CAT DBT - Shield 1082 2305-2x3926-1750 Operating Maintenance Manual

Operating Manual DBT - Shield 1082/2305-2x3926-1750 Doc. no.: 7420 120 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 Telefax: +49 (0) 23 06 / 709 - 421

Email: infodbt@dbt.de 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. 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.

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Index

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

1.3

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

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

1.5 1.6

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

2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 2.7 2.8 2.9 2.12

Overview of the safety instructions . . . . . . . . . . . . . . . 2.16

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

3.3

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

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

3.3 3.5

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

3.6

4. Installation

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

4.3

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

4.3

Power take-off connections . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.5 4.6

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

4.7

Test-Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

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

4.8

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

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

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

4.8 4.10 4.10

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Index 5. Operation and maintenance Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

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

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

5.3 5.6

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

5.9

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

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

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

5.15 5.23 5.25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.29 5.30 5.32 5.32 5.35 5.35 5.36 5.36 5.36

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

6.3

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

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

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

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

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

6.5 6.6 6.9 6.10 6.11

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

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

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

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

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

6.15 6.16 6.17 6.20 6.22

Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.23 PANZERMATIC® PM4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.25 Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

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

6.26 6.29

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31 Screws with metric coarse thread DIN 13 . . . . . . . . . . . . . .

6.31

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

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

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

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

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

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

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

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Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

Index 7. For your information 7.3

Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

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

7.4

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

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

7.4 7.5

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

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Index

DBT - Shield 1082/2305-2x3926-1750

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 1082/2305-2x3926-1750 with the following type specification: Identification no.:

7420 120 000 00 01

Year of construction: 2003 Prop force in kN:

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.

E DBT GmbH, Lünen 2003

2 x 3926

availability of operating manual

Dok. Nr.: 7420 120 000 BA 00

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.

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1.3

Before starting work 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 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.

1.4

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– supervise

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.

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Observe the information given and follow the procedural instructions.

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1.5

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

Try to memorize the symbols and their meanings.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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

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.

1.6

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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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.

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety.

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

supplementary regulations

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

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

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

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

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J of the miners’ accident insurance association.

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, 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 - Schild 1082/2305-2x3926-1750

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

Use the shield only in conformance with specifications!

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

– lowering, – pulling up, – alignment, and – setting; J the following conveyor operations: DBT GmbH, Lünen 2003

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– advancing, – retracting; J forming an abutment for:

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

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

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

shield,

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

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

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

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2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

lighting signalling systems and protective devices

Maintain the lighting systems in a functional condition.

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

support lock-out switch

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

Only applicable for shields provided with electrohydraulic control systems.

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

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

moving parts

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

automatic mode

2.6

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

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

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EMERGENCY STOP

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

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

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

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

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

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

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

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

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

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

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

Damage of this kind necessitates elaborate and expensive repair work.

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

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

Firmly secure all components which might start moving.

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

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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

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Safety instructions Operation

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shield control

inclined faces

Dok. Nr.: 7420 120 000 BA 00

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

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

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

Carefully read the instructions for operating the control system used.

Do not stay in the shield whose functions you are to operate. Always operate the shield only from the adjacent shield.

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

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

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

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

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

Ensure that the water spray system responds during advancement.

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

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

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

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

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

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2.9

Safety instructions shield alignment

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

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

roof falls

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

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

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.

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.

2.10

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– the canopy will be loaded excessively in longitudinal direction

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– the stabilizing cylinder locks

Safety instructions For raising the conveyor, only use: J high-strength undamaged round link steel chains, J the fastening points provided for the purpose. Check that the

fastening points are undamaged before attaching a load,

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J lifting gear with sufficient permissible load-bearing capacity.

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2.11

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

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

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

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

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

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

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

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

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

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

or is only done outside the required safety area,

J relieve the load on the components which are under hydraulic

pressure or mechanical stress.

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.

2.12

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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.

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

Safety instructions Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid penetrating the skin can cause serious infections.

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

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

Hydraulics handling of hydraulic fluids

It is vital that you observe the operating manual of the mine for the hydraulic fluid used. Any additional information, if required, can be taken from the safety data sheet of the hydraulic fluid producer.

Never use hydraulic fluids for rinsing or cleaning.

maintenance, repair

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

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention 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-

DBT GmbH, Lünen 2003

E

mally rigid or hard.

J the outer sheath of the hoses is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

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

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After completion of any repair work, check the depressurized system first to make sure all connections are correct. Next, apply pressure to the hydraulic system and check that the installation is leakproof and functioning properly. 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. Never install hydraulic hoses which are more than 2 years old, even if they don’t show any visible signs of damage.

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2.13

Safety instructions

Fig. 2:

Example: 4SP hydraulic hose, designation

3

2 1

6 5

4 1 hose type 2 nominal diameter 3 date of manufacture

4 manufacturer 5 flame-resistant and antistatic 6 standard

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses. Immediately replace damaged 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 of hydraulic hose lines, slack WRONG

RIGHT

J are not twisted.

Fig. 4:

Laying of hydraulic hose lines, twist RIGHT

WRONG

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter).

2.14

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installation of hydraulic hoses

E

Replace hydraulic hoses at the first suspicion of damage.

Safety instructions Fig. 5:

Laying of hydraulic hose lines, bend RIGHT

WRONG

J cannot chafe.

Fig. 6:

Laying of hydraulic hose lines, crossing RIGHT

WRONG

E

J are not kinked.

DBT GmbH, Lünen 2003

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

by the movement of the machine (Fig.: 7).

Fig. 7:

Laying of hydraulic hose lines, connections at movable parts RIGHT

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WRONG

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.

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

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

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

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

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

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 and the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

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

2.16

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

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 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.

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

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.

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

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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 ”Recommended lubricating greases and pastes”.

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

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.

NOTICE! Make sure that all securing elements needed during transportation have been removed. See chapter 3, section ”Transport”.

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

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2.17

Overview of the safety instructions 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.

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

Chapter 5: Operation and maintenance

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.

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.

WARNING! During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system.

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

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

WARNING! The control elements on the control valve block may only be used in an emergency and during repairs and only in com-

2.18

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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.

E

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.

Overview of the safety instructions pliance 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 electrohydraulic 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.

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.

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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.

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.

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.

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.

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.

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.

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2.19

Overview of the safety instructions 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.

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.

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

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

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

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

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.

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.

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

E

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Overview of the safety instructions 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.

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.

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.

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CAUTION! The pressure setting must not be changed.

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.

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

NOTICE! New seals must be fitted whenever a pressure relief valve is replaced.

NOTICE! How to operate the PANZERMATIC control unit is not subject of this manual. See separate operating instructions.

NOTICE! Use only hydraulic fluids approved by DBT! These fluids have been tested at DBT and guarantee a reliable operation of the hydraulic system.

IMPORTANT! We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems.

The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to observe the manufacturer’s instructions for use.

IMPORTANT! Further information is contained in DIN 24320.

