CAT DBT Shield 1067 2743-2X3739-1750 Operating Manual - PDF DOWNLOAD

Operating manual DBT - Shield 1067/2743-2X3739-1750 Doc. no.: 7420 186 000 BA 00

DBT GmbH Industriestraße 1 Telephone: +49 (0) 23 06 / 709 - 0 E-mail: infodbt@dbt.de D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Internet: www.dbt.de A Bucyrus International, Inc. company

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

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

We reserve the right to introduce modifications as a result of technical developments without previous notice.

DBT GmbH, Lünen 2007 E A Bucyrus International, Inc. company

Contents

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

1.3

Persons for whom the operating manual is intended . . . .

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

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

1.3 1.4 1.4

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

2.3

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

Repair and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

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

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

2.5 2.5

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

2.6

DBT GmbH, Lünen 2007

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

3.3

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

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.5

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

3.6

Shield transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport securing devices . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 3.9

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

4.3

Installation of the support units . . . . . . . . . . . . . . . . . . .

4.3

Pressure equalization of the electronic control system . . .

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

Establish a link between the connections . . . . . . . . . . . . . .

4.5 4.6 4.9

Requirements for the face hydraulic system . . . . . . . 4.10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

How to put the support into operation . . . . . . . . . . . . . . . . .

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4.11 4.12

Contents 5. Operation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.3 5.6

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

5.9

Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.15 Arrangement of hydraulic components on the support . . .

Functions of the HP ball valves . . . . . . . . . . . . . . . . . . . . . .

Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Operation and functions of the electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shield functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.15 5.17 5.18 5.24 5.36 5.37 5.39 5.40 5.42 5.43 5.44 5.45 5.45 5.45

Remedying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 Troubleshooting tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3/2-way or pilot solenoid valve . . . . . . . . . . . . . . . . . . . . . . .

Piloted check valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressure relief valve defective . . . . . . . . . . . . . . . . . . . . . . .

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

5.46 5.46 5.49 5.49 5.50 5.50 5.50

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

6.3

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

Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base frame with lemniscatic links and relay bar assembly Relay bar assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Prop head with pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Technical data, steel structure . . . . . . . . . . . . . . . . . . . . . . .

6.4 6.6 6.7 6.9 6.11 6.13 6.14 6.15

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic prop, two-stage . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 6.22

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

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

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

Carry out every six months . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43

Contents Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Baselift cylinder (lifting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinder . . . . . . . . . . . . . . . . . . . .

6.24 6.25 6.25 6.26 6.26

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28 Shield control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic control unit PM4 . . . . . . . . . . . . . . . . . . . . . . . . . .

6.30 6.31

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.32 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.33 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.33 6.36

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.38

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7. For your information

Doc. no.: 7420 186 000 BA 00

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

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

North America, Canada, South America . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.4

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

7.6

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

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

7.6 7.7

Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.8

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

Referenced European standards and directives . . . . . . . .

7.8 7.8

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Contents

DBT - Shield 1067/2743-2X3739-1750

1

About this manual

Before starting work

About this manual This chapter contains important information to make it easier for you to use this manual. It provides you with 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 applies to the support being used. Compare the data given below with the data given on the type plate of the support. Where to find the type plate on the support is described in chapter 7 of this operating manual.

This operating manual is designed for: DBT shield 1067/2743-2X3739-1750 with the ID number 7420 186 000 00 01 and is only permitted to be used for shields of this type. Only use the operating manual which applies to the respective support. Failure to do so will pose a danger to yourself and others.

DBT GmbH, Lünen 2007

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Tab. 1: Type specification for DBT shield 1067/2743-2X3739-1750 Device number Prop, prop force Year Use of manufacturing 7420 186 000 00 01 2 x 3739 kN availability of operating manual

2007

Face shield

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

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

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

– initiate and/or – supervise the activities listed above.

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

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

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1.3

Before starting work Purpose of this operating manual operating manual

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

Therefore, read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and 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 chapter 2 “Your safety” closely. This chapter contains important information indicating potential hazards.

Observe this information and follow the procedural instructions.

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

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences include light to moderately serious injuries and machine damage.

Notice!

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

Important!

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

1.4

J

Items in lists are marked with bullets.

–

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

.

The hand symbol prompts you to take action.

Several successive paragraphs marked with the hand symbol represent a sequence of actions which must be executed in the order specified.

Follow these instructions step-by-step in order to perform the work safely and efficiently.

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Danger!

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

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Try to memorize the symbols and their meanings.

2

Your safety

Personnel

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

The shield support was manufactured in accordance with the state of the art and generally recognized safety standards and regulations. However, a residual risk still exists which may expose you to hazardous situations when working with or on the shields. 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 mines inspectorate J of the mining supervisory authorities.

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Personnel Persons employed in the operation, repair and overhaul of hydraulic and/or electrohydraulic shield supports must be specially qualified.

In addition to having had training in mining technology, the following minimum requirements must be met.

Operation and maintenance Operation and maintenance of the shield supports may only be performed by trained personnel. qualification

The training must be specific to the type of shield actually being used.

The electrohydraulic and hydraulic control systems may only be operated by personnel who have been adequately trained to operate the present control system.

The content of the operating manual, especially the chapter on safety, must constitute a part of this training.

They must possess and furnish proof of adequate familiarity with the J mechanical system J hydraulics J control systems.

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2.3

Personnel Repair and maintenance In general, repair work may only be performed by persons who have the 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, e.g. pressure relief valves J hydraulic props and cylinders J control units, 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 1067/2743-2X3739-1750

Operating conditions Operating conditions Intended use The shield has been designed and manufactured exclusively for use as a support unit for longwall faces.

Use the shield only as intended.

Intended uses are: J propping the roof against the floor J ensuring an adequate travel way J the following shield operations:

– lowering – pulling up – aligning – setting J the following conveyor operations:

– advancing E

– retracting DBT GmbH, Lünen 2007

J forming an abutment for:

– the conveyor and mining equipment – conveyor steering devices – devices for raising the conveyor – conveyor steering cylinders

Unauthorized use All uses which are not expressly included in the list of “intended uses” are considered to be unauthorized uses and are not permissible with the shield.

Unauthorized use includes: J pushing the shield back into the caving area J raising the conveyor by means of the hydraulic force of the

shield J setting the canopy in roof falls.

Further information about this can be found in the “Operation” section of this chapter and in chapter 5 in the “Operation of the shield” section.

DBT does not accept any liability for damage resulting from any such unauthorized use.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

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 you are performing J the time which you will probably require.

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

lighting system signaling systems and safety equipment

Maintain the lighting systems in working condition.

Maintain the signaling systems and safety equipment in working condition.

support lock-out switch

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

- Only applicable for shields provided with electrohydraulic shield control systems Actuate the support lockout switch (repair switch) before performing: J maintenance work J inspection work J repair work 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 bases and relay bar assemblies J canopies J lemniscatic links J side seals J front cantilevers J hydraulic props and cylinders J steering devices.

automatic mode

2.6

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

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

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

EMERGENCY STOP

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Observe the acoustic and visual start-up warnings. Pay special attention to the start-up warnings for the conveyor and for the mining equipment.

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

Never stand under unsecured or suspended loads.

Observe the specified storage periods and the storage instructions.

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

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. This measure also helps to prevent the inadvertent reinstallation of these components elsewhere.

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

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

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J relay bars (face side and gob side). transporting

Connect the hoisting gear only at the attachment points provided for that purpose. Observe the different load limits of the lifting 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 in special figures which are added in the appendix of the operating manual, if required.

Do not damage the polished surfaces of the cylinders and the props. Damage of this kind necessitates elaborate and expensive repair work.

Only use transport straps for round components, such as cylinders and props, which are not provided with lifting points. 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 involved.

Firmly secure all components which might start moving on their own.

Observe the position of the center of gravity, especially during transport with floor conveying devices. 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 Use appropriate loading equipment for the safe transfer of the transport units.

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

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

The shield can be secured, for instance, by placing hardwood wedges between the pairs of lemniscatic links.

Self-blocking hardwood wedgesbetween the lemniscatic links stabilize the position of the caving shield

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Fig. 1:

transport securing devices

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

When removing the transport securing element of the flipper, ensure that nobody is standing in its swiveling area as the flipper may swing downward.

travel way

Make sure that the minimum dimensions specified for the travel way in the shield are maintained at all times. The minimum dimensions are: J width: 600 mm J height: 400 mm.

Any devices added to the shield later, such as steering devices, may reduce the minimum travel way. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travel way is maintained.

2.8

DBT - Shield 1067/2743-2X3739-1750

Safety instructions Operation shield control unit

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

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

Check to determine whether all safety equipment on the shield is present and functional. See also chapter 6.

You may only operate the shield control system if you have extensive knowledge of the control elements and their functions. It is necessary that you have been trained on the respective control system and know the contents of the respective operating manual for that control system.

You should not be in the same shield as the one you wish to operate. Only operate the shield from a neighboring shield.

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

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During manual operation, the operator must always keep an eye on the movement range of the support unit before and while the support is being moved, and prevent any hazards by acting with caution.

Always set the shield until the full setting pressure has been reached, since good roof support 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 travel way.

Clean the operating controls of the control units regularly. Ensure that the operating symbols are clearly recognizable This measure avoids operating errors and accidents which would result from this.

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

This way you will be able to extend the relay bar assembly without obstacles and advance the conveyor without problems.

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

On an inclined face, the conveyor must be anchored adjacent to the support, if necessary. This way you can prevent the conveyor from shifting to the side relative to the support. And it reduces the risk of the relay bar assembly jamming between the bases.

Hydraulic anchorages must always be charged to the specified working pressure since this is the only way sufficient anchorage between the support 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. Always operate the shield to be advanced from within the neighboring shield above. This reduces your risk of injury by falling rocks and also gives you a better view of the advancing operation.

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2.9

Safety instructions shield alignment

The shields must be aligned at right angles with respect to the conveyor and parallel with respect to each other. Use the aligning devices or the side seals for aligning the shields.

Align the shields as early as possible. Use the aligning devices or the side seals for aligning the shields.

Early alignment prevents: J getting under the canopy of the adjacent shield J canting of the shields J slipping of the shields J delays in supporting 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 so that J the maximum admissible angle of inclination of the canopy is

exceeded J the stabilizing cylinder locks J the canopy will be loaded excessively in the longitudinal direc-

During the temporary support of a roof fall, ensure that the sloping canopy does not get in the way of passing mining equipment. residual stroke

Ensure that sufficient residual stroke is still present in the props as the seam height decreases. This prevents the shields from jamming between the roof and floor.

retracting the conveyor

If possible, retract the conveyor back by operating the respective functions of the electronic shield control unit. If this isn’t possible, do as specified in the respective operating instructions of the mine.

Secure all mining equipment against unauthorized starting.

Isolate your working area so that no unauthorized persons may enter this area.

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

raising the conveyor

Secure your working area against falling rock. 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 to their points of attachment.

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

Check the setting pressure again. Under no circumstances should you disengage the canopy from the roof. It must always be in full contact over the entire length.

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

2.10

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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

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tion

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

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

J lifting gear with adequate load-carrying capacity. attaching loads

Use only permitted attachment points. Reset all shields to which you wish to attach loads. Make sure that the entire length of the canopy always fits closely against the entire length of the roof.

Afterwards, check the setting pressure once again.

Maintenance Make sure that all safety and safety equipment of the support units are complete and functional. If the safety and protective equipment is included in the DBT scope of delivery, refer to chapter 6 for their location.

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

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

DBT GmbH, Lünen 2007

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

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

Immediately replace damaged components affecting safety. Stop and lockout the respective shield immediately if component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible foreman without delay.

Use only spare parts which conform to the specified technical requirements. This is best ensured by using original DBT spare parts.

Please refer to the spare parts catalog for the equipment to find the order numbers for the required spare parts.

Do not make modifications or carry out conversions which might impair the safety of the shield. DBT must be informed 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 invalidate the DBT declaration of conformity and a new conformity test will be required.

During work on the relay bar assembly, isolate the working area for the mining equipment.

You may only carry out work in the mining area if J the roof has been secured against falling rock J the coal face has been secured against collapsing J the mining equipment and conveyor have been shut down and

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

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2.11

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

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

pressure or mechanical stress.

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

The support must be mechanically secured for all work where there is a danger of the support retracting automatically.

On inclined faces secure the components to be replaced against slipping by using chains or lifting gear, for example.

Immediately after completion of work, reinstall any protective plates or similar items which have been removed, and check them for correct function.

Hydraulic system handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

When dismantling protective devices that contain hydraulic components, keep in mind that these components may be pressurized.

You could be severely injured by hydraulic fluid jetting out wildly.

Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

maintenance, repair

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

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace defective caps without delay.

inspection

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: J the hoses are not pinched or trapped J the hoses have no bubbles or blisters J the hoses or the outer sheaths of the hoses are not abnormally-

rigid or hard J the outer sheath of the hose is not damaged J the connectors are securely inserted into the sockets J the connections are leak-tight.

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

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

Before removing coupling clips to disconnect hydraulic hose lines, turn the hose at the coupling clip to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the line.

Only secure the staple locks of the hydraulic elements with the proper coupling clips. Always fasten the clips completely with both sides.

Never use nails, wire or similar materials to secure the connectors.

2.12

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protective devices - hydraulic system

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 2:

Example: 4SP hydraulic hose, identification 3 2 1

6

DBT GmbH, Lünen 2007

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

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a hydraulic hose that is thrashing about Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged. laying hydraulic hoses

Lay the hydraulic hoses correctly behind the brackets and clips provided for them.

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

Laying hydraulic hose lines, slack RIGHT

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WRONG

2.13

Safety instructions J are not twisted Fig. 4:

Laying hydraulic hoses, twisting RIGHT

WRONG

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter) Fig. 5:

Laying hydraulic hoses, bending WRONG

DBT GmbH, Lünen 2007

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RIGHT

J cannot chafe Fig. 6:

Laying hydraulic hoses, crossing RIGHT

WRONG

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

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

2.14

DBT - Shield 1067/2743-2X3739-1750

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

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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2.15

DBT GmbH, Lünen 2007

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Safety instructions

2.16

DBT - Shield 1067/2743-2X3739-1750

3

Storage and transport

Storage

Storage and transport This chapter contains important information concerning the proper storage and transport of the shields.

Observance of the instructions and tips will increase the service life of the shields. In addition, you will be instructed how to perform the tasks involved with transport safely and efficiently.

Reading this chapter carefully will help you to simplify your day-today work.

Storage Storage of new equipment corrosion protection

The surfaces of the equipment are coated with temporary corrosion protection. If stored properly, the equipment parts will be protected for a period of six months, starting from the date of delivery.

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Prior to delivery, hydraulically operated equipment is filled with the anticorrosion and antifreeze fluid HYDROCOR® CV50* and tested.

The fluid remains in the hydraulics system for the purpose of transport and (if required) subsequent storage.

HYDROCOR® CV50 is frost-free down to -40 °C and protects the used metallic materials from corrosion. It contains a color indicator which reacts when the pH value drops. The color of the medium changes from “red” to “yellow” here. The yellow coloration indicates that the anticorrosion protection is no longer adequate.

Additional information concerning the characteristics of the HYDROCOR® CV50 can be obtained as needed from the respective manufacturer’s data sheet.

Water-bearing parts, such as the parts for the water spraying system of a shield, must be completely emptied or might have to be filled with an antifreeze medium. short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components don’t have to be removed. They do however still need to be specially protected against environmental influences, and also against high temperatures, e.g. by suitable protective plates and/or sheathings for the control systems and by supplementary covering of the equipment. If the storage period exceeds four weeks, additional special precautions must be taken, depending on the ambient conditions. For example, it may be necessary to remove the electronic control unit for the purpose of proper storage.

long-term storage

If storage is expected to last longer than six months, then all of the cavities in the hydraulic components must be filled completely with a corrosion inhibitor, such as HYDROCOR® CV 50. The fluid must possess corrosion protection properties and be frost-proof within the temperature range intended for the application. All connections must be sealed with durable and suitable plugs.

