CAT Operating Manual DBT-Shield 1829 3658-2x5906-2050 (7420150000 BA 00) - PDF DOWNLOAD

Operating Manual DBT-Shield 1829/3658-2x5906-2050 Doc. No.: 7420 150 000 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

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

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

2.5 2.5

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

2.6

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Overview of the safety instructions . . . . . . . . . . . . . . . 2.16 DBT GmbH, Lünen 2005

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

3.3

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

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

3.3 3.5

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

3.6

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

4.3

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

4.3

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

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

4.5 4.11

Requirements for the face hydraulic system . . . . . . . 4.12 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

4.13 4.14

Corrosion protection of hydraulic components . . . . . 4.15

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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 on the shield . . . . . . . .

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

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

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

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

5.15 5.31 5.32 5.34 5.37

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.41 5.41 5.44 5.44 5.45 5.45 5.45

6. Technical data Shield description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Main assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

6.4 6.6 6.9 6.11 6.12 6.13 6.14

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.15 6.22

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Seal cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.24 6.25 6.25 6.26 6.26 6.27

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5.38 5.39 5.39 5.40 5.40 DBT GmbH, Lünen 2005

Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

6.28

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30 Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.32 6.32

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.34 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.35 6.38

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.40

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7. For your information

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

7.3

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

7.3

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

7.5

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

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

7.5 7.5

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Contents

DBT-Shield 1829/3658-2x5906-2050

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 1829/3658-2x5906-2050 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 1829/3658-2x5906-2050 Identification no.

Prop force Year of Application construction 7420 150 000 00 01 2 x 5906 kN 2005 face shield 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 J of the miners’ accident insurance association.

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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 1829/3658-2x5906-2050

Conditions of operation Conditions of operation Intended use The shield has been designed and manufactured exclusively for use as a support unit for longwall faces.

Use the shield only as intended!

Intended uses are: 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, E

– retracting;

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J forming an abutment for:

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

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

Unauthorized uses 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 information 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 does not accept any liability for the consequences of unauthorized uses.

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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.

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.

support lock-out switch

- 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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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 relay bar (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.

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2.7

Safety instructions 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, 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.

Securing by means of hardwood wedges

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Fig. 1:

transport securing devices

If the shield is provided with movable side seals these are pretensioned by spring force. Therefore do not use force to remove the transport securing device of the side seals. Use the hydraulic control system to adjust the 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.

2.8

DBT-Shield 1829/3658-2x5906-2050

Safety instructions Operation shield control

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. See also chapter 6 ”Technical Data”.

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.

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.

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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.

DBT GmbH, Lünen 2005

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.

Clean the control elements of the control units regularly. 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

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.

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2.9

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

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 canopy will be loaded excessively in longitudinal direction

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

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.

2.10

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J the stabilizing cylinder locks

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

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

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

J lifting gear with 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 ”Technical Data” for their location.

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

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

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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.

Replace damaged components affecting safety immediately. 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 mining 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.

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2.11

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

or is only done outside the required safety area,

J relieve the load on the components which are under hydraulic

pressure or mechanical stress.

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.

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.

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handling of hydraulic fluids

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Hydraulics

Safety instructions Before removing staple locks to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is still pressurised. If the hose is difficult to turn or does not turn at all the line is still pressurised. Be sure to depressurise the line.

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. permissible 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

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1

6 1 manufacturer 2 hose type 3 date of manufacture, 1st quarter 2002

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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2.13

Safety instructions 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 WRONG

DBT GmbH, Lünen 2005

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RIGHT

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter),

Fig. 5:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

Laying hydraulic hoses, crossing RIGHT

2.14

WRONG

DBT-Shield 1829/3658-2x5906-2050

Safety instructions 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 WRONG

DBT GmbH, Lünen 2005

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RIGHT

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2.15

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.

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 plug (item 23, see fig.

15) 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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DBT GmbH, Lünen 2005

If the points of attachment on the caving shield and on the canopy 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

E

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.

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 ”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 ”Lubricating greases and pastes”.

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 injury to persons and damage to property.

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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.

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.

After interconnecting the hoses, keep the blind reducing socket and the straight socket in the bag provided for that purpose.

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

Chapter 5: Operation 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.

You must check the position of the block ball valve before operating function key 8.

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.

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2.17

Overview of the safety instructions You must check the position of the block ball valve before operating function key 8.

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.

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. Observe the separate manual for the control unit.

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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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.

E

Do not put the filter into operation, before making sure that all connections have been made properly. Observe the separate operating manual for the filter.

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.

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.

DBT GmbH, Lünen 2005

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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.

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.

Please observe that the holder must be in top position when the shield is lowered completely.

The hoses are provided with a marking. Please note that the hose end closer to the marking has to be connected to the pilot valve.

See also separate operating manual for the control unit.

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2.19

Overview of the safety instructions 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.

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.

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.

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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.

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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.

Overview of the safety instructions NOTICE! Remove transport locks items (20*, 25*), and (26*, 44*), as well as (26*, 56*) during commissioning.

Apply lubricant B6 EWN7068 to all connections and sliding surfaces.

The technical data of the cylinders are given in the section “Technical data, hydraulic cylinder” 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.

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

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! With the shield at maximum closed or extended height the ”canopy – caving shield” coupling point will shift accordingly when lowering or raising the canopy.

DBT GmbH, Lünen 2005

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

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.

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

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2.21

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Overview of the safety instructions

2.22

DBT-Shield 1829/3658-2x5906-2050

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.

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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.

*

Doc. No.: 7420 150 000 BA 00

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

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3.3

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.

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.

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.

3.4

plastic deformation

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.

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long-term storage

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Storage

Storage 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 ”Permissible media” 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.

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.

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.

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corrosion protection

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3.5

Transport Transport

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.

electrical and electronic components

3.6

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.

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transport units

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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 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 customer.

Tab. 2: Transport units

transport safety devices

Designation

Transport position

support unit complete

as for normal use

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: Tab. 3: Transport safety devices Part

Transport safety device

Flipper

pin and retaining clips

1

side seal, moveable side

pin and retaining clip

4

relay bar, faceside

transport rod

1

relay bar, gobside

chain

1

hydraulics

hydraulic ports not used are closed with protection caps or plugs

-

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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 and on the canopy 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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3.7

Transport Fig. 8:

Transport of shields as complete unit B X4 X3

S0

Y SY

H

X4 X1 X2 S1

SX

S2

L

S1 slot hole, 2 x on the coal face end of the base, load-bearing capacity: 15000 kg S2 slot hole, 2 x on the gob side end of the base, load-bearing capacity: 15000 kg X1, X2 securing elements to fix the relay bar during transport, faceside and gobside X3 securing elements to fix the flipper X4 securing elements to fix the moveable side seals Y transport safety device between canopy and base e.g. turnbuckle not included in the scope of delivery So center of gravity

For transportation use the four slot holes S1 and S2.

Tab. 4: Shield support 7420 150 000 00 01 dimensions and weights

3.8

Variant

Order no.

Length L in mm

Width B in mm

Height H in mm

Sx/Sy in mm

Weight approx in kg

01

7420 150 000 00 01

7689

1950

1829

1429/1081

33184

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7911

Transport Fig. 9:

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

2

1 transport rod

1

2 spring clip 2x

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Fig. 10: Securing elements to fix the relay bar, chain (gobside)

1

3

2

1 chain 6x42 2 hex. head screw M 12x45-8.8

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3 hex. nut M 12-8

3.9

Transport Fig. 11:

Securing elements to fix the flipper

1

2

2 spring clip

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1 pin

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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 ”Lubricating greases and pastes”.

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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 ”Lubricating greases and pastes”.

DBT GmbH, Lünen 2005

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 injury to persons 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 canopy.

