 8,5

Na+ - content

not specified

Mg+ - content

not specified

water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content

≤

145 mg/l

NO3- - content

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 Kol/ml

Ratio of solid foreign matter at 1,2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

- / 18 / 14

Lubricating greases and pastes DBT GmbH, Lünen 2005

E

IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... . general properties

lubricating greases A1

Lubricating greases base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble in water

temperature of application:

-20 to +120 °C

flash point:

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to (EWN * 7068) Tab. 18: Lubricating greases for general application

lubricating greases A2

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Flash point in °C

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

Tab. 19: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*

Doc. No.: 7420 145 000 BA 00

Flash point in °C

EWN = DBT standard

SSVR / 01

6.31

Operating media IMPORTANT! The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

Lubricating pastes lubricating pastes B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Type

gleitmolybdän

gleitmo 805 *)

Base Li

NLGI class

Flash point °C

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän ”gleitmo 805” lubricating pastes B6

Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water:

non-soluble in water

Temperature of application:

-34 to +120 °C

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent & lubricant 785 (flash point 132 °C) IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

*)

6.32

The products listed in table 18 are suitable lubricating greases for filling of adjacent cavities.

DBT-Shield 1321/3048-2x5655-1860

DBT GmbH, Lünen 2005

Supplier

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Tab. 20: Lubricating pastes free from molybdenum disulfide

Tightening torques Tightening torques Screws with ISO metric thread Tab. 21: Recommended tightening torques at µges. = 0.14 Thread 1) (mm)

(mm)

E

MA (Nm) 8.8

10.9

12.9

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

-

1100

-

d

coarse thread

M8

M 24

DBT GmbH, Lünen 2005

Tightening torque 4)

Pitch P

fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3,5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

IMPORTANT! The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

1) 2) 3) 4)

Doc. No.: 7420 145 000 BA 00

dimensions in brackets in exceptional cases only according to works standard (EWN 6110), February 1985 edition only for expansion screws having a reduced shaft cross-section of 24.2 mm the tightening torques comply with EWN 6003 works standard.

SSVR / 01

6.33

DBT GmbH, Lünen 2005

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Tightening torques

6.34

DBT-Shield 1321/3048-2x5655-1860

7

For your information

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service addresses Germany

DBT GmbH Industriestraße 1 D-44534 Lünen Tel: Fax:

+49 / 23 06 70 9 - 0 +49 / 23 06 70 9 - 14 21

E-mail: infodbt@dbt.de Internet: http://www.dbt.de Great Britain

DBT GB Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS

DBT GmbH, Lünen 2005

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Tel: Fax:

+44 / 11 59 51 - 2500 +44 / 11 59 32 - 9683

E-mail: info@dbtgb.com Internet: http://www.dbt.de USA

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

+ 001 / 72 47 43 12 - 00 + 001 / 72 47 43 12 - 01

E-mail: infodbt@dbt.de Internet: http://www.dbt.de Australia

DBT Australia (Pty.) Ltd. 537 Lake Road Argenton, NSW 2284 Tel: Fax:

+61 / 2 49 58 31 33 +61 / 2 49 58 57 54

E-mail: infodbt@dbt.de Internet: http://www.dbt.de

Doc. No.: 7420 145 000 BA 00

SSVR / 01

7.3

Our service China

DBT China Beijing Representative Office Room 502, Prime Tower No. 22 Chaowai Street Beijing 100020 Tel: Fax:

+86 / 10 65 88 - 2998 +86 / 10 65 88 - 6570

E-mail: Info.beijing@dbtchina.com Internet: http://www.dbt.de DBT Langfang Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone 065001 Hebei Province P.R. Tel: Fax:

+ 86 / 3 16 60 86 - 840 (& 841, 842, 843) + 86 / 3 16 60 86 - 845

E-mail: Info.langfang@dbtchina.com Internet: http://www.dbt.de South Africa

DBT Africa Pty. Ltd.

DBT GmbH, Lünen 2005

Tel: Fax:

E

Corner of Gamma and Zeta Roads Industries West Germiston, 1401 + 27 / 11 82 58 21 2 + 27 / 11 82 57 38 9

E-mail: infodbt@dbt.de Internet: http://www.dbt.de France

DBT France S.A.R.L. 1, rue d‘Annecy, BP 144 57150 Creutzwald Tel: Fax:

+ 33 / 38 72 92 08 0 + 33 / 38 79 02 30 9

E-mail: info@dbtfrance.com Internet: http://www.dbt.de Poland

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48-32-3170 500 +48 32 3170 509

OOO DBT RUS ul. Nevskogo, 4 office 303, 304, 305 654006 Novokuzneck, Kemerovskaja obl.

Tel: Fax:

+7 / 38 43 78 10 35 +7 / 38 43 78 10 36

E-mail: dbtkuzbass@uku.com.ru Internet: http://www.dbt.de

7.4

DBT-Shield 1321/3048-2x5655-1860

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

Fig. 62: Identification plate, example

1

DBT GmbH 2 5

6

7

2

12345

E

01/05

4

678

7420 140 311 00 00 3926 kN

1 manufacturer 2 last 5 digits of SAP-no. resp. order-no.

3 month and year of manufacture 4 current component no.

DBT GmbH, Lünen 2005

3

5 drawing no.

6 number of props 7 rated yield force of props

Shield number The shields are numbered consecutively. Plates showing the shield number are fitted at the faceside of the base at the left.

Fig. 63: Shield number at the base, example

Tab. 22: Allocation of shield numbers

Doc. No.: 7420 145 000 BA 00

shield no.

order no

G1 to G8

7420 145 000 00 01 face endshield

SSVR / 01

application

7.5

DBT GmbH, Lünen 2005

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Identification of shields

7.6

DBT-Shield 1321/3048-2x5655-1860