It is highly recommended that the equipment not be stored outdoors. It should be stored in a dry, well-ventilated room. If this is not possible for the entire support unit, for example, then the hydraulic and electronic components might have to be dismantled and stored separately. *

Doc. no.: 7420 186 000 BA 00

HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

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3.3

Equipment which is stored outdoors must be protected against direct sunlight, precipitation and contamination, for example by using tarpaulins. It must also be stored in such a way that liquids will not be able to accumulate in hollow spaces. Liquids which get into hollow spaces during transport or handling must be able to drain freely.

electrical equipment, rubber and plastic parts

Electrical equipment, electronic components, replacement parts made of rubber or plastic - such as seals and hoses - and pressure fluids must be generally stored in closed spaces at 15 °C to 25 °C, and protected against direct sunlight. Exceptions: see “short-term storage”

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. A storage period of approximately two years is therefore specified for these parts as a guide value.

moisture and dirt

All hydraulic elements must be appropriately protected against the penetration of dirt and moisture during storage. The connection surfaces of the hydraulics components that remain in the device must be protected against corrosion and sealed with blind plates. Hydraulic plug connections and electrical cables must be sealed with suitable caps or plugs.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be carried out. This will make it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

This can be checked by DBT upon the request of the mine. The mining company will bear the cost for this.

HFA fluids

The regulations stipulated by the manufacturer or of the supplier take precedence in every instance involving the storage of HFA fluids and/or concentrates for the production of HFA fluids. Supplementary information can also be found in the section “Permissible media” in this manual.

When removing stock from storage or when placing it there, take care to ensure that any new supplies are stored separately from existing stock in such a way that old stock is always taken first when supplies are required for use. Label the containers accordingly.

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storage outdoors

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Storage

Storage Storing used equipment The points listed above, with the exception of the one concerning anticorrosion protection, can be applied analogously for the storage of hydraulic components that have already been in use.

If the hydraulics system is to be temporarily put out of operation, then the entire hydraulics system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor (e.g.

HYDROCOR® CV 50). If this is not done, the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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corrosion protection

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3.5

Transport Transport Warning!

Use only load handling devices which comply with the technical and legal regulations for transporting loads.

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

Use only suitable load handling devices.

points of attachment

Where technically possible, the load units have suitable, fixed lifting points for transport and installation. Otherwise, corresponding thread bores or other fastening options are to be provided for temporarily fixing the points of attachment.

More detailed information about the arrangement and capacity of the points of attachment can be found in the figures of the replacement part catalog or the special figures for transport subassemblies which, if applicable, can be found in the appendix of this manual.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic parts which were previously operated with a frost-sensitive medium, such as an oil-in-water emulsion (HFAE), must be completely emptied and then filled with a frost-proof corrosion inhibitor, for example HYDROCOR® CV 50. If the fluids could not be completely exchanged due to technical reasons, a corrosion inhibitor is to be selected which can be mixed with the medium originally used and it is to be made sure that the media are sufficiently mixed.

Transport of equipment at temperatures in the range of -21 °C to -40 °C is only permissible when certain measures have been 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 may only be loaded statically or quasi-statically. Here, external forces are only to be applied to the lifting points and mounting device surfaces as specified in special figures, if available.

The equipment may not be transported at temperatures below -40 °C. During transport of this equipment with floor conveying devices 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 maximum 25 km/h for truck transport.

electrical and electronic components

3.6

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors or outdoor storage of the equipment during winter.

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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In agreement with the customer, the transport units were defined taking the special local conditions into account as follows: - The support units are transported as a complete unit.

DBT GmbH, Lünen 2007

transport units

Transport transport units

A support unit can be transported as a completely assembled unit or divided into subassemblies. If it is necessary to disassemble it into transport units, this is planned and agreed upon in close cooperation with the customer.

Tab. 2: Transport units

transport securing devices

Designation

Transport position

Complete support unit

General purpose

Remarks

For the purpose of safe transport, the movable parts of every transport unit are to be fastened in addition to the standard available transport securing devices, e.g. on side seals and flipper, so that their positions cannot shift inadvertently. Specifically, the following listed transport securing devices are provided on the transport units.

Tab. 3: Transport securing devices Part

Transport securing device

Quantity

Relay bar Face side

Transport rod

1

Gob side

Chain

1

Unused hydraulic connections are protected by protective caps or plugs

-

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Hydraulic system

DBT GmbH, Lünen 2007

Caution!

Transport securing devices may get damaged during transport to the mine, for example when loading and unloading the transport units. Therefore, check all transport securing devices for damage and replace damaged ones before allowing the units to be transported into the mine shaft. Damaged transport securing 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 securing devices.

Caution!

If the attachment points on the caving shield are to be used to transport the assembled head drive, the canopy and base must first be mechanically connected to each other using an additional transport securing device so that they cannot move apart.

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3.7

Transport Shield transport Fig. 8:

Transporting the face shield as a complete unit

Sy

1067

SO

Sx X1

X2

6700

1700

S3 S1

890

1200

S2

4585 S2

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S1

S1 Slot, 2x face side on the canopy, load capacity: 15000 kg S2 Transport ring, 2x on the caving shield, load capacity 8000 kg S3 Transport ring, 2x on the base, load capacity 15000 kg X1, X2 Transport securing device for relay bar, face side and gob side So Center of gravity

Caution!

For transporting, use the four lifting points S2 and S3.

Tab. 4: Shield transport 7420 186 000 00 01, dimensions and weight

3.8

Device number

L Length in mm

W Width in mm

H Height in mm

So Sx/Sy in mm

Weight in kg

7420 186 000 00 01

6700

1700

1067

1 691 / 585

20 500

DBT - Shield 1067/2743-2X3739-1750

Transport Transport securing devices Relay bar assembly Fig. 9:

Relay bar assembly, gob side

132

134

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133

132 chain 6x42 133 hex. head screw M 12x45-8.8 134 hex. nut VM 12-8

Fig. 10: Relay bar assembly, face side

131

131

130

132 130 transport rod

131 spring clip 6

When the support unit is delivered, the connections for the supply lines are bypassed using the hose lines. These are then later used for connecting to the neighboring shield.

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3.9

Transport Transport safety device, lifting cylinder Caution!

In the transport position (shield completely retracted), the supply block can collide with the cylinder bracket. For this reason, during transport, the cylinder bracket of the lifting cylinder must be folded in.

In order to be able to fold in the cylinder bracket of the lifting cylinder:

. Remove the securing device pin (b) and the coupling clip (c). . Fold the cylinder bracket (a) toward the coal face side. . Re-insert the securing device into the journal bearing to prevent its loss.

Lifting cylinder with folded in cylinder bracket for transport

a

b, c

a cylinder bracket b pin 16x117

c coupling clip

Shield transport Fig. 12: Shield in transport position

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Fig. 11:

4

Installation

Pre-assembly of the support units

Installation In this chapter, you will be given information about installing the support units. Please pay special attention to the warnings and tips.

Warning!

In addition to the safety instructions given in this manual, also make sure you observe the special safety instructions and operation instructions which apply to the operation of the mine.

Failure to do so can lead to extremely serious accidents which may be fatal.

Caution!

Before the hydraulic lines are connected with one another, the sockets and nipples of the plug-O connections must be treated with the molybdenum disulphide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, Section “Lubricating greases and pastes”.

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Caution!

Before putting the transport units of the steel structure together, all slide surfaces must be treated with the molybdenum disulphide-free B6 lubricating paste in accordance with EWN 7068. See chapter 6, Section “Lubricating greases and pastes”.

Pre-assembly of the support units The support units are delivered completely pre-assembled. Accordingly, no further pre-assembly is required on the mechanics and hydraulics of the support units.

Installation of the support units Caution!

For transport underground, only the lifting points described in greater detail in chapter 3 “Transport” may be used. Further information about this can be found in chapter 3 “Transport”.

Failure to comply can lead to personal injury and property damage. installation plan

The support units are installed in the face according to the installation plan of the mine.

Important!

When installing the shields in the face, be sure to pay attention to the shield numbers. Since some support units may be equipped with different functions, their arrangement on the face is not arbitrary!

identification for installation in the face

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In order to identify the support units or their transport units more easily for the purpose of assembling and installing in the face, they should be labelled with a sequential number. They should correspond to the order in which the support units are to be arranged in the face, for example. The numbers should be written in color so that they are clearly visible on the surface of the parts.

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4.3

Installation of the support units shield number

The shield number serves as an identification feature. All shields are numbered sequentially. Permanently attached tags with the respective shield number are located underneath the canopy above the PM4.

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Fig. 13: Shield number under the canopy

Tab. 5: Allocation of the shield numbers

4.4

Shield number

Device number

168 to 210

7420 186 000 00 01 Face shield

Use

DBT - Shield 1067/2743-2X3739-1750

Installation of the support units Pressure equalization of the electronic control system The support units can be utilized in a number of different height positions at various prevailing air pressure levels.

These are equipped with a vented cap screw in order to enable pressure equalization between the internal and external pressure of the electronic control system housing.

. Release the pressure relief screw (hex socket 4 mm key width) on the control system by several rotations.

Pressure equalization is signaled by an audible hissing.

Caution!

Make sure that the vented cap screw for pressure equalization on the control system is released. The foil displays may become damaged if no pressure equalization is established.

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Fig. 14: Example of a vented cap screw on an electronic control system

a

b

a vented cap screw

b electronic control system

. Afterwards, rotate the pressure relief screw until it is once again hand-tight.

Caution!

Take care to ensure that the vented cap screw is made handtight again after pressure equalization at the control system.

If this is not done, then dirt and moisture could penetrate the control unit and firedamp protection is no longer ensured.

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4.5

Installation of the support units Supply connections During installation, pressure can be applied to the individual shield using the so-called auxiliary supply and operated.

The shield has an auxiliary supply on the left side under the canopy.

The auxiliary supply must be connected to connections a and b (Fig.16).

Fig. 15: View of the supply block and auxiliary connection, left

19

a

X

11

30

P

10 W

R

29

3 accumulator cartridge 10 HP ball valve DN 25, in the pressure supply line to the shield 11 HP ball valve DN 12, for auxiliary supply 19 supply block 29 HP ball valve DN 10, in the spray line

4.6

30 HP ball valve DN 20, in the water circuit 30 plug DN 10 with pressure relief a PM4 control unit X auxiliary supply P pressure line, DN 40SS R return line, DN 50 W water line, DN 50

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3

Installation of the support units Fig. 16: View of the auxiliary supply, left, connected (left) or with plug (right) b

c

a

a

b

b a

22

11 4

11

c

11 HP ball valve DN 12, for auxiliary supply a pressure line auxiliary supply

b return line auxiliary supply c plug for auxiliary supply

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Notice!

The auxiliary supplies a and b must be sealed with plugs c during normal operation.

Fig. 17: Plug on the supply block a

13

23

19

30

W

R

7 P 7 water filter DN 20 13 PRV, 80 bar 19 supply block 23 plug DN 10 30 HP ball valve DN 20, blue, for water circuit

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P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a vented cap screw

4.7

Installation of the support units For operating the shield with the help of the auxiliary supply, the shield functions must be activated via an additional external PM4 control unit. This is connected to the internal PM4 control unit via a corresponding cable (see separate operating manual for the PM4 control unit).

For utilization of the auxiliary supply, the connections P, R and W (see Fig. 15) on the supply block must with blocked with the hoses that will later be responsible for the connection with the neighboring shield (this corresponds as a rule to the status at the time of delivery). Should the blocking of the supply hoses not be possible in this way, then the connections must be sealed with corresponding plugs.

To connect the shields with one another, proceed as follows:

. Close the HP ball valve, item 11, as well as HP ball valve, item 10 (see Fig. 15).

. Remove the plugs c from connections a and b (see Fig. 16) of the auxiliary supply.

. Connect the auxiliary supply to the pressure and return line of the pump.

Make sure that the HP ball valves, item 9 (see chapter 5, page 5.33 Fig. 46 and 47), are also open on the prop control valves.

The shield is now movable via the external control units.

. Move the shield to the desired position.

In order to relieve the pressure hose,

. short-circuit the HP ball valve, item 11, and activate the function “Advance conveyor” briefly until the pressure hose is relieved (support is not yet connected to the conveyor).

Warning!

Pressure may build up in the return line due to incorrect operation. This must be relieved via the pressure release valve (Fig. 17, item 23) by screwing in the pressure relief screw.

After relieving the pressure, this screw must be screwed all the way out again.

Make sure that all hose lines are depressurized before you release the connection lines on the distribution block!

. Relieve the connections of the auxiliary supply. . Disconnect the connection lines of the auxiliary supply and seal the connections with the plugs.

. Release the three connection lines P, R and W on the distributor block and connect them to the neighboring shield.

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. Then open the HP ball valve, item 11, again.

Installation of the support units Establish a link between the connections The hydraulic connections to the support units are designed as plug-type connections in accordance with DIN 20043.

The supply block for supplying the shield hydraulics is located in the middle under the canopy between the two props. The connection to the supply block of the neighboring support is made using three hose lines: one pressure line (DN 40SS), one return line (DN 50) and one water line (DN 50), see Figure 15, and chapter 5, Fig.33, and the hydraulic circuit diagrams in chapter 6 of this manual.

electrical shield control system

The support units are equipped with a type PM4 electronic control device. The control unit and the electrohydraulic control unit are connected via a solenoid driver module. The connection cables required for this are included in the delivery of the PM4 control system.

For more details on how to connect the control device, please refer to the separate operating manual for the PM4 control system. An overview of the design of the control system is also given in chapter 6 of this operating manual in the Section “Shield control”.

additional equipment

The shield units are designed to accommodate the installation of additional equipment which is not included in the DBT scope of delivery. For example:

E

hydraulic system

DBT GmbH, Lünen 2007

J lighting system J two-way intercom system.

The information required for the installation of additional equipment can be found in the corresponding operating manual of the respective manufacturer.

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4.9

Requirements for the face hydraulic system Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulics components included in the DBT scope of delivery: Pressure fluid according to list of approved products. See section “Operating media” in chapter 6 of the operating manual.

Contamination Class 18/14 pursuant to ISO 4406.

permissible pressure

Nominal pressure

320 bar

Admissible tolerance ¦ 10% of nominal pressure

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Caution!

If there is a pressure drop, dangerous situations may arise, leading to accidents involving damage to property and/or injuries to personnel.

Make sure that the system pressure can never fall below 180 bar anywhere in the face hydraulics.

E

If the face hydraulics are designed such that they are unstable or too weak, there could be a temporary pressure drop during operation.

In the event that the pressure falls to 180 bar or less, there is a risk of malfunctions occurring in the electrohydraulic control system.

Valve functions might not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Commissioning Commissioning Warning!

The first start-up and test run may only be carried out by a well-trained and experienced crew which is familiar with the special conditions in underground mining, especially with the safety requirements. The crew must also be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

Notice!

Make sure that all transport securing devices required for transport have been removed.

See chapter 3, Section “Transport”.

To be observed prior to start-up Start-up may only be carried out by trained and qualified personnel.

If the support is being used for the first time, it is absolutely imperative that the start-up be carried out under the direction of the DBT installation service.

Please observe the following items: J Mechanics: DBT GmbH, Lünen 2007

E

. Make sure that all transport securing devices have been removed.

. Check all mechanical connections on the support units. . Check the plugs of the relay bar assembly.

When the relay bar assembly is designed with a plug-in crawl pan, it must be made sure that it is plugged in correctly. Under no circumstances may the crawl pan be plugged in for normal operation in the “lowering position” 1) J Hydraulic system:

. Check the entire hydraulic system for leaks. Seal any leaky connections immediately.

. Especially check whether hinges and hoses can be damaged due to movements of the support.

Danger!

Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others could be seriously injured or even killed!

Make sure that hydraulic hoses can’t be damaged by movements of the support.

Lay the hydraulic hoses correctly behind the brackets provided for them.

1) maximum possible plugging.

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4.11

Commissioning . Check the hydraulic supply pressure. . Check the load-carrying function of the prop. The current pressure under the piston of a prop can be queried on the PM4 control device. Here, you can query the pressure for a neighboring support or the support in which you are currently located. The pressure gauge on the prop control valve of the prop indicates the pressure directly.

. check all operation elements to make sure they are working properly. Test whether the function is correctly executed when the corresponding operating element is activated.

J Signaling and lighting systems, information plates

Important!

For further information, please see the corresponding separate operating manual of the respective manufacturer.

. Check all signaling systems. . Make sure that the face lighting is sufficient.

J EMERGENCY STOP systems.

. Check that all EMERGENCY STOP systems function properly.

J Mining and conveying

. Before start-up, check all functions of the face system. . Test to make sure the entire face system (mining equipment, conveying system, supports) is working together perfectly.

