Cat DBT Shield 2700 6000-2x5278-1750 Operating Manual

Operating Manual DBT - Shield 2700/6000-2x5278-1750 Doc. no.: 7420 084 000 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.

DBT GmbH, Lünen 2002 E

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

1.3

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

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

1.4 1.5

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 2.11

Overview of the safety instructions . . . . . . . . . . . . . . . 2.15

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

3.3

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

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

3.3 3.4

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

3.5

4. Installation

Doc. no.: 7420 084 000 BA 00

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

4.3

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

4.3

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

4.4

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

4.5

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

4.5

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

4.6

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

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

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

4.6 4.8 4.8

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

5.3

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

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

5.3 5.6

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

5.8

Safe working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.14 Location of hydraulic components at the shield . . . . . . . . .

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

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

5.14 5.25 5.27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5.31 5.31 5.32 5.32

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 Fault finding on shield hydraulic system . . . . . . . . . . . . . . .

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

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

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

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

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

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

5.33 5.33 5.37 5.37 5.38 5.38 5.38

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

6.3

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

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

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

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

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

Technical data of the shield . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 6.6 6.8 6.9 6.10 6.11

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

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

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

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

Shifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.13 6.15 6.16 6.17 6.18 6.19 6.22

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

6.24

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.25

DBT - Shield Type 2700/6000-2x5278-1750

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 Anchoring device “base - base” . . . . . . . . . . . . . . . . . . . . . .

Anti-topple device “canopy - canopy” . . . . . . . . . . . . . . . . .

6.26 6.28

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29 Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

Recommended lubricating greases and pastes . . . . . . . . .

6.29 6.32

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Screws with metric coarse thread DIN 13 . . . . . . . . . . . . . .

6.34

7. For your information

Doc. no.: 7420 084 000 BA 00

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

7.3

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

7.3

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

7.4

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

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

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

7.4 7.4 7.5

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DBT - Shield Type 2700/6000-2x5278-1750

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 2700/6000-2x5278-1750 with the following type specification: Identification no.:

7420 084 000 00 01 7420 084 000 00 02

Year of construction: 2002 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.

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DBT GmbH, Lünen 2002

2 x 5278

availability of operating manual

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

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields. Every person working on the face or in the intersection between face and entry must read this operating manual.

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

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

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1.3

Before starting work Purpose of this operating manual operating manual

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

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

questions

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

safety

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

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Observe the information given and follow the procedural instructions.

1.4

DBT - Shield Type 2700/6000-2x5278-1750

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.

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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.

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

J

Items in lists are marked with 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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1.5

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DBT GmbH, Lünen 2002

1.6

DBT - Shield Type 2700/6000-2x5278-1750

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety.

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

supplementary regulations

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

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

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

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

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J of the miners’ accident insurance association.

DBT GmbH, Lünen 2002

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 - Shield Type 2700/6000-2x5278-1750

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:

– advancing, E

– retracting; DBT GmbH, Lünen 2002

J forming an abutment for:

– the conveyor and the mining machine, – anchorage units, – 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. Detailed informa-

tion on this subject is given in chapter 5 “Operation” 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.

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

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

EMERGENCY STOP

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, J canopies, J links, J side seals, J front cantilevers, J hydraulic props and cylinders.

2.6

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signalling systems and protective devices

Maintain the lighting systems in a functional condition.

DBT GmbH, Lünen 2002

lighting

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. Dispatch these components for repair immediately.

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 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.

Mechanically secure the caving shield against lowering during: J installation of the canopy, J installation of the props and cylinders, J work on the open hydraulic system, J work in the shield.

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

The side seal is pretensioned by a spring. 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

Ensure that the minimum dimensions specified for the travelway within the shield are always maintained.

J width: 600 mm J height: 400 mm

Additional access-blocking devices must be installed if the height is less than the minimum because of the presence of further equipment (for instance, because of anchoring devices between shield and conveyor).

2.8

DBT - Shield Type 2700/6000-2x5278-1750

Safety instructions Operation shield control

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.

Observe the entire zone of motion of the shield, in order to recognize and avoid hazards in due time.

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

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

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

Keep the floor free from debris. This way you will be able to extend the shifting unit without hindrance and to advance the conveyor without problems.

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

Secure the conveyor by anchorages. This measure is required to prevent displacement of the conveyor with respect to the shield and the shifting unit jamming in the base skid.

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.

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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.

Align the shields as soon as possible. Use the steering device or the side seals. 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. This could lead to excessive stress and strain on the components if the maximum angles of inclination are exceeded.

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

It is necessary that you familiarize yourself with the circuit and line diagrams of the installation before starting to pull the conveyor back.

Secure the entire mining machine against unauthorized starting.

Isolate your place of work to prevent access to this area by other persons.

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

raising of conveyor

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

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

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

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

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

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

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

2.10

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

residual stroke

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

Safety instructions Maintenance Be sure to observe the indicated intervals for maintenance and inspections.

Examine the shield at least once per shift for externally visible damage.

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

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

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

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

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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.

Secure the shield before any work mechanically to prevent the canopy or the caving shield from lowering inadvertently by e.g. placing hardwood wedges between the pairs of links.

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2.11

Safety instructions 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

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

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-

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

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DBT GmbH, Lünen 2002

J the outer sheath of the hoses is not damaged.

E

mally rigid or hard.

Safety instructions Fig. 2:

Example: 4SP hydraulic hose, designation

3

2 1

6 4 1 hose type 2 nominal diameter 3 date of manufacture

5 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.

DBT GmbH, Lünen 2002

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Replace hydraulic hoses at the first suspicion of damage. installation of 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 RIGHT

WRONG

J are not twisted.

Fig. 4:

Laying of hydraulic hose lines, twist RIGHT

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WRONG

2.13

Safety instructions J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter).

Fig. 5:

Laying of hydraulic hose lines, bend RIGHT

WRONG

J cannot chafe.

Fig. 6:

Laying of hydraulic hose lines, crossing WRONG

J are not kinked.

J do not have to withstand tensile strains.

J are protected against thermal radiation.

J are accessible at all times.

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

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

Fig. 7:

Laying of hydraulic hose lines, connections at movable parts RIGHT

2.14

WRONG

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DBT GmbH, Lünen 2002

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RIGHT

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

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

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

Use only suitable load handling devices.

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

DBT GmbH, Lünen 2002

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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.

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

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Overview of the safety instructions WARNING! Do not install shut-off valves into the return lines as otherwise a dangerously high pressure may build up which could e.g. cause 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”.

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”.

NOTICE! Make sure that all securing elements needed during transportation have been removed.

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.

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DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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.

E

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.

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

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! 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.

DBT GmbH, Lünen 2002

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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! The control elements on the control 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.

WARNING! You are only allowed to operate the controls of the control 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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Overview of the safety instructions 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.

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.

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.

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DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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.

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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.

Overview of the safety instructions CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

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

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

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

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

DBT GmbH, Lünen 2002

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WARNING! During normal operating mode the push buttons at the pilot valves of the control 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.

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 blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

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

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2.19

Overview of the safety instructions 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.

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.

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

Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates.

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 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.

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

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DBT GmbH, Lünen 2002

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

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

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

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.

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DBT GmbH, Lünen 2002

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.

exposure to sunlight

Protect the equipment against direct exposure to sunlight.

Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15 °C to 25 °C.

natural ageing

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

moisture and dirt

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

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

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

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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.

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.

plastic deformation

During long-term storage, the sealing elements may suffer plastic deformation due to the weight of the components. This may render the seals useless or reduce the life of the seals. Therefore, props and cylinders, for example, should only be stored in an upright position. If this is not possible with the components installed, they have to be dismantled.

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.

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

3.4

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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DBT GmbH, Lünen 2002

short-term storage

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Storage

Transport 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.

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.

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transport units

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 kph for truck transport. electrical and electronic components

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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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3.5

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.

flipper

chain

1

side seal, moveable side

pin

4

shifting unit, faceside

transport rod

1

shifting unit, gobside

chain

1

J Hydraulic system:

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

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DBT GmbH, Lünen 2002

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.

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

Transport Fig. 8:

Transport of shields as complete unit W X4 X3 Y

H

S 0

SY

X4

X1 S3

X2 S4

Sx L S3 S4 X1, X2

slot hole, 2 x on the coal face end of the base, load-bearing capacity: 15000 kg slot hole, 2 x on the gob side end of the base, load-bearing capacity: 15000 kg securing elements to fix the relay bar during transport, faceside and gobside

X3 X4

securing elements to fix the flipper securing elements to fix the moveable side seals

Y

transport safety device between canopy and base not included in the scope of delivery center of gravity

So

Tab. 1: Shield support 7420 084 000 00 .. , Dimensions and weights of variants

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Variant

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Order no.