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4.3

Installation of the shield units

Tab. 5: Allocation of shield numbers

4.4

shield no.

order no

application

1 to 143

7420 150 000 00 01

face shield

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

The shield numbers are provided at the L.H. side under the canopy near the prop head.

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Fig. 12: Shield number at the canopy, example

Installation of the shield units Supply connections During installation, the individual shields can be supplied with pressure and operated using the socalled auxiliary supply line.

Fig. 13: Auxiliary supply line

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a

a auxiliary supply line

The auxiliary supply line must be connected to ports a and b (Fig. 14).

Fig. 14: View on the auxiliary supply line

b

a

35a Z a Druckleitung

b Rücklaufleitung c

35a HP ball valve a pressure line b return line

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c plug Z detail see fig. 15

4.5

Installation of the shield units Fig. 15: Detail Z: auxiliary supply line with plug DN 10.

a

35a

23

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).

The ports for the auxiliary supply line are located at the L.H. side under the canopy (see fig. 14 and in chapter 5, Hydraulic flow plan, fig. 32).

When using the auxiliary supply line, ports P1 and R2 of the manifold block must be connected with W1 and R1 respectively (see fig.

16, schematic diagram) by means of the hoses which later provide the connection with the adjacent shield (as a rule, this is the assupplied condition).

Should it not be possible to connect the supply hoses this way the ports at the manifold block must be closed by plugs.

Ports P1, W1, R1, and R2 at the manifold block side where no hoses are connected must be closed by plugs.

On the shield at hand the hoses are connected for transport as follows: J Pressure line P1, L.H., is connected with water line W1, R.H.,

by means of blind reducing socket DN 50 / DN 40SS .

J Return line R2, L.H., is connected with return line R1, R.H. by

means of straight socket DN 50.

4.6

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a vented cap screw

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23 plug DN 10 with vented cap screw 35a HP ball valve, pressure feed line (open as shown)

Installation of the shield units Fig. 16: Schematic of hose routing for transport P1

P1

W1

W1

R1

R1

R2

R2 a c

b P1 pressure supply line DN 40SS R1 return line DN 50 R2 return line DN 50

a manifold block b blind reducing socket DN 50/DN 40SS c straight socket DN 50

W1 water line DN 50

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Fig. 17: Arrangement of supply hoses during transport and for commissioning by means of the auxiliary supply line

IMPORTANT! After interconnecting the hoses, keep the blind reducing socket and the straight socket in the bag provided for that purpose.

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4.7

Installation of the shield units For commissioning and to interconnect the shields please proceed as follows:

. Close the high-pressure ball valve item 36a at the dual filter. (see fig. 20 and in chapter 5, Hydraulic flow plan, fig. 32)

. Remove the sealing plugs from ports a and b (see fig. 14) of the auxiliary supply line.

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

. Open the high-pressure ball valve, item 35a, see fig. 15, of the auxiliary supply line.

(After the valve has been opened the pump pressure will be available at the electrohydraulic control).

All high-pressure ball valves 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 35a, see fig. 15, to in-

. Detach the connecting lines P1, R1, R2, or W1 which are to

provide the connection to the adjacent shield from the manifold block. Remove the sealing plugs and coupling sleeves and connect the supply hoses with the adjacent shield.

. 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.

When commissioning the installation, the ball valves 36a, see fig.

20, at the filter of the shields must be open.

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WARNING! Incorrect operation can cause pressure to build up in the return line. Such pressure has to be relieved via the plug (item 23, see fig. 15) 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!

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terrupt any further pressure supply.

Installation of the shield units Fig. 18: View on the manifold block with hoses routed for transport 36b

39

P1 40 R1

W1 R2

35b 32 29

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35b

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a

33a

29 manifold block 32 HP ball valve, shuts off water supply 33a HP ball valve, interrupts the line to the stabilizing cylinder compensating valve 35b HP ball valve, when closed the respective prop does not extend 36b HP ball valve, behind manifold block, interrupts the main pressure line to the shield

39 rotating coupling DN 40

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40 rotating coupling DN 50 R1 return line, DN 50 R2 return line, DN 50 P1 pressure line, DN 40SS W1 water line, DN 50 a spraying hose

4.9

Installation of the shield units Fig. 19: Manifold block, port configuration P1

P2

W1 W2

R1 R3 R2 R4

W3

P3

P4

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W4 R5 R6

R1, R2 return line, DN 50, shield-to-shield connection R3 return line, DN 32, leading to prop return line R4 return line, DN 25, return to control R5 return line, DN 10, leading to pressure-relief valve, item 18 R6 return line, DN 20, collecting line, connects all pressure-relief valves P1 pressure line, DN 40SS, shield-to-shield connection

4.10

P2 pressure line, DN 25, leading to control P3 pressure line, DN 10 P4, P5 pressure line, DN 20 W1 water line, DN 50, shield-to-shield connection W2 water line, DN 20, spray line W3 water line, DN 20, leading to water valve control W4 water line

DBT-Shield 1829/3658-2x5906-2050

Installation of the shield units Fig. 20: View of the dual filter, back flush type

30 36a

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30 dual filter, back flush type

36a HP ball valve, in main pressure line

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

The manifold block for the supply of the shield hydraulics is located centrally between the base skids. Connection to the manifold block of the adjacent support is provided by means of four hose lines: a pressure line (DN 40SS), two return lines (DN50) and a water line (DN50). See also hydraulic diagrams in chapter 6 of this manual.

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 lighting system, 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.

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4.11

Requirements for the face hydraulic system Requirements for 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

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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permissible pressure

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Pressure fluid according to list of approved products, see section ”Permissible media” in chapter 6 of this manual.

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 E

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

DBT GmbH, Lünen 2005

removed.

. 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.

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4.13

Start-up . Check supporting power of the props. 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.

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 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.

Start-up of the shields 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 con-

veyor,

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.

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. Check that all emergency stop systems function properly.

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J Emergency stop systems

Corrosion protection of hydraulic components . 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.

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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 “Permissible media” in chapter 6.

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4.15

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Corrosion protection of hydraulic components

4.16

DBT-Shield 1829/3658-2x5906-2050

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 releases 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.

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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 and the mining machine must be at a standstill during the process of breaking up the layers of rock and coal.

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

5.4

DBT-Shield 1829/3658-2x5906-2050

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.

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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 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. 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.

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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.

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DBT-Shield 1829/3658-2x5906-2050

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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. 21: W r o n g , shields have not been advanced in the right time

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Fig. 22: 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.

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5.7

Basic requirements 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.

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

To prevent damage in case the return line is closed safety valves must be installed in the return lines (see hydraulic layout, if provided by DBT). If the hydraulic layout is provided by the operator we recommend to install safety valves into the return line, spaced 50 m apart. The valves should be set to 25 bar and relieve to atmosphere. damage, 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 1829/3658-2x5906-2050

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. 23: 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. 24: Shield with extremely inclined canopy

α1

s1

s2 α2 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 in the roof.

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Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 25) 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. 25: 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.

WRONG

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 26) or by leveling off the canopy.

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

Fig. 26: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

CORRECT

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5.11

Operation of the shield 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.

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. range of adjustment / changing seam thickness

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,

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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J removing accumulated dirt from the canopies.

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J avoiding the accumulation of debris and fine coal on the floor,

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.

DBT GmbH, Lünen 2005

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When pulling up the shields, always observe the specified sequence of steps. If not, the conveyor steering 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 steering 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.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

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).

5.14

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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

E

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. Observe the separate manual for the control unit.

Location of hydraulic components on the shield The hydraulic components are listed in the table below.