Warning!

Bent support canopies may not project into the mining area.

How to put the support into operation Move the support units to their original positions, i.e.: J Shields and conveyors are aligned in a straight line.

J The shields are aligned at right angles to the conveyor.

J The shield canopies are aligned parallel to the floor.

Check the support for any installation errors or other sources of error:

. Check all line connections established during the installation of the shields, especially all supply lines of the shield hydraulics for completeness and correctness.

4.12

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

sufficient signage. It is imperative that you observe the regulations of the responsible mines inspectorate.

E

. Check whether the face area, especially the travel way, has

Commissioning Warning!

Shut-off valves may not be installed into the return lines for the shield hydraulics, as otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in persons being seriously injured or even killed.

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

. Check all functions of the shield control unit.

Do not allow the support to be operated until all defects have been eliminated and the support has been found to be in perfect working order.

Corrosion protection of hydraulic components The DBT hydraulic components are checked before delivery with an anticorrosion medium.

DBT GmbH, Lünen 2007

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When these components are put into operation, no special measures have to be taken with regard to corrosion protection since the testing and anticorrosion medium used is completely compatible with the approved operation fluids of the group HFA. See section “Permissible media” in chapter 6 of this operating manual.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

4.13

DBT GmbH, Lünen 2007

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Commissioning

4.14

DBT - Shield 1067/2743-2X3739-1750

5

Operation

Requirements

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

Danger!

You are only allowed to operate the shield control system if you have extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control system and have consolidated your knowledge during a corresponding training session on the object. Should this not be the case, you are not allowed to operate the control system. Inform your superior immediately and request the required training.

DBT GmbH, Lünen 2007

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Warning!

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

The regulations concerning the safe operation of your mine must be strictly followed. Apply the following instructions in addition to and in accordance with the individual safety regulations of the mine.

Requirements Operating conditions face crew

The face crew must be informed about possible hazards. 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 the case of accumulations of debris.

face equipment

The face must be sufficiently illuminated.

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

The face conveyor must be equipped with a start-up warning system and a shutdown and lockout device.

conveyor overload

Large layers of coal and rock cannot be broken up unless the face conveyor and the mining equipment are at a standstill. They must be broken up to such an extent that the free passage of crude ore under the shield canopies is ensured. Compressed-air picks have to be kept on hand for this purpose.

In the event that this breaking up cannot be accomplished to the extent required, then the layers of coal and rock may not be transported until it is has been ensured that nobody will endangered as a result. Any work on the face must be stopped until the transport of the rock and coal layers has been completed.

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5.3

Requirements travel way

The minimum required dimensions for the travel way must be maintained at all times.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travel way: 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 travel way must be removed immediately. This applies particularly for low seam heights.

If variable-length crawl pans are used, care has to be taken that a safe travel way of adequate width is maintained.

roof support work

Roof support work must be carried out so that the filling section of the face conveyor remains unobstructed. This means that the canopies of the support units must be set against the roof immediately after the support unit has been lowered and advanced.

work in the mining area

Work in the mining area may not be carried out unless the mining equipment and the face conveyor have first been locked-out and secured to prevent restarting. Work in the mining area may only be carried out from a safe position.

The conveyor and the space above the conveyor may only be entered if the roof has been secured against falling rock.

With greater thicknesses, the coal face must also be protected against the coal collapsing in these places. On faces equipped with shield supports, 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 support unit advancing.

If support units are not equipped with flippers, some other kind of protection must be applied for sufficient shielding of the mining area from the rest of the face. e.g. extra-high spill plates, wire mesh, nets 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 falling rock and coal layers.

In faces at inclined angles, additional barricades, such as air cushions, must be set up above the work area in the conveyor to protect against subsequently falling material. The design and amount of required safety equipment depends on the local conditions.

5.4

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

If the area behind the front props is to be used as a travel way, e.g. in cases of thick seams, in the presence of steeply inclined faces or if the shield support can be advanced up to the conveyor, then travel way must be marked at the ends of a longwall by a sign.

E

If the height of the travel way is restricted by the use of additional equipment, e.g. for conveyor steering devices, care has to be taken that a safe travel way of adequate height is maintained.

Requirements repair work

Before you start work on the hydraulic system, you must always first make sure that the respective section of the system has been depressurized. Also, take appropriate measures to prevent the pressure from being reactivated by unauthorized personnel.

If the support units are to be detached from the conveyor, mining must either be completely stopped or it must be otherwise ensured that mining can be continued only outside of the safety zone required for safely carrying out repair work.

Parts which are under mechanical or hydraulic tension must be relieved before they can be released or dismantled. The tension can be relieved, for example, by aligning, lifting or lowering.

If in exceptional cases, the tension cannot be relieved completely, it must be reduced as far as possible and the respective part must be secured by suitable means, such as chains or locking elements, so that the tension can be safely absorbed as it is released. All work in this area may only be carried out from a safe position.

Safety equipment increases security and may only be removed if it is required for carrying out work. The safety equipment should be reinstalled immediately following completion of the work.

The water spraying system serves to actively counteract dust. Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily depending on the operating state of the system, for example when pushing the shield and when the mining equipment passes the support. The water spraying valves are controlled by the program of the electronic shield control or directly by means of the hydraulic shield control system.

conveyor steering device

On an inclined face, the conveyor must be anchored adjacent to the support, if necessary. This way you can prevent the conveyor from shifting to the side with respect to the support. This allows you to reduce the risk that the relay bar assembly will get stuck in the base frame.

DBT GmbH, Lünen 2007

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water spraying system

The intended working pressure must always be applied to the hydraulic conveyor steering device. This is the only way to guarantee that there will be sufficient bracing between the support and conveyor.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering device can become damaged and unfit for use.

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5.5

Requirements Safety requirements automatic mode

Exercise special care and caution when traveling a face working in automatic mode. Make sure you observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be aware that the shield which you are in is controlled by the automatic system. For this reason, make sure you observe the acoustic and visual warnings from the control unit of the currently controlled shield.

Press the “support lockout” switch if you have to be in the shield for a longer period of time.

operating the support unit

The support unit must always be operated from a safe position and from a neighboring support unit.

Never stand in a support unit which hasn’t been set.

Never allow body parts to get between the canopy and the roof, bases and the floor, the base and relay bar assembly or between the side seals of neighboring support units.

You may not lower or advance a support unit if there are persons in the vicinity of the support unit or in the support unit.

You may not lower or advance a support unit manually if the mining equipment is directly in front of or in the range of action of the support.

Advancing should be started in the lower section and move upwards in faces with an inclined angle. The neighboring control offers the operator in the above-lying support unit protection and allows the support unit being pulled up to be monitored.

The prop of the support units must always be set until the set pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for support units with special functions, such as abutments for conveyor steering device.

The supports must be advanced as soon as possible to prevent the potential danger of roof falls.

5.6

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

No one may be in a support unit while it is being advanced.

E

During manual operation, the operator must always keep an eye on the movement range of the support unit before and while the support is being moved, and prevent any hazards by acting with caution.

Requirements Fig. 18: W r o n g , support advanced too late

DBT GmbH, Lünen 2007

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Fig. 19: R i g h t , support advanced in time

When taking down a step in the roof, a shield canopy which is angled downwards must not get in the way of mining equipment passing by.

Before a support unit can be pulled up, the flipper must be completely folded in. Under no circumstances may the support be advanced against the coal face with the flipper extended. Failure to observe this can lead to serious damage, especially to the flipper cylinders and the flipper suspension.

When advancing the support, make sure that the shield canopy doesn’t get under the side seal of a neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged. control system, hydraulics

Do not operate the shield control system incorrectly.

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

Hoses must remain free to move. They may not be squeezed or overstretched. Make sure the hose lines are bundled properly.

Damaged hydraulic hoses and hose connections must be replaced immediately. This work may only be carried out by skilled personnel.

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5.7

Requirements The shield canopy and caving shield must be mechanically secured against falling when hose lines between piloted check valves and props or other hydraulic cylinders lying in the flow of force, such as stabilizing cylinders or adjusting cylinders are to be replaced. Analogously, this also applies for work on the hinges of the support unit.

Shut-off valves may not be installed in the return lines.

To make sure the return lines can’t be closed, safety valves must be installed in the return line (see hydraulic layout, if prepared by DBT). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line. The valves should be set to 25 bar and to spray in the atmosphere. damage, spare parts

Special incidents, especially any found deficiencies and damage, must be reported immediately.

DBT GmbH, Lünen 2007

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Machines and hydraulic parts may only be replaced with original parts.

5.8

DBT - Shield 1067/2743-2X3739-1750

Operation of the shield Operation of the shield Well-trained operating personnel, knowledge and compliance with the safety regulations, as well as the operating instructions listed below largely prevent dangerous situations from arising, and are good preconditions for the fail-safe interaction of the support and mining within the longwall system.

If the support is equipped with an electrohydraulic control unit, it is imperative that the operator be familiar with the separate operating manual for this control system.

The support units must always be set until the setting pressure has been reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for support units with special functions, such as abutments for anchoring devices.

In general, the supports should be advanced to support the exposed roof surface as quickly as possible.

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

DBT GmbH, Lünen 2007

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shield canopy position

The support units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible.

Within the framework of the maximum inclination and swivel angles specified on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

Caution!

Never exceed the permissible angle of inclination of the canopy.

Exceeding the permissible angle of inclination of the canopy specified in chapter 6 of the section “Technical data” can lead to the support becoming damaged. This especially applies for stabilizing cylinders, their mounting elements and fulcrum points on the shield canopy and caving shield.

Fig. 20: Shield support in normal position

α=0 M

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

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5.9

Operation of the shield Caution!

Never extend or retract the stabilizing cylinders of the shield completely.

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm.

The same applies to the adjusting cylinder of the front cantilever.

This is the only way that any potential, suddenly occurring load surges can be “cushioned” by the hydraulic safeguard of the stabilizing cylinders.

If there isn’t sufficient residual stroke available, this could result in serious damage to the support under unfavorable conditions - high force and unfavorable lever ratio.

Fig. 21: Shield support with extremely inclined shield canopy

α1

s1

s

2

α

2

M

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

Caution!

Ensure that the stabilizing cylinder has sufficient residual stroke when there is a tendency toward roof falls and/or an extremely soft floor.

This is especially true if the shield control system is equipped with an automatic positive setting function. Then there is a danger that under unfavorable conditions, for example, a soft floor and possibly an additional tendency toward roof falls, that the automatic positive setting function leads to the stabilizing cylinders not having enough residual stroke or even becoming “locked”. For this reason, move the support in such or similar cases without automatic positive set.

5.10

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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M

Operation of the shield Caution!

Keep the canopy from being excessively inclined by filling out the roof falls, for example, or by underpinning smaller roof falls with a horizontally positioned shield.

At this point, we again explicitly emphasize that any damage caused by not complying with these instructions is not covered by the warranty.

Caution!

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield), which is specified in chapter 6, section “Technical data” of this manual, is exceeded, this could lead to damage to props, hydraulic props and their fastening elements, as well as to the part hinges.

Since angle changes in the ends of the shield canopies or base ends involve major height changes, 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 roof falls.

DBT GmbH, Lünen 2007

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Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in roof falls (see Fig. 22), when the stabilizing cylinder is completely extended. There must always be enough residual stroke available so that dynamic loads from the roof can be absorbed by the hydraulically secured stabilizing cylinder.

Fig. 22: W r o n g, do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended.

WRONG

Roof falls can be overcome by filling them (see Fig. 23) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

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5.11

Operation of the shield Fig. 23: R i g h t, fill out roof falls

RIGHT

When underpinning a step in the roof, ensure that a shield canopy angled downward doesn’t get in the way of the mining equipment passing by.

The retracted height of the support units must be suitable for the lowest seam height.

The support must be operated so that there is always sufficient residual stroke remaining for lowering the support unit. Otherwise, the support unit can get stuck between the roof and floor and be seriously damaged by suddenly occurring load surges, caused by a rock burst, for example. Load surges cannot be hydraulically cushioned if there is not sufficient hydraulic fluid under the piston of the prop or if this is already in the lower end position.

The minimum residual stroke required for lowering the support unit can be maintained by: J keeping the face opening sufficiently large with the aid of the

mining equipment J avoiding the accumulation of debris and fine coal on the floor J preventing accumulation build-up on the shield canopies.

Before advancing a support unit, the floor should be free of rough debris so that the entire forward movement can be done without obstacles and the following return operation isn’t hindered for the conveyor. Also, aligning operations can be carried out more easily.

If the seam height increases considerably and the hydraulic stroke is not sufficient, the props must be extended in time or replaced by props with greater stroke. Here, only approved parts can be used.

When the props are extended or shortened, the shield canopy must be securely supported. Before a prop can be lowered for the purpose of dismantling, it must be secured against tipping over.

5.12

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

support range of adjustment/ changing face thickness

E

Accumulation on the shield canopy can be avoided by grinding while advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy.

Operation of the shield operating in inclines

Especially when operating in inclines, the support units must be prevented from slipping and jamming by correcting their alignment in time by using side seals and aligning devices. This prevents a shield canopy from underpinning its neighboring unit, often causing considerable damage.

Since in inclined works, support unit advancing usually begins in the lower lying part of the face, it is important that the face end shields are well-aligned. Usually hydraulic end supports and aligning devices are used on the shield canopies and the base frame or between the base frame and shield canopies.

Automatic controls can be used for the side seals which prevent a lowered support unit from tipping over during the exchanging operation. Other aligning operations which might be necessary are only possible using manual control, however.

The side seal of the caving shield may only be used for aligning with respect to the neighboring shield when this has been aligned to the same extent.

DBT GmbH, Lünen 2007

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On an inclined face, the conveyor must be anchored with respect to the support. This way, you can prevent the conveyor from shifting to the side with respect to the support. And this way you lessen the danger of jamming the relay bar assembly in the base frame, which would hinder the shield advancing.

When advancing the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering device can become damaged and unfit for use. Further information can be found in chapter 6, section “Accessories”, or in the operating manual for the conveyor steering device, if necessary. unfavorable mine floor conditions

In the case of unfavorable floor conditions, the base frame of the support unit can sink into the floor. Then the base frame must be lifted when the shield is pulled up so that the system follows the course of the seam and doesn’t sink into the floor.

For support units which are equipped with a special hydraulic lifting device, it is lifted out by actuating a valve, or automatically during advancing.

For support units without a lifting device, the procedure is different, depending on the model: J Individual bases on two-prop shields can usually be lifted hy-

draulically by actively lowering a prop.

J Support units with an undivided base frame must be lifted and

supported using standard mining methods.

Important!

Familiarity with the circuit diagram and skilled personnel are required for both procedures. Make sure that you observe the safety regulations under all circumstances.

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5.13

Work safety Work safety For the purpose of safe operation, the supports are equipped with a neighboring control. This means that the support functions are operated using the control unit on the right or left neighboring support or with the automatic sequential phase control.

Warning!

Never be on a support which is currently being moved. Circumstances which are not always apparent may lead to unexpected movements in the support units. This could result in serious injury or even death.

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

Caution!

Take care not to damage the pilot valve buttons. Sticking buttons might lead to malfunctions and cause an accident.

Observe the following safety regulations:

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: J Malfunction of the electronic control system J External obstructions:

– Shield is wedged in between the neighboring shields.

– Tip of the canopy is stuck in the roof.

– Floor step or debris is blocking the base.

2. If the automatic function of the electronic control system is not working properly, the support can be manually controlled using the individual control of the control unit of a neighboring shield. See the separate operating manual for the electronic control system.

3. If the cause is an external obstruction, try to get the shield free by manually moving the neighboring shields.

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DBT GmbH, Lünen 2007

If groups of shields are automatically advanced, no one may be in the area between the operator and the moved shield.

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Make sure that your body is completely under a set shield. Keep away from shields which are in the process of being moved or which are to be moved soon.

Operation of the shield hydraulics Operation of the shield hydraulics Warning!

During normal operation, the support may only be moved by means of the control unit of the electrohydraulic neighboring control unit. Always observe the instructions in the control unit’s separate operating manual.

Arrangement of hydraulic components on the support The following table indicates the hydraulic components for the support.