Length in mm

Width in mm

Height in mm

Sx/Sy in mm

Weight in kg

01 7420 084 000 00 01

7917

1610

2700

1897/1460

39850

02 7420 084 000 00 02

7917

1610

2700

1905/1455

39940

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DBT GmbH, Lünen 2002

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DBT - Shield Type 2700/6000-2x5278-1750

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”.

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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

Shield no.

Order no.

Application

5 .... 80

7420 084 000 00 01

face shield

1 .... 4

7420 084 000 00 02

end shield

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

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each shield unit. This pipe provides the hydraulic supply to the individual shield unit. The manifold pipes of adjacent shield units are connected with the use of three hose lines: A pressure line (DN 40), a return line (DN 50) and a water line DN 25. 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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Fig. 9:

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

320 bar

admissible tolerance

10 % of nominal pressure

DBT GmbH, Lünen 2002

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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.

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4.5

Start-up Start-up 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 removed

. Check all mechanical connections on the shields . Check attachment of the shifting unit On shifting units with adjustable crawl pan make sure that the crawl pan has been attached properly. Never use the last slot for connection.

J Hydraulic system

. Test the entire hydraulic system for leaks. Seal any conneccould 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)

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

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. Check whether shield movements, particularly in the links,

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tions that are leaking.

Start-up 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

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

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

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4.7

Start-up Start-up of the shields Bring the shields into initial position.

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

. Check all lines by means of the line plans.

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

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

. Check all functions of the shield control system.

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

4.8

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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.

E

Corrosion protection of hydraulic components

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 2002

E

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.

Doc. no.: 7420 084 000 BA 00

VPVU / 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.

5.4

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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

E

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

Basic requirements repair work

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

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

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

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

DBT GmbH, Lünen 2002

E

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

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

anchorage device

On inclined faces, the conveyor has to be secured by anchorages.

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.

Doc. no.: 7420 084 000 BA 00

VPVU / 01

5.5

Basic requirements Safety requirements 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 or between the side seals of adjacent shields.

The operator must always watch the area of movement of the shield before and while the shield is moved and try to prevent hazards by cautious behavior.

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

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.

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.

Fig. 10: W r o n g , shields have not been advanced in the right time

5.6

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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.

E

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

Basic requirements Fig. 11:

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.

DBT GmbH, Lünen 2002

E

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

hydraulics, controls

Take care to avoid misoperation of the shield control.

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

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

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

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

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.

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

Doc. no.: 7420 084 000 BA 00

VPVU / 01

5.7

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.

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. 12: Shield in the normal position

a=0 M

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

5.8

DBT - Shield Type 2700/6000-2x5278-1750

E

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.

DBT GmbH, Lünen 2002

canopy adjustment

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. 13: Shield with extremely inclined canopy

s

1

a

1

DBT GmbH, Lünen 2002

E

M

a2

s2

M

M = height of the set shield a = 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.

Doc. no.: 7420 084 000 BA 00

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5.9

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.

Fig. 14: 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. 15) or by leveling off the canopy.

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

5.10

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 14) 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.

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.

Operation of the shield Fig. 15: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

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

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.

DBT GmbH, Lünen 2002

E

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

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

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

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

Doc. no.: 7420 084 000 BA 00

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5.11

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.

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.

5.12

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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.

E

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.

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 : 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.

DBT GmbH, Lünen 2002

E

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

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).

Doc. no.: 7420 084 000 BA 00

VPVU / 01

5.13

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 The following table is valid for all variants of the shield.

Tab. 2: Hydraulic components Qty.

Description

Location

1

1

control valve block

between the front lemniscatic links, at holder

2

2

prop check valve

one at each prop

3

1

check valve

R.H. front lemniscatic link, inner side

isolates the annulus side of the shifting cylinder

4

4

pilot-operated check valve

under the canopy, between the prop heads

isolates the annulus side resp. piston side of the flipper cylinder or the flipper extension cylinder

5

9

pressure relief valve, 420 bar

- at check valve item 3 - at check valve item 4 - at caving shield; hose terminal, at ball valve item 23 - at caving shield; hose terminal, link cylinder check valve

6

2

pressure relief valve,440 bar

one at each prop

7

1

check valve

at manifold pipe, in return line

8

1

filter

at R.H. front lemniscatic link

9

1

water spray valve

at R.H. front lemniscatic link

10

1

twin check valve

flanged to the stabilizing cylinder

11

1

accumulator cartridge

at control valve block, rear side

12

1

hose lines

subassembly

14

1

retainer and accessories

subassembly

15

1

manifold pipe

between the front lemniscatic links

20

2

pressure gauge

at the prop check valve port “A”; at both props

22

1

block ball valve

at L.H. front lemniscatic link

23

4

block ball valve

- at caving shield; hose terminal, sealing cylinder supply line - at the manifold pipe, supply line for the water spray system

24

2

block ball valve

at the prop check valve

isolates the pressure supply to the piston chamber of the prop

25

1

block ball valve

at the manifold pipe

isolates pressure supply to the shield hydraulics

5.14

Remark

DBT GmbH, Lünen 2002

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Item

subassembly

extending / retracting the pusher cylinder

DBT - Shield Type 2700/6000-2x5278-1750

Operation of the shield hydraulics Hydraulics of the shield

DBT GmbH, Lünen 2002

E

Fig. 16: Hydraulics of the shield

1 control valve block 2 prop check valve 3 check valve 4 pilot-operated check valve 5 pressure relief valve, 420 bar 6 pressure relief valve, 440 bar 7 check valve 8 filter 9 water spray valve 10 twin check valve

11 accumulator cartridge 12 hose lines 14 retainer and accessories 15 manifold pipe 20 pressure gauge 22 block ball valve 23 block ball valve 24 block ball valve 25 block ball valve

please refer also to the spare parts catalog

Doc. no.: 7420 084 000 BA 00

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5.15

Operation of the shield hydraulics Fig. 17: Hydraulic flow plan, overview.

Z1

Z4

Z4

Z8

Z6

Z3

Z7

Z2 Z5

1 control valve block 2 prop check valve 3 check valve 4 pilot-operated check valve 5 pressure relief valve, 420 bar 6 pressure relief valve, 440 bar 7 check valve 8 filter 9 water spray valve 10 twin check valve

functions of the control valve block: 1 extend link cylinder 2 retract link cylinder 3 extend props 4 extend seal cylinders, caving shield 5 retract props 6 retract seal cylinders, caving shield 7 advance shield 8 advance conveyor hydraulic cylinders: Z1 prop Z2 shifting cylinder Z3 link cylinder Z4 seal cylinder

11 accumulator cartridge 12 hose lines 14 retainer and accessories 15 manifold pipe 20 pressure gauge 22 block ball valve 23 block ball valve 24 block ball valve 25 block ball valve

9 retract seal cylinders, canopy 10 extend seal cylinders, canopy 11 retract flipper extension cylinders 12 extend flipper extension cylinders 13 retract flipper cylinder 14 extend flipper cylinder 15 extend lift cylinder 16 activate water spray system

Z5 lift cylinder Z6 flipper cylinder Z7 flipper extension cylinder Z8 pusher cylinder

please refer also to the spare parts catalog

5.16

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

Z1

Operation of the shield hydraulics Fig. 18: Hydraulic lines, overview I

2 20

3

8

5

Z1

9

6 23b

24

1 Z5

23a 25

Z2 7 11

15

24

DBT GmbH, Lünen 2002

E

22

Z1 2

20

6

1 control valve block 2 prop check valve 3 check valve 4 pilot-operated check valve 5 pressure relief valve, 420 bar 6 pressure relief valve, 440 bar 7 check valve 8 filter 9 water spray valve 10 twin check valve functions of the control valve block: 1 extend link cylinder 2 retract link cylinder 3 extend props 4 extend seal cylinders, caving shield 5 retract props 6 retract seal cylinders, caving shield 7 advance shield 8 advance conveyor hydraulic cylinders: Z1 prop Z2 shifting ram Z3 link cylinder Z4 seal cylinder

Doc. no.: 7420 084 000 BA 00

Z8

11 accumulator cartridge 12 hose lines 14 retainer and accessories 15 manifold pipe 20 pressure gauge 22 block ball valve 23 block ball valve 24 block ball valve 25 block ball valve 9 retract seal cylinders, canopy 10 extend seal cylinders, canopy 11 retract flipper extension cylinders 12 extend flipper extension cylinders 13 retract flipper cylinder 14 extend flipper cylinder 15 extend lift cylinder 16 activate water spray system

Z5 lift cylinder Z6 flipper cylinder Z7 flipper extension cylinder Z8 pusher cylinder