IMPORTANT! The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they Dok. Nr.: 7420 120 000 BA 00

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2.21

Overview of the safety instructions 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.

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

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

2.22

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3

Storage and transport

Storage

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

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

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

Storage Storage of new equipment corrosion protection

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

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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.

HYDROCOR ® CV50 is equipped with a color indicator, which is responsive on the pH-value of the fluid. The color of the fluid will change from ”red” to ”yellow” in case the pH-value drops down. A yellow colored fluid indicates insufficient corrosion protection.

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

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

*

short-term storage

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

long-term storage

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

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

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

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3.3

Storage storage outdoors

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

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

electrical equipment, rubber and plastic parts

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

natural ageing

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

moisture and dirt

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

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

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

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

random sample inspection

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

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

HFA fluids

With respect to the storage of HFA fluids or concentrates for the production of HFA fluids in any case the regulations of the manufacturer or supplier of those media have to be observed first.

Supplementary information is given in the section ”Pressure fluids of group HFA” in this manual.

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

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plastic deformation

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

Storage 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 safety devices and transport units

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: J Support unit, complete

Transport position: as for normal use Transport safety devices: Part

Transport safety device

Quant.

shifting unit, faceside

transport rod

1

shifting unit, gobside

chain

1

J Hydraulic system:

All hydraulic ports not used are closed with protection plugs for transport.

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

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

Fig. 8:

Transport of shields as complete unit

W

S1 Y

H SY

S0

S2

X1 S3

X2 S4

Sx L S1 S2 S3 S4 X1, X2 Y So

slot hole 2 x on the coal face end of the canopy, load-bearing capacity: 8000 kg attaching eye, 2 x on the gob side end of the caving shield, load-bearing capacity: 8000 kg slot hole, 2 x on the coal face end of the base, load-bearing capacity: 8000 kg slot hole, 2 x on the gob side end of the base, load-bearing capacity: 8000 kg securing elements to fix the relay bar during transport, faceside and gobside transport safety device between canopy and base, e.g. turnbuckle, not included in the scope of delivery center of gravity

Tab. 1: Shield support 7420 120 000 00 .. , Variant

Order no.

01 7420 120 000 00 01

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Length in mm 6327

Width in mm 1700

Height in mm 1082

Sx/Sy in mm 1560 / 602

Weight in kg 19410

3.7

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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 ”Recommended lubricating greases and pastes”.

DBT GmbH, Lünen 2003

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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 ”Recommended lubricating greases and pastes”.

Pre-assembly of the shield units The shields are delivered as completely pre-assembled units. hence, no further pre-assembly is required for the mechanical and hydraulic systems of the shields.

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

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

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

identification for installation in the face

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 sign plate with the shield number is placed at the base. The shield units are numbered consecutively, see following table.

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4.3

Installation of the shield units Shield number, example

4.4

Shield no.

Order no.

Application

1 .... 192

7420 120 000 00 01

face shield

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Fig. 9:

Installation of the shield units Power take-off connections Fig. 10: View into the support L.H. side Shield in transport position. Supply hoses short circuited as ready for transport and power take off.

PTO PTO

P

R

10

11 12a

b 12b a c DBT GmbH, Lünen 2003

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a shield number b connecting cable, serves to establish the connection to the PM4 control unit c supply hoses P PTO pressure supply, connected as shown R PTO return line, connected as shown 10 ball valve, at the manifold block; serves to shut off the pressure supply to the shield hydraulics during normal operation; must be closed for PTO operation or the supply lines c must be short circuited as shown

11 ball valve (not visible here) at the aux. PTO pressure supply port; should be closed 12a ball valve (not visible here), serves to flush water spray nozzles with high pressure; must be closed during PTO and normal operation 12b ball valve, disables lift cylinder function if closed as shown

During all the PTO operations the shield functions must be operated from the outside of the shield using an auxiliary PM4 control unit connected to the shield control via connecting cable (b), see figure 10 above.

The Power Take-Off (PTO) nipples are located in front of the manifold block. See figure 10 above and circuit diagrams in chapter 6, section ”Hydraulic System”. The PTO connections are provided for connecting the shield to a hydraulic supply unit when the shield is set for the first time. The pressure line to the shield hydraulic can be shut off using the shut-off tap (10) at the manifold pipe.

The ball valve (11) serves to shut off the pressure supply at the aux. PTO port “P”.

In case of supply by way of the PTO connections, the connections on the manifold pipe are short-circuited with the use of hose lines, which later serve as connection with the manifold pipe of the adjacent shield. See fig. 10, above.

During normal operation the supply to the support shield unit proceeds exclusively by means of the manifold pipe. The PTO connections are then closed by plugs.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

4.5

Installation of the shield units Coupling between the connections The hydraulic connectors are plug-type connectors according to DIN 20043.

A manifold block for the shield hydraulic system is located under the canopy in front of the prop heads of each shield unit. This manifold block provides the hydraulic supply to the individual shield unit.

The manifold blocks of adjacent shield units are connected with the use of three hose lines: A pressure line (DN 40), a return line (DN 50) and a water line (DN 50). See the hydraulic block diagram in chapter 6.

control unit

The shield units are equipped with an electronic control unit of type PM4. 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 PM4 control system. How to connect the control unit is described in the separate operating manual for the PM4 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: – lighting system – 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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hydraulic system

Requirements to the face hydraulic system Requirements to the face hydraulic system hydraulic medium

For all hydraulic components included in the scope of supply of DBT, the hydraulic medium must meet the following requirements: Pressure fluid according to list of approved products, see section ”Operating media” in chapter 6 of this manual.

Purity class 18 / 14 to ISO 4406 nominal pressure

310 bar

admissible tolerance

10 % of nominal pressure

DBT GmbH, Lünen 2003

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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.

Test-Run 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 and the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

NOTICE! Make sure that all securing elements needed during transportation have been removed. See chapter 3, section ”Transport”.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

4.7

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

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

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

Please observe the following items: J Mechanics

. Check to make sure that all transport safety devices have been . Check all mechanical connections on the shields . Check attachment of the shifting unit

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

J Hydraulic system

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

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

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

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

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

. Check the hydraulic supply pressure. . Check supporting power of the props. (observe pressure gauge reading)The actual pressure under the piston of a prop can be read off the PM4 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..

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removed

Start-up . Check all operating elements to make sure that the correct

function is executed when actuating the respective operating element.

J Signalling and lighting systems

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

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

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

J Emergency stop systems

. Check that all emergency stop systems function properly.

J Mining and conveying DBT GmbH, Lünen 2003

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. 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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

4.9

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

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

. Check all line connections made during the installation of the

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

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

. Check the function of the hydraulic and water supply systems . Check all functions of the shield control system.

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

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

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

The testing fluid is fully compatible with the permissible media listed in the “Approval list”, see section “Hydraulic Fluids of Group HFA” in chapter 6.

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for the face.

5

Operation

Basic requirements

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

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

DBT GmbH, Lünen 2003

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

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

Basic requirements Conditions for operation face crew

The face crew must be informed about possible danger situations.