Tab. 6: Hydraulic components Item 01

DBT GmbH, Lünen 2007

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02

Quantity Designation 1 Electrohydraulic control unit, 10-way 1 Water valve

03

1

04

1

05 06 07

1 1 1

08

1

09

2

10

1

11

1

12

2

Arrangement Behind the supply block (19), centered under the canopy To the left, next to the PM4 under the canopy Accumulator cartridge On the electrohydraulic control unit (1) CV DN 13, hydraulically piloted Underneath the canopy behind the left-hand prop next to the PRV (15a) Twin check valve On the stabilizing cylinder (Z3) CV, NW 25 On the supply block (19) Water filter DN 20 To the right, behind the supply block (19) Dual filters, can be backIn front of the right prop next to the flushed supply block (19) HP ball valve, DN 20 On prop respectively, face side red handle HP ball valve, DN 25 On the supply block (19) red handle HP ball valve, DN 12 In front of the dual filter (8), under red handle the canopy

Remarks On a support

HP ball valve, DN 10 red handle

a) For stabilizing cylinders (Z3)

a) On the right prop at the compensating valve (25) b) Next to PRV (15b) to the left under the canopy Behind the supply block (19) On prop respectively, face side a) On the CV, hydr. piloted (4) b) To the left, under the canopy next to the HP ball valve (12b) 2x on the stabilizing cylinder

13 14 15

1 2 2

PRV, 80 bar PRV, 420 bar PRV, 380 bar

16

2

Pressure relief valve, 450 bar

17

1

CV, DN 10

18

1

CV, NW 20

19

1

Supply block

20 21

1 1

22 23

1 1

24

1

Hose lines Water spraying system accessories Brackets and accessories Plug DN 10 with pressure relief Behind the supply block (19), next to the HP ball valve (30) and pressure relief valve (13) Prop CV, NG 20 On the left prop, face side

On a support On a support For shifting rams (Z2)

For stabilizing cylinders (Z3) In the return line For water circulation

In the pressure supply line to the prop In the pressure supply line to the shield For auxiliary supply

b) For lifting cylinders (Z4) In the return line For piston space a) For shifting ram (Z2) b) For lifting cylinder (Z4)

Both for piston and annular space On the right beneath the canopy In the line for backflushing the water spraying system On the right, underneath the canIn the water feed behind the opy, next to CV (17) water filter (7) Centered under the canopy in front On a bracket of the two props Subassembly Subassembly Subassembly

Without compensating valve

CV = check valve, PRV = pressure relief valve, HP = high pressure

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5.15

Operation of the shield hydraulics Quantity 1 2 1

30

1

35

2

Designation Prop CV, NG 20 Pressure gauge port HP ball valve DN 10, blue handle HP ball valve DN 20, blue handle Glycerine pressure gauge

S1 Z1 Z2 Z3 Z4

2 2 1 1 1

Pressure sensors Prop Shifting ram Stabilizing cylinder Lifting cylinder

Arrangement On the right-hand prop, face side On each prop, face side On the supply block (19)

Remarks With compensating valve

Behind the supply block (19), next to pressure relief valve (13) On each prop CV (24, 25), face side On prop respectively, face side

In the water circuit

In the spray line

DBT GmbH, Lünen 2007

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Item 25 28 29

CV = check valve, PRV = pressure relief valve, HP = high pressure

5.16

DBT - Shield 1067/2743-2X3739-1750

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 9, 10, 12a, 12b, 30

The following ball valves are closed during normal operation: J 11, 29

DBT GmbH, Lünen 2007

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Tab. 7: HP ball valves Item

Color

Designation

9

Red

HP ball valve, DN 20

10

Red

HP ball valve, DN 25

11

Red

HP ball valve, DN 12

Pressure supply during start-up and for auxiliary devices

12a

Red

HP ball valve, DN 10

Interrupts the connection of the stabilizing cylinder/compensating valve

12b

Red

HP ball valve, DN 10

Used for blocking the pressure supply to the lifting cylinder

29

Blue

HP ball valve, DN 10

30

Blue

HP ball valve, DN 20

Function Is used for shutting-off the pressure supply to the prop piston space Is used for shutting-off the pressure supply line to the shield

Used for shutting-off the spray line Used for shutting-off the water supply

Use During maintenance work on the prop and any possible disassembly During maintenance and repair work on the shield For moving the shield during start-up and for connecting hydraulically operated auxiliary devices In order to deactivate the compensating function of the stabilizing cylinder Used for holding the lifting cylinder in a certain position as well as deactivating the lift function For cleaning soiled components In order to deactivate the function of the water spraying system

Fig. 24: HP ball valve, shown opened and closed

open

closed

Through-flow for medium enabled

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Through-flow for medium stopped

5.17

Operation of the shield hydraulics Shield hydraulics Fig. 25: Shield hydraulics, face shield, arrangement (1) Image caption: see Table 6

Z

Y

Detail Y

Detail X

14

9

35 14

12a

9

35 28

28

25

Detail Z

24

6

10

29 22

5.18

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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X

Operation of the shield hydraulics Fig. 26: Shield hydraulics, face shield, arrangement (2) Image caption: see Table 6

16

5 15a 4 View X

1

13 18

30

DBT GmbH, Lünen 2007

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3

23

17 2 12b 8

15b

11 7 X

19

10

21

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5.19

Operation of the shield hydraulics Fig. 27: Functions of the electrohydraulic control unit, instruction plate

10

9

X10 10

X9 8

9 X8 8

7

X7

7 X6

6

6

X5

5

5

X4 4

X3

3

4

X2 3

2

X1 X2

2

2 P

1

T

SP

10 Functions shield advance

conveyor push

3

1

4

2 legs raise

extending lift-cyl

canopy tip up

5 6 canopy tip down

sprays clean

9 12 legs lower

Tab. 8: Electro-hydraulic control units with 8 functions, allocation of functions Function, designation

5.20

Function No.

Advance shield

1

Set props

2

Slide conveyor

3

Extend lifting cylinder

4

Extend stabilizing cylinder

5

Retracting stabilizing cylinder

6

-

7

-

8

Clean sprays

9

Lowering props

10

DBT - Shield 1067/2743-2X3739-1750

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1

Operation of the shield hydraulics Fig. 28: Functions of the water valve unit, instruction plate water curtain

W4

W3 side plate sprays

water curtain

W2

W1 water spray canopy

Tab. 9: Water valve unit with 4 functions, allocation of functions Function, designation

Function No. W1

Water spraying system, canopy

W2

Water spraying system, side seal

W3

Water spraying system, face side

W4

DBT GmbH, Lünen 2007

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Lemniscatic links, water spraying system

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5.21

Operation of the shield hydraulics Fig. 29: Shield hydraulics, face shield Image caption: See Table 6 coal

3

11 10

water curtain

13

P P

DN50 DN50

P

R W X2

2 1

8

DN40SS

23

2 P T

X2 4 3

X1

X4 6 5

X3

X6 8 7

X5

X8

1

10 9

X10

X9

X7

6

W R

R

1

2

3

4

5

6

7

9

8

10

19

P

29 7

30

18

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W1

W2

W3

W4

17

2

Z4 20 15b

12b

28 9 35

28 9

PI

14

24 X X

35

14 25

12a

water spray lemniscate

SI

21 4

Z2 Z1

Z1

water spray canopy

15a side plate sprays

side plate sprays 16

Z3 5 16

5.22

DBT - Shield 1067/2743-2X3739-1750

Operation of the shield hydraulics Fig. 30: Hydraulic lines (1), overview for face shield Image caption: see Table 6 16

5

A

B

DB

DA

16

Z3

Z2

15a

DBT GmbH, Lünen 2007

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4

Z1

Z1 1

3

17 18 PBA PB PA A AA

Z PBA PB PA A AA

28

14 S1

35

25

Z4

9

30

28

15b

R

W

DN50 W R

DN50

P

R

P W

W R

12b

7

DN40SS P

R

P

6

35

2

13 23

8

24 9

W4W2

14 12a

W3W1

S1

19 29

11

Doc. no.: 7420 186 000 BA 00

10

SSVA / 01

5.23

Operation of the shield hydraulics Shield components Main components Fig. 31: Shield, front view

a

11

e c

51

b

41

d

1 31

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

a PM4 control unit b electrohydraulic control unit c supply block d lifting cylinder e dual filter

Fig. 32: Shield, rear view

70

70 caving flap

5.24

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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61

Operation of the shield hydraulics Hydraulic supply block Fig. 33: View of the supply block from the front 6

10

19

P

22

R

30

W

DBT GmbH, Lünen 2007

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13

3

29 1

1 electrohydraulic control unit 3 accumulator cartridge 6 CV, NW25 10 HP ball valve DN 25, in the pressure supply line to the shield 13 PRV, 80 bar 19 supply block

Doc. no.: 7420 186 000 BA 00

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22 holder 29 HP ball valve DN 10, blue, for spray line 30 HP ball valve DN 20, blue, for water spraying system P pressure line DN 40SS R return line DN 50 W water line DN 50

5.25

Operation of the shield hydraulics Fig. 34: Side view of the supply block

8

a

23 13

19

P

7 water filter DN 20 8 dual filter, can be backflushed

30 HP ball valve DN 20, blue, for water spraying system P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a solenoid driver module

13 PRV, 80 bar 19 supply block 23 plug DN 10

Check valve, hydraulically piloted Fig. 35: View of the hydraulically piloted CV

4

15a

4 CV, hydraul. piloted, for shifting ram

5.26

15a PRV, 380 bar, for shifting rams

DBT - Shield 1067/2743-2X3739-1750

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7

R

30

DBT GmbH, Lünen 2007

W

Operation of the shield hydraulics Control units Fig. 36: View of the control units from the front 19

a P

R

W

1

30 10 29

DBT GmbH, Lünen 2007

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5 16 1 electrohydraulic control unit 5 twin CV 10 HP ball valve DN 25, in the pressure supply line 16 PRV, 450 bar 19 supply block 29 HP ball valve DN 10, blue, for spray line

Doc. no.: 7420 186 000 BA 00

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30 HP ball valve DN 20, blue, for water spraying system P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a PM4 control unit

5.27

Operation of the shield hydraulics Fig. 37: View of the electrohydr. control unit (10 functions)

b

d

c

a 2

6

1

2 double 3/2 way magnetic pilot solenoid valve

a push-button b instruction plate c accumulator cartridge

6 filter cartridge

d bracket

Important!

Observe that - starting from the marking on the cable - the end of the cable with the shorter distance has to be connected to the pilot valve. See also the separate operating manual for the control unit.

Fig. 38: View of the solenoid driver module and dual filter

a

8

W

R P

8 dual filter, can be backflushed a solenoid driver module

5.28

P pressure line, DN 40SS R return line, DN 50 W water line, DN 50

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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1 distributor block

Operation of the shield hydraulics Fig. 39: View of the water valve unit, to the right underneath the canopy

15b

12b a

DBT GmbH, Lünen 2007

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2

2 water valve unit 12b HP ball valve, DN 10, for lifting cylinder

15b PRV, 380 bar, for lifting cylinder a PM4 control unit

Fig. 40: View of the dual filter

8

a 11

8 dual filter, can be backflushed 11 HP ball valve, DN 20, for auxiliary supply

Doc. no.: 7420 186 000 BA 00

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a solenoid driver module

5.29

Operation of the shield hydraulics Fig. 41: Water filter

7 13

30

7 water filter 30 HP ball valve DN 20, in the water circuit

13 PRV, 80 bar, in the return line

Fig. 42: Infrared sensor

DBT GmbH, Lünen 2007

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a

8 a IR sensor

5.30

8 dual filter

DBT - Shield 1067/2743-2X3739-1750

Operation of the shield hydraulics Brackets Fig. 43: Bracket for control unit a

15

1

6

2

12

DBT GmbH, Lünen 2007

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5

1 holder 2 support 5 coupling clip DN 10 6 pin

Doc. no.: 7420 186 000 BA 00

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12 hex. head screw M10x20-A 2-70 15 spring cotter 4 a instruction plate

5.31

Operation of the shield hydraulics Fig. 44: Bracket for PM4 b

a

c 1

6

15b 12b 7 2

15b PRV, 380 bar

1 holder 2 water spray valve 6 cyl. screw M10x16-1.4571 7 water filter 12b HP ball valve DN10

c support lock-out switch

Fig. 45: Bracket for PM4, rear view 8 1

7

2

6

5

a

1 support 2 bracket 5 cyl. screw M12x90-1.4301 6 cyl. screw M10x16-1.4571

5.32

7 hex nuts M12-A 4-80 8 hexagon screw M12x30-A 2-70 a PM4 control unit

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

b emergency stop switch

E

a PM4 control unit

Operation of the shield hydraulics Prop Fig. 46: Right prop, with and without cover, view from the face side

b S1

35

12a

a 28 14 9

DBT GmbH, Lünen 2007

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25

9 HP ball valve DN 20, in the pressure supply line

25 prop control valve 28 pressure gauge connection 35 pressure gauge S1 pressure sensor a compensating valve b cover

12a HP ball valve DN 10, on the compensating valve for the stabilizing cylinder 14 PRV, 420 bar Fig. 47: Left-hand prop, with and without cover, view from the face side

a S1

14

35 9

28

24

9 HP ball valve DN 20, in the pressure supply line to the prop 14 PRV, 420 bar 24 prop control valve

Doc. no.: 7420 186 000 BA 00

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28 pressure gauge connection 35 pressure gauge S1 pressure sensor a cover

5.33

Operation of the shield hydraulics Fig. 48: Prop, view from the gob side

a

a a annular space on the prop pipe

The plug (23) with pressure relief located on the supply block is for reducing any pressure that may arise in the return line. This can be necessary for instance when the supply line connections have been bypassed for transport and increased pressure has built up in the return line during installation.

Fig. 49: Plug behind the supply block 23 13

19

30

13 PRV, 80 bar 19 supply block

5.34

23 plug DN 10 with pressure relief 30 HP ball valve DN 20, blue, for water spraying system

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

The shield is equipped with a with a plug DN 10 with vented cap screw on the supply block (19).

E

Plug with pressure relief

Operation of the shield hydraulics Stabilizing cylinder Fig. 50: View of the stabilizing cylinder

View Z

Z3

16

DBT GmbH, Lünen 2007

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Z

16 5

5 dual check valve 16 PRV, for piston space side and annular space side

Doc. no.: 7420 186 000 BA 00

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Z3 stabilizing cylinder

5.35

Operation of the shield hydraulics Operation of the manual dual backflush filter Warning!

Do not put the filter into operation before making sure that all connections have been properly established. normal operation

The filter is in normal mode with both levers are parallel. It must be backflushed when the contamination of the filter elements leads to reduced flow or pressure loss.

backflushing

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid) the frequency of backflushing cannot be predetermined. We recommend backflushing both filters routinely once per shift Warning!

Never put both levers into the backflush position simultaneously. Always backflush one filter element at a time. Otherwise, the flow of the emulsion can be completely interrupted and the filter elements won’t be backflushed.

Only one filter element may be backflushed at a time. Simply turn one of the levers by 90° and after about 2 seconds, put it in its original position. Then repeat the procedure with the other lever.

Fig. 51: View of the dual filter, can be backflushed

B B

8

A

A

8

8 dual filter, can be backflushed A normal operation: both levers in position “A”

5.36

B backflushing: one of the levers in position “B”

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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Note that a volume flow of at least 70 l/min is required.

Operation of the shield hydraulics Repair and emergency operation This section contains information on the functions and operation of the hydraulic control system, which may only be used in exceptional cases such as for repair and emergencies.

In the following, it is assumed that the shield has already been correctly installed. It is also assumed that all shut-off valves are open as during normal operation.

Operation of the control unit of the electronic control system is not described here, but in a separate operating manual for the control unit instead.

The fundamental design of the support unit and the shield control system is shown in the chapter “Technical description”, chapter 6 of this manual.

Furthermore, it is assumed that the reader is familiar with the fundamental principles of the hydraulic shield support and the operation of the control device.

DBT GmbH, Lünen 2007

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Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special operating instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury or death.

The shield support is operated in normal operation exclusively by means of the electronic control system. It is imperative that you observe the instructions in the control unit’s separate operating manual.

The drawings Fig. 52 and 53 show the position of the PM4 control unit and the electrohydraulic control unit on the support.