DBT GmbH, Lünen 2005

E

Tab. 6: Hydraulic components Item 01

Qty. 1

02

2

03

1

Description electrohydraulic control unit 14 functions prop check valve, pilot-operated water valve unit

04 05 06 07 08

1 1 1 1 2

check valve, pilot-operated twin check valve check valve DN 10 check valve NW 20 check valve NW 20

09

1

check valve NW 25

10

2

check valve DN 32

11 12 13

1 1 2

compensating valve check valve DN 12 pressure relief valve, 500 bar

14

2

pressure relief valve, 400 bar

15

4

pressure relief valve, 470 bar

16

2

pressure relief valve, 380 bar

17

2

pressure relief valve, 420 bar

18 20

1 1

pressure relief valve, 80 bar accumulator cartridge

21 22 23

1 2 1

25 26 27 28 29 30

1 1 1 1 1 1

twin check valve pressure gauge port plug DN 10 with vented cap screw hose lines spraying system retainers and accessories filter manifold block dual filter

31

4

high-pressure ball valve DN 10

32

1

high-pressure ball valve DN 20

Doc. No.: 7420 150 000 BA 00

SUVR / 01

Location rear end, centric under the canopy

Remark

gobside, at each prop L.H., next to electrohydraulic control unit above control unit flanged to stabilizing cylinder (Z3) behind water valve (item 3) behind water valve (item 3) at each prop check valve (item 2), gobside at manifold block (item 29), R.H. front at manifold block (item 29), L.H. and R.H. L.H. at prop, gobside at manifold block (item 29) bottom at each prop check valve (item 2), gobside a) at check valve (item 4) b) at high-pressure ball valve (item 33e) a) 1x at each prop b) 2x on stabilizing cylinder a) at manifold (item 43) b) at seal cylinder (Z4) annulus in caving shield at twin check valve (item 21) of flipper cylinder (Z6) at manifold block (item 29) electrohydraulic control unit (item 1) flipper cylinder (Z6) each prop check valve (item 2) in return line of auxiliary supply line

at manifold block (item 29) centric between the base skids R.H. under canopy a) in spraying line b) on manifold block (item 42) c) 2x for side seal spraying system on manifold block (item 29)

for shifting ram

for stabilizing cylinder in return line rock burst valve a) for shifting ram b) for baselift cylinder

in return line

relief valve subassembly subassembly subassembly for water circuit can be backflushed via control unit blue handle in water circuit, blue handle

5.15

Operation of the shield hydraulics Item 33

Qty. 6

Description high-pressure ball valve DN 10

Location a) behind L.H. prop, gobside

Remark a) interrupts line to stabilizing cylinder b) interrupts prop lowering

b) at each prop c) in side seal annulus d) in caving shield side seal annulus e) under canopy above control unit L.H. under canopy behind prop

34

1

block ball valve

35

3

high-pressure ball valve

a) in pressure feed line to auxiliary supply line b) at each prop, gobside

36

2

high-pressure ball valve

a) at dual filter (item 30) b) behind manifold block (item 29)

glycerine pressure gauge rotating coupling DN 40

at each prop check valve (item 2) at manifold block (item 29)

40

3

rotating coupling DN 50

at manifold block (item 29)

42

1

distributor

43

2

distributor

44 45

1 4

plate hex. head bolt M 8x30

under the canopy, L.H. behind prop under the canopy, L.H. behind prop at R.H. prop, gobside to fasten the plate (item 44)

S1 Z1 Z2 Z3 Z4 Z5 Z6

2 2 1 1 4 1 1

pressure sensor prop shifting ram stabilizing cylinder seal cylinder baselift cylinder flipper cylinder

W1 W2 W3 W4

5.16

connection to pressure line (P), DN 40 SS rotating coupling for ports R1, R2 and W1 in water circuit in side seal circuit E

2 1

e) for baselift cylinder presetting for function 8 (retract baselift or seal cylinder) a) interrupts auxiliary supply line pressure supply b) interrupts prop setting red handle a) interrupts main pressure supply line to shield b) interrupts main pressure supply line to shield red handle

DBT GmbH, Lünen 2005

37 39

c) for side seal, compl. d) for caving shield side seal

at each prop, gobside

canopy water sprays link water sprays water curtain side seal water sprays

DBT-Shield 1829/3658-2x5906-2050

Operation of the shield hydraulics Shield hydraulics Fig. 27: Shield hydraulics, arrangement (1), key, see table 6

23, 35a

1 3

27 25

DBT GmbH, Lünen 2005

E

12

S1

15a 13 33b 22

37

S1 37 8

33a

15a 13 33b 22

35b 2

35b

2

8

11

Doc. No.: 7420 150 000 BA 00

SUVR / 01

45 44

5.17

Operation of the shield hydraulics Fig. 28: Shield hydraulics, arrangement (2), key, see table 6

29

17

40

39

28

40

32 21

10

40 26

DBT GmbH, Lünen 2005

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31a

14 33e

4 20

23 35a 7 6

30 36a

10

9

42 34 31b 43

5

36b

18 12

33c, 33d 16a

31c

15b 31c 16b

5.18

DBT-Shield 1829/3658-2x5906-2050

Operation of the shield hydraulics

DBT GmbH, Lünen 2005

E

Fig. 29: Functions of electrohydraulic control unit, symbol plates

14 functions

Tab. 7: Electrohydraulic control unit with 14 functions, allocation of functions Function

Doc. No.: 7420 150 000 BA 00

Function no.

advance shield

1

set both props

2

advance conveyor

3

lower both props

4

extend stabilizing cylinder

5

retract stabilizing cylinder

6

extend seal cylinder

7

retract seal cylinder or baselift cylinder

8

extend flipper cylinder

9

retract flipper cylinder

10

dual filter

11

dual filter

12

sprays clean

13

extend baselift cylinder

14

SUVR / 01

5.19

Operation of the shield hydraulics Fig. 30: Water valve unit functions, symbol plates

Tab. 8: Water valve unit with 4 functions, allocation of functions Function No.

Function canopy water sprays

W1

link water sprays

W2

water curtain

W3

side seal water sprays

W4

J Lever pointing towards the shield center retracts the baselift

cylinder.

J Lever pointing downwards (or to the face) retracts the side seal

cylinder.

Fig. 31: Position of ball valve (item 34) as presetting for function 8 42

31b

34

43

33c

33d 16a pressure relief valve, 380 bar 31b high-pressure ball valve, interrupts link spraying system of caving shield spraying system 33c high-pressure ball valve, for side seal, compl.

5.20

16a

33d high-pressure ball valve, for caving shield side seal 34 block ball valve, position determines whether to retract baselift or seal cylinder 42 distributor 43 distributor

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

Function key 8 operates two functions. Which function is operated depends on the position of the block ball valve (fig. 31, item 34):

E

DANGER! You must check the position of the block ball valve before operating function key 8.

Operation of the shield hydraulics Fig. 32: Shield hydraulics key, see table 6 40

18 39

1

29

23 DN 40-SS DN 50 DN 50 DN 50

P W R1 R2

9

36b 12

35a

10 31a

43

20

36a 32

33c

30

34

28

6 7 15b

16a

33d

3

E

16b

W2

DBT GmbH, Lünen 2005

Z4 Z3 Z4

5

15 15b

Z4

31b 42

Z2

Z4

4

W4

W4

14a

31c

Z5

31c 25

35b

33e

8 22

35b 14b

15a

15a

13

W1

26

8 22 13

W3

33a 44, 45

11

2 37

Z1 33b

2 37

Z1 33b

17

Z6 21

Doc. No.: 7420 150 000 BA 00

SUVR / 01

17

5.21

Operation of the shield hydraulics Fig. 33: Hydraulic lines, overview (1)