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

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

face equipment

The face must be illuminated sufficiently.

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

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

conveyor overload

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

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

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

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. extrahigh spill plates, wire mesh, nets, etc. or the like.

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

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

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

E

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

Basic requirements repair work

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

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

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

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

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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. 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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

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

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Fig. 12: 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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

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 of nominal diameter 32 relieving to atmosphere should be installed additionally into the return line, spaced about 40 m apart. Relief pressure 25 bar. damages, spare parts

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

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

5.8

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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. 13: Shield in the normal position

α=0 M

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

Dok. Nr.: 7420 120 000 BA 00

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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. 14: Shield with extremely inclined canopy

s

1

α

1

α2

s2

M

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

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

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

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M

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

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

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

E

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

Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 15) 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.

DBT GmbH, Lünen 2003

Fig. 15: W r o n g, by no means must the tip of the canopy be set in a cavity, if the stabilizing cylinder is fully extended.

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 16) or by leveling off the canopy.

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

Fig. 16: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

Dok. Nr.: 7420 120 000 BA 00

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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.

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

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

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

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

draulically 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.

Dok. Nr.: 7420 120 000 BA 00

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5.13

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

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

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

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

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

Always observe these safety rules :

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

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

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

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

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

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

Location of hydraulic components at the shield Fig. 17: Shield hydraulics, location of components key, see table 2

19

11 12a 14 1 17c 29c 17b 4 16c 29a 29b 5

16b

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21

12b 16d 30 7 3 17a 8 aux. water PTO ”P” 22 20 31

10

PTO ”R” 6

16

aux. PTO ”P” 23

15 13 P R W

24 2

28

9

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12c

9

SUVP / 01

28

2

15

13

5.15

Operation of the shield hydraulics Tab. 2: Hydraulic components Item

Qty.

Description

Location

1

1

electrohydraulic control valve block, 12 functions

at holder, under the rear canopy

2

2

prop check valve NG 20

gobside at prop

3

1

accumulator cartridge

at the control valve block, front side, port “SP”

4

1

pilot-operated check valve

L.H. under the canopy

5

1

twin check valve

at the stabilizing cylinder

6

1

check valve

at the manifold block

return line

7

1

filter

at the manifold block, gobside

water line

8

1

dual filter, back flush type

R.H. under the canopy

supply line for the shield hydraulics

9

2

high-pressure ball valve, “red”

at the prop check valves, item 2

supply line to the piston chamber of prop

10

1

high-pressure ball valve, “red”

at the manifold block

supply line for the shield hydraulics

11

1

high-pressure ball valve, “red”

L.H. under the canopy

aux. PTO port “P”

12

3

high-pressure ball valve, “red”

a) L.H. under the canopy

a) high pressure flushing the water spray system b) shut off supply line to piston chamber of lifting cylinder c) shut off supply line of compensating valve (item 24)

Remark

c) at the R.H. prop 13

2

glycerine pressure gauge

at the prop check valves, item 2

14

1

pressure relief valve 80 bar

at the manifold block

return line

15

2

pressure relief valve 400 bar

at the prop check valves, item 2, faceside

rapid flow type

16

4

pressure relief valve 400 bar

17

3

water spray valve

a) not applicable b) at the twin-check valve, item 5 c) at the pilot-operated check valve, item 4 d) at the high-pressure ball valve, item 12 b lateral under the canopy, 1x L.H. (a), 2x R.H. (b and c)

19

1

manifold block

20

1

hose lines

see separate parts catalog

21

1

water spray system

see separate parts catalog

22

1

retainers and accessories

see separate parts catalog

23

1

socket with release

at manifold block, gobside

24

1

compensating valve

R.H. prop, prop check valve

28

2

auxiliary port for pressure gauge

at prop check valves

29

3

high-pressure ball valve, “blue”

L.H. under the rear canopy

shuts off water supply to the a) front row of water curtain b) rear row of water curtain c) water spray system except of front row nozzles

30

1

high-pressure ball valve, “blue”

at the manifold block

supply line for the water spray system

31

1

ball valve

R.H. under the canopy

shut off water supply at the auxiliary water port

5.16

a) canopy laterally b) water spray system c) water curtain

under the canopy in front of the prop heads

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b) R.H. under the canopy

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shift cylinder circuit

Operation of the shield hydraulics Shield hydraulics Fig. 18: Hydraulic circuit diagram, overview Please, refer also to table 2 and the spare parts catalog.

PTO ”R” 6 19 10

PTO ”P”

14

aux. water 23

30

7

3

31

11

aux. PTO ”P” components of the shield hydraulic: 1 control valve block 2 prop check valve 3 accumulator cartridge 4 piloted check valve 5 twin check valve 6 check valve 7 filter 8 dual filter, back flush type 9 high-pressure ball valve “red” 10 high-pressure ball valve “red” 11 high-pressure ball valve “red” 12 high-pressure ball valve “red” 13 pressure gauge 14 pressure relief valve, 80 bar 17b 15 pressure relief valve, 400 bar 16 pressure relief valve, 400 bar 17 water spray valve 19 manifold block 29c 20 hose lines 21 water spray system 22 retainer and accessories 23 socket with release 24 compensating valve 28 auxiliary port for pressure gauge 29 high-pressure ball valve “blue” 30 high-pressure ball valve “blue” 31 block ball valve S1 pressure sensor

12a

1

8

17a

DBT GmbH, Lünen 2003

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17c

29b

29a 20 2

15 13

16d

28

9

13 15

21

S1

12

28 2 24 4 16c 16b

12c

5 16b NOTE: The components marked in “blue” are part of the water spray system.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 stabilizing cylinder Z4 base lift cylinder control valve block functions: 1 advance shield 2 extend props 3 push conveyor 4 extend base lift cylinder 5 extend stabilizing cylinder 6 retract stabilizing cylinder 7 flush filter chamber 1 8 flush filter chamber 2 9 water curtain 10 lateral water sprays 11 water spray system 12 retract props

5.17

Operation of the shield hydraulics Fig. 19: Hydraulic lines, overview key, see Fig. 18

R port, topside

PTO ”R”

PTO ”P”

10

6

P port, underside

31

19 30

14 23 R port, topside

7 W port, center

12b PTO ”P” (aux.)

12a

Z1

Z1

Z4

16d

15

2 13

9

9

12c

24

Z3

16c

5

29a 29b

17b

2 13

1(3)

4

15

28

E

28

DBT GmbH, Lünen 2003

11

8

17a

16b

17c 29c

link cyl. piston chamber

Z2

NOTE: The components marked in “blue” are part of the water spray system.

5.18

DBT - Schild 1082/2305-2x3926-1750

Operation of the shield hydraulics Fig. 20: Single shield unit, faceside view

c

a

b

DBT GmbH, Lünen 2003

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d

a PTO port “P”

Dok. Nr.: 7420 120 000 BA 00

b PTO port “R”

SUVP / 01

c PM4 control unit

d supply hoses

5.19

Operation of the shield hydraulics Fig. 21: Shield hydraulics, arrangement of control elements, view under the rear canopy

aux. water

31

PTO ”P”

19

10

6

PTO ”R”

a

aux.