VPVU / 01

5.17

Operation of the shield hydraulics Fig. 19: Hydraulic lines, overview II

Z4

2

Z4

20

Z4

Z4

Z1 24

6

9

Z6

23d 5 5

Z7

10

5

4 4

4 4

5

5

11

1

Z3

5

5 5

23c

Z6 24

2

20

6

1 control valve block 2 prop check valve 3 check valve 4 pilot-operated check valve 5 pressure relief valve, 420 bar 6 pressure relief valve, 440 bar 7 check valve 8 filter 9 water spray valve 10 twin check valve functions of the control valve block: 1 extend link cylinder 2 retract link cylinder 3 extend props 4 extend seal cylinders, caving shield 5 retract props 6 retract seal cylinders, caving shield 7 advance shield 8 advance conveyor hydraulic cylinders: Z1 prop Z2 shifting ram Z3 link cylinder Z4 seal cylinder

5.18

DBT GmbH, Lünen 2002

E

Z1

11 accumulator cartridge 12 hose lines 14 retainer and accessories 15 manifold pipe 20 pressure gauge 22 block ball valve 23 block ball valve 24 block ball valve 25 block ball valve 9 retract seal cylinders, canopy 10 extend seal cylinders, canopy 11 retract flipper extension cylinders 12 extend flipper extension cylinders 13 retract flipper cylinder 14 extend flipper cylinder 15 extend lift cylinder 16 activate water spray system

Z5 lift cylinder Z6 flipper cylinder Z7 flipper extension cylinder Z8 pusher cylinder

DBT - Shield Type 2700/6000-2x5278-1750

Operation of the shield hydraulics Fig. 20: Single shield unit

2

1 3

DBT GmbH, Lünen 2002

E

1 manifold pipe 2 PM4 control unit 3 protective flap for control valve block Fig. 21: View on the manifold pipe

25

(R) P

23a W 23b

R return line, DN 50, hidden P pressure line, DN 40 W water line, DN 25

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23a isolating valve, water supply for the water spray system 23b Isolating valve, auxiliary water supply 25 isolating valve, pressure supply of the shield hydraulics

5.19

Operation of the shield hydraulics Fig. 22: Control valve block

b c e a d

a pilot valve b solenoid driver c connecting cable

a

b

a PM4 control unit b retainer

5.20

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

Fig. 23: PM4 control unit fitted at adjustable retainer

E

d symbol plate e push button

Operation of the shield hydraulics Fig. 24: Adjustable retainer for PM4 control unit

2

(5)

6,8 B 6

a

A adjustable hinge mounted link B adjustable hinge mounted link 1 retainer

2 cover 5 hex. socket head cap screw M12x55-A 2-70 6 hex. head bolt M16x45 - 8.8, tightening torque 195 Nm 7 hex. head bolt M16x50 - 8.8, tightening torque 195 Nm 8 washer

1

9 hex. nut M16-8

A 8

DBT GmbH, Lünen 2002

E

7,9

Before starting to operate the shield adjust the retainer such that all the control elements on the PM4 single control unit are easily accessible.

At hinge link (A), adjust the inclination of the retainer (1).

. Secure the retainer to prevent it turning over. . Loosen hex. head bolts (7) at the bottom of the retainer. . Swivel retainer into the desired position and fix temporarily. . Tighten hex. head bolts (7) of hinge links (A) at the bottom of the retainer to the specified torque.

. Remove temporary fixing device.

At hinge link (B), you adjust the inclination of the cover (2) with respect to the retainer.

. Secure the cover to prevent it turning over. . Loosen hex. head bolts (6) at the cover. . Swivel cover into the desired position and fix temporarily. . Tighten hex. head bolts (6) of hinge links (B) to the specified torque.

. Remove temporary fixing device.

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5.21

Operation of the shield hydraulics Fig. 25: View on the L.H. front lemniscatic link, ball valve serves to actuate the pusher cylinder 22 ball valve function: A retract pusher cylinder B extend pusher cylinder

A

22

DBT GmbH, Lünen 2002

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B

Fig. 26: View on the R.H. front lemniscatic link, back-flush filter

8 back-lush filter

8

normal operation: both levers in position “A” back-flushing: one of the levers in position “B”

A A B B

5.22

DBT - Shield Type 2700/6000-2x5278-1750

Operation of the shield hydraulics Fig. 27: View on the hose terminal at the caving shield 5 pressure relief valve 23c isolating valve, seal cylinders canopy side seal, annulus side 23c isolating valve, seal

5

cylinders caving shield side seal, annulus side

23d 23c

DBT GmbH, Lünen 2002

E

Fig. 28: View on the L.H. prop from the gobside 2 prop check valve 6 pressure relief valve 20 pressure gauge 24 block ball valve, isolates the prop piston chamber from pressure supply, open as shown

2

24

20

6

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5.23

Operation of the shield hydraulics Fig. 29: View on the R.H. prop from gobside

24 2

DBT GmbH, Lünen 2002

E

20

6

2 prop check valve 6 pressure relief valve 20 pressure gauge 24 block ball valve, isolates the prop piston chamber from pressure supply, open as shown

5.24

DBT - Shield Type 2700/6000-2x5278-1750

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 2002

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WARNING! The control elements on the control 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. 30: Protective flap for control valve block

a

a protective flap

Figure 30 above shows the arrangement of the protective flap covering the control valve block

Doc. no.: 7420 084 000 BA 00

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5.25

Operation of the shield hydraulics Fig. 31: Control valve block, arranged between the front lemniscatic links

e d

1 a c

b

1 control valve block a push button b symbol plate

c pilot valve d connecting cable e solenoid driver

The symbol plate is located at the control 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.

5.26

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

Fig. 32: Symbol plate for 16 function control valve block

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

WARNING! You are only allowed to operate the controls of the control 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 2002

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

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

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

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

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

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

Doc. no.: 7420 084 000 BA 00

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5.27

Operation of the shield hydraulics Extend stabilizing cylinder 1 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.

2

Retract stabilizing cylinder

Set both props 3

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.

Extend seal cylinders at the caving shield

4

5

6

5.28

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

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

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

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

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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

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

E

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Operation of the shield hydraulics Advance shield 7

8

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

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

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

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

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

Retract seal cylinders at the canopy

DBT GmbH, Lünen 2002

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9

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

Extend seal cylinders at the canopy

10

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

Retract flipper cylinder

11

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

Extend flipper cylinder

12

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

Retract flipper extension cylinders

13

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

Extend flipper extension cylinders

14

Doc. no.: 7420 084 000 BA 00

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.

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5.29

Operation of the shield hydraulics Extend lift cylinder 15

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.

16

Activate water spraying system

DBT GmbH, Lünen 2002

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

5.30

DBT - Shield Type 2700/6000-2x5278-1750

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 hydraulic control

J After the first 100 hours of operation, the filter cartridge located

in the control block and at the manifold pipe must be replaced on every shield unit.

J All pressure relief valves must be tested for correct function at

least once a year, and in any case after every face move.

J For reasons of safety and for ensuring correct function of the

unit, all high pressure hydraulic hoses must be replaced every 2 years, regardless of recognizable damage.

hydraulics

DBT GmbH, Lünen 2002

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Daily inspection

. Check all shield units by visual inspection for hydraulic fluid escaping on the: J hose lines, J control valve blocks, J valves J props, J shifting ram and lift cylinder J stabilizing cylinder, seal and flipper cylinders.

. Check pressure gauges at the props. steel structure

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

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5.31

Maintenance 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.

Assessment of damage according to schedule

DBT GmbH, Lünen 2002

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The supervisory personnel should record all damages in a monthly damage report. Frequently recurring causes can thus be detected, analyzed, and ultimately eliminated. This helps to decrease operating costs.

5.32

DBT - Shield Type 2700/6000-2x5278-1750

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

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

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

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

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

DBT GmbH, Lünen 2002

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Fault localization failure to lower the shield

Doc. no.: 7420 084 000 BA 00

Possible cause The shut-off valve for pressure supply at the manifold pipe of the shield is closed.

Check required 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.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses

Check for damaged or kinked hoses in prop circuit.

Props are damaged.

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

Lack of fluid from control valves

Disconnect the hose to prop and check for adequate flow, if none, remove hose from control valve and check port for flow, and if still no flow, check feed lines to control unit.

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5.33

Trouble shooting Possible cause The shut-off valve for pressure supply at the manifold pipe of the shield is closed.

Check required 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 or under adjacent shields.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free.

System pressure is too low for operation.

Check pumps are ‘ON’.

Check all ‘shut-off’ valves are ‘OPEN’.

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Props are damaged.