Z2 5 Z3

15b 16b

KR

Z4 36b

P1

KR

P1 P2

39

10 31a

40 18

36a

16a

33d

40

33c

30 9

29

DN 25

43

35b

8

2

33b 37

33b S1

22

TZ

DN 10

3 1, 20

13

S1

BPB PA AA

15a

W4

8

11

33a

35b

34

W1 W3

22

7

6

37 44, 45

DBT GmbH, Lünen 2005

R2

10

12

E

40

R1

KR

W1

14b

4

2

13

14a

23

15a 33e

Z5

Z6

KR

K

R

35a

21 17

5.22

DBT-Shield 1829/3658-2x5906-2050

Operation of the shield hydraulics Fig. 34: Hydraulic lines, overview (2) key, see table 6

31c

31c

28

32

DBT GmbH, Lünen 2005

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31b

42

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.23

Operation of the shield hydraulics Fig. 35: Shield 11 51

31

c d b

21

a

21

DBT GmbH, Lünen 2005

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41

61 e f 1

1 base 11 canopy 21 side seal 31 caving shield 41 prop 51 stabilizing cylinder 61 hydraulics

5.24

a PMC® -R control unit b electrohydr. control unit c flipper d flipper cylinder e manifold block f baselift cylinder

DBT-Shield 1829/3658-2x5906-2050

Operation of the shield hydraulics Fig. 36: View on the manifold block with hoses routed for transport 36b

39

P1 40 W1

R1

R2

35b 32 29 35b a

33a

29 manifold block

DBT GmbH, Lünen 2005

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32 high pressure ball valve, shuts off water supply 33a high pressure ball valve, interrupts the line to the stabilizing cylinder compensating valve 35b high pressure ball valve, when closed the respective prop does not extend

36b high pressure ball valve, behind manifold block (hidden) 39 rotating coupling DN 40 SS 40 rotating coupling DN 50 R1 return line, DN 50 R2 return line, DN 50 P1 pressure line, DN 40 SS W1 water line, DN 50 a spraying hose

Fig. 37: View of the dual filter,

30 36a

30 dual filter, back flush type

Doc. No.: 7420 150 000 BA 00

SUVR / 01

36a high pressure ball valve, in main pressure line

5.25

Operation of the shield hydraulics Fig. 38: Units 4

14a 33e c

20

3 1

a b 1 electrohydr. control unit 3 water valve unit 4 check valve, hydr. released 14a pressure relief valve, 400 bar,

DBT GmbH, Lünen 2005

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20 accumulator cartridge

33e high-pressure ball valve, for baselift cylinder a PMC®-R control unitt b holder for PMC®-R control unit c symbol plate

Fig. 39: PMC®-R control unit, on adjustable holder

c d

a

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

5.26

b c emergency-stop button d locallockout button

DBT-Shield 1829/3658-2x5906-2050

Operation of the shield hydraulics Fig. 40: Adjustable holder for PMC®-R control unit

b 3

B

a 8

DBT GmbH, Lünen 2005

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1

A

1 holder 2 bracket 3 rocker arm

a PMC®-R control unit b electrohydr. control unit A PMC®-R inclination angle

8 collared pin

B holder height adjustment

Before operating the shield support for the first time, adjust the holder such that you have good access to operate the PMC®-R control unit.

. Use the rocker arms (3) to adjust the height of the holder (B) to the desired working position.

. Fix the rocker arms in position by means of the collared pins suspended from the chains.

. Adjust angle of inclination (A) of the control unit to the desired working position by means of the rocker arms (3).

. Fix the rocker arms in position by means of the collared pins suspended from the chains.

IMPORTANT! Please observe that the holder must be in top position when the shield is lowered completely.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.27

Operation of the shield hydraulics Fig. 41: L.H. prop, view from the gobside, shown without protective cover

Z

33a

35b high-pressure ball valve, interrupts set prop action Z detail see fig. 42

Fig. 42: Detail Z: showing L.H. prop, turned, partly without hoses

15a

13

11 33b 2

37

2 prop control valve 11 compensating valve 13 pressure relief valve 500 bar, rock burst valve

5.28

15a pressure relief valve 470 bar, with return port 33b high-pressure ball valve, DN10, interrupts lower prop action 37 glycerine pressure gauge

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

33a high-pressure ball valve, interrupts line to stabilizing cylinder compensating valve

E

35b

Operation of the shield hydraulics Fig. 43: R.H. prop, view from the gobside, shown without protective cover

Z 37 37 35b

E

32

DBT GmbH, Lünen 2005

32 high-pressure ball valve DN 20 blue 35b high-pressure ball valve, interrupts set prop action

37 glycerine pressure gauge Z detail see fig. 44

Fig. 44: Detail Z: showing R.H. prop, turned, partly without hoses

15a

13 S1

33b

2

2 prop control valve 13 pressure relief valve 500 bar, rock burst valve

33b high-pressure ball valve DN 10, interrupts lower prop action S1 pressure sensor

15a pressure relief valve 470 bar, with return port

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.29

Operation of the shield hydraulics Fig. 45: View under the canopy left rear corner

42

34

43 31b 33c 16a

31b high-pressure ball valve, interrupts link spraying system of caving shield spraying system 33c high-pressure ball valve, for side seal, compl.

33d high-pressure ball valve, for caving shield side seal 34 block ball valve, position determines whether to retract baselift or seal cylinder 42 distributor 43 distributor

Fig. 46: View under the canopy left rear corner

31c

31c high-pressure ball valve DN 20 (closed, as shown) for side seal spraying

5.30

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

16a pressure relief valve, 380 bar

E

33d

Operation of the shield hydraulics Operation of the dual backflush filter WARNING! Do not put the filter into operation, before making sure that all connections have been made properly. Observe the separate operating manual for the filter. flushing

The filter needs flushing when the contamination of the filter elements causes reduced flow or pressure losses.

In which time intervals to flush the filter elements depends on the degree of contamination of the emulsion used (HFA fluid) and therefore has to be defined individually. We recommend to flush the dual filter regularly once every shift.

The filter elements are flushed alternatingly by operating function keys 11 and 12 of the electrohydraulic control unit.

Please keep in mind that a minimum volume flow of 70 l/min is required for flushing.

DBT GmbH, Lünen 2005

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Fig. 47: double filter, backflushing via control unit

30

36a

30 dual filter, backflush type

Doc. No.: 7420 150 000 BA 00

SUVR / 01

36a high-pressure ball valve, interrupts main pressure supply line to shield

5.31

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 data”, section ”Shield description” of this manual.

5.32

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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.

E

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.

Operation of the shield hydraulics Figure 48 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. 48: Control unit arrangement

d

1 20

3

b

DBT GmbH, Lünen 2005

E

a 1 electrohydr. control unit 3 water valve unit 20 accumulator cartridge

c a control unit PMC®-R b emergency stop button c locallockout button d symbol plate

Fig. 49: Electrohydraulic control (14 functions), centric under the canopy e

d

20 c

a b

1 1 electrohydraulic control 20 accumulator cartridge a push button b pilot valve

c connecting cable d valve solenoid driver e symbol plate

IMPORTANT! The hoses are provided with a marking. Please note that the hose end closer to the marking has to be connected to the pilot valve. See also separate operating manual for the control unit.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.33

Operation of the shield hydraulics Fig. 50: Symbol plate for 14 function control valve block

The symbol plate is located at the control valve block above 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.

Operation and functions of the control valve block

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.

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.

5.34

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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.

E

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.

Operation of the shield hydraulics 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.

1

DBT GmbH, Lünen 2005

E

2

3

4

Doc. No.: 7420 150 000 BA 00

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.

Set both props Before this function is initiated the canopy should be aligned properly. 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 for the stabilizing cylinder is not barred. The canopy bar may then have to be aligned again.

Compensating valve The compensating valve (see figure 42, item 11) and the related isolating valve (see figure 41, item 33a) are located at the L.H. prop as seen looking towards the coal face. When the isolating valve 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.

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.

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.

Retract both props (release support actively) 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.

SUVR / 01

5.35

Operation of the shield hydraulics 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.