PTO ”P”

S2

11

12b

12a

30 P R

W

3 17 29c DBT GmbH, Lünen 2003

E

1 8

1 control valve block 8 dual backflush filter 10 ball valve, open as shown, shuts off pressure supply to the shield hydraulics completely, if supplied via manifold block or aux.

PTO “P” 11 ball valve, closed as shown shuts off aux. PTO pressure line

5.20

12a ball valve, open as shown enables high-pressure flushing of the water spray system, if open; must be closed during normal operation 12b ball valve, closed as shown shuts of pressure supply to the lift cylinder, piston chamber 19 manifold block 29c ball valve, shuts off water supply to the water spray system

30 ball valve, closed as shown shuts of water supply to the shield completely 31 ball valve, shuts off water supply to the aux. water port a PM4 control unit P, R, W supply hoses S2 infrared sensor

DBT - Schild 1082/2305-2x3926-1750

Operation of the shield hydraulics Fig. 22: PM4 control unit L.H. under the canopy

a

b

c

Fig. 23: Control valve block

DBT GmbH, Lünen 2003

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a PM4 control panel b Emergency-Stop button c local-Lockout button

b d a

3

a push button b connecting cable to the solenoid driver c symbol plate d retainer 3 accumulator cartridge

Dok. Nr.: 7420 120 000 BA 00

c

SUVP / 01

5.21

Operation of the shield hydraulics Fig. 24: R.H. prop, faceside view

15 13

24

9 2

28

DBT GmbH, Lünen 2003

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2 prop check valve 9 block ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown 12c ball valve, closed as shown enables auto aligning function of the canopy, if open 13 pressure gauge 15 pressure relief valve 24 compensating valve 28 auxiliary port for pressure gauge

12c

Fig. 25: L.H. prop, faceside view

13

15

9 S1 2 prop check valve 9 block ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown 13 pressure gauge 15 pressure relief valve 28 auxiliary port for pressure gauge S1 pressure sensor

5.22

28

2

DBT - Schild 1082/2305-2x3926-1750

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

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

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

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

DBT GmbH, Lünen 2003

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

Fig. 26: PM4 control unit L.H. under the canopy

a

b

c

a PM4 control panel b Emergency-Stop button c local-Lockout button

Figure 26 above shows the arrangement of the PM4 control unit.

How to use the PM4 control unit is not described in this manual.

See separate manual for the PM4 control unit.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.23

Operation of the shield hydraulics Fig. 27: Control valve block

b d a

3

a push button b connecting cable to the solenoid driver c symbol plate d retainer 3 accumulator cartridge

c

DBT GmbH, Lünen 2003

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Figure 27 above shows the arrangement of the control valve block at the rear shield canopy.

Fig. 28: Symbol plate of 12 function control valve block

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

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

5.24

DBT - Schild 1082/2305-2x3926-1750

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

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

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

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

DBT GmbH, Lünen 2003

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

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

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

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

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

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

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.25

Operation of the shield hydraulics Advance shield Before this function is initiated, the side seal of the shield must be released, if applicable, 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 / leg raise Before this function is initiated the canopy must be aligned correctly. The lift cylinder will be retracted automatically.

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

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

The canopy bar may then have to be aligned again.

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

Fig. 29: R.H. prop, faceside view

12c 24

9 block ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown 12c ball valve, closed as shown enables auto aligning function of the canopy, if open 24 compensating valve

5.26

9

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

The compensating valve and the related isolating valve are located at the R.H. prop as seen looking towards the coal face. See figure 29. When the isolating valve (12c), see figure 29, is open (lever aligned to the direction of flow), the compensating valve is active. If the isolating valve valve is closed (lever across to the direction of flow), the compensating valve has no function.

E

Compensating valve

Operation of the shield hydraulics

Advance conveyor / conveyor push 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.

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

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

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

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

The ball valve (12b), see figure 30, serves to enable / disable this function.

DBT GmbH, Lünen 2003

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Fig. 31: Ball valves R.H. under the canopy

12b

12b ball valve, closed as shown shuts of pressure supply to the lifting cylinder, piston chamber

Extend stabilizing cylinder / canopy tip up

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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.27

Operation of the shield hydraulics Retract stabilizing cylinder / canopy tip down

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

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

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

CAUTION! Do not actuate functions 7 and 8 simultaneously, because the emulsion flow will be completely shut off and backflushing will be impossible.

Back flush filter chamber 2 The function is performed as long as the button is held depressed.

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

Activate lateral water spraying system at the canopy The function is performed as long as the button is held depressed.

Activate water spraying system at the canopy top The function is performed as long as the button is held depressed.

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

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

5.28

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

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

E

Back flush filter chamber 1

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 PM4 control unit.

Special measures One week after start-up

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

E DBT GmbH, Lünen 2003

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.

filter cartridges

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

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

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

pressure relief valve

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

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

hydraulic high-pressure hoses

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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.29

Maintenance 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.

Regular measures Once per shift

. Flush both chambers of the backflush filter at least once per shift for a few seconds to clean the filter elements.

Daily inspection hydraulics

. Check all shield units by visual inspection for hydraulic fluid escaping on the:

– hose lines, – control valve blocks,

– props, – shifting ram and lift cylinder – stabilizing cylinder, seal 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 inspection control unit

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

. Clean the control units, especially the control panel.

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

5.30

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

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– valves

Maintenance

props

. Apply grease A2 according to EWN 7068 at least once per

week to the the grease nipples at both sleeve holders of each prop until grease escapes at the dirt stripper.

Fig. 32: Grease nipples at the prop

b

DBT GmbH, Lünen 2003

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a

a grease nipple at the sleeve holder b escaping grease at the dirt stripper

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.31

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

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

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

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

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

5.32

possible cause

check / measure required

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

Open shut-off valve.

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

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

Open shut-off valve.

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

Canopy is trapped by adjacent shields.

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

Pilot piston in the prop check valve is not operating.

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

Prop check valve may be faulty.

Damaged or trapped hoses.

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

Props are damaged.

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

No pressure at control valve block output.

Disconnect hose at lowering port of prop.

Check for any medium leaking. If not, disconnect hose at control valve block. If no leakage, check feed line to control valve block.

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

failure to lower the shield

E

Fault localization

Trouble shooting failure to set the shield

Possible cause

Check / measure required

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

Open shut-off valve.

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

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

Open shut-off valve.

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

Canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that - hydraulic system works correctly.

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

DBT GmbH, Lünen 2003

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

Prop check valve may be faulty.

failure to advance the shield

Damaged or trapped hoses.

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

Props are damaged.

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

Possible cause

Check / measure required

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

Open shut-off valve.

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

Canopy is trapped by adjacent shields.