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

Possible cause The shut-off valve for pressure supply at the manifold pipe of the shield is closed.

Check required Open shut-off valve.

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

Shield is trapped by adjacent shields.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free.

Step on roof or floor preventing advance.

Lower shield sufficiently to clear the step or put baselift function ‘ON’.

System pressure is too low for operation.

Check pumps are ‘ON’.

Check all ‘shut-off’ valves are ‘OPEN’.

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in supply line to face.

Shifting ram is faulty.

Check cylinder for damage.

Check for POCV (load lock) malfunction.

Operate ‘Bankpush’ with hose disconnected on piston side, if fluid flows without ram operating, change ram.

failure to advance the shield

POCV = pilot operated check valve

5.34

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

failure to set the shield

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

Check required Check the POCV by replacing unit. Continue trouble shooting if pressure continues to drop.

Props are damaged.

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

Check if fluid is flowing from prop lower port/hose without large prop movement. If so: pistion packing defective. Replace prop.

Faulty pressure reliefvalve.

Check pressure gauge for reading.

Is pressure relief valve weeping?

Replace pressure relief valve and check functions.

Possible cause The shut-off valve for pressure supply at the manifold pipe of the shield is closed.

Check required Open shut-off valve.

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

Shield canopy is trapped by adjacent shields.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free.

Canopy is trapped by adjacent side seals.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free or pull in side seals.

System pressure is too low for operation.

Check pumps are ‘ON’.

Check all ‘shut-off’ valves are ‘OPEN’.

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilising cylinder is damaged.

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

DBT GmbH, Lünen 2002

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failure to operate the tip up function

Possible cause Faulty POCV.

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5.35

Trouble shooting Possible cause The shut-off valve for pressure supply at the manifold pipe of the shield is closed.

Check required Open shut-off valve.

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

Canopy is trapped by adjacent shields.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free.

Canopy is trapped by adjacent side seals.

Check the shield is not ‘iron-bound’ and if necessary, operate or lower adjacent shields to free or pull in side seals.

System pressure is too low for operation.

Check pumps are ‘ON’.

Check all ‘shut-off’ valves are ‘OPEN’.

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

Check if there is enough pressure to operate the piston (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 The shut-off valve on the shield is closed.

Check required Open shut-off valve. Feed line must be open to allow pressure to the shield hydraulics.

System pressure is too low for operation.

Check pumps are ‘ON’.

Check all ‘shut-off’ valves are ‘OPEN’.

Check pressure delivered by pumps is correct.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit

Baselift cylinder is damaged.

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

Shield is not lowered from roof.

Lower shield to attempt to operate baselift.

Wait until shield is advanced and attempt function again.

failure to operate baselift function

5.36

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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failure to operate the tip down function

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 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 block several times.

internal leakage

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

E

valve replacement

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

DBT GmbH, Lünen 2002

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 block several times.

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

. Check valve and replace, if defective.

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5.37

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.

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.

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.

The permissible pressure for the pressure relief valves used on this shield is 462 bar and is indicated by a blue and white color code.

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 blocks, the filter elements must be replaced.

5.38

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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

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Faulty pressure relief valve

6

Technical data

Shield variants

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

Shield variants Type 2700/6000 - 2x5278-1750 The two-leg shield units basically comprise the following main components: J base with lemniscatic links, shifting unit and baselift cylinder J canopy with flipper J caving shield J side seal, moveable at L.H. side only J hydraulic props J hydraulic equipment with hose lines and controls

Two different versions of the same type of shield will be supplied: DBT GmbH, Lünen 2002

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Tab. 3: Variants of the shield (1) Variant Application

Order-no.

Dimensions max. / min. in mm LxWxH

Weight in kg

01

face shield

7420 084 000 00 01

6472 x 1900 x 6000 7920 x 1610 x 2700

39850

02

end shield

7420 084 000 00 02

6472 x 1900 x 6000 7920 x 1610 x 2700

39940

Tab. 4: Variants of the shield (2)

Doc. no.: 7420 084 000 BA 00

Variant Application

Shield no.

Special features

01

face shield

5 .... 80

shifting cylinder dia. 165

02

transition shield

1 .... 4

shifting cylinder dia. 200

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6.3

Shield variants The shield is provided with a solid base which has the two interconnected skids separated by a tunnel. The bases are equipped with different shifting cylinders depending on their use. See table 4 above.

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. All the canopies are equipped with a flipper.

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

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

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

DBT GmbH, Lünen 2002

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

6.4

DBT - Shield Type 2700/6000-2x5278-1750

Shield variants Main subassemblies Fig. 33: Components of the shield type 11

21

31

51

41 61 71

DBT GmbH, Lünen 2002

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L

1 oder 2

Tab. 5: Components of the shield type 2700/6000-2x5278-1750 according to drawing no. 7420 084 000 00 ..

Item

Doc. no.: 7420 084 000 BA 00

Variant

Order-no.

Weight approx approx. in kg

01

02

1 base

X

-

7420 084 300 00 01

14285

2

-

X

7420 084 300 00 02

14395

11 canopy

X

X

7420 084 400 00 00

9217

21 side seal

X

X

7420 084 700 00 00

3035

31 caving shield

X

X

7420 084 800 00 00

6668

41 prop

X

X

8250 062 000 00 00

2690

51 stabilizing cylinder

X

X

8241 171 000 00 00

279

61 hydraulic control

X

X

8112 111 000 00 00

200

71 gobside flap

X

X

7420 085 891 00 00

55

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6.5

Shield variants Base with lemniscatic links and central shifting unit Fig. 34: Base 13 14

1 shifting cylinder ZE-165/100-1130 (only for base variant 01)

2 shifting cylinder ZE-200/140-1130 (only for base variant 02)

3 lift cylinder ZE-150/90-240

1 oder 2

15

4 11

others: fastening and securing elements, see spare parts catalog

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 - Shield Type 2700/6000-2x5278-1750

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31, 37, 38

DBT GmbH, Lünen 2002

4 pusher cylinder ZE-135/120-300 6 shifting unit 26 11 base subassembly 13 lemniscatic link, R.H. front 22, 23 40, 41, 42 14 lemniscatic link, L.H. front 15 lemniscatic link, rear 22 prop retainer R.H. 25 23 prop retainer L.H. 24 24 lift cylinder bearing 3 25 walkway box S1 26 travel path 31 lemniscatic pin 37 locking plate 38 washer 40 foam filler, front 41 foam filler, middle 6 42 foam filler, rear S1 attaching eye, load-bearing capacity: 15000 kg

Shield variants Shifting unit Fig. 35: Shifting unit 10, 17, 18 1 13

12, 14, 19

2

17

5

11, 15, 16 1 relay bar 2 bar 5 clevis 13 pin 17 staple others: fastening elements, see spare parts catalog

DBT GmbH, Lünen 2002

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

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

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

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

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

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

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

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

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

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

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6.7

Shield variants Shield canopy The canopy of a shield has the two 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 canopies of all shield variants are equipped with an an adjustable side seal at the L.H. side and a flipper.

Fig. 36: Canopy 2

8, 9, 10 11, 15

14 S1

S2

S3 5, 6, 7

12, 13

1 canopy, subassembly 2 flipper 5, 6, 7 securing and fastening elements for the prop head 12, 13 securing and fastening elements for the stabilizing cylinder 8 .. 11, 15 securing and fastening elements for the hinged link canopy / caving shield 14 securing spring S1 attaching eye, load-bearing capacity: 15000 kg S2 attaching eye, load-bearing capacity: 8000 kg S3 attaching eye, load-bearing capacity: 5000 kg

6.8

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

1

Shield variants Fig. 37: Flipper 4

2 3

1

5 11 1 flipper cylinder ZE-165/100-615 2 flipper extension cylinder ZE 115/80-285 3 flipper 4 flipper extension

12 5 fork link 11 link 12 fork others: fastening and securing elements, see spare parts catalog

Caving shield DBT GmbH, Lünen 2002

E

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

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

Fig. 38: Caving shield 1

15 S1

6

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

Doc. no.: 7420 084 000 BA 00

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7, 16 S2

S2

6.9

Shield variants Side seal Fig. 39: Side seal 54 12

40 42 10

54 40

42

40 40 10

11

41 55 43 55 1 5

41

20, 25

13

CAUTION! Remove securing elements and devices for transport, items 20 and 25, at moveable side before start-up.

L. H. side moveable design as shown.

R.H. side moveable design mirror inverted.