6

Retract stabilizing cylinder

7

8

Extend seal cylinders This function is designed to correct the attitude of a shield with respect to its adjacent shield. The seal cylinders are extended as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached. When not activated, the side seal is pressed outwards by the force of the pressure springs.

Retract seal cylinder or baselift cylinder Function key 8 operates two functions. Which function is operated depends on the position of the block ball valve (item 34):

. Lever pointing towards the shield center retracts the baselift cylinder.

. Lever pointing downwards (or to the face) retracts the side seal cylinder.

DANGER! You must check the position of the block ball valve before operating function key 8.

The seal or baselift cylinders are retracted as long as the button is held depressed or until the end position has been reached.

When not activated, the side seal is always pressed outwards by the force of the pressure springs.

9

5.36

Extend flipper cylinder 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.

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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.

E

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Operation of the shield hydraulics 10

11

Retract flipper cylinder 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.

Flushing filter The function is performed as long as the button is held depressed.

12

Flushing filter The function is performed as long as the button is held depressed.

13

Clean sprays The function is performed as long as the button is held depressed.

14

Extend baselift cylinder 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.

Functions of the water valve unit DBT GmbH, Lünen 2005

E

Fig. 51: Water valve unit functions, symbol plate

W1

Cannopy water spray The function is performed as long as the button is held depressed.

W2

Lemniscate water spray The function is performed as long as the button is held depressed.

W3

Water curtain The function is performed as long as the button is held depressed.

W4

Side seal sprays The function is performed as long as the button is held depressed.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.37

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.

hydraulic control

Special measures

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.

5.38

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.

DBT-Shield 1829/3658-2x5906-2050

E

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.

DBT GmbH, Lünen 2005

one week after start-up

Maintenance 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. 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, E

– valves, DBT GmbH, Lünen 2005

– props, – shifting ram and baselift cylinder, – stabilizing cylinder, steering and flipper cylinders.

. 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 maintenance 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”.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.39

Maintenance Fig. 52: Grease nipples at the prop

b

a

a grease nipple at the sleeve holder

b escaping grease at the dirt stripper

ders. 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.

5.40

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

. Apply a preservative to the piston rods of the hydraulic cylin-

E

To be done every six months

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.

DBT GmbH, Lünen 2005

E

Fault localization failure to lower the shield

Doc. No.: 7420 150 000 BA 00

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. Make sure hoses are laid properly.

Props are damaged.

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

SUVR / 01

5.41

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.

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.

Check for damaged or kinked hoses in prop circuit. Replace hoses if required. Make sure hoses are laid properly.

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.

Shield is trapped by adjacent shields.

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

failure to advance the shield

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

5.42

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.

Make sure hoses are laid properly.

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.

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

E

Damaged or trapped hoses.

Trouble shooting failure to maintain the prop pressure after setting the support

Check / measure required

Faulty prop check valve.

Replace prop check valve. 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 GmbH, Lünen 2005

E

failure to operate the tip up function

Possible cause

failure to operate the tip down function

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.43

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.

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

manifold pipe.

. 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.

5.44

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

valve replacement

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 prop annulus side to be checked.

To this end, detach the hose line at the prop annulus port (located at the prop pipe) temporarily and admit pressure to the control port (extend prop) of the pilot-operated check valve.

. 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.

Faulty pressure relief valve

DBT GmbH, Lünen 2005

E

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.

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.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

5.45

DBT GmbH, Lünen 2005

E

Trouble shooting

5.46

DBT-Shield 1829/3658-2x5906-2050

6

Technical data

Shield description

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

Shield description Type:

1829/3658-2x5906-2050

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 hydraulic props, J hydraulic equipment with hose lines and controls.

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

DBT GmbH, Lünen 2005

E

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. The canopy is equipped with a flipper.

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.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

6.3

Shield description Main assemblies Fig. 53: DBT-Shield, dimensions

1335

HI

2438

HA

5505 4040

211,3 1000

3725

DBT GmbH, Lünen 2005

E

L

M B 200

420 1030 1800

HA extended height = 3658 HI closed height = 1829 L transport length = 7689

6.4

M support centers = 2050 B width = 1950

DBT-Shield 1829/3658-2x5906-2050

Shield description Fig. 54: Main components 51

11

61

41

1

6

5

31

DBT GmbH, Lünen 2005

E

21

1 skid (base of shield) 5 transport bar 6 securing spring 11 canopy 21 side seal

31 caving shield 41 prop 51 stabilizing cylinder 61 electro hydraulic control

Tab. 9: DBT-Shield 7420 150 000 00 01, main assemblies Item

Description

Ident. No.

1

skid (base of shield)

7420 150 300 00 01

11340

11

canopy

7420 150 400 00 01

10366

21

side seal

7420 150 700 00 01

1939

31

caving shield

7420 150 800 00 01

5067

41

prop

8250 115 000 00 00

1876

51

stabilizing cylinder

8241 287 000 00 00

223

61

hydraulic control, 14 functions

8112 213 000 00 00

123

Doc. No.: 7420 150 000 BA 00

SUVR / 01

Weight ca. in kg

Remark shifting ram Ø 165 baselift cylinder central shifting unit, 4010 long

8241 285 000 00 00 8241 289 000 00 00

electrohydr. control unit hose lines spraying system retainers

8154 117 000 00 00 8112 213 010 00 00 8112 213 020 00 00 8112 213 030 00 00

7420 150 330 00 00

6.5

Shield description 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.

DBT GmbH, Lünen 2005

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

6.6

DBT-Shield 1829/3658-2x5906-2050

Shield description Fig. 55: Base 19

66

40

30

850

31, 56

245

680

1030

55, 42

850

1211,3

30

3725

420

66

1030

41 21 65, 44, 64 11

43, 67 17

68

1890 13

15

6

DBT GmbH, Lünen 2005

E

16

20

2

1 shifting ram ZE-165/100-1055 2 baselift cylinder ZE-150/90-300 6 shifting unit 11 base 13 front lemniscatic link, R.H. 14 front lemniscatic link, L.H. 15 rear lemniscatic link, R.H. 16 rear lemniscatic link, L.H. 17 prop retainer, R.H. 18 prop retainer, L.H.

Doc. No.: 7420 150 000 BA 00

63, 65, 45

18

1

19 ram socket 20 running board, L.H. 21 running board, R.H. 30 locking plate 31 bolt 16x117 40 link pin Ø169,3x642 41 link pin Ø144,3x607 42 pin Ø50x155 43 pin Ø29x62 44 retaining clip

SUVR / 01

46

14

45 thrust piece 46 cover plate 55 staple DN 40 56 staple NW 8/10 63 hex. head bolt M 16x55 64 hex. head bolt M 16x80 65 hex. nut M 16 66 locking clip 5,6 67 locking clip 4 68 spring clip 5

6.7

Shield description Shifting unit 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. The component of force produced by the lifting cylinder is transmitted into the floor via the relay bar of the shifting unit.

Fig. 56: Shifting unit 4009,3 3741,3

15 5

340

270

390

2

6

7 8 4

1

1 relay bar 2 clevis assembly for conveyor 3 pin 58x187 4 bolt 53x210 5 spring clip 8 6 pin

11

3

10

7 pin 16x138 8 locking clip 3,2 10 hex. head bolt M 16x110 11 hex. nut V M 16 15 washer

Functional description 1. Initial position of shield The shifting ram 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.

6.8

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

E

390

270

265

150

285

Shield description 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 ram is switched to ”retract”.

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.

The shield canopy is equipped with a movable side seal on the R.H. side and a flipper.