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

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

Dok. Nr.: 7420 120 000 BA 00

System pressure is too low for operation.

Check that - hydraulic system works correctly.

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

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

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

Prop check valve may be faulty.

Damaged or trapped hoses.

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

Shifting ram is defective.

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

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

SUVP / 01

5.33

failure to operate the tip up function

failure to operate the tip down function

5.34

Possible cause

Check / measure required

Faulty prop check valve.

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

Props are damaged.

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

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

Faulty pressure relief valve.

Check pressure gauge reading. Is pressure relief valve weeping?

If so, replace pressure relief valve and check functions.

Possible cause

Check / measure required

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

Open shut-off valve.

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

Shield canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that - hydraulic system works correctly.

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

Pilot-operated check valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

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

Possible cause

Check / measure required

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

Open shut-off valve.

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

Shield canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that - hydraulic system works correctly.

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

Pilot-operated check valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

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

Stabilizing cylinder is damaged.

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

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

failure to maintain the prop pressure after setting the support

E

Trouble shooting

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

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

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

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

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

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

internal leakage

. Try to locate the defective valve by operating the individual

valve replacement

DBT GmbH, Lünen 2003

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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 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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

5.35

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

. Pump props up to roof at set pressure. . Isolate the annulus side of the prop. To this end, detach the

control line at the pilot-operated check valve (item 11, see hydraulic flow plan) temporarily and admit pressure to the control port of the POCV.

. Remove the pilot-operated check valve (item 11, see hydraulic flow plan) temporarily to open the annulus port of the prop.

. Operate the ”set prop” function from adjacent shield.

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.

5.36

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

Faulty pressure relief valve

E

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.

6

Technical data

Description

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

Description Type 1082/2305-2x3926-1750 The two-leg shield units basically comprise the following main components: J base with lemniscatic links, shifting unit and baselift cylinder J canopy J caving shield J side seal, bothsided welded on J hydraulic props

DBT GmbH, Lünen 2003

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J hydraulic equipment with hose lines and controls

Tab. 3: Face shield Shield-no.

Order-no.

1 ... 192

7420 120 000 00 01 face shield

Application

Dimensions max. / min.

L x W x H in mm --x1700x2305 6327x1700x1082

Weight in kg 19410

The shield is provided with a solid base which has the two interconnected skids separated by a tunnel. The shifting unit is arranged in the tunnel in the middle of the base. the shifting cylinder is reverse mounted.

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

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

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

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

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

The shield units are equipped with all hydraulic components needed to perform a electrohydraulic adjacent control system using the PM4 electronic control unit.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.3

Description

DBT GmbH, Lünen 2003

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Fig. 33: Main dimensions

6.4

DBT - Schild 1082/2305-2x3926-1750

Description Main subassemblies Fig. 34: Components of the shield type 1082/2305-2x3926-1750 11 31

1 42

41 46

DBT GmbH, Lünen 2003

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37 36

Tab. 4: Components of the shield type 1082/2305-2x3926-1750 according to drawing no. 7420 120 000 00 01 item description

order-no.

weight approx. in kg

Dok. Nr.: 7420 120 000 BA 00

1 base

7420 120 300 00 01

7426

11 canopy

7420 120 400 00 01

5815

31 caving shield

7420 120 800 00 01

3153

36 cover plate

7420 037 851 00 00

57

37 clamping joint

7420 037 860 00 00

1

41 prop

8250 052 000 00 00

930

42 foam filler

0000 000 405 17 41

--

46 stabilizing cylinder

8241 222 000 00 00

143

51 hydraulic control

8112 148 000 00 00

140

SUVP / 01

6.5

Description Base with lemniscatic links and central shifting unit

DBT GmbH, Lünen 2003

E

The solid base transmits the shield load of the hydraulic props into the floor. The props are supported in an articulated manner in ball sockets welded to the base and secured by bolted prop retainers.

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

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

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

6.6

DBT - Schild 1082/2305-2x3926-1750

Description Fig. 35: Base

DBT GmbH, Lünen 2003

E

A

view “A”

1 2 5 10 11 13 15 16

baselift cylinder ZE-135/90-240 shifting ram ZE-135/90-1130 shifting unit base, subassembly front lemniscatic link rear lemniscatic link prop retainer R.H. prop retainer L.H.

Dok. Nr.: 7420 120 000 BA 00

17 18 19 20 21 25 26 27

SUVP / 01

pin dia 16x117 baselift cylinder bearing staple lemniscatic pin dia. 148 x 533 lemniscatic pin dia. 130 x 533 locking plate pin dia. 50 x 135 pin dia.34 x 90

28 filler 29 collard pin dia 22/18-180/175 35 staple 43 retaining clip 44 retaining clip S1 attaching eye, load-bearing capacity: 8000 kg other see spare parts catalog

6.7

Description Shifting unit Fig. 36: Shifting unit

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

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

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

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

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

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

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

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

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

6.8

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

The conveyor shifting unit is arranged in the middle of the base. 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.

E

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

Description 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 canopie is equipped with an welded on side seal at both sides.

Fig. 37: Canopy

DBT GmbH, Lünen 2003

E

S2

S1

S2

S3

S3

1 5 6 7 8 9

canopy, subassembly prop head retainer pin dia. 24.3x156 retaining clip 5x32 pin dia. 53 x 155 staple

S1 attaching eye, load-bearing capacity: 8000 kg S2 attaching eye, load-bearing capacity: 3000 kg S3 attaching eye, load-bearing capacity: 1000 kg

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.9

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.

The side seals are welded on at both sides.

DBT GmbH, Lünen 2003

E

Fig. 38: Caving shield

S2 S2

S1 S1

1 5 6/7 8 9

6.10

caving shield, subassembly pin dia. 118.5x328 lemniscatic pin dia. 143x488 / 130x488 pin dia. 53x155 pin dia. 12x120/115

15 / 16 20 26 S1 S2

retainer staple DN40 retaining clip lifting eye, load-carrying capacity: 5000 kg lifting eye, load-carrying capacity: 8000 kg

DBT - Schild 1082/2305-2x3926-1750

Description Technical data of the shield, steel structure operating mode . . . . . . . . . . . . . . . . . . . . immediate forward system

DBT GmbH, Lünen 2003

E

permissible inclination, omnidirectional up to

deg

15

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

1082

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

2305

hydraulic height adjustment of shield . . mm

1223

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

1067 1130

distance of prop centers (inclination) . . . mm

890

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

3360

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

1250

width of canopy incl. side seals . . . . . . . mm

1700

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

4610

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

5.13 44.91

width of caving shield, incl. side seals . . mm

1690

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

1610

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

35725

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

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 310 bar setting pressure . . . . . . . . . kN b) at 420 *) bar yield pressure . . . . . . . . . kN

1651 5081 6883

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 1651 a) at 310 bar setting pressure . . . . . . . . kN/m2 558 b) at 420 *) bar yield pressure (distance canopy tip to face low / high) . kN/m2 628 / 756

*) max. permissible yield pressure 420 bar , actual setting 400 bar as requested by the customer

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.11

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

During normal operation the functions of the shield units are to be operated by use of the PM4 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.