1 hydraulic cylinder ZE 80/63-315 5 side seal, canopy 7 side seal, caving shield 10 ..13 guide pin 20, 25 securing elements for transport 40, 41 compression spring 42, 43 guide pin 54, 55 cover plate others fastening and securing elements, see spare parts catalog

6.10

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

7

E

20, 25

Shield variants

DBT GmbH, Lünen 2002

E

Technical data of the shield closed height . . . . . . . . . . . . . . . . . . . . . . . mm

2700

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

6000

hydraulic height adjustment of shield . . mm

3300

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

1000 1130

distance of prop centers (inclination) . . . mm

950

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

2900

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

1050

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

1600

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

4050

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

14 56.8

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

1600

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

1610

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

42536

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

1750

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

5000 7879 10833

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 5000 a) at 320 bar setting pressure . . . . . . . . kN/m2 849 b) at 440 bar yield pressure (distance canopy tip to face low / high) . kN/m2 983/1168

Doc. no.: 7420 084 000 BA 00

VPVU / 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. variants, differences in design normal and exceptional operation

The hydraulic system is the same for all shield variants.

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

DBT GmbH, Lünen 2002

E

WARNING! During normal operating mode the push buttons at the pilot valves of the control 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 - Shield Type 2700/6000-2x5278-1750

Hydraulic system Shield hydraulics

DBT GmbH, Lünen 2002

E

Fig. 40: Hydraulics of the shield

1 control valve block 2 prop check valve 3 check valve 4 pilot-operated check valve 5 pressure relief valve, 420 bar 6 pressure relief valve, 440 bar 7 check valve 8 double backflush filter 9 water spray valve 10 twin check valve

11 accumulator cartridge 12 hose lines 14 retainer and accessories 15 manifold pipe 20 pressure gauge 22 block ball valve 23 ball valve 24 ball valve 25 ball valve

Please refer also to the spare parts catalog.

Doc. no.: 7420 084 000 BA 00

VPVU / 01

6.13

Hydraulic system Fig. 41: Hydraulic flow plan, overview Please refer also to the spare parts catalog.

Z1

Z4

Z4

Z8

Z6

Z3

Z7

Z2 Z5

12 hose lines

4 pilot-operated check valve 5 pressure relief valve, 420 bar

15 manifold pipe

6 pressure relief valve, 440 bar 7 check valve 8 double backflush filter 9 water spray valve 10 twin check valve control valve block functions: 1 extend stabilizing cylinder 2 retract stabilizing cylinder 3 extend props 4 extend side seal cylinder, caving shield 5 retract props 6 retract, side seal cylinder, caving shield 7 advance shield 8 advance conveyor hydraulic cylinders: Z1 prop Z2 shifting cylinder Z3 stabilizing cylinder Z4 side seal cylinder

6.14

11 accumulator cartridge

1 control valve block 2 prop check valve 3 check valve

14 retainer and accessories 20 pressure gauge 22 block ball valve 23 ball valve 24 ball valve 25 ball valve 9 retract, side seal cylinder, canopy 10 extend side seal cylinder, canopy 11 retract flipper extension cylinder 12 extend flipper extension cylinder 13 retract flipper cylinder 14 extend flipper cylinder 15 extend lift cylinder 16 activate water spraying system

Z5 lift cylinder Z6 flipper cylinder Z7 flipper extension cylinder Z8 pusher cylinder

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

Z1

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”.

DBT GmbH, Lünen 2002

E

Fig. 42: Double telescopic prop, type SD 5280-400-2050/5210-BD

1 prop base 2 piston pipe 3 bottom valve 21 piston rod 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.

Doc. no.: 7420 084 000 BA 00

VPVU / 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.

Load is transmitted mechanically from the canopy to the inner prop via the prop head. The inner prop bears on the pressure fluid under its piston. This fluid is trapped by the check valve. The further course of load transmission is as described under a). prop lowering

6.16

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 - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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. 43:

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

2

1

3

5

4

DBT GmbH, Lünen 2002

E

Type b)

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.

Doc. no.: 7420 084 000 BA 00

VPVU / 01

6.17

Hydraulic system Shifting cylinder Fig. 44: Shifting cylinder

Types of shifting rams in use with the different base variants:

1 cylinder tube 2 reed rod 4 piston rod

6 piston 10 annular magnet Please refer also to the spare parts catalog.

Fig. 46: Shifting cylinder type ZE-200/140/1130-SC-W-CR

1 cylinder tube 2 reed rod 3 piston rod

6.18

5 piston 7 annular magnet Please refer also to the spare parts catalog.

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

Fig. 45: Shifting cylinder type ZE-165/100-1130-SC-W-CR

Hydraulic system Technical data of hydraulic cylinders

DBT GmbH, Lünen 2002

E

double telescopic prop, double-acting - 2 stages

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

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

Doc. no.: 7420 084 000 BA 00

Type SD 5280-400-2050/5210-BD, drawing no. 8250 062 000 00 00 prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

2050

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

5210

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

3160

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

400 / 285

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

370 / 265

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

1256.6/638

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

181.4/86.4

prop force at 320 bar setting pressure . kN

4021.1

prop force at 440 bar yield pressure . . . kN

5529

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

580.5

Type ZE-165/100-1130-SC-W-CR, drawing no. 8241 173 000 00 00, equipped with reed contact rod, in use with base variant 01 only stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

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

165

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

100

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

213.8

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

135.3

thrust at 320 bar . . . . . . . . . . . . . . . . . . . . kN

684

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

433/568.3

Type ZE-200/140-1130-SC-W-CR, drawing no. 8241 176 000 00 00, equipped with reed contact rod, in use with base variant 02 only stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1130

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

200

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

140

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

314.2

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

160.2

thrust at 320 bar . . . . . . . . . . . . . . . . . . . . kN

1005.4

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

512.6/672.8

VPVU / 01

6.19

Hydraulic system stabilizing cylinder, double-acting

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

690

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

200

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

125

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

314.2

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

191.4

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

1005.4/1319.6

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

612.5/803.9

Type ZE-150/90-240-LI-BD, drawing no. 8241 169 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

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

150

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

90

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

176.7

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

113.1

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

565.4 / ---

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

361.9 /---

side seal cylinder, double-acting

flipper cylinder, double-acting

6.20

Type ZE-80/63-315-RI-BD, drawing no. 9571 170 100 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

315

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

80

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

63

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

50.3

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

19.1

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

160.9 / ---

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

62/80.2

Type ZE-165/100-615-KD-W-BD, drawing no. 8241 175 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

600

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

165

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

100

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

213.8

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

135.3

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

684/898

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

433/568.3

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

E

baselift cylinder, double-acting

Type ZE-200/125-690-EC-W-BD, drawing no. 8241 171 000 00 00

Hydraulic system

flipper extension cylinder, double-acting

DBT GmbH, Lünen 2002

E

pusher cylinder, double-acting

Doc. no.: 7420 084 000 BA 00

Type ZE-115/80-285-KD-W-BD, drawing no. 8241 174 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

285

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

115

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

80

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

103.8

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

53.6

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

332.4/---

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

171.5/---

Type PU-135/120-300, drawing no. 8241 046 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

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

135

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

120

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

143.1

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

30

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

458/---

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

96.1/---

VPVU / 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. 6: Pressure relief valves, use of different types Pre-setting in bar

Order-no.

Application

Type

general use except of props

pre-loaded by pressure spring

420 7337 486 420 00 00

only at props

pre-loaded by pressure spring

440 8220 059 440 00 00

CAUTION! The pressure setting must not be changed.

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 - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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

E

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

Electrohydraulic control system Electrohydraulic control system Fig. 47: Control valve block, 16 functions

b c e a d

DBT GmbH, Lünen 2002

E

a pilot control valve for electromagnetic operation b solenoid driver c connecting cable

d symbol plate e push button

WARNING! During normal operating mode the push buttons at the pilot valves of the control 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.

Doc. no.: 7420 084 000 BA 00

VPVU / 01

6.23

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

DBT GmbH, Lünen 2002

E

Fig. 48: PanzermaticÒ PM4, schematic diagram

1 control unit 3 solenoid driver 9 pressure sensor 10 infrared receiver

6.24

22 stop switch 27 warning light others: see spare parts catalog

DBT - Shield Type 2700/6000-2x5278-1750

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15° 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 2002

E

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

Angle a2 measured with retracted stabilizing cylinder Inclination = at height M

Shield Variant

Order-no.

01 and 02

7420 084 000 00 ..