1

13, 12, 20

18, 19

17, 11, 21

10

14

370

250

22

0

15

1335

23 5375

6375

2

1030

A

1930

DBT GmbH, Lünen 2005

E

Fig. 57: Canopy

Z

1 canopy 2 flipper 10 lock, left 11 retainer 12 journal 73x134 13 pin Ø20x160

Doc. No.: 7420 150 000 BA 00

14 hinge pin Ø154,3x598 15 pin Ø20x135 17 pin 18 pin Ø63x185 19 staple DN 40 20 spring clip 5x32

SUVR / 01

21 locking clip 2,5 22 spring clip 5 23 securing spring Z flipper transport locks

6.9

Shield description Prop head IMPORTANT! Insert the journals of the prop head retention system into the bores provided in the seat before installing the prop head. Secure the journals by means of the retaining elements (pin, spring clip) in the second groove.

After the prop head has been installed push the journals into the prop head bores. Secure the journals by the retaining elements in the first groove.

Fig. 58: Prop head attachment

DBT GmbH, Lünen 2005

E

13, 20 12 20

12 journal 73x134 13 pin 20x160 Fig. 59:

6.10

20 spring clip 5x32

Prop head

DBT-Shield 1829/3658-2x5906-2050

Shield description 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. 60: Caving shield 1440 410

1

410

2025

12

E

2500

2490

10

480

DBT GmbH, Lünen 2005

7 5

4

6 8, 11 2

470

3

470 1030

1175

1930 S1 S1

1 caving shield, subassembly 2 lock 180 mm 3 lock 155 mm 4 lock 5 link pin Ø169,3x642

Doc. No.: 7420 150 000 BA 00

6 link pin Ø144,3x607 7 pin Ø53x185 8 pin Ø12x120/115 10 staple DN 40 11 locking clip

SUVR / 01

12 spring clip 5 S1 lifting eye, load-carrying capacity: 15000 kg

6.11

Shield description Side seal NOTICE! Remove transport locks items (20*, 25*), and (26*, 44*), as well as (26*, 56*) during commissioning.

Apply lubricant B6 EWN7068 to connections and sliding surfaces.

26

56

44

31

26 42

1

40

22 41

41

10

10

26* 44*

32

48

32

56* 26* 48 32 51

53 57

E

32

13

43

12

48

35 1

22

22 42

30

31

1

40

45

50

26

29

31 1950 + 200 mm

29

33

DBT GmbH, Lünen 2005

Fig. 61: Side seal for face shields 50

32 49

32 58 52

54

34

5

54

32 34

49

7 20*

52 59

25* 55

34

25*

46

20* 46 33

1 hydraulic cylinder ZE-119-63/50-215 5 side seal, canopy, R.H. 7 side seal, caving shield, R.H. 10 guide pin 12 guide pin 13 guide pin 20 transport retainer 22 pin Ø28x93 25 staple DN 12 26 staple DN 25 29 threaded pin M 10x25 30 threaded pin M 10x12

6.12

31 split pin 32 locking clip 4 33 locking clip2,5 34 hex. head bolt M 12x20 35 cylinder liner 40 compression spring 18x130x800 41 compression spring 12x79x560 42 guide pin133x1370 43 guide pin103x1370 44 pin Ø34x273 45 pin Ø34x64 46 pin Ø12x120/115 47 pin

47

33

25

48 pin 49 pin 50 cylinder liner 51 pin 52 lock 53 lock 54 cover plate for canopy 55 cover plate 56 pin 34x293 57 plug, R.H. 58 plug 180 mm 58 plug 155 mm

DBT-Shield 1829/3658-2x5906-2050

Shield description Flipper Fig. 62: Flipper

19 21

22

14

23

(1400)

20

1

995 1300

17

12

16

1 hydraulic cylinder ZE-125/90-535 2 flipper 11 fork 12 lemniscatic link 13 lemniscatic link 14 lock

Doc. No.: 7420 150 000 BA 00

24

155

2

137

DBT GmbH, Lünen 2005

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168

18 11

13

15

15 pin Ø44,5x304 16 pin Ø44,5x250 17 pin Ø44,5x184 18 pin Ø30,5x115 19 pin Ø43,5x159 20 hex. head bolt M10x60-8.8

SUVR / 01

21 hex. nut M 10-8 22 hex. head bolt M 16x170-10.9 23 hex. nutM 16-8 24 locking clip EWN 6303-4

6.13

Shield description

6.14

15

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

1829

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

3658

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

1829

advance stroke . . . . . . . . . . . . . . . . . . . . . mm

1000

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

1055

distance of prop centers (inclination) . . . mm

1030

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

4040

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

1465

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

1950

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

5505

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

12.5

shield extended . . . . . . . . . . . . . . . . . . . . . deg.

56.1

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

1950

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

1800

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

37334

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

2050

support resistance at average seam height of . . . . . . . . . . . . . mm

2400

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

7763

b) at 470 bar yield pressure . . . . . . . . . . kN

11401

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm

2400

a) at 320 bar setting pressure . . . . . . . . kN/m2

635

b) at 470 bar yield pressure (distance canopy tip to face low / high) . kN/m2

799 / 933

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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

E

Technical data of the shield, steel structure

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. normal and exceptional operation

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

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.

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.

Shield hydraulics DBT GmbH, Lünen 2005

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The hydraulic components are listed in the table below.

Tab. 10: Hydraulic components Item 01

Qty. 1

02

2

03

1

Description electrohydraulic control unit 14 functions prop control valve, pilot-operated water valve unit

04 05 06 07 08

1 1 1 1 2

check valve, pilot-operated twin check valve check valve DN 10 check valve NW 20 check valve NW 20

09

1

check valve NW 25

10

2

check valve DN 32

11 12 13

1 1 2

compensating valve check valve DN 12 pressure relief valve, 500 bar

14

2

pressure relief valve, 400 bar

15

4

pressure relief valve, 470 bar

16

2

pressure relief valve, 380 bar

17

2

pressure relief valve, 420 bar

18 20

1 1

pressure relief valve, 80 bar accumulator cartridge

21

1

twin check valve

Doc. No.: 7420 150 000 BA 00

SUVR / 01

Location rear end, centric under the canopy

Remark

gobside, at each prop L.H., next to electrohydraulic control unit above control unit flanged to stabilizing cylinder (Z3) behind water valve (item 3) behind water valve (item 3) at each prop check valve (item 2), gobside at manifold block (item 29), R.H. front at manifold block (item 29), L.H. and R.H. L.H. at prop, gobside at manifold block (item 29) bottom at each prop check valve (item 2), gobside a) at check valve (item 4) b) at high-pressure ball valve (item 33e) a) 1x at each prop b) 2x on stabilizing cylinder a) at manifold (item 43) b) at seal cylinder (Z4) annulus in caving shield at twin check valve (item 21) of flipper cylinder (Z6) at manifold block (item 29) electrohydraulic control unit (item 1) flipper cylinder (Z6)

for shifting ram

for stabilizing cylinder in return line rock burst valve for shifting ram for baselift cylinder

in return line

6.15

Hydraulic system Location Remark each prop check valve (item 2) in return line of auxiliary supply line relief valve

1 1 1 1 1 1

Description pressure gauge port plug DN 10 with vented cap screw hose lines spraying system retainers and accessories filter manifold block dual filter

25 26 27 28 29 30 31

4

high-pressure ball valve DN 10

32

1

high-pressure ball valve DN 20

a) in spraying line b) on manifold block (item 42) c) 2x for side seal spraying system on manifold block (item 29)

33

6

high-pressure ball valve DN 10

a) behind L.H. prop, gobside b) at each prop c) in side seal annulus d) in caving shield side seal annulus e) under canopy above control unit L.H. under canopy behind prop

subassembly subassembly subassembly for water circuit

at manifold block (item 29) centric between the base skids R.H. under canopy

34

1

block ball valve

35

3

high-pressure ball valve

a) in pressure feed line to auxiliary supply line b) at each prop, gobside

36

2

high-pressure ball valve

a) at dual filter (item 30) b) behind manifold block (item 29)