DBT GmbH, Lünen 2003

E

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.

6.12

DBT - Schild 1082/2305-2x3926-1750

Hydraulic system Shield hydraulics Fig. 39: Shield hydraulics, location of components key, see table 2

21

19

11 12a 14 1 17c 29c 17b 4 16c 29a 29b 5

DBT GmbH, Lünen 2003

E

12b 16d 30 7 3 17a 8 aux. water PTO ”P” 22 20 31

10

PTO ”R” 6

16b

16

aux. PTO ”P” 23

15 13 P R W

24 2

28

1 2 3 4 5 6 7 8 9

9

12c

control valve block prop check valve accumulator cartridge piloted check valve twin check valve check valve filter dual filter, back flush type high-pressure ball valve “red”

Dok. Nr.: 7420 120 000 BA 00

9

28

10 11 12 13 14 15 16 17 19

high-pressure ball valve “red” high-pressure ball valve “red” high-pressure ball valve “red” pressure gauge pressure relief valve, 80 bar pressure relief valve, 400 bar pressure relief valve, 400 bar water spray valve manifold block

SUVP / 01

2

15

13

20 21 22 23 24 28 29 30 31

hose lines water spray system retainer and accessories socket with release compensating valve auxiliary port for pressure gauge high-pressure ball valve “blue” high-pressure ball valve “blue” ball valve

6.13

Hydraulic system Fig. 40: Hydraulic circuit diagram, overview Please, refer also to table 2 and the spare parts catalog.

PTO ”R” 6 19 10

PTO ”P”

14

aux. water 23

30

7

3

31

11

aux. PTO ”P” components of the shield hydraulic: 1 control valve block 2 prop check valve 3 accumulator cartridge 4 piloted check valve 5 twin check valve 6 check valve 7 filter 8 dual filter, back flush type 9 high-pressure ball valve “red” 10 high-pressure ball valve “red” 11 high-pressure ball valve “red” 12 high-pressure ball valve “red” 13 pressure gauge 14 pressure relief valve, 80 bar 17b 15 pressure relief valve, 400 bar 16 pressure relief valve, 400 bar 17 water spray valve 19 manifold block 29c 20 hose lines 21 water spray system 22 retainer and accessories 23 socket with release 24 compensating valve 28 auxiliary port for pressure gauge 29 high-pressure ball valve “blue” 30 high-pressure ball valve “blue” 31 block ball valve S1 pressure sensor

8

17a

17c

29b

29a 20 2

15 13

16d

28

9

13 15

21

S1

12

28 2 24 4 16c 16b

12c

5 16b NOTE: The components marked in “blue” are part of the water spray system.

6.14

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 stabilizing cylinder Z4 base lift cylinder control valve block functions: 1 advance shield 2 extend props 3 push conveyor 4 extend base lift cylinder 5 extend stabilizing cylinder 6 retract stabilizing cylinder 7 flush filter chamber 1 8 flush filter chamber 2 9 water curtain 10 lateral water sprays 11 water spray system 12 retract props

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

1

E

12a

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. 41: Double telescopic prop, type SD2900-345-940/1990-BN lower stage 525 upper stage 525

DBT GmbH, Lünen 2003

E

retracted 940 extended 1990

1 prop base 2 piston pipe 3 bottom valve 21 piston rod 41 grease nipple please, refer also to the spare parts catalog

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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.15

Hydraulic system Function prop setting

Pressure fluid is admitted under the piston of the center prop through the piston chamber connection. The center prop will extend first and the pressure fluid displaced from the annulus is passed into the return line. If the piston of the center prop contacts the threaded bush before the canopy comes to rest against the roof, the inner prop will extend. Pressure fluid is admitted through the check valve.

Loading props a) Center prop extended only Load is transmitted mechanically from the canopy to the inner prop via the prop head and, then, to the valve housing installed in the inner prop. The further transmission of load is hydraulically via the pressure fluid under the center prop into the foot of the prop and from there mechanically into the base.

The hydraulic pressure under the center prop cannot exceed the pre-determined value as a pressure relief valve is installed in the respective control valve. When the preset pressure is exceeded, the pressure relief valve will open and permit fluid to escape and the prop yields with the rated prop resistance.

prop lowering

6.16

The pressure fluid under the center prop is connected to the return by means of the prop control valve.

Both stages of the prop can be power lowered. The inner prop will start to close when the center prop is closed completely and the check valve is opened by the tappet.

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

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).

E

b) Center Prop and Inner Prop Extended

Hydraulic system Hydraulic cylinder, double and single acting design

The following figure shows the main components of a hydraulic cylinder. The cylinders differ mainly by the arrangement of the connections. They can be roughly divided into two groups: a) arrangement of connections at the outer cylinder b) arrangement of connections at the piston rod

Fig. 42: Hydraulic cylinder, typical example Type a)

2

1

3

5

4

DBT GmbH, Lünen 2003

E

Type b)

Type a): Connection at the outer cylinder Type b): Connection at the piston rod 1 outer cylinder 2 cylinder bottom 3 piston rod 4 guide bush 5 connection 6 connection

2

3

1

4

6

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

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

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

The end of the piston rod can either be attached directly or it is designed in such a way that the means of attachment - e.g. rod head or fork head - can be screwed on and secured against working loose by clamping screws or a spring dowel sleeve.

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

If a double-acting cylinder is to be used as single-acting cylinder only, the annulus connection must be provided with a screw with filter element to avoid contamination by dirt. If the cylinder is used without the seals which seal off the annulus, the grooves for the seals have to be filled with lubricating grease.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.17

Hydraulic system Stabilizing cylinder Fig. 43: Hydraulic cylinder, type ZE-165/100-420-EC-BN

stroke 420

1 cylinder pipe 21 piston rod

23 piston

other: see spare parts catalog

Baselift cylinder Fig. 44: Hydraulic cylinder, type ZE135/90-240-LI-CR

stroke 240 retracted 518 extended 758

1 cylinder pipe 2 wearing liner

6.18

3 piston rod 4 piston

other: see spare parts catalog

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

E

retracted 860 / extended 1280

Hydraulic system Shifting ram Fig. 45: Hydraulic cylinder type ZE-135/90-1130-SC-W-CR

stroke 1130

DBT GmbH, Lünen 2003

E

retracted 1469 / extended 2599

3 cylinder pipe 4 reed rod

Dok. Nr.: 7420 120 000 BA 00

21 piston rod 22 piston

SUVP / 01

28 annular magnet see spare parts catalog

6.19

Hydraulic system Technical data of hydraulic cylinders

stabilizing cylinder, double-acting

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

940

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

1990

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

1050

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

345/ 250

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

320/ 230

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

934.8/490/9

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

130.6/75.4

prop force at 310 bar setting pressure . kN

2898

prop force at 400 *) bar yield pressure . . kN

3739

retracting force at 310 bar . . . . . . . . . . . . kN

405

Type ZE-135/90-1130-SC-W-CR, drawing no. 8241 085 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