=1 in ° 9.6

M in mm 2700

= in ° 13.7

M in mm 6000

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

Doc. no.: 7420 084 000 BA 00

VPVU / 01

6.25

Accessories Accessories Anchoring device “base - base” Fig. 49: Anchoring device “base - base”

shield 3

residual stroke

L.H. design as shown R.H. design mirror inverted

sequence of shield advance must be:

2-1-3

DBT GmbH, Lünen 2002

residual stroke

apply lubricant B6 according to EWN 6003 at joints and sliding surfaces

E

shield 2

shield 1

tightening torques for bolts according to EWN 6003

1 hydraulic cylinder 10 pin 11 chain shackle 12 washer, special design 13 protective cover for hydraulic cylinder 14 cover 40 attaching device for hydraulic cylinder 41 chain guide

6.26

42 chain guide 43 attaching device for chain (item 70) 44 locking device 45 pin 46 distance bush 70 chain 71 chain connector, flat type others: fastening and securing elements, see spare parts catalog

DBT - Shield Type 2700/6000-2x5278-1750

Accessories Fig. 50: Hydraulic control unit for the anchoring device “base - base”

shield 1

shield 2

DBT GmbH, Lünen 2002

E

shield 3

Doc. no.: 7420 084 000 BA 00

VPVU / 01

6.27

Accessories Anti-topple device “canopy - canopy” Fig. 51: Anti-topple device “canopy - canopy”

DBT GmbH, Lünen 2002

E

1 hydraulic cylinder 5 chain shackle 6 chain connector, flat type 10 anchoring bracket 11 bracket 16 universal joint 17 universal joint 18 pin 19 pin others: fastening and securing elements, see spare parts catalog Fig. 52: Hydraulic control unit for anti-topple device “canopy - canopy”

shield 1 shield 2

shield 3

R - return line P - pressure line

6.28

DBT - Shield Type 2700/6000-2x5278-1750

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. 7: Approval list (Part 1) Manufacturer

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

E

DBT GmbH, Lünen 2002

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

ARAL Lubricants

Fuchs/Century

Doc. no.: 7420 084 000 BA 00

Product designation

VPVU / 01

6.29

Operating media Tab. 8: 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.

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.

6.30

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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

Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates.

E

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.

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.

DBT GmbH, Lünen 2002

E

Tab. 9: Chemical composition of the test water samples used type X test water (NCB 18 to Luxembourg Report)

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.

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6.31

Operating media Recommended 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.

Tab. 10: Lubricating greases for general application 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. 11: 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

6.32

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

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Supplier

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.

DBT GmbH, Lünen 2002

E

Tab. 12: Lubricating pastes free from molybdenum disulfide Supplier

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

1) If necessary, neighboring cavities must be filled using a lubricating grease according to table 10 above.

2) If necessary, neighboring hollows must be filled using the special lubricant type: Klüber Lubrication Staburags NBU 30

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: Temperature of application:

non-soluble in water -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.

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6.33

Tightening torques Tightening torques Screws with metric coarse thread DIN 13 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 32 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.

6.34

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

Thread 1)

E

Recommended tightening torques at mtotal = 0.14

Tab. 13:

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 Internet: http://www.dbt.de

Africa

DBT Africa (PTY) ltd.

DBT GmbH, Lünen 2002

E

Corner of Gamma and Zeta Roads Industries West Germiston, 1401 Südafrika Phone: + 27 (0)11 8 25 82 12 Fax: + 27 (0)11 8 25 73 89 E-mail: infodbt@dbt.de Internet: http://www.dbt.de

Doc. no.: 7420 084 000 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. 53: Type plate, example

1

DBT 2 3

7420.084.311.00.00

5278

2

kN

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

Fig. 54: Shield number, example

7.4

shield number

order number

application

5 .... 80

7420 084 000 00 01

face shield

1 .... 4

7420 084 000 00 02

end shield

DBT - Shield Type 2700/6000-2x5278-1750

DBT GmbH, Lünen 2002

3 number of props 4 prop force

E

4 1 manufacturer 2 order number

Identification of shields

DBT GmbH, Lünen 2002

E

Referenced standards and guidelines

Doc. no.: 7420 084 000 BA 00

Designation

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 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

VPVU / 01

7.5

E

DBT GmbH, Lünen 2002

7.6

DBT - Shield Type 2700/6000-2x5278-1750

Operating Manual DBT - Control valve block - 16 functions Doc. no.: 8154 052 000 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.

DBT GmbH, Lünen 2002 E

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

1.3

Who is this operating manual intended for? . . . . . . . . . . . .

What is the purpose of this operating manual? . . . . . . . . .

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

1.3 1.3 1.4

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

2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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

2.6

Overview of the safety instructions . . . . . . . . . . . . . . . 2.11

DBT GmbH, Lünen 2002E

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

3.3

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

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

3.3 3.4

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

3.5

Transport crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight of the control valve block . . . . . . .

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.5

4. Installation Requirements to the face hydraulic system . . . . . . . .

4.3

Removal of the control valve block . . . . . . . . . . . . . . . . . . .

Installation of the control valve block . . . . . . . . . . . . . . . . . .

4.3 4.4

5. Operation

Doc. no.: 8154 052 000 BA 00

Operation and function of the pilot valves . . . . . . . . .

5.3

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

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

5.3 5.3

Filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

VUVU / 01

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.4 6.4 6.5 6.5 6.5 6.5

Power supply to the pilot control valves . . . . . . . . . . .

6.6

Connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Hydraulic flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

Recommended lubricating greases and pastes . . . . . . . . .

6.8 6.11

7. For your information Our service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

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

Referenced Standards and Guidelines . . . . . . . . . . . . . . . .

7.3 7.4

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002E

6. Technical data

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 and characters used.

Before starting work Take care to ensure that the operating manual available to you is applicable for the type of control valve block used. Failure to do so can result in a safety hazard for yourself and others. Ensure that the data on the control valve block comply with the data given in the operating manual.

This operating manual is designed for DBT control valve block (16 functions) with the order No.: 8154 052 00000 00 and is only permitted to be used for control valve blocks of this type. operating manual

An operating manual for the control valve block must always be available. Ask for a new manual immediately if the existing manual is no longer complete or has become illegible.

DBT GmbH, Lünen 2002

E

Who is this operating manual intended for?

This operating manual is intended for all persons involved in the J installation, J maintenance, J repair, J operation and J dismantling

of the control valve block.

In addition, the supervisory personnel who initiate and/or supervise the activities just indicated must also observe this operating manual.

What is the purpose of this operating manual? efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the control valve block.

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.

safety

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

operating cost warranty

Observe the information given and follow the procedural instructions. This is the only way to minimize operating costs and to assert warranty claims.

Doc. no.: 8154 052 000 BA 00

VUVU / 01

1.3

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.

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

1.4

J

Lists are marked with bullets.

–

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.

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

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

E

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

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

The control valve block 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 control valve block. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

supplementary regulations

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

E

J of the miners’ accident insurance association.

DBT GmbH, Lünen 2002

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

Operation and maintenance qualification

Operation and maintenance of the shield control is only allowed to be performed by trained personnel. The training shall be matched to the type of shield control actually used. 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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VUVU / 01

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 control blocks, J working valves, J pilot control valves, J safety components, e.g. pressure relief valves, etc.

DBT GmbH, Lünen 2002

E

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

2.4

DBT - control valve block, 16 functions

Conditions of operation Conditions of operation Use in conformance with specifications The control valve block has been designed and manufactured exclusively as part of the control system for shields. It is only allowed to be used in connection with an electronic control unit, such as for example a PM4.

Use the control valve block only as intended.

Intended uses are: J The control valve block is combined with an electronic control

unit - as for example a single control unit of type PM4. Together they form a control unit designed to operate the functions of a shield support. The two devices are part of an adjacent control system for electrohydraulic shield supports for use in underground mining. The control valve block is an essential component of this electrohydraulic shield control. Operation of the functions is not allowed to be made direct by pressing the buttons of the control valve block, but via the respective single control unit which must be located in one of the adjacent shields. By means of this control unit the pilot valves of the control block are actuated manually or program-controlled.

J Additionally, there are two exceptional circumstances under DBT GmbH, Lünen 2002

E

which the control block also serves as direct ”control unit”: - emergency operation and - repair operation.

In these cases the individual functions of the electrohydraulic shield support are executed direct at the pilot valve of the control valve block. Thus, the functions of the shield can be operated even if the single control unit is locked out or has failed - but only in well-founded exceptions and under strict observance of the special safety regulations of the mine operator for these cases.

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

Unauthorized use:: J Use of the control valve block as ”control unit” to operate the

functions of the shield in normal operation.

Actuating the shields exclusively by pushing a button on the pilot valve block is unauthorized use since operation of the shield functions must be performed from an adjacent shield.

By unauthorized uses you endanger yourself and others. You could be severely injured or even killed. Therefore only use the control valve block as intended!

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

Doc. no.: 8154 052 000 BA 00

VUVU / 01

2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Please also observe the operating manuals for the shield support and the control unit.

Always familiarize yourself with your working environment first before taking up work.