37 39

2 1

glycerine pressure gauge rotating coupling DN 40

at each prop check valve (item 2) at manifold block (item 29)

40

3

rotating coupling DN 50

at manifold block (item 29)

42

1

distributor

43

2

distributor

44 45

1 4

plate hex. head bolt M 8x30

under the canopy, L.H. behind prop under the canopy, L.H. behind prop at R.H. prop, gobside to fasten the plate (item 44)

S1 Z1 Z2 Z3 Z4 Z5 Z6

2 2 1 1 4 1 1

pressure sensor prop shifting ram stabilizing cylinder seal cylinder baselift cylinder flipper cylinder

W1 W2 W3 W4

6.16

can be backflushed via control unit blue handle in water circuit, blue handle a) interrupts line to stabilizing cylinder b) interrupts prop lowering c) for side seal, compl. d) for caving shield side seal e) for baselift cylinder presetting for function 8 (retract baselift or seal cylinder) a) interrupts auxiliary supply line pressure supply b) interrupts prop setting red handle a) interrupts main pressure supply line to shield b) interrupts main pressure supply line to shield red handle connection to pressure line (P), DN 40 SS rotating coupling for ports R1, R2 and W1 in water circuit in side seal circuit

at each prop, gobside

canopy water sprays link water sprays water curtain side seal water sprays

DBT-Shield 1829/3658-2x5906-2050

E

Qty. 2 1

DBT GmbH, Lünen 2005

Item 22 23

Hydraulic system Shield hydraulics Fig. 63: Shield hydraulics, arrangement (1) key see table 10

23, 35a

1 3

27 25

DBT GmbH, Lünen 2005

E

12

S1

15a 13 33b 22

37

S1 37 8

33a

15a 13 33b 22

35b 2

35b

2

8

11

Doc. No.: 7420 150 000 BA 00

SUVR / 01

45 44

6.17

Hydraulic system Fig. 64: Shield hydraulic, arrangement (2) key see table 10

29

17

40

39

28

40

32 21 40

10

26

DBT GmbH, Lünen 2005

E

31a

14 33e 36b 4 20

23 35a 9

7 6 30 36a

42 34 31b 43

5

10

18 12

33c, 33d 16a

31c

15b 31c 16b

6.18

DBT-Shield 1829/3658-2x5906-2050

Hydraulic system

DBT GmbH, Lünen 2005

E

Fig. 65: Functions of electrohydraulic control unit, symbol plates

14 functions

Tab. 11: Electrohydraulic control unit with 14 functions, allocation of functions Function

Doc. No.: 7420 150 000 BA 00

Function no.

advance shield

1

set both props

2

advance conveyor

3

lower both props

4

extend stabilizing cylinder

5

retract stabilizing cylinder

6

extend seal cylinder

7

retract seal cylinder or baselift cylinder

8

extend flipper cylinder

9

retract flipper cylinder

10

dual filter

11

dual filter

12

sprays clean

13

extend baselift cylinder

14

SUVR / 01

6.19

Hydraulic system Fig. 66: Water valve unit functions, symbol plates

Tab. 12: Water valve unit with 4 functions, allocation of functions Function

Function No. W1

link water sprays

W2

water curtain

W3

side seal water sprays

W4

DBT GmbH, Lünen 2005

E

canopy water sprays

6.20

DBT-Shield 1829/3658-2x5906-2050

Hydraulic system Fig. 67: Shield hydraulics key, see table 10

40

18 39

1

29

23

35a

DN 40-SS

P DN 50 W DN 50 R1 DN 50 R2

9

36b 12

10 31a

43

20

36a 32

33c

30

34

28

6 7 15b

16a

33d

3 16b

W2

DBT GmbH, Lünen 2005

E

Z4 Z3 Z4

5

15 15b

Z4

31b 42

Z2

Z4

4

W4

W4

14a

31c

Z5

31c 25

35b 33e

8 22

35b 14b

15a

15a

13

W1

26

8 22 13

W3

33a 44, 45

11

2 37

Z1 33b

2 37

Z1 33b

17

Z6 21

Doc. No.: 7420 150 000 BA 00

SUVR / 01

17

6.21

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. 68: Double telescopic prop, Typ SD-5900-400-1360/3130-CR 4

X 21

4

section X

DBT GmbH, Lünen 2005

E

2

42 b a e

1

c

1 prop base 2 piston pipe 4 pressure relief valve 21 piston rod 42 lubricating nipple

a valve connection plate b annulus port c cam e load ring 3000 kg

Tab. 13: telescopic prop length [mm]

stroke [mm]

identification number telescopic prop

retracted

extended

upper stage

lower stage

8250 115 000 00 00

1360

3130

855

915

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.

6.22

DBT-Shield 1829/3658-2x5906-2050

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.

prop loading

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. b) Center prop and inner prop extended

DBT GmbH, Lünen 2005

E

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

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.

Just a few millimeters before the piston pipe ”touches down” the check valve is opened by the tappet with the pressure fluid under the piston pipe acting as a spring lifting the piston pipe to close the valve again. When the prop is lowered over the complete stroke this procedure is repeated several times.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

6.23

Hydraulic cylinder Hydraulic cylinder Design 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. 69:

Hydraulic cylinder, typical example

Type a)

2

1

3

5

4

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, hydraulic cylinder” 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.

6.24

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

E

Type b)

Hydraulic cylinder Shifting ram Fig. 70: Hydraulic cylinder, type ZE-165/100-1055-SC-W-CR,

62

70

d

L

c

4

b

2 7

1 e

b piston chamber port c shifting unit adapter d load ring 3000 kg e journal L retracted 1419 - extended 2474

1 cylinder tube 2 reed contact rod 4 piston rod 7 screw joint a annulus port

E DBT GmbH, Lünen 2005

a

Stabilizing cylinder Fig. 71: Hydraulic cylinder, type ZE-200/125-500-EC-CR

a

b

65

65

11

d

L

c

1 1 cylinder tube 11 piston rod a valve connection plate b pressure relief valve port, annulus

Doc. No.: 7420 150 000 BA 00

SUVR / 01

c pressure relief valve port, piston chamber d load ring 3000 kg L retracted 945 - extended 1445

6.25

Hydraulic cylinder Baselift cylinder Fig. 72: Hydraulic cylinder, type ZE-150/90-300-LI-CR 2 a

c 415

b

1

3 a piston chamber port b annulus port c load ring 1000 kg L retracted 588 - extended 888

Seal cylinder Fig. 73: Hydraulic cylinder, type ZE-119/63/50-215

30 2

L

b

a 1

1 cylinder tube 2 piston rod

6.26

a piston chamber port b annulus port L retracted 440 - extended 655

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

1 cylinder tube 2 piston rod 3 wearing bottom

E

L

Hydraulic cylinder Flipper cylinder Fig. 74: Hydraulic cylinder, type ZE-125/90-535-KO-W-CR

32 70 L a b

7

4

c

2

DBT GmbH, Lünen 2005

E

1

Doc. No.: 7420 150 000 BA 00

1 cylinder tube 2 reed contact rod 4 piston rod

a valve connection plate b shifting ram adapter c load ring 1000 kg

7 screw joint

L retracted 822 - extended 1357

SUVR / 01

6.27

Hydraulic cylinder Technical data of hydraulic cylinders

stabilizing cylinder, double-acting

baselift cylinder, double-acting

6.28

prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1360

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

3130

hydraulic stroke . . . . . . . . . . . . . . . . . . . . . mm

1770

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

prop force at 470 bar yield pressure . . . kN

5906

retracting force at 320 bar . . . . . . . . . . . . kN

580

Type ZE-165/100-1055-SC-W-CR, drawing No. 8241 285 000 00 00, equipped with Reed contact rod stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1055