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

135

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

90

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

143.1

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

79.5

thrust at 310 bar . . . . . . . . . . . . . . . . . . . . kN

443.7

pulling force at 310 bar . . . . . . . . . . . . . . kN

246.5

Type ZE-165/100-420-EC-BN, drawing no. 8241 222 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

420

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

165

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

100

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

213.8

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

135.3

thrust at 310 / 400 **) bar . . . . . . . . . . . . . kN

663/855

pulling force at 310 / 400 **) bar . . . . . . . kN

419/541

*) max. permissible yield pressure 420 bar , actual setting 400 bar as requested by the customer **) max. permissible yield pressure 470 bar , actual setting 400 bar as requested by the customer

6.20

DBT - Schild 1082/2305-2x3926-1750

E

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

Type SD-3900-345-940/190-BN, drawing no. 8250 052 000 00 00

DBT GmbH, Lünen 2003

double telescopic prop, double-acting - 2 stages

Hydraulic system Type ZE-135/90-240-LI-CR, drawing no. 8241 224 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

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

135

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

90

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

143.1

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

79.5

thrust at 310 / --- bar . . . . . . . . . . . . . . . . kN

443.7 / ---

pulling force at 310 / --- bar . . . . . . . . . . . kN

246.5 / ---

DBT GmbH, Lünen 2003

E

baselift cylinder, double-acting

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.21

Hydraulic system Pressure relief valves Pressure relief valves protect the hydraulic equipment (e.g. props or cylinders) connected with them from overload. When the opening pressure is reached, pressure fluid is discharged to atmosphere.

For the type of valve used please see the following table, the hydraulic flow plan or the spare parts catalog.

Tab. 5: Pressure relief valves, use of different types application

type

pre-setting in bar

order-no.

general use except of props

pre-loaded by pressure spring

400

7337 486 400 00 00

only at the props piston side

pre-loaded by pressure spring

400

8220 027 400 00 00

only at the props annulus side

pre-loaded by pressure spring

80

8220 042 080 00 00

NOTICE! New seals must be fitted whenever a pressure relief valve is replaced.

The pressure to which a valve is preset is stamped on. Furthermore, pressure relief valves are painted in different colors to identify the different pressure ranges.

Color identification of pressure relief valves

6.22

Color

Pressure range (bar)

black

0 - 49

black-and-white

50 - 99

brown

100 - 149

brown-and-white

150 - 199

green

200 - 249

green-and-white

250 - 299

blue

300 - 349

blue-and-white

350 - 399

red

400 - 449

red-and-white

450 - 499

yellow

500 - 549

yellow-and-white

550 - 599

orange

600 - 649

orange-and-white

650 - 699

DBT - Schild 1082/2305-2x3926-1750

DBT GmbH, Lünen 2003

The preset pressure of a pressure relief valve must not exceed the nominal pressure of the consumer.

E

CAUTION! The pressure setting must not be changed.

Electrohydraulic control system Electrohydraulic control system Fig. 46: Control valve block, 12 functions

1 5

2

DBT GmbH, Lünen 2003

E

1 2 3 4 5

3

4

control valve block accumulator cartridge pilot control valve for electromagnetic operation push-button for manual operation plug contact, electrical connection to the control unit

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

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

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.23

Electrohydraulic control system PANZERMATIC® PM4 NOTICE! How to operate the PANZERMATIC control unit is not subject of this manual. See separate operating instructions.

DBT GmbH, Lünen 2003

E

Fig. 47: Panzermatic PM4, schematic diagram

1 control unit 3 solenoid driver

6.24

5 pressure sensor 19 infrared receiver

other: see spare parts catalog

DBT - Schild 1082/2305-2x3926-1750

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15° 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.

DBT GmbH, Lünen 2003

E

The articulation of the canopy is limited by the hinged joint between canopy and caving shield.

Angle α2 measured with retracted stabilizing cylinder

Shield Variant

Order-no.

01

7420 120 000 00 ..

Inclination α at height M α1 in ° 5.1

M in mm 1082

α2 in ° 15.9

M in mm 2305

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.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.25

Operating media Operating media Hydraulic fluids of group HFA NOTICE! Use only hydraulic fluids approved by DBT! These fluids have been tested at DBT and guarantee a reliable operation of the hydraulic system.

Hydraulic fluid concentrates List of approved water-miscible hydraulic fluid concentrates for the production of fire-resistant hydraulic fluids of Group HFA. Tab. 6: Approval list (Part 1)

type X test water

type Y test water

type Z test water

P 87 AF

not tested

1.5 %

3%

Carl Bechem

Fimitol P 87 AF

not tested

1.5 %

3%

Castrol

Anvol C 18

not tested

5%

not tested

Anvol C 19

not tested

5%

not tested

Anvol SF 2000

not tested

2.5 %

not tested

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

5%

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1.5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1.5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

not tested

Quintolubric 814-01

not tested

5%

not tested

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

DBT - Schild 1082/2305-2x3926-1750

E

Recommended concentration for use with process water according to the chemical composition

ARAL Lubricants

Fuchs/Century

6.26

Product designation

DBT GmbH, Lünen 2003

Manufacturer

Operating media Tab. 7: Approval list (Part 2) Manufacturer

Product designation

Recommended concentration for use with process water according to the chemical composition type X test water

type Y test water

type Z test water

GS 460 N

not tested

1.5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1.5 %

Hydrocor TS 100 N

not tested

2%

not tested

Isosynth VX 110 BF 1) 2)

not tested

1.5 %

1.5 %

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTh Theunissen i

1) Will be distributed as “Anvol JD 2000” by Castrol.

2) Only permissible is the variant manufactured in Germany.

The variant of Isosynth VX 110 BF, manufactured and distributed in USA, is not permissible because of different ingredients.

DBT GmbH, Lünen 2003

E

IMPORTANT! We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems.

The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

Storage of the hydraulic fluid concentrate Do not store the hydraulic fluid at temperatures below 5° C. Avoid excessive heating of the fluids. Protect the concentrate against direct exposure to sunlight.

IMPORTANT! Be sure to observe the manufacturer’s instructions for use.

Preconditions for use underground The approval of the responsible Mines Inspectorate is required for use underground.

The approval presupposes an examination by the RW TÜV/Essen and of the Hygiene Institute of the Ruhr/Gelsenkirchen (Germany).

For use in international mining, the relevant national regulations must be observed. Approval by the responsible authorities may be necessary. Responsibility for the approvals procedure lies with the equipment operator.

Suitability of the hydraulic fluid The suitability of the hydraulic fluid for use in mining equipment must be demonstrated by positive experience in practice. Should a product exhibit any negative characteristics during operation, we reserve the right to delete the product from our approval list.

Working concentration of the hydraulic fluid The recommended working concentration of the products essentially corresponds to the concentration at which the product passed the crevice corrosion test in accordance with the DBT Works Standard or RAG Standard.