Never stay under a shield that is not secured.

Always wear your personal protective clothing and equipment.

Please observe the visual and audible pre-start warnings. Particularly observe the pre-start warning signals of the conveyor and the mining machine.

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.

If the shield is equipped with an electrohydraulic control unit you have to operate the support lock-out switch (repair switch) in order to lock out the shield. After this has been done, the shield cannot be operated from the control unit.

Actuate the support lock-out 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 side seals, J base skids, J shifting units, J lemniscatic links, J hydraulic props and cylinders, J canopies and J flippers.

2.6

DBT - control valve block, 16 functions

E

EMERGENCY STOP

Employ only control valve blocks which are in a technically flawless condition.

DBT GmbH, Lünen 2002

prerequisite

Safety instructions Storage and Transport Never store materials of any kind in the travelway or in your working area.

Immediately remove defective components from the face in order not to hinder the face crew and to prevent these parts being reinstalled elsewhere.

Pass them on for servicing without delay.

Observe the specified storage time limits and the storage instructions.

Installation Always secure all moving components mechanically before relieving the pressure in the hydraulic system.

Always depressurize the hydraulic systems before starting work on them.

Ensure that no dirt enters the hydraulic system.

Remove the protection caps on the ports only immediately before installing the control block.

Operation

DBT GmbH, Lünen 2002

E

Operate the manual repair control only when it is absolutely necessary. Whenever possible, control a shield by the electronic control unit of an adjacent shield.

Check that all protective devices on the shield are in place and function properly.

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

Observe the entire zone of motion of the shield, in order to recognize and avoid hazards in due time.

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 yourself and others.

Close off your working area to prevent the mining machine going there. Stop and lockout the mining machine and the conveyor to prevent restarting.

Secure the shield mechanically to prevent it from lowering under its own weight before starting work, e.g. by: J supporting the canopies J positioning wooden wedges between the lemniscatic links.

Stop work on the shield immediately if conveying and mining work is being carried out in your working area.

Refit any protective devices removed immediately after completion of the work and check that they function properly.

Ensure that the prescribed maintenance and inspection intervals are observed. See also chapter 5 ”Operation”.

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2.7

Safety instructions original spare parts

Use only spare parts which satisfy the specified technical requirements. This is best ensured with original DBT spare parts.

Please refer to the spare parts catalog for the order numbers.

Do not carry out modifications or conversions. Modifications and conversions must be approved by DBT. Never use the control block without filter cartridge. Failure to fit a filter or using a filter with insufficient mesh size could cause malfunctions and damage of the control block.

Hydraulics

handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

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.

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

2.8

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

J the hoses or the outer sheathes of the hoses are not abnormally

E

J the hoses have no bubbles or blisters.

Safety instructions permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 1:

Example: 4SP hydraulic hose, designation

3

2 1

6 4

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1 hose type 2 nominal diameter 3 date of manufacture

5 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.

Replace hydraulic hoses at the first suspicion of damage. installation of 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. 2:

Laying of hydraulic hose lines, slack RIGHT

WRONG

J are not twisted.

Fig. 3:

Laying of hydraulic hose lines, twist RIGHT

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WRONG

2.9

Safety instructions J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter).

Fig. 4:

Laying of hydraulic hose lines, bend RIGHT

WRONG

J cannot chafe.

Fig. 5:

Laying of hydraulic hose lines, crossing WRONG

J are not kinked.

J do not have to withstand tensile strains.

J are protected against thermal radiation.

J are accessible at all times.

Push hydraulic hoses into the sockets by hand only. 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. 6).

Fig. 6:

Laying of hydraulic hose lines, connections at movable parts RIGHT

2.10

WRONG

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

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RIGHT

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

Chapter 3: Storage and transport NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before installation and connection of the control block.

Chapter 4: Installation

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DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

DANGER! Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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”.

NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals.

The information required for start-up and operation of the electrohydraulic control is given in the manual for the respective control system used.

NOTICE! Do not secure the control valve block with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the control valve block and prevent slipping.

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Overview of the safety instructions Chapter 5: Operations and maintenance DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the control block if you have the required knowledge.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

NOTICE! The recommended maintenance intervals must be understood as a guideline and must be adapted to the individual operating conditions . Depending on the actual operating conditions the maintenance intervals possibly must be shortened or can be prolonged.

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

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DBT GmbH, Lünen 2002

CAUTION! Use filter cartridges only once and do not try to clean them.

Soiling in the hydraulic system is a frequent cause of costly repairs.

Always use only new filter cartridges and seals.

E

WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

Overview of the safety instructions Chapter 6: Technical data WARNING! As soon as the current drops to a level below 30 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

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! Please use the spare parts catalog supplied when ordering spare parts.

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

Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates.

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

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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 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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DBT - control valve block, 16 functions

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and transport of the control valve block.

Observance of the instructions and tips will increase the service life of the control valve block. 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

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 the 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. A yellow colored fluid indicates insufficient corrosion protection.

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DBT GmbH, Lünen 2002

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.

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

Protect the equipment against direct exposure to sunlight.

Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15 °C to 25 °C.

natural ageing

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

moisture and dirt

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.

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

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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.

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.

plastic deformation

During long-term storage, the sealing elements may suffer plastic deformation due to the weight of the components. This may render the seals useless or reduce the life of the seals. Therefore, props and cylinders, for example, should only be stored in an upright position. If this is not possible with the components installed, they have to be dismantled.

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.

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

3.4

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.

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

short-term storage

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Storage

Transport Transport Transport crates Several control valve blocks are packed together in transport crates.

They should remain in these crates until they reach their final place of installation in order to protect them from damage.

Ensure that the crates are not damaged during transport. Pay attention in particular that they do not: J fall or J burst open

during transport.

Protect the transport crates from moisture. temperatures below freezing

Before transporting the control valve block at temperatures below freezing, the block must be completely emptied and then filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50).

E

If the control block is subjected to temperatures below -20 °C during transport special measures are required. In this case, please contact the DBT service department prior to the commencement of transport to clarify the requirements.

DBT GmbH, Lünen 2002

Dimensions and weight of the control valve block J depth:

340 mm

J width:

393 mm

J height:

148 mm

J weight:

87.2 kg

Plugs The connections of the individual control blocks are sealed with plastic plugs to protect these from damp, dirt and damage.

NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before installation and connection of the control block.

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DBT - control valve block, 16 functions

4

Installation

Requirements to the face hydraulic system

Installation This chapter contains information on the installation and removal of the control valve block. Please pay particular attention to the warnings and tips.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

Requirements to the face hydraulic system NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals.

The information required for start-up and operation of the electrohydraulic control is given in the manual for the respective control system used.

For all hydraulic components included in the scope of supply of DBT, the hydraulic medium must meet the following requirements:

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– 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

Installation of the control valve block Removal of the control valve block Before starting the installation or replacement of control valve blocks, you must take safety precautions: safety

. Close off your working area to prevent other persons getting there.

. Arrange for the mining work to be stopped in this area. . Inform your colleagues about the type and duration of the repair work and about your exact location.

. Actuate the support lock-out switch . Secure the shield to prevent it from lowering under its own weight; e.g. by placing hardwood wedges between the pairs of lemniscatic links or by supporting the canopy otherwise. shut off hydraulic pressure

. Depressurize the hydraulic system of the shield in question. . Check that the hydraulic lines are really depressurized.

remove control valve block

When everything is OK, you can proceed with the next steps.

. Mark the connecting cables and hydraulic hoses to prevent confusions.

. Pull the connecting cables from the covers of the pilot control valves.

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Installation of the control valve block DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

. Loosen all hydraulic connections on the rear of the control valve block and ensure that the connections are not damaged or soiled.

. Secure the control valve block with hoists and transport belts.

NOTICE! Do not secure the control valve block with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the control valve block and prevent slipping.

. Pull the control valve block out of the mounting.

Installation of the control valve block Fig. 7:

Mounting arrangement, example

b

8

4 (7)

3

10 6

1

a 1 mounting 3 pin 4 stud bolt 6 hex. head bolt M10x25 7 nut, M10

8 locking clip 10 spring clip a control valve block b solenoid driver module

. Place the control valve block into the mounting and tighten the bolts (M10) properly.

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. Loosen the bolts of the control valve block mounting.

Installation of the control valve block 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”.

. Connect the hydraulic hoses, ensuring that the connections are not confused.

Observe the hose connection plan and the markings on the hoses.

DANGER! Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely. safety

. Check the hose connections again. The hose nipples must fit tightly in the sockets and be secured with staples. Make sure to insert both ends of the staples and push them in completely.

Ensure that the connections are leak-tight.