Operation of the PM4 control device is not described in this operating manual. For information on this, please refer to the separate operating manual for the PM4 control device.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

5.37

Operation of the shield hydraulics Fig. 52: View of the control units from the front 19

a P

R

W

1

30 10 29

5

1 electrohydraulic control unit 5 twin CV 10 HP ball valve DN 25, in the pressure supply line 16 PRV, 450 bar 19 supply block 29 HP ball valve DN 10, blue, for spray line

30 HP ball valve DN 20, blue, for water spraying system P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a PM4 control unit

Fig. 53: View of the electrohydr. control unit (10 functions)

b

d

c

2

a

6

1 1 distributor block 2 double 3/2-way magnetic pilot solenoid valve 6 filter cartridge

5.38

a push-button b instruction plate c accumulator cartridge d bracket

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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16

Operation of the shield hydraulics The symbol plate is located on the canopy behind the electrohydraulic control unit. The symbols correspond to the various functions which are initiated by actuating the respective button. The meaning of the symbols and functions are described below.

Fig. 54: Functions of the electrohydraulic control unit, instruction plate 8 functions shield advance

1 2 legs raise

conveyor push

3 4 extending lift-cyl

canopy tip up

5 6 canopy tip down

sprays clean

9 10 legs lower

Operation and functions of the electrohydraulic control unit This section provides information on the functions of the electrohydraulic control unit. Always observe the instructions contained in the operating manuals of the electrohydraulic control unit and the electronic control unit.

DBT GmbH, Lünen 2007

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Warning!

You are only allowed to operate the controls of the electrohydraulic control unit when you know exactly what effects the functions have with respect to the shield support. You must have attended a special training course to this purpose. Otherwise, there is a risk of operating errors. This could result in serious injury and even fatal accidents.

Controlling the shields during repair operation is especially dangerous because you are then operating the shield directly and immediately under where you are standing. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

While actuating the shield using repair mode, no other persons may stand in the shield’s area of movement.

There are two push-buttons on the cover of each individual pilot solenoid valve. When you actuate a button, the corresponding work valve is operated immediately.

The function stops as soon as you release the button.

Danger!

Jammed or locked buttons can cause uncontrolled movements of the shield. This could seriously injure or kill you.

For this reason never lock the buttons and ensure that damaged pilot solenoid valves are replaced immediately.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

5.39

Operation of the shield hydraulics Warning!

Manual actuation of a button on one of the pilot solenoid valves initiates the direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”. This can cause dangerous situations which can result in very serious injury.

Shield functions (8 functions) 1

Advance shield Before executing this function, “Lower prop” must have been executed for both props.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

As long as the function is activated, the piloted check valve, which hydraulically blocks the ring space of the shifting ram, is opened automatically.

E

Set props Before this function is actuated, the shield canopy must be correctly aligned. The lifting cylinder retracts automatically. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

While the props are being set, a canopy, which has too steep a setting angle, aligns itself automatically to the roof as long as the function of the compensating valve for the stabilizing cylinder is not blocked.

compensating valve

3

The compensating valve (Fig. 46, item a) and the associated shutoff valve (Fig. 46, item 12a) are on the right prop when looking at the coal face. When the shut-off valve is open (lever in the direction of flow), the compensating valve is activated. When the shut-off valve is closed (lever perpendicular to direction of flow), the compensating valve has no function.

While the props are being set, the compensating valve limits the pressure of the stabilizing cylinder to 200 bar as long as the pressure under the piston of the prop doesn’t exceed 100 bar. This means that the stabilizing cylinder retracts if the canopy is set too steeply. The canopy only presses with the tip against the roof and aligns itself to the roof then automatically.

Slide conveyor Before initiating this function, ensure that the support unit is completely set.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

4

Extend lifting cylinder The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

5.40

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

2

Operation of the shield hydraulics 5

Extend stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

Caution!

Do not exceed the permissible inclination.

Observe the value for minimum residual stroke.

6

Retracting stabilizing cylinder Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

DBT GmbH, Lünen 2007

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Caution!

Do not exceed the permissible inclination.

Observe the value for minimum residual stroke.

9

Clean sprays The function is carried out as long as the button and one of the buttons of the water unit (W1, W2, W3 or W4) is pressed.

10

Lowering props Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

5.41

Operation of the shield hydraulics Functions of the water valve unit Fig. 55: Functions of the water valve unit, instruction plate (4 functions) water curtain

W4

W3 side plate sprays

water curtain

W2

W1 water spray canopy

Lemniscatic links, water spraying system The function is executed as long as the button is pushed.

W1 Water spraying system, canopy W2

The function is executed as long as the button is pushed.

The function is executed as long as the button is pushed.

Water spraying system, face side W4

The function is executed as long as the button is pushed.

Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

5.42

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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Water spraying system, side seal W3

Maintenance Maintenance Warning!

If the operational safety is endangered, damaged components must be replaced immediately. If this is not possible, you must immediately shut down the shield and secure it. Immediately notify the entire face crew and your superiors. electronic control system

Refer to the separate operating manual for the PM4 control device.

hydraulic controlsystem

Special measures

one week after start-up

At the latest one week after start-up, the filter cartridges on the electrohydraulic control units of the shield control system in the entire face must be spot-checked for contamination. If inspection indicates that the probability of malfunctions caused by contaminated filter elements is high, all filter cartridges along the face must be replaced.

DBT GmbH, Lünen 2007

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After extensive work on the hydraulics system or after the start-up of a new face, there is an increased risk of dirt having found its way into the hydraulics system. Depending on the degree of contamination, this can cause the filter cartridges in the system to become clogged. As a result, it is possible that functions run slowly or even can no longer be carried out. We therefore recommend that the measures outlined above be taken in order to avoid malfunctions in the operation of the shield hydraulics. piston rods

The piston rods of cylinders, which are usually only rarely extended and retracted completely, for example props and stabilizing cylinders, must be thoroughly cleaned every 6 months and then treated with a suitable corrosion inhibitor on all shields which are equipped with a water spraying system.

filter cartridges

The filter cartridges on the supply block and on the electrohydraulic control unit of the shield control system serve to protect the downstream hydraulic components against damage caused by contaminants in the hydraulic medium. These only have to be regularly replaced if the filtering system of the longwall supply unit is inadequate.

Therefore, it is very important to ensure the required hydraulic medium quality.

If problems occur in the preparation of the hydraulic fluid, there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation.

E. g., the filters described above should be spot-checked regularly for contamination. If necessary the filter cartridges must be replaced regularly as a precautionary measure.

Doc. no.: 7420 186 000 BA 00

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5.43

Maintenance pressure relief valves

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

Pressure relief valves which are pretensioned with gas pressure must be additionally spot-checked at regular intervals to ensure their correct function. We recommend such spot checks at quarterly intervals.

All high-pressure hydraulic hose lines must be replaced irrespective of any visible damage at the latest after two years of operation for safety reasons and to ensure correct function of the system. If this deadline cannot be met because the end the section planned to be mined will only be reached shortly after this deadline, and it is impossible to replace the hose lines in the face, then an exception can be made and the replacement of these hose lines can wait until after the respective section has been completed.

dual filters, can be backflushed

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid) the frequency of backflushing cannot be predetermined. We recommend backflushing both filters routinely once per shift.

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid: – hose lines – electrohydraulic control unit – valves – props – shifting rams and lifting cylinders – link, steering and flipper cylinders.

. Check the pressure gauges on the props for visible damage and correct function. steel support cage

. Check all shields by visually inspecting them for damage to the steel structure, for instance: – on the relay bar assembly – pin connections and retainers – on the side seal – on brackets, etc.

5.44

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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high-pressure hydraulic hoses

Maintenance . Lubricate the dirt strippers of both telescope stages via the

hydraulic prop

lubricating nipples. Use the lubricating grease A2 in accordance with EWN 7068. See chapter 6, section “Lubricating greases and pastes”.

Fig. 56: Lubricating nipples on the hydraulic props

b

DBT GmbH, Lünen 2007

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a

a lubricating nipples on the guide bushing

b grease escaping at dirt stripper

Weekly maintenance control system

. Check each control system for correct functioning. . Replace defective control systems or individual components immediately.

. Clean the control systems, especially the operating panel.

Notice!

It is important that the control system symbols are easily legible. This prevents the risk of operational errors and any resulting accidents.

Carry out every six months

. Apply a corrosion inhibitor to the piston rods of the hydraulic cylinders. More detailed information is contained in this chapter in the section “Special measures”.

Assessment of damage according to schedule We recommend keeping a record of any damage found. The records should be evaluated regularly, for example every month, and summarized in a damage report. This will enable you to detect frequently occurring damage and take preventative action. This will heighten system availability and lower operating costs accordingly.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

5.45

Remedying faults Remedying faults Troubleshooting tips The shield hydraulics of a support unit consist of a multitude of individual components. The linking of the components with each other is shown in the schematics and hose diagrams for the shield hydraulics. Also refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

Functional errors can, in principle, occur in all components. The majority of faults on hydraulic valves is, however, caused by hydraulic bypass flows. These are normally audible to the operator.

The following information is provided to assist you in the detection and elimination of faults.

Fault localization support cannot be lowered

5.46

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the piston space of the prop is closed.

Open the shut-off valve.

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

Control piston on the prop control valve isn’t working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Replace the hose lines if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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Warning!

There is a heightened risk of accidents when performing troubleshooting work on hydraulic systems. In particular, malfunctions in the hydraulic system and hydraulic medium escaping at high pressure can cause serious injury.

Therefore, take special care and always wear the specified protective clothing.

Failure to comply with these instructions can result in serious injury.

Remedying faults Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the piston space of the prop is closed.

Open the shut-off valve.

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Control piston on the prop control valve isn’t working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Replace the hose lines if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The support is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the support.

Steps on roof or floor prevent advance of the support.

Lower canopy sufficiently to clear the step or lift the base to pass over a rise on the floor.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

The control piston on the piloted check valve does not work.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked shifting ram hose lines. Replace the hose lines if necessary. Make sure hoses are laid properly.

Shifting ram is defective.

Check whether - the shifting ram is damaged - the piloted check valve is working correctly.

Remove the hose from the connection on the piston side and execute the function “advance conveyor”. If pressure fluid escapes, replace the shifting ram.

DBT GmbH, Lünen 2007

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support cannot be set

support cannot be advanced

Doc. no.: 7420 186 000 BA 00

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5.47

canopy cannot be positioned

canopy cannot be lowered

5.48

Possible cause

Remedy

Prop control valve is defective.

Replace prop control valve. Continue troubleshooting if the pressure continues to drop.

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lower connection and check whether pressure fluid is escaping even though the prop is no longer being extended.

If applicable: piston packing defective, replace prop.

Pressure relief valve defective.

Monitor pressure drop on the pressure gauge.

Is pressure fluid leaking from the pressure relief valve? If applicable: Replace the pressure relief valve and retest the function.

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Piloted check valve isn’t working.

Check whether the pressure is sufficient to control the valve. Minimum approximately 80 bar.

The check valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Piloted check valve isn’t working.

Check whether the pressure for controlling the valve is sufficient. Minimum is about 80 bar.

The check valve may be defective.

Damaged or trapped hose lines.

Check hose lines for controlling the prop/stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

set pressure is not reached/ prop pressure drops again after setting

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Remedying faults

Remedying faults 3/2-way or pilot solenoid valve The valve is jammed or a by-pass has formed due to internal leakage. The latter can normally be detected on the work valves of the electrohydraulic control unit by an easily 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 solenoid valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, for example discharged fluid.

The 3/2-way valve or the pilot solenoid valve can therefore be faulty. valve sticks

. Try to solve the problem by initiating the function several times on the control unit or the electrohydraulic control unit.

internal leakage

. Locate the faulty valve by initiating the functions individually one by one.

If the noise stops while a function is initiated, this valve is faulty.

You may have to press the button for the faulty function for several seconds before the noise ceases.

E

valve replacement

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

DBT GmbH, Lünen 2007

pipe distributor.

. Then operate the functions manually to depressurize the system.

. Replace the 3/2-way valve or pilot solenoid valve.

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

. Try to solve the problem by initiating the function several times on the control unit or the electrohydraulic control unit.

If the problem occurs once more, the valve may be defective.

. Check the valve and replace if defective Checking the check valves on the props To check the prop check valves please proceed as follows:

. Set the prop until the set pressure has been reached. . Remove the hose line “Set props” at the piloted check valve.

If fluid escapes at the connection of the piloted check valve, it is defective.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

5.49

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

. Set the prop until the set pressure has been reached. . Depressurize the annular space side of the prop to be checked.

To do this, temporarily remove the hose line from the prop annular space connections (located on the prop pipe) and apply pressure to the control connection (extend prop) of the piloted check valve.

. Activate the function “Set prop”.

If there is an internal by-pass in the prop, for example due to damaged piston packing, fluid will flow out of the prop lower connection.

If this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

In the hydraulic circuit of a support unit, various models of pressure relief valves are used. For example, pressure relief valves are used on the props which have a high flow rate. While the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow.

Pressure relief valves for different cylinders of for the piston and ring sides of a cylinder can be set to different maximum pressure values. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

Defective or blocked filter Operation of the shield is slow although the system pressure lies in the normal range.

It is also possible that the hydraulic system has been contaminated, for example during repair work on the hydraulic system.

. Check the filters in the hydraulic system.

Backflush filters can be cleaned by backflushing. The filter elements must be replaced on fine-mesh filters, such as on the electrohydraulic control unit.

5.50

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Leaking pressure relief valves can normally be detected by the discharge of fluid, or a pressure drop is displayed on the pressure gauge. If fluid is already discharged at working pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

E

Pressure relief valve defective

6

Technical data

Description

Technical data This chapter contains the technical description of the support and its main subassemblies as well as the technical data for the described subassemblies.

Description Type

1067/2743-2X3739-1750 face shield

Two-prop shields mainly consist of the following listed main subassemblies: J base frame with lemniscatic links, relay bar assembly, shifting

ram and baselift cylinder, J canopy, J caving shield, J hydraulic props, J hydraulic equipment with hose lines and controlsystem.

DBT GmbH, Lünen 2007

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Tab. 10: Shield support, dimensions and weight

Use

Device number

Face shield

7420 186 000 00 01

Dimensions, LxWxH max./min. in mm

6 736 x 1 700 x 1 067 6 238 x 1 700 x 2 743

Approximate weight in kg 20 500

base frame

The shield is equipped with a one-piece base frame. This consists of two bases which are tightly connected to each other, in the middle of which is the channel for the relay bar assembly.

caving shield

The caving shield is a one-piece steel construction. It is flexibly connected with the canopy and also to the base frame by means of the so-called lemniscatic link.

canopy

The shield canopy transmits the support load of the props into the roof. The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

control arms

hydraulic system

The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

The structuring of the support is carried out with the aid of programmed calculation processes. This ensures that the support resistance and range of vertical adjustment is co-ordinated in optimum fashion. The multistage hydraulic props have the same load capacity at all stages and act on both sides.

The shield units are equipped with all components required for realising an electrohydraulic neighboring control with the electronic PM4 control system.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.3

Description Main subassemblies Shield support Fig. 57: Shield, front view

a

11

e c

51

b

41

d

31

1

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

a PM4 control unit b electrohydraulic control unit c supply block d baselift cylinder (lifting) e dual filter

Fig. 58: Shield, rear view

70

70 caving flap

6.4

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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61

Description Tab. 11: DBT shield 7420 186 000 00 01, subassemblies used Approximate weight in kg

Designation

ID No. No

Remarks

0001

Base

7420 186 300 00 01

8 162 Shifting ram Baselift (lifting) cylinder Relay bar assembly

0011

Canopy

7420 186 400 00 01

5 750

0031

Caving shield

7420 115 800 00 01

3 707

0041

Hydraulic prop

8250 131 000 00 00

1 062

0051

Stabilizing cylinder

8241 222 000 00 00

140

0061

Shield control system - 10 functions (2 funktions not allocated)

8112 270 000 00 00

240 Electrohydr. control unit Lines Water spraying system Brackets

0070

Caving flap

7420 115 090 00 00

55.5

8241 230 000 00 00 8241 224 000 00 00 7420 186 330 00 01

8154 180 000 00 00 8112 270 010 00 00 8112 270 020 00 00 8112 270 030 00 00

DBT GmbH, Lünen 2007

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Item

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.5

Description Main dimensions Fig. 59: Shield, dimensions 4610

3360

1981

2469

200

1067

65

2743

1120

947

1800

Shield clearance 1750 1700 890 a

340 1610 a shield number

6.6

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

E

6736

Description Base frame with lemniscatic links and relay bar assembly The solid base frame transmits the shield load of the hydraulic props into the floor. The props are simply supported in the ball sockets in the bases and are held on both sides by prop retainers Both pairs of lemniscatic links are hinged to the base frame with a pin connection.