Dok. Nr.: 7420 120 000 BA 00

SUVP / 01

6.27

Operating media Quality of the process water The quality of the process water is a critical factor for the functional reliability of the emulsion. The water must not contain any solid or liquid impurities and must satisfy the bacteriological requirements for drinking water (DIN 2000).

The figures quoted for the concentration of the hydraulic fluids were obtained from trials with test water samples.

The chemical composition of the test water samples used are shown in the table below for your orientation.

type Y test water (DIN 24320 resp.

Luxembourg Report)

type Z test water (NCB 19 to Luxembourg Report)

pH value

6.5 - 8.5

6.5 - 8.5

6.5 - 8.5

hardness mmol/l

2.5 (=14°d)**

3.58 (= 20°d)**

7.5 (= 42°d)**

chloride

200 mg/l

200 mg/l

200 mg/l

sulfate

240 mg/l

150 mg/l

720 mg/l

nitrate

0 mg/l

20 mg/l

0 mg/l

magnesium

30 mg/l

50 mg/l

90 mg/l

sodium

130 mg/l

115 mg/l

130 mg/l

calcium

50 mg/l

61 mg/l

150 mg/l

iron, max.

0.3 mg/l*

0.3 mg/l*

0.3 mg/l*

* These values deviate from the quoted standard or from the Luxembourg Report. ** °d = degree German hardness (is no longer permissible in accordance with the applicable legal regulations. The information given is intended only for orientation.)

If the process water available does not have the demanded quality, the special approval of DBT must be obtained before use.

Emulsion values pH value: 7.5 - 9.5 Permissible bacteria in the emulsion: ≤ 105 Kol/ml The maximum permissible temperature is 55° C; normally 45° C, should not be exceeded. A higher working temperature will reduce the consistency of the emulsion and shorten the service life of the seal material.

Checking of the emulsion values At least once per week, check: J the pH value J the concentration

test method: by agreement with the concentrate manufacturer

J the microbial load

test method: dip slides

IMPORTANT! Further information is contained in DIN 24320.

6.28

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type X test water (NCB 18 to Luxembourg Report)

E

Tab. 8: Chemical composition of the test water samples used

Operating media Lubricating greases and pastes Lubricating greases general properties

lubricating greases for general application

base:

lithium soap

NLGI class:

2

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

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly.

DBT GmbH, Lünen 2003

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Tab. 9: Lubricating greases for general application Supplier

Type

ARAL

Aralub HL 2

BP

BP Energrease LS 2

ESSO

BEACON 2

MOBIL

MOBILUX 2

SHELL

Shell Alvania Grease R 2

TEXACO

MULTIFAK 20

CALYPSOL

Multipurpose grease 20

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating grease A 1 according to the DBT works standard EWN 7068 is: Calypsol multipurpose grease 20 lubricating greases for application under high pressure

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

Tab. 10: Lubricating greases containing additives Supplier

Type

ARAL

Aralub HLP 2

BP

BP Energrease LS-EP 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

SHELL

Shell Alvania E.P. Grease 2

TEXACO

MULTIFAK EP 2

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating grease A 2 according to the DBT works standard EWN 7068 is: Shell Alvania E.P. Grease 2

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6.29

Operating media IMPORTANT! The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

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

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

Lubricating pastes Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Tab. 11: Lubricating pastes free from molybdenum disulfide Type

Base

NLGI class

gleitmolybdän

gleitmo 805 1)

Li

2

Klüber Lubrication

Altemp Q NB 50 2)

Ba-complex

2/3

Liqui Moly

LM 841 1)

Li

2

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” 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 and lubricant 785 IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

1) The products listed in table 11 are suitable lubricating greases for filling of adjacent cavities.

2) The suitable product for filling of adjacent hollows is the grease Klüber Lubrication Staburags NBU30, which has the same base (barium complex soap).

6.30

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Supplier

Tightening torques Tightening torques Screws with metric coarse thread DIN 13 Recommended tightening torques at µges. = 0.14

DBT GmbH, Lünen 2003

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Tab. 12:

Thread 1)

Pitch

Tightening torque 4)

(mm)

(mm)

MA (Nm)

d

P

8.8

10.9

12.9

M8

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

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

DM 27 2)

3

580

-

-

M 30

3,5

1310

1845

2215

M 30 3)

2

-

1450

-

(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

1)

dimensions in brackets in exceptional cases only

2)

according to works standard (EWN 6110), February 1985 edition

3)

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

4)

the tightening torques comply with EWN 6003 works standard.

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

Dok. Nr.: 7420 120 000 BA 00

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E DBT GmbH, Lünen 2003

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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 address Germany

DBT GmbH Service Industriestraße 1 D-44534 Lünen Phone: + 49 (0) 23 06 / 70 9 - 0 Fax:

+ 49 (0) 23 06 / 70 9 - 421

E-mail: infodbt@dbt.de

DBT GmbH, Lünen 2003

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Internet: http://www.dbt.de

USA

DBT America Inc Service 2045 West Pike Street Houston, PA 15342 - 1010 Phone: + 001 / 724 / 743 - 1200 Fax:

+ 001 / 724 / 743 - 1201

E-mail: infodbt@dbt.de Internet: http://www.dbt.de

Dok. Nr.: 7420 120 000 BA 00

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7.3

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

Fig. 48: Type plate, example

DBT GmbH 2 12345

6

2

7

06/03

4

678

7420 120 311 00 00 4113 kN

The shields are numbered consecutively. A plate showing the shield number is fitted to base.

Fig. 49: Shield number, example

7.4

shield number

order number

application

1 .... 192

7420 120 000 00 01

face shield

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5

1 manufacturer 2 last 5 digits of SAP-no. resp. order-no.

3 month and year of manufacture 4 current component no.

5 drawing no.

6 number of props 7 rated yield force of props

3

DBT GmbH, Lünen 2003

1

Identification of shields Referenced standards and guidelines Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery

DIN EN 982

Safety of machinerySafety requirements for fluid power systems and their components

DIN EN 60445

Identification of Connections

DIN EN 62079

preparation of instructions

DIN 2000

Central drinking water supply Guidelines regarding requirements for drinking water, planing, construction operation and maintenance of plants

DIN 6789

Documentation System

DIN 8418

Information for Users

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self-Advancing Supports

DIN 24320

Fire Resistant Hydraulic Fluids

DIN 24343

Hydraulic fluid power systems and components; list for attendance inspection of hydraulic equipments

DIN 24346

Hydraulic Systems; Design Principles

*EWN 6003

Pretensioning forces and tightening torques

*EWN 7068

Lubricants

*EWN 7069

Nonmetallic surface protection

ISO 4406

Hydraulic fluid power - fluids method for coding the level of contamination by solid particles

DBT GmbH, Lünen 2003

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Designation

*)EWN = DBT standard

Dok. Nr.: 7420 120 000 BA 00

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DBT GmbH, Lünen 2003

7.6

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