. After connecting the hoses and checking the connections, plug DBT GmbH, Lünen 2002

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the connecting cable of the electrohydraulic control unit into the respective sockets of the pilot valves. Observe the circuit diagram and the markings on the cables.

. Check all the connections once more against the hose connection diagram.

. Test all functions of the shield and remove the securing devices installed at the beginning of the work.

WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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DBT - control valve block, 16 functions

5

Operation

Operation and function of the pilot valves

Operation This chapter contains information on the operation of the control valve block and on its functions. Be sure to also observe the operating manuals for the support and the control unit.

DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the control block if you have the required knowledge.

Operation and function of the pilot valves Control of the shields is particularly dangerous in repair mode, as you then directly control the shield under which you are working. It is therefore extremely important that you know and understand the different functions and sequences of movement of the shield control.

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If you are operating the shield in repair control mode, no one else is allowed to remain in the movement area of the shield.

Operation Two push buttons are provided on the cover of each pilot valve. By pressing a button you directly actuate the respective directional valves.

The function is terminated as soon as you release the button.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

Fig. 8:

Push buttons

Function variable functions

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The function of the individual pilot valves is variable and depends on the external connections. The assignment Function/Push-button is shown on a symbol plate located underneath the pilot valves.

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Filter cartridge Filter cartridge A fine-mesh filter cartridge is provided in the manifold which protects the valves in the pilot control circuit of the control valve block against damage from impurities in the hydraulic medium. The filter cartridge should be exchanged at regular intervals.

NOTICE! The recommended maintenance intervals must be understood as a guideline and must be adapted to the individual operating conditions . Depending on the actual operating conditions the maintenance intervals possibly must be shortened or can be prolonged.

Replace the filter cartridge: J after the 1st week

– when installing a new system and – after extensive repairs on the hydraulic system.

Replacing the filter cartridge Preparation

. Secure the shield mechanically to prevent it from lowering under its own weight WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

. Close the shut-off valve in the pressure feed line P. . Check the system for any residual pressure. This pressure can build up in the hydraulic system as a result of the loads on the props and cylinders.

. Depressurize the system. Make sure to observe the hose connection diagram and hydraulic circuit diagram.

When the hydraulic circuit has been depressurized, you can continue with the next working steps.

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DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

CAUTION! Use filter cartridges only once and do not try to clean them.

Soiling in the hydraulic system is a frequent cause of costly repairs.

Always use only new filter cartridges and seals.

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J every 3 months (guideline)

Filter cartridge Unscrew the filter cartridge

. Remove any dust and dirt from the control valve block.

CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Unscrew the filter cartridge using a screwdriver.

Unscrew the filter cartridge

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Fig. 9:

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

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Filter cartridge Screw in the new filter cartridge

. Screw in the new filter cartridge.

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Fig. 10: Fitting the new filter cartridge

. Tighten the cartridge finger-tight (15 Nm). . Check that the cartridge is fitted leak-tight.

When you have completed the check without finding any faults, the control valve block can be pressurized again. Remove the securing elements only when you are sure that the hydraulic components function properly.

5.6

DBT - control valve block, 16 functions

6

Technical data

Description

Technical data This chapter contains important and useful information on the design and materials used, etc. A list of media approved by DBT (hydraulic fluids and process water) can be found at the end of the chapter.

IMPORTANT! Please use the spare parts catalog supplied when ordering spare parts.

Description Functions The control valve block permits to control 16 independent functions.

The directional valves of the control block are actuated via solenoid-operated pilot valves. Operation of the pilot valves requires an electronic control unit such as for example a shield control unit of type PM4.

Front view of the control valve block

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Fig. 11:

1

2 1 hydraulic ports 2 manifold block

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5 5 pilot control valves

6.3

Description Design The main components of the control valve block are: J manifold block with

– directional valves, – check valve, – filter cartridge – accumulator port and – connecting sockets J channel plate J pilot control valves

Dimensions and weight depth/ width/ height

340 mm / 393 mm / 148 mm

weight

87.5 kg

Pressure 350 bar

DBT GmbH, Lünen 2002

test pressure

320 bar E

permissible working pressure

Fig. 12: Front view of the control valve block

1 7

2 3 5 1 connecting sockets 2 manifold block 3 channel plate 5 pilot control valves

6.4

6 6 push buttons 7 plug contact, electrical connection to the control unit

DBT - control valve block, 16 functions

Description Materials employed The control valve block is made of corrosion-resistant materials such as stainless steel, brass, bronze, etc.

The connection between manifold block and channel plate is sealed with O-rings. The seal materials are designed for operation with HFA hydraulic fluids (oil-in-water emulsions).

Mountings There are 4 threaded bores (M 10) on the top of the control valve block and 2 bores (M 10) on each side.

Fig. 13: Threaded bores

M10

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M10

M10

Valves Directional valves: J 5 x 3/2-way directional control valves (NG 16) J 12 x 3/2-way directional control valves (NG 10)

They are controlled by pilot control valves.

Pilot control valves: J 8 x double 3/2-way directional control valves (NG 0.5)

They are operated by a control unit (e.g. PM4). The pilot valves can also be operated direct in an emergency or for repair purposes. To this end, the valve covers are provided with 2 push buttons each.

Filter The filter cartridge protects the pilot control circuit against impurities. Use only new filter cartridges, never ”cleaned” cartridges.

Only new filter cartridges have the necessary filtration properties (mesh size = 25 mm).

See also chapter Operation, “Replacing filter cartridge”.

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Power supply to the pilot control valves Power supply to the pilot control valves Power is supplied from the single control unit. A four-pin connector is provided on the housing cover of each pilot valve for connection of the required cables.

Connection data double 3/2-way pilot solenoid valve NG 0.5 approval No.

96.D7019x

approval office:

INERIS

rated voltage:

12 V, DC

perm. deviation: -2 V switching current:160 mA current reduction:max. down to 30 mA WARNING! As soon as the current drops to a level below 30 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

Hirschmann

solenoid design: Thomas Magnete, Type: 81-9133-040/002

Hydraulic flow diagram Fig. 14: Control valve block, 16 functions

6.6

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

connectors:

E

protection type: EExib l

Connections Connections The connection ports for the hydraulic lines are located on the rear of the control valve block.

Fig. 15: Rear view of the control valve block

15 13 11 16 14 12

4

9

10 6

1

8

3

5

P

2 T

3

7

SP

Hydraulic connections

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large-volume consumers

medium-volume consumers

low-volume consumers

pressure supply, tank line and accumulator cartridge

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connections:

4 x DN 20 socket, plug-type

marking:

3, 3, 7, 8

flow rate:

max 400 l/min

application:

large-volume consumers

connections:

1 x DN 12 socket, plug-type

marking:

5

flow rate:

max 180 l/min

application:

medium-volume consumers

connections:

12 x DN 10 socket, plug-type

marking:

1, 2, 4, 6, 9, 10, 11, 12, 13, 14, 15, 16

flow rate:

max 80 l/min

application:

low-volume consumers

connections:

2 x DN 25 socket, plug-type 1 x DN 20 socket, plug-type

marking:

P T SP

application:

pressure supply to the system, return line to the tank socket for accumulator cartridge

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- pressure supply, DN 25 - tank line, DN 25 - accumulator cartridge socket, DN20

6.7

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. 1: 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

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

ARAL Lubricants

Fuchs/Century

6.8

Product designation

DBT GmbH, Lünen 2002

Manufacturer

Operating media Tab. 2: 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.

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

Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates.

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.

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6.9

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.

6.10

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

type X test water (NCB 18 to Luxembourg Report)

E

Tab. 3: Chemical composition of the test water samples used

Operating media Recommended 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.

Tab. 4: Lubricating greases for general application 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

DBT GmbH, Lünen 2002

E

Supplier

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. 5: 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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6.11

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. 6: 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

1) If necessary, neighboring cavities must be filled using a lubricating grease according to table 4 above.

2) If necessary, neighboring hollows must be filled using the special lubricant type: Klüber Lubrication Staburags NBU 30

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: Temperature of application:

non-soluble in water -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.

6.12

DBT - control valve block, 16 functions

DBT GmbH, Lünen 2002

E

Supplier

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 Verkauf / Service Industriestraße 1 44534 Lünen GERMANY

DBT GmbH, Lünen 2002

E

Phone: + 49 / 23 06 / 70 9 0 Fax: + 49 / 23 06 / 70 9 421 Internet: http://www.dbt.de E-mail: infodbt@dbt.de

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7.3

Our service Referenced Standards and Guidelines

7.4

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 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 - control valve block, 16 functions

DBT GmbH, Lünen 2002

Designation

E

The following table shows only a selection of the standards and guidelines employed by us during the development and manufacture of the control block.