Characteristic for the base frame is the placement of the relay bar assembly in the middle between the two bases. The relay bar assembly is reverse-mounted, which means the force applied across the piston surface area of the shifting ram is used to advance the shield. Correspondingly, the conveyor is pushed with the smaller force, which is generated via the ring surface.

The fork joint of the relay bar assembly establishes the connection to the conveyor.

With the help of the baselift cylinder, the shield can be lifted during shield advance.

E

Fig. 60: Base, dimensions

DBT GmbH, Lünen 2007

1465

1060

200

65

2153

890 3100 1610

3906

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.7

Description Fig. 61: Base, positions 7 10

1

9

a

2

8

5

15, 16, 17

E

21, 22 11, 13, 25 12, 23, 24 1 shifting ram ZE-135/90-1130 2 lifting cylinder ZE-135/90-240 5 base 6 shifting unit 7 lemniscatic link, front 8 lemniscatic link, rear 9 prop retainer, right 10 prop retainer, left 11 cylinder bracket 12 pin 60/50x116 13 pin Ø16x117

14 lemniscatic link pin Ø153.5 15 lemniscatic link pin Ø123.5x537 16 locking plate 17 locking clip 4.5 21 pin Ø34x80 22 spring clip 6 23 pin 25/16x125 24 locking clip 3.2 25 coupling clip a load ring 15000 kg For parts not listed here, please refer to the replacement parts list supplied.

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.

6.8

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

6

14, 16, 17

Description Relay bar assembly The relay bar assembly is located in the middle of the base frame.

It consists mainly of the relay bar, shifting ram, baselift cylinder and the required connection elements. It serves to advance the conveyor and the shield.

The shifting ram is reverse mounted with the force of the cylinder is transmitted to the relay bar. Here, the force on the piston surface side is used to advance the shield, while the smaller force of the annular surface is used to push the conveyor.

With the help of the lifting equipment, the base frame can be lifted from the floor during pulling up.

The baselift cylinder is located in the middle of the base frame. The force of the baselift cylinder acts on the floor via the relay bar.

Fig. 62: Relay bar assembly, dimensions and positions 3657

200

225 350

215

280

300

105

DBT GmbH, Lünen 2007

E

3442

3885 12 12, 13 8, 9

7

3

11 a

2

4

1

5, 6 1 relay bar 2 clevis assembly for conveyor 3 pin 80/50x290 4 washer 48 5 pin 12/20x70 6 locking clip 2.5 7 shear pin 70/53x144 8 pin Ø16x130 9 form spring

10 pin 65/58x180 11 hex. head screw M 16x120.-A 4.80 12 hex. nut M 16-1.4301 13 protective plug a load ring 3000 kg For parts not listed here, please refer to the replacement parts list supplied.

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.9

Description Functional description 1. Original position of the shield The shifting ram is retracted.

2. Advancing the shield While the shield is being advanced, the baselift cylinder presses on the relay bar, causing the bases to be lifted up off the floor.

Warning!

Body parts which get caught between moving parts of the relay bar assembly and support can be crushed.

For this reason, make sure that you keep a distance from shields which are being advanced or are to be advanced soon.

3. Setting the support When setting the support, the baselift cylinder retracts again automatically.

DBT GmbH, Lünen 2007

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4. Advancing the conveyor The shifting ram is retracted.

6.10

DBT - Shield 1067/2743-2X3739-1750

Description Shield canopy The canopy transfers the supporting force of the props to the roof.

It is articulated and connected to the caving shield with pins. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the props are fastened to the canopy and can be rotated.

Caution!

To avoid overloading the stabilizing cylinder, you must make sure that the setting angle of the shield canopy doesn’t exceed the maximum permissible value, e.g. when the canopy is set in a roof fall.

Notice!

The lifting points in the canopy (see Fig. 64) are for fastening lifting tackle and may only be used when the shield is completely set.

Pay attention to the load limits.

The force of the hydraulic support may not be used for lifting.

890 Doc. no.: 7420 186 000 BA 00

SSVA / 01

200

0

240

1120

4480

1015

480

195

1700

DBT GmbH, Lünen 2007

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Fig. 63: Canopy, dimensions

6.11

Description Fig. 64: Canopy, positions b, 19 1 c 17, 18

13, 14

15, 16

10 pawl R90 11 retaining bolt Ø24.3x156 12 locking clip 3.2 13 lemniscatic link pin Ø123.5x537 14 securing device 15 pin, Ø12x120 16 locking clip 2.5

a

17 pin Ø53x155 18 locking element with connector 19 spring cotter 5 a load ring load capacity 1000 kg b load ring load capacity 3000 kg c lifting point (clip) load capacity 8000 kg

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.

6.12

DBT - Shield 1067/2743-2X3739-1750

E

1 canopy

10

DBT GmbH, Lünen 2007

11, 12

Description Prop head with pawl Fig. 65: Prop head attachment

11, 12

DBT GmbH, Lünen 2007

E

10

12

10 11

10 pawl R90 11 retaining bolt, Ø24.3x156

Doc. no.: 7420 186 000 BA 00

SSVA / 01

12 locking clip 3.2

6.13

Description Caving shield The caving shield protects the face area toward the caving area.

It is connected to the shield canopy and with the base frame via the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the shield canopy to provide stability for the articulation.

Fig. 66: Caving shield, dimensions and positions

1950

1650

890 1690

E

4

DBT GmbH, Lünen 2007

3

S2 1

S2 8, 9, 10

S1 11 6, 7

S1

1 caving shield 3 lemniscatic link pin Ø153.5x472 4 lemniscatic link pin Ø123.5x472 6 pin Ø53x155 7 locking element with connector 8 securing device

9 pin 15/12x120 10 locking clip 2.5 11 spring cotter 5 S1 load ring, load capacity: 5000 kg S2 load ring, load capacity: 8000 kg

Notice!

Apply lubricant B6 according to EWN 7068 to all connecting points and slide surfaces.

6.14

DBT - Shield 1067/2743-2X3739-1750

Description Technical data, steel structure Face shield, device number 7420 186 000 00 01

DBT GmbH, Lünen 2007

E

Securing from tipping permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

Doc. no.: 7420 186 000 BA 00

15

Height, retracted . . . . . . . . . . . . . . . . . . . . mm

1067

Height, extended . . . . . . . . . . . . . . . . . . . mm

2743

Height adjustment . . . . . . . . . . . . . . . . . . . mm

1676

Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1067

Shifting ram stroke . . . . . . . . . . . . . . . . . . mm

1130

Prop clearance in inclines . . . . . . . . . . . mm

890

Forepole of canopy . . . . . . . . . . . . . . . . . . mm

3360

Rear projection of canopy . . . . . . . . . . . . mm

1250

Canopy width . . . . . . . . . . . . . . . . . . . . . . . mm

1700

Canopy length . . . . . . . . . . . . . . . . . . . . . . mm

4610

Caving shield inclination, support retracted . . . . . . . . . . . . . . . . . . . degrees

4.35

Support extended . . . . . . . . . . . . . . . . . . . degrees

45.95

Width of caving shield . . . . . . . . . . . . . . . mm

1690

Base frame width . . . . . . . . . . . . . . . . . . . mm

1610

Total area of the base frame . . . . . . . . . . cm2

38037

Support center distance . . . . . . . . . . . . . . mm

1750

Support force for medium seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm

1800

a) for 310 bar setting pressure . . . . . . . . kN

4863

b) for 400 bar nominal pressure . . . . . . . kN

6274

Support resistance for each m2 of roof surface with medium seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm

1800

a) for 310 bar setting pressure . . . . . . . . kN/m2

533

b) for 400 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

571 / 688

SSVA / 01

6.15

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. You can find additional information in the spare parts catalogue of the shield support.

The pilot solenoid valves of the electrohydraulic control unit are equipped with buttons, which allow the shield functions to be operated manually. A symbol plate shows the function/button allocation.

Warning!

During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

The buttons on the pilot solenoid valves should only be used in exceptional cases, for example for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations of the mine.

Shield hydraulics The following table indicates the hydraulic components for the support.

02

Quantity Designation 1 Electrohydraulic control unit, 10-way 1 Water valve

03

1

04

1

05 06 07

1 1 1

08

1

09

2

10

1

11

1

12

2

Arrangement Behind the supply block (19), centered under the canopy To the left, next to the PM4 under the canopy Accumulator cartridge On the electrohydraulic control unit (1) CV DN 13, hydraulically piloted Underneath the canopy behind the left-hand prop next to the PRV (15a) Twin check valve On the stabilizing cylinder (Z3) CV, NW 25 On the supply block (19) Water filter DN 20 To the right, behind the supply block(19) Dual filters, can be In front of the right prop next to the backflushed supply block (19) HP ball valve, DN 20 On prop respectively, face side red handle HP ball valve, DN 25 On the supply block (19) red handle HP ball valve, DN 12 In front of the dual filter (8), under red handle the canopy

Remarks On a support

HP ball valve, DN 10 red handle

a) For stabilizing cylinders (Z3)

13 14 15

1 2 2

PRV, 80 bar PRV, 420 bar PRV, 380 bar

16

2

PRV, 450 bar

a) On the right prop on the compensating valve (25) b) Next to PRV (15b) to the left under the canopy Behind the supply block (19) On prop respectively, face side a) On the CV, hydr. piloted (4) b) To the left, under the canopy next to the HP ball valve (12b) 2x on the stabilizing cylinder

17

1

CV, DN 10

On the right beneath the canopy

On a support On a support For shifting rams (Z2)

For stabilizing cylinders (Z3) In the return line For water circulation

In the pressure supply line to the prop In the pressure supply line to the shield For auxiliary supply

b) For lifting cylinders (Z4) In the return line For piston space a) For shifting ram (Z2) b) For lifting cylinder (Z4) Both for piston and annular space In the line for backflushing the water spraying system

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

6.16

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Item 01

E

Tab. 12: Hydraulic components

Hydraulic system Item 18

Quantity Designation 1 CV, NW 20

Arrangement On the right, underneath the canopy, next to CV (17) Centered under the canopy in front of the two props

1

Supply block

20 21

1 1

22 23

1 1

24 25 28 29

1 1 2 1

30

1

35

2

S1 Z1 Z2 Z3 Z4

2 2 1 1 1

Hose lines Water spraying system accessories Brackets and accessories Plug DN 10 with pressure relief Behind the supply block (19), next to the HP ball valve (30) and pressure relief valve (13) Prop CV, NG 20 On the left prop, face side Prop CV, NG 20 On the right-hand prop, face side Pressure gauge port On prop respectively, face side HP ball valve DN 10, On the supply block (19) blue handle HP ball valve DN 20, Behind the supply block (19), next blue handle to pressure relief valve (13) Glycerine pressure gauge On each prop CV (24, 25), face side Pressure sensors On prop respectively, face side Prop Shifting ram Stabilizing cylinder Lifting cylinder

Subassembly Subassembly Subassembly

Without compensating valve With compensating valve In the spray line In the water circuit

DBT GmbH, Lünen 2007

E

19

Remarks In the water feed behind the water filter (7) On a bracket

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.17

Hydraulic system Shield hydraulics Fig. 67: Shield hydraulics, face shield, arrangement (1) Image caption: see Table 12

Z

Y

Detail Y

Detail X

14

9

35 14

12a

9

35 28

28

25

Detail Z

24

6

10

29 22

6.18

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

E

X

Hydraulic system Fig. 68: Shield hydraulics, face shield, arrangement (2) Image caption: see Table 12

16

5 15a 4 View X

1

13 18

30

DBT GmbH, Lünen 2007

E

3

23

17 2 12b 8

15b

11 7 X

19

10

21

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.19

Hydraulic system Fig. 69: Functions of the electrohydraulic control unit, instruction plate 10 Functions shield advance

conveyor push

canopy tip up

3

1

5

4

2 legs raise

extending lift-cyl

sprays clean

9 10

6

legs lower

canopy tip down

Tab. 13: Electrohydraulic control unit with 10 functions, allocation of functions Function, designation

Function No.

Advance shield

1

Set props

2

Slide conveyor

3

Extend baselift cylinder

4

Extend stabilizing cylinder

5

Retracting stabilizing cylinder

6

Not allocated

7

Not allocated

8

Clean sprays

9

Lowering props

10

W4

W3 side plate sprays

DBT GmbH, Lünen 2007

water curtain

E

Fig. 70: Functions of the water valve unit, instruction plate water curtain

W2

W1 water spray canopy

Tab. 14: Water valve unit with 4 functions, allocation of functions Function, designation

6.20

Function No.

Lemniscatic links, water spraying system

W1

Water spraying system, canopy

W2

Water spraying system side seal

W3

Water spraying system, face side

W4

DBT - Shield 1067/2743-2X3739-1750

Hydraulic system Fig. 71: Shield hydraulics, face shield Image caption: See Table 12 coal

3

11 10

water curtain

13

P P

DN50 DN50

P

R W X2

2 1

8

DN40SS

23

2 P T

X2 4 3

X1

X4 6 5

X3

X6 8 7

X5

X8

1

10 9

X10

X9

X7

6

W R

R

1

2

3

4

5

6

7

9

8

10

19

P

29 7

30

18

DBT GmbH, Lünen 2007

W1

W2

W3

E

W4

17

2

Z4 20 15b

12b

28 9 35

28 9

PI

14

24 X X

35

14 25

12a

water spray lemniscate

SI

21 4

Z2 Z1

Z1

water spray canopy

15a side plate sprays

side plate sprays 16

Z3 5 16

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.21

Hydraulic system Hydraulic prop, two-stage The two-stage hydraulic prop is double-acting and designed for the same load-carrying capacity in all stages. Equal load-bearing capacity is ensured by a piloted check valve which is installed in the piston pipe.

The bottom and top of the prop are designed as a globe joint. This allows the prop to be joined to the support via a rotatable fastening.

The prop head is fastened by means of two clampable pawls on the canopy, which engage in the recesses on the prop head. The cams of the prop base are clamped with the so-called prop retainers on the base of the support.

The technical data can be found in the section “Technical data, Hydraulic Cylinders”.

Fig. 72: Double-telescopic prop, Type SD-3700-345-1086/2466-BN

DBT GmbH, Lünen 2007

E

21

2

b

41

a d

1

c 1 prop base 2 piston pipe 21 piston rod 41 lubricating nipple

a piston space connection b annular space connection c safety cam d load ring 3000 kg

Tab. 15: Telescopic prop Length in mm

6.22

Stroke in mm

ID No. Telescopic prop

Retracted

Extended

Upper stage

Lower stage

8250 131 000 00 00

1086

2466

685

695

DBT - Shield 1067/2743-2X3739-1750

Hydraulic system Warning!

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

Never close the lowering connections on double-acting props so that they’re pressure-tight! Otherwise, pressure might build up in the annular space when extending the prop, which is several times more than the set pressure.

Function Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the annular space is conducted away into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends.

The pressure fluid is supplied at the same time via the check valve in the bottom of the piston pipe.

loading props

a) Piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. The additional force distribution is transmitted hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the base frame.

DBT GmbH, Lünen 2007

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set props

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated check valve.

If the pressure on the pressure relief valve is exceeded, the pressure fluid flows from the prop and the prop is pushed in under the nominal prop force. b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure fluid, which is blocked by the check valve in the bottom of the piston pipe.

The further course of the force flow up to the setting of the piston pipe is as described under a). lowering props

The pressure fluid is connected to the return under the piston pipe via the control valve for the prop.

Both stages of the prop can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston rod can then retract.

A few millimetres before the piston pipe is “fully retracted”, the check valve is opened by a tappet, whereby the pressure fluid underneath the piston pipe acts like a spring lifting the piston pipe to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.23

Hydraulic cylinder Hydraulic cylinder Construction The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Model a) Connections arranged on the outer cylinder Model b) Connections arranged at the end of the piston rod.

Fig. 73: Hydraulic cylinder, typical example Model a)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

1

3

3

5

4

1

4

6

4 guide bushing 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical Data, Hydraulic Cylinders” section for the support unit used.

Warning!

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

Never close the prop-lowering connections of double-acting props pressure-tight!

Otherwise, when extending the cylinder, pressure can build up in the annular space which is several times more than the set pressure!