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

165

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

100

piston surface area . . . . . . . . . . . . . . . . . . cm2

213.8

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

135.3

thrust at 320 bar / --- bar . . . . . . . . . . . . . kN

684 / ---

pulling force at 320 bar / 400 bar . . . . . . kN

433 / 541

Type ZE-200/125-500-EC-CR, drawing No. 8241 287 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

500

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

200

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

125

piston surface area . . . . . . . . . . . . . . . . . . cm2

314.2

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

191.4

thrust at 320 / 470 bar . . . . . . . . . . . . . . . kN

1005 / 1477

pulling force at 320 / 470 bar . . . . . . . . . kN

612 / 900

Type ZE-150/90-300-LI-CR, drawing No. 8241 289 000 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

DBT-Shield 1829/3658-2x5906-2050

E

shifting ram double-acting, el. connection, reverse-mounted

Type SD-5900-400-1360/3130-CR, drawing No.. 8250 115 000 00 00

DBT GmbH, Lünen 2005

double telescopic prop, double-acting - 2 stages

Hydraulic cylinder

seal cylinder, double-acting

DBT GmbH, Lünen 2005

E

flipper cylinder, el. connection double-acting

Doc. No.: 7420 150 000 BA 00

thrust at 320 / 400 bar . . . . . . . . . . . . . . . kN

566 / 707

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

362 / ---

Type ZE-119-63/50-215-N, drawing No. 9571 191 200 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

63

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

50

piston surface area . . . . . . . . . . . . . . . . . . cm2

31.2

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

11.5

thrust at 320 / --- bar . . . . . . . . . . . . . . . . kN

99.8 / ---

pulling force at 320 / 380 bar . . . . . . . . . kN

36.8 / 43.7

Type ZE-125/90-535-KO-W-CR, drawing No. 8241 288 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

535

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

125

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

90

piston surface area . . . . . . . . . . . . . . . . . . cm2

122.7

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

59.1

thrust at 320 / 420 bar . . . . . . . . . . . . . . . kN

392.6 / 515.3

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

189.1 / 248.2

SUVR / 01

6.29

Pressure relief valves 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.

type

set pressure in bar

order no.

for return line

spring-loaded

80

8220 042 080 00 00

general application, spring-loaded not for props and stabilizing cylinders

380

7337 486 380 00 00

for shifting ram and baseliftcylinder

spring-loaded

400

7337 871 400 00 00

for flipper cylinder

spring-loaded

420

7337 486 420 00 00

only at stabilizing cylinder

spring-loaded

470

8220 028 470 00 00

only for prop

spring-loaded

500

9580 185 000 00 00

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.

6.30

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

application

E

Tab. 14: Pressure relief valves, use of different types

Pressure relief valves Tab. 15: Typical letter code 420 or 42 1)

09

03

xy

set pressure

week

year

made by last

The color code may consist of one or two colors. It characterizes the setting pressure range. The following figure 75 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. 75: Typical pressure relief valve

a color code b protection cap b

a

DBT GmbH, Lünen 2005

E

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

Tab. 16: Color codes for pressure relief valves, overview

1)

Doc. No.: 7420 150 000 BA 00

color

pressure range (bar)

black

0 - 49

black / white

50 - 99

brown

100 - 149

brown / white

150 - 199

green

200 - 249

green / white

250 - 299

blue

300 - 349

blue / white

350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow /white

550 - 599

orange

600 - 649

orange / white

650 - 699

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

SUVR / 01

6.31

Shield control system Shield control system Electrohydraulic control unit Fig. 76: Electrohydraulic control, 14 functions

a 1

4

2

3 a connecting accumulator cartridge 1 control valve block

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! Please refer to the separate operating manual for the PMC®-R control unit.

Fig. 77: Control unit type PMC®-R, input configuration front view

rear view

6.32

A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

PMC®-R inputs A1 = L.H. adjacent unit A2 = lamp B1 = pressure sensor, L.H. B2 = not used C1 = not used C2 = not used D1 = reed rod push ram D2 = reed rod flipper cylinder E1 = pressure sensor, R.H. E2 = not used F1 = R.H. adjacent unit F2 = solenoid driver module of unit

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

E

2 pilot control valve for electromagnetic operation

3 push-button for manual operation 4 plug contact, electrical connection to the control unit

Shield control system Fig. 78: Electronic shield control unit, type PMC®-R, schematic diagram 1 rear view

L.H. adjacent unit

R.H. adjacent unit

F1

A1

4 5a

5b

E

b

DBT GmbH, Lünen 2005

a

1 control unit (SCU) 4 solenoid driver 5a pressure sensor, left 5b pressure sensor, right

Doc. No.: 7420 150 000 BA 00

SUVR / 01

a reed rod push ram b reed rod flipper * shrink-on marks to valve blocks others: see spare parts catalog

6.33

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. 79: Angles α 1 / α 2

α1 α2

Tab. 17: Angles α 1 / α 2 at height M Inclination α at height M

Shield Order-no.

7420 150 000 00 01

α1 in °

α2 in °

M in mm

3

14

1829 bis 2129

15

15

2129 bis 3358

14

11,7

3358 bis 3658

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.

IMPORTANT! With the shield at maximum closed or extended height the ”canopy – caving shield” coupling point will shift accordingly when lowering or raising the canopy.

6.34

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

E

M

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.

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

DBT GmbH, Lünen 2005

E

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.

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.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

6.35

Permissible media If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive the respective certificate by DBT GmbH. 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

E

Fig. 80: Typical certificate

6.36

DBT-Shield 1829/3658-2x5906-2050

Permissible 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 DBT GmbH, Lünen 2005

E

J Microbial load

– 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 18 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.

Doc. No.: 7420 150 000 BA 00

SUVR / 01

6.37

Permissible media 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.

Tab. 18: Properties of the process water, limit values Limit value

Appearance, color, smell

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

electrical conductivity

< 1800 µS/cm

pH-value

6,5 ..... 8,5

Na+ - content

not specified

Mg+ - content

not specified

water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content

≤

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

Lubricating greases general properties

lubricating greases A1

base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble in water

temperature of application:

-20 to +120 °C

flash point:

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN *) 7068 Tab. 19: Lubricating greases for general application

lubricating greases A2

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load. *)

6.38

Flash point in °C

Supplier

EWN = DBT standard

DBT-Shield 1829/3658-2x5906-2050

DBT GmbH, Lünen 2005

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Test criterium

Permissible media Tab. 20: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Flash point in °C

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.

DBT GmbH, Lünen 2005

E

Tab. 21: Lubricating pastes free from molybdenum disulfide Supplier

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.

*)

Doc. No.: 7420 150 000 BA 00

The products listed in table 19 are suitable lubricating greases for filling of adjacent cavities.

SUVR / 01

6.39

Tightening torques Tightening torques Screws with ISO metric thread Tab. 22: Recommended tightening torques at µges. = 0.14 Tightening torque 4)

Pitch P (mm)

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

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)

6.40

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.

DBT-Shield 1829/3658-2x5906-2050

E

(mm)

DBT GmbH, Lünen 2005

Thread 1)

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

E

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 150 000 BA 00

SUVR / 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 1829/3658-2x5906-2050

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

Fig. 81: Identification plate, example

1

DBT GmbH 2

12345

5 6

7

2

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 to the lefthand faceside of the canopy.

Fig. 82: Shield number at the canopy, example

Tab. 23: Allocation of shield numbers

Doc. No.: 7420 150 000 BA 00

shield no.

order no

application

1 to 143

7420 150 000 00 01

face shield

SUVR / 01

7.5

DBT GmbH, Lünen 2005

E

Identification of shields

7.6

DBT-Shield 1829/3658-2x5906-2050