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against working loose using clamping screws or a clamping sleeve connection.

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

If a double-acting cylinder is to be operated as a single-acting cylinder the annular space connection must be protected using filter screw to prevent the penetration of dirt. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

6.24

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Model b)

E

2

Hydraulic cylinder Stabilizing cylinder Fig. 74: Hydraulic cylinder ZE-165/100-420

55

55 L a d

21 1

E

1 cylinder tube

d load ring 1000 kg L retracted 860 extended 1280 stroke 420

DBT GmbH, Lünen 2007

21 piston rod a valve connection plate

Shifting ram Fig. 75: Hydraulic cylinder type ZE-135/90-1130

62

70 L

21

a b 4

3

25 d c e 3 cylinder tube 4 reed rod 21 piston rod 25 screw fitting a annular space connection b piston space connection

Doc. no.: 7420 186 000 BA 00

SSVA / 01

c reed rod adaptor d load ring 1000 kg e bearing pin L retracted 1469 extended 2599 stroke 1130

6.25

Hydraulic cylinder Baselift cylinder (lifting) Fig. 76: Hydraulic cylinder ZE-135/90-240

355

c

a

2

b 1 L

1 cylinder tube 2 piston rod 3 wearing bottom a piston space connection

DBT GmbH, Lünen 2007

E

3 b annular space connection c load ring 1 000 kg L retracted 525 - extended 765 stroke: 240

Technical data, hydraulic cylinder hydraulic prop, double-acting, 2-stage

6.26

Type SD-3700-345-1086/2466-BN, device no. 8250 131 000 00 00 Length a) Retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1086

b) Extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2466

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1380

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

345/250

Piston rod diameter . . . . . . . . . . . . . . . . . mm

320/230

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

934.8/490.9

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

130.6 / 75.4

Prop force with setting pressure, 310 bar setting pressure . . . . . . . . . . . . . kN

2898

Setting pressure, 400 bar setting pressure . . . . . . . . . . . . . kN

3739

Retracting force at 310 bar . . . . . . . . . . . kN

405

DBT - Shield 1067/2743-2X3739-1750

Hydraulic cylinder stabilizing cylinder, double-acting

DBT GmbH, Lünen 2007

E

shifting ram, double acting, reverse mounted

baselift cylinder, double-acting

Doc. no.: 7420 186 000 BA 00

Type ZE-165/100-420,

device no. 8241 222 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

420

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 310 / 400 bar . . . . . . . . . kN

663 / 1196.2

Pulling force at 310 / 400 bar . . . . . . . . . kN

419 / 541

Type ZE-135/90-1130, version with reed rod

device no. 8241 230 000 00 00

Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1 130

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

135

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

143.1

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

79.5

Thrust at 310 bar . . . . . . . . . . . . . . . . . . . kN

443.7

Pulling force at 310 bar . . . . . . . . . . . . . . kN

246.5

Type ZE-135/90-240

device no. 8241 224 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

135

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

143.1

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

79.5

Thrust force at 310 bar . . . . . . . . . . . . . . kN

443.6

Pulling force at 310 bar . . . . . . . . . . . . . . kN

236.5

SSVA / 01

6.27

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalogue.

Model

Setting pressure in bar

Device No.

For return line

Spring-loaded

80

8220 042 080 00 00

For shifting rams and Spring-loaded lifting cylinders

380

7337 486 380 00 00

For props

Spring-loaded

420

8220 027 420 00 00

For stabilizing cylinders

Spring-loaded

450

7337 486 450 00 00

Caution!

The setting pressure of pressure relief valves should not be changed! Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system’s circuit diagram. Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Defective seals lead to leaky plug connections and impair the operational safety of the hydraulics.

Always fit new seals when replacing a pressure relief valve. identification

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The letter code includes the following information: J setting pressure, target value, J the week the setting was made, J the year the setting was made, J last changes made by.

6.28

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Application

E

Tab. 16: Pressure relief valves, use of the various models

Pressure relief valves Tab. 17: Letter code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last changes made by:

Color coding is with either one or two colors. It indicates the range within which the setting pressure is located. The following Fig. 77 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 77: Pressure relief valve, example

b

a

a color code b protective cap

DBT GmbH, Lünen 2007

E

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

Tab. 18: Color codes for pressure relief valves, overview

1)

Doc. no.: 7420 186 000 BA 00

Color

Pressure range (bar)

Black

0 - 49

Black/White

50 - 99

Brown

100 - 149

Brown/White

150 - 199

Green

200 - 249

Green/White

250 - 299

Blue

300 - 349

Blue/White

350 - 399

Red

400 - 449

Red/White

450 - 499

Yellow

500 - 549

yellow/white

550 - 599

Orange

600 - 649

Orange/White

650 - 699

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

SSVA / 01

6.29

Shield control unit Shield control unit Electrohydraulic control unit The electrohydraulic control unit has 10 functions.

Fig. 78: Electrohydraulic control unit, 10 active functions, 2 functions are not allocated

a connection (DN 20) for accumulator cartridge 1 distributor block 2 pilot valves with electromagnetic operation

2

3

4

3 button for manual operation 4 contact for electrical connection to the solenoid driver module

Warning!

During normal operation the buttons on the pilot solenoid valves of the electrohydraulic control unit should not be used to activate functions. Failure to observe this warning can result in unexpected and hazardous situations, e. g. if interlocking functions are deactivated as a result.

The buttons on the pilot solenoid valves should only be used in exceptional cases for repair and maintenance work. In such cases it is imperative to observe the applicable special safety regulations of the mine.

6.30

DBT - Shield 1067/2743-2X3739-1750

E

1

DBT GmbH, Lünen 2007

a

Shield control unit Electronic control unit PM4 Fig. 79: Control unit PM4, input allocation PM4 inputs A1 = neighboring unit to the right A2 = not allocated

Front view

B1 = infrared receiver B2 = not allocated C1 = pressure sensor, right C2 = pressure sensor, left D1 = not allocated D2 = shifting ram sensor E1 = not allocated

Rear view A2

B2

A1

B1

C2

C1

D2

D1

E2

E1

F2

E2 = not allocated F1 = neighboring unit to the left F2 = solenoid driver module

F1

Notice!

Always observe the instructions in the PM4 control unit’s separate operating manual.

Fig. 80: Control unit PM4, diagram E

Rear view DBT GmbH, Lünen 2007

A2 B2 C2 D2 E2 F2

Front view 1

A1 B1 C1 D1 E1 F1

F1

A1 3

5A

19

5b

*

*

*

*

a

F1

PA PM4 A1 1 shield control device (SCU) 3 solenoid driver module 5a pressure sensor, right 5b pressure sensor, left 19 infrared receiver

Doc. no.: 7420 186 000 BA 00

SSVA / 01

a reed rod, shifting ram A1 right-hand neighbor F1 left-hand neighbor * Marking for connection on valve block Other components: see spare parts catalog

6.31

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 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

Fig. 81: Angles α1/ α2

α1 α2

Tab. 19: Angles α1/ α2 at height M Shield

Inclination a at height M

ID No.

α1 in °

α2 in °

4 - 10

0 - 10

1067 to 1300

7420 186 000 00 01

10 - 15

10 - 15

>1300 to <1500

15

15

1500 to 2743

M in mm

Caution!

Exceeding the specified permissible angles can lead to damage to the props and cylinders and their fastening elements, as well as to the part hinges.

6.32

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

E

M

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by DBT GmbH. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

For the operation of hydraulic components from DBT GmbH, generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWN 8350 or an exemption permit of DBT GmbH is available to the respective operator.

DBT GmbH will not accept any warranty claims for components which have been or are operated using a different hydraulic fluid.

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

DBT GmbH, Lünen 2007

E

If a mine only uses individual hydraulic components without using DBT shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by DBT. The same applies, for example, to hydraulic chain tensioner devices, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by DBT GmbH on request.

Suitability test Before the certificate of DBT GmbH is issued for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorised by DBT GmbH. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

In addition, a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

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

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.33

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of DBT GmbH hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can respectively be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

DBT GmbH, Lünen 2007

E

Fig. 82: Typical certificate

6.34

DBT - Shield 1067/2743-2X3739-1750

Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: see certificate DBT GmbH, Lünen 2007

E

J Microbial load

– Target value: ≤ 105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following Table (Tab. 20) lists limits for the essential properties and components of the water.

If the limits shown are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not met this should be taken into consideration when selecting a concentrate. Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will also lead to the loss of the certificate, even if they are within the limit values mentioned.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.35

Permissible media Tab. 20: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 µS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe-content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

Ratio of solid foreign matter at 1.2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

-/18/14

Lubricating greases properties

lubricating grease A1

Base:

Lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presence of water:

practically non-soluble in water

Temperature range of application:

-20 to +120 °C

Flashpoint:

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *) 7068).

Tab. 21: Lubricating greases for general application Flashpoint in °C

Supplier

Model

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

*) EWN = DBT works standard

6.36

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Important!

The lubricants to be used are specified in the respective chapters, e.g. Installation, Maintenance.

E

Lubricating greases and pastes

Permissible media lubricating grease A2

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

Tab. 22: Lubricating greases with additives Flashpoint in °C

Supplier

Model

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

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 that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

lubricating paste B3

DBT GmbH, Lünen 2007

E

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

Tab. 23: Lubricating pastes free of molybdenum disulphide Supplier

Model

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 according to the DBT works standard EWN 7068 is used: Lubricating molybdenum “gleitmo 805” lubricating paste B6

Separating agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support.

Behaviour in the presence of water: non-soluble in water Temperature of application:

-34 to +120 °C

When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B 6 in accordance with the DBT works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flash point 132 °C) Important!

The instructions for mixing lubricating greases also basically apply to the lubricating pastes. *) The products listed in Table 21 are suitable lubricating greases for filling of adjacent cavities.

Doc. no.: 7420 186 000 BA 00

SSVA / 01

6.37

Tightening torques Tightening torques Screws with ISO metric thread Tab. 24: Tightening torques at µtotal = 0.14 Tightening torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

30 m

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

36 m

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

1) 2) 3) 4)

6.38

The dimensions listed in brackets are used in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

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

The tightening torques comply with the DBT works standard (EWN 6003).

DBT - Shield 1067/2743-2X3739-1750

E

(mm)

DBT GmbH, Lünen 2007

Thread 1)

7

For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Head Office) Industriestraße 1 D-44534 Lünen, Germany Tel: +49/23 06 70 9 - 0 Fax: +49/23 06 70 9 - 1421 E-mail: infodbt@dbt.de

Great Britain

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

DBT GmbH, Lünen 2007

E

Tel: +44 /11 59 51 - 2500 Fax: +44/ 11 59 32 - 9683 E-mail: martin.daldrup@dbtgb.com DBT GB Limited Engineering 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48 / 32 31 70 - 500 Fax: +48 / 32 31 70 - 509 E-mail: dbtpolska@dbtpolska.com

Russia

DBT Moscow office Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: dbt@co.ru OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7/38 43 35 - 3441 Fax: +7/38 43 35 - 3442 E-mail: office@dbtrus.ru

Doc. no.: 7420 186 000 BA 00

SSVA / 01

7.3

Service addresses North America, Canada, South America USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@dbtamerica.com DBT America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia DBT Australia Pty. Ltd.

DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: zelda.stephens@dbtafrica.com

Asia China

DBT China Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@dbtchina.com

7.4

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

Tel: +61/24 91 4 - 7144 Fax: +61/24 91 4 - 7169 E-mail. Ron.Spencer@dbtaustralia.com Internet: http://www.dbt.de

E

Customer Service 20 Killara Close, Beresfield, New South Wales 2322

Service addresses DBT (Langfang) Mine Technik Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@dbtchina.com DBT Tangshan Machinery Ltd. No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86/31 53 20 - 3117 (& 3445, 3404) Fax: +86/31 53 20 - 3438 E-mail: Info.tangshan@dbtchina.com Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209

DBT GmbH, Lünen 2007

E

Tel: +86/47 78 28 - 7245 (& 7514, 7290) Fax: +86/47 78 28 - 7431 E-mail: Info.shenhua@dbtchina.com India

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

Doc. no.: 7420 186 000 BA 00

SSVA / 01

+91/33 24 2 - 0272 +91/33 24 2 - 8684

7.5

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

Fig. 83: Type plate, example

DBT GmbH

1 2

1 manufacturer 2 SAP/Order No. 3 date of manufacture 4 serial no.

7.6

678

5

7420 186 000 00 01

7

3739 kN

5 sevice number 6 number of props 7 prop force E

2

4

DBT GmbH, Lünen 2007

6

12345 3 11/07

DBT - Shield 1067/2743-2X3739-1750

Identification of the shields Shield number The shield number serves as an identification feature. All shields are numbered sequentially. Permanently attached tags with the respective shield number are located underneath the canopy above the PM4.

DBT GmbH, Lünen 2007

E

Fig. 84: Shield number Under the canopy

Tab. 25: Allocation of the shield numbers

Doc. no.: 7420 186 000 BA 00

Shield number

Device number

168 to 210

7420 186 000 00 01 Face shield

SSVA / 01

Use

7.7

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 26: National standards and directives, extract

Designation

Title

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation system Plug connectors for hydraulics Fire-resistant hydraulic fluids Maintenance and inspection for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for pins T-head bolts Greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1)

1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 27: European standards and directives, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 DIN EN 1710 DIN EN 1552

Date of issue

Title

EC directive of the European Parliament and Council on 1998-06-22 the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and 1994-03-23 protective systems intended for use in potentially explosive atmospheres Safety of Machinery 2004-04 Safety of Machinery 2004-04 Non-electrical devices for use in potentially explosive 2002-04 atmospheres - Part 1: Basic methods and requirements Electrical apparatus for explosive gas atmospheres 2004-12 - Part 0: General requirements Basic and safety principles for man-machine interfaces 2000-08 Creating manuals 2001-11 - Structure, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water - Distillation method Equipment and components for use in areas susceptible to 2006-01 firedamp in underground mines Mobile extracting machines at the face - safety require2003-09 ments for shearer loaders and plough systems 1)

7.8

EWN = DBT works standard

DBT - Shield 1067/2743-2X3739-1750

DBT GmbH, Lünen 2007

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EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11

Operating Manual DBT - Electrohydraulic Control Unit, 10 Functions Doc. No.: 8154 118 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

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

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

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

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

DBT GmbH, Lünen 2006 E

Contents

Contents 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 2.3

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

2.4

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

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

2.4 2.4

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

2.5

DBT GmbH, Lünen 2006

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Overview of the safety instructions . . . . . . . . . . . . . . . . 2.10

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Holder with Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.5 3.5

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

4.3

Installation of the elektrohydraulic control . . . . . . . . .

4.4

Removal of the elektrohydraulic control . . . . . . . . . . . . . . . .

Installation of the elektrohydraulic control . . . . . . . . . . . . . .

4.4 4.5

5. Operation

Doc. No.: 8154 118 000 BA 00

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

5.3

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

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

5.3 5.3

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

5.4

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.4 5.5

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Contents Accumulator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Replacing the accumulator cartridge . . . . . . . . . . . . . . . . . .

5.8

6.3

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

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

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

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

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

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

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

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

6.3 6.4 6.4 6.4 6.4 6.5 6.5 6.5

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

6.6

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

6.7

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

6.7

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.8 6.11

7. For your information Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Northamerica, Canada, Southamerica . . . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

South Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.5

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

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

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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 electrohydraulic control unit used. Failure to do so can result in a safety hazard for yourself and others. Ensure that the data on the electrohydraulic control unit comply with the data given in the operating manual.

This operating manual is designed for Electrohydraulic control unit - 10 functions - with the order No.: 8154 118 000 00 00 and is only permitted to be used for electrohydraulic control units of this type.

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operating manual

An operating manual for the electrohydraulic control unit 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 2006

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 electrohydraulic control unit.

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 electrohydraulic control unit.

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.

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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 - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

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.

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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 electrohydraulic control unit 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 electrohydraulic control unit. 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

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J of the miners’ accident insurance association.

DBT GmbH, Lünen 2006

Personnel Persons employed in the operation, repair, and overhaul of hydraulic and/or electrohydraulic control unit 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.

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.

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

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2.3

Conditions of operation Conditions of operation Use in conformance with specifications The electrohydraulic control unit 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 PMC®-R. Use the electrohydraulic control unit only as intended.

Intended uses are: J The electrohydraulic control unit is combined with an electronic

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 electrohydraulic control unit. 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 electrohydraulic control unit as ”control unit” to oper-

ate 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 electrohydraulic control unit as intended!

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

2.4

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

J Additionally, there are two exceptional circumstances under

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control unit - as for example a single control unit of type PMC®-R. 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 electrohydraulic control unit 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 electrohydraulic control unit, 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 programcontrolled.

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.

prerequisite

EMERGENCY STOP

DBT GmbH, Lünen 2006

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support lock-out switch

Employ only electrohydraulic control units which are in a technically flawless condition.

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

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.

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.

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2.5

Safety 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 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.

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”. 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.

2.6

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

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Maintenance

Safety instructions 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 check that: J the hoses are not pinched or trapped.

J the hoses have no bubbles or blisters.

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

rigid or hard.

J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

DBT GmbH, Lünen 2006

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

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

Never use nails, wire or similar materials for securing.

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 1:

Example: 4SP hydraulic hose, designation 3 2 1

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

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5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

2.7

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

Never try to repair damaged hydraulic hoses.

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

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

Always lay hydraulic hoses so that they: J always have a little slack, Fig. 2:

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 3:

Laying hydraulic hoses, twisting WRONG

DBT GmbH, Lünen 2006

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RIGHT

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter),

Fig. 4:

Laying hydraulic hoses, bending RIGHT

2.8

WRONG

DBT - Electrohydraulic Control Unit - 10 Functions

Safety instructions J cannot chafe, Fig. 5:

Laying hydraulic hoses, crossing RIGHT

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, E

J kinked,

DBT GmbH, Lünen 2006

J crushed, J driven over or J twisted (Fig.: 6) by the movement of the equipment.

Fig. 6:

Laying hydraulic hoses, connections on moving parts RIGHT

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WRONG

2.9

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.

IMPORTANT! Ensure when transporting the shield that the holder with the control unit is fixed in position in such a way that it will not collide with other components when the shield is being lowered.

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!

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 ”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 unit is given in the manual for the respective control system used.

Do not secure the electrohydraulic control unit with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the electrohydraulic control unit and prevent slipping.

2.10

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

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.

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Chapter 4: Installation

Overview of the safety instructions IMPORTANT! Before commissioning the shield, take care to ensure that the symbol plate is positioned such that the symbols are clearly legible.

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.

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.

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.

DBT GmbH, Lünen 2006

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Do not operate the control valve block without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the control valve block or the shield. This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

CAUTION! Only use each filter cartridge once and do not attempt to clean it.

Dirt in the hydraulic system is a frequent cause of costly repairs. You should generally only use new filter cartridges and seals.

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.

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

Always ensure that your working area is clean.

Impurities in the hydraulic medium 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.

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2.11

Overview of the safety instructions IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

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

The accumulator cartridge is not included in the scope of supply of the control valve block. Please remember this information when ordering replacement parts.

A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

Chapter 6: Technical data WARNING! As soon as the current drops to a level below 40 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

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.

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

Further information is contained in DIN 24320.

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

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

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

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

2.12

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

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

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

3

Storage and transport

Storage

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

Observance of the instructions and tips will increase the service life of the electrohydraulic control. 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 2006

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.

short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must, however, be particularly protected against environmental influences, including high temperatures, for example by suitable covers or sheathings for the controls and by additionally covering the equipment.

*)

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

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3.3

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

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

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 chapter 6, in the section ”Permissible media”.

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 - Electrohydraulic Control Unit - 10 Functions

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long-term storage

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Storage

Transport Transport Transport crates Several electrohydraulic controls 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 electrohydraulic control at temperatures below freezing, the block must be completely emptied and then filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50).

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If the electrohydraulic control unit 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 2006

Dimensions and weight depth: . . . . . . . . . . . . . . . . . . . . width: . . . . . . . . . . . . . . . . . . . . . height: . . . . . . . . . . . . . . . . . . . . weight: . . . . . . . . . . . . . . . . . . . .

280 mm 298 mm 154 mm 46,5 kg

Plugs The connections of the individual electrohydraulic control units 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 connection of the electrohydraulic control unit.

Holder with Control unit IMPORTANT! Ensure when transporting the shield that the holder with the control unit is fixed in position in such a way that it will not collide with other components when the shield is being lowered.

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Transport

3.6

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4

Installation

Requirements to the face hydraulic system

Installation This chapter contains information on the installation and removal of the electrohydraulic control. 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 unit 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: J Pressure fluid according to list of approved products, see secDBT GmbH, Lünen 2006

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tion ”Operating media” in chapter 6 of this manual.

J Purity class 18 / 14 to ISO 4406

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Installation of the electrohydraulic control Installation of the electrohydraulic control Removal of the electrohydraulic control Before starting the installation or replacement of electrohydraulic controls, 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.

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.

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 electrohydraulic control and ensure that the connections are not damaged or soiled.

. Secure the electrohydraulic control with hoists and transport belts.

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

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

. Loosen the bolts of the electrohydraulic control mounting. . Pull the electrohydraulic control out of the mounting.

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remove electrohydraulic control

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

DBT GmbH, Lünen 2006

shut off hydraulic pressure

Installation of the electrohydraulic control Installation of the electrohydraulic control Fig. 7:

Installation example 2 6

5

1

15

12

8 7 1, 2 mounting 5 staple DN 10 6 pin 7 symbolplate

11

8 symbol plate mounting bracket 11 hex. head bolt M 6x8 12 hex. head bolt M 10x20 15 spring clip

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. Place the electrohydraulic control into the mounting and tighten

DBT GmbH, Lünen 2006

the bolts (M10) properly.

IMPORTANT! Before commissioning the shield, take care to ensure that the symbol plate is positioned such that the symbols are clearly legible.

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

. 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.

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Installation of the electrohydraulic control 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

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.

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

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5

Operation

Operation and function of the pilot valves

Operation This chapter contains information on the operation of the electrohydraulic control unit 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 electrohydraulic control unit 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. This symbol plate should be attached to the electrohydraulic control unit underneath the pilot valves.

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Filter cartridge Filter cartridge A filter cartridge is provided in the manifold section of the electrohydraulic control unit. It protects the valves of the control unit against damage from impurities in the hydraulic medium.

Maintenance intervals IMPORTANT! The maintenance intervals recommended are standard values.

Special operating conditions may require different maintenance intervals. It is absolutely necessary that you adapt the maintenance intervals to the individual operating conditions. after one week

The filter cartridge in the manifold section should be checked for soiling one week after start-up of an electrohydraulic control system, at the latest. Replace the filter cartridge, if soiled.

according to schedule

If problems occur in the preparation of the medium there will be an increased risk of failures due to clogged filters. To maintain the operational reliability of the installation, certain measures may then have to be taken regularly. For example, you should take the precaution to maintain regular random inspections of the filter cartridges of all electrohydraulic control units on the face. It may be necessary to replace the filter cartridges at regular intervals as a precaution.

A filter cartridge is provided in the manifold block of the electrohydraulic control unit to protect the valves in the pilot circuit of the control unit against damage from impurities in the medium. This filter cartridge requires maintenance. Regular replacement, however, is only necessary when the filtration in the face supply unit is insufficient. Therefore, take care to ensure a high level of quality when processing the hydraulic medium.

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

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If a large number of electrohydraulic control units have been placed in service on a face at the same time, it is sufficient to examine the filter cartridges randomly. If the inspection reveals that there is a high probability of failures due to soiled filter cartridges all filter cartridges on the face must be replaced.

Filter cartridge Replacing the filter cartridge CAUTION! Only use each filter cartridge once and do not attempt to clean it. Dirt in the hydraulic system is a frequent cause of costly repairs. You should generally only use new filter cartridges and seals.

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 E

build up in the hydraulic system as a result of the loads on the props and cylinders.

DBT GmbH, Lünen 2006

. 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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5.5

Filter cartridge Unscrew the filter cartridge

. Remove any dust and dirt from the electrohydraulic control unit.

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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DBT - Electrohydraulic Control Unit - 10 Functions

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 electrohydraulic control unit can be pressurized again. Remove the securing elements only when you are sure that the hydraulic components function properly.

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Accumulator cartridge Accumulator cartridge WARNING! Do not operate the control valve block without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the control valve block or the shield. This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

IMPORTANT! The accumulator cartridge is not included in the scope of supply of the control valve block. Please remember this information when ordering replacement parts.

IMPORTANT! A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

Fig. 11:

Accumulator cartridge, arrangement

a

a accumulator cartridge

Replacing the accumulator cartridge Preparations

. Secure the shield mechanically to prevent it from lowering under its own weight.

WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

. Close the shut-off valve in the pressure feed line. . Operate the opposite acting pairs of hydraulic functions several times alternating, to depressurize the hydraulic system of the shield support.

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The accumulator cartridge is located at the front of the manifold block, to the left of the solenoid pilot valves. See Fig. 11.

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Accumulator cartridges must be checked for correct operation at regular intervals. We recommend to perform this test on a random sample basis. For this purpose, select a few samples and replace them by new cartridges. Test the samples to make sure they function properly. If they do, they can be installed again.

Accumulator cartridge . Check the control valve block for any residual pressure.

Observe also the hose connection diagram and hydraulic circuit diagram.

Only when you are sure the system has been depressurized, you can continue with the next working steps.

Removing the accumulator cartridge CAUTION! Impurities in the hydraulic medium can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Remove any dust and other impurities from the accumulator

cartridge and the surroundings in order to prevent dirt entering the hydraulic system during assembly / disassembly of the accumulator cartridge.

WARNING! If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

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Fig. 12: Replacing the accumulator cartridge

b

a a staple

b accumulator cartridge

. Pull the staple (a) out to below. . Pull the accumulator cartridge (b) out to the front.

Installing the accumulator cartridge The new accumulator cartridge is installed in the reverse order of removal. Prior to installation, apply a separating agent/lubricant (B6 acc. to EWN 7068) to the surfaces to be joined. See also chapter 6, section ”Lubricating greases and pastes”.

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Accumulator cartridge

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6

Technical data

Description

Technical data This chapter contains important and useful information on the design and materials used. Information on permissible hydraulic fluids and recommendations on lubricants can be found at the end of the chapter.

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

Description Functions The electrohydraulic control unit permits to control 10 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 PMC®--R.

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Fig. 13: Electrohydraulic control unit, front view

a

b

c

a accumulator cartridge port, DN20 b manifold block

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c pilot control valves

6.3

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

– directional valves, – check valve, – filter cartridge – accumulator cartridge port and – connecting sockets J pilot control valves Fig. 14: Electrohydraulic control unit

DBT GmbH, Lünen 2006

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a

b

e

d

c a rear connecting sockets

d push buttons e plug contact, electrical connection to the control unit

b manifold block c pilot control valves

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

The seal materials are designed for operation with HFA hydraulic fluids (oil-in-water emulsions).

Dimensions and weight depth: . . . . . . . . . . . . . . . . . . . . . . width: . . . . . . . . . . . . . . . . . . . . . . height: . . . . . . . . . . . . . . . . . . . . . weight: . . . . . . . . . . . . . . . . . . . . .

280 mm 298 mm 154 mm 46,5 kg

Pressure permissible working pressure: . test pressure: . . . . . . . . . . . . . . .

6.4

350 bar 400 bar

DBT - Electrohydraulic Control Unit - 10 Functions

Description 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 µm).

See also chapter: Operation; “Replacing filter cartridge”

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

Fig. 15: Threaded bores M10

M10

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M10

Valves Directional valves: J 3 x 3/2-way directional control valves (NG 20) J 8 x 3/2-way directional control valves (NG 13)

They are controlled by pilot control valves.

Pilot control valves: J 5 x double 3/2-way directional control valves (NG 0.5)

The pilot control valves are operated by a control unit (e.g.

PMC®-R). They 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.

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.

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Hydraulic flow diagram Specification of the double 3/2-way directional control valves Classification according to directive 94/9/EG (ATEX): . . . . . . . . . . . . . . . . protection type: . . . . . . . . . . . . . . . . . . connectors: . . . . . . . . . . . . . . . . . . . . . solenoid design: . . . . . . . . . . . . . . . . . rated voltage: . . . . . . . . . . . . . . . . . . . perm. deviation: . . . . . . . . . . . . . . . . . switching current: . . . . . . . . . . . . . . . . current reduction: . . . . . . . . . . . . . . . .

group I, category M2 EExib l OS4 solenoid, round, 57 ohm type: DMA3 12 V, DC -2%/+10% approx. 190mA down to approx. 40 mA

WARNING! As soon as the current drops to a level below 40 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

Tab. 1: Certified Dust-Ex unit certification body

approval no.

Europe

INERIS, ATEX

05 ATEX 0049

USA

MSHA

18-ISA050002-0

Australia

Telesafe, ANZEx

05.4015X

Hydraulic flow diagram Fig. 16: Electrohydraulic control unit, 10 functions

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area of application

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

Fig. 17: Electrohydraulic control unit, rear view

10

8

6

4 2

2

1 P

9

7

5

3

T

Hydraulic connections connections: . . . . . . . . . . . . 3 x DN 20 socket, plug-type 1, 2, 2, SP (accumulator cartridge marking: . . . . . . . . . . . . . . . . port, front) flow rate: . . . . . . . . . . . . . . . . max. 340 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . large-volume consumers

medium-volume consumers

connections: . . . . . . . . . . . . 2 x DN 12 and 6 x DN 10 socket, plug-type marking: . . . . . . . . . . . . . . . . DN 12: 3, 10 DN 10: 4, 5, 6, 7, 8, 9, flow rate: . . . . . . . . . . . . . . . . max. 180 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . medium-volume consumers

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large-volume consumers

pressure supply and tank line

connections: . . . . . . . . . . . . 2 x DN 25 socket, plug-type marking: . . . . . . . . . . . . . . . . P (pressure supply) T (tank line) flow rate: . . . . . . . . . . . . . . . . max. 340 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . pressure supply to the system resp. return line to the tank

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6.7

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

For the operation of hydraulic components of DBT GmbH generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWM 8350 or an exemption permit of DBT GmbH is available to the respective operator. DBT GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

Suitability test Before the certificate of DBT GmbH is issued for a hydraulic fluid the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by DBT GmbH. For the tests, the criteria as specified in EWN 8350 will be applied. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to J stability J sealing materials J corrosion

In addition, a chemical ”fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

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

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If a mine only uses individual hydraulic components without applying DBT shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid as is used for the existing shield support shall be allowed to be used for these individual components, subject to approval by DBT. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by DBT GmbH upon request.

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

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of hydraulic systems of DBT GmbH for each product tested. The respective certificate shall be valid for a period of one year and, after a simplified test, can be extended for an additional year each. The certificate shall become invalid if one or several of the prerequisites for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

The following illustration shows a typical certificate.

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Fig. 18: Typical certificate

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6.9

Permissible media Hydraulic fluid maintenance A consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

These properties include: temperature, foaming, pH-value, concentrate ratio, and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously the properties listed in the following should be checked at least once every week: J pH-value

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: see certificate – Target value: < 105 Kol/m In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible max. temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following table 2 lists limit values for the essential properties and components of the water.

If the limit values shown are maintained it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not met this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will also lead to the loss of the certificate even if they are within the limit values mentioned.

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J Microbial load

Permissible media Tab. 2: Properties of the process water, limit values Test criterium

Limit value

Appearance, color, smell

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

electrical conductivity

< 1800 µS/cm

pH-value

6,5 ..... 8,5

Na+ - content

not specified

Mg+ - content

not specified

water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 Kol/ml

Ratio of solid foreign matter at 1,2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

- / 18 / 14

Lubricating greases and pastes DBT GmbH, Lünen 2006

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

Lubricating greases general properties

base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water: practically non-soluble in water

lubricating greases A1

temperature of application:

-20 to +120 °C

flash point:

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN 1) 7068 Tab. 3: Lubricating greases for general application

lubricating greases A2

Flash point in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

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

Tab. 4: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

1)

Doc. No.: 8154 118 000 BA 00

Flash point in °C

EWN = DBT standard

VTVL / 02

6.11

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

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

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

Lubricating pastes lubricating pastes B3

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

Type

Base

NLGI class

flash point °C

gleitmolybdän

gleitmo 805 *)

Li

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän ”gleitmo 805” lubricating pastes B6

Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water: non-soluble in water Temperature of application:

-34 to +120° C

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent and lubricant 785 (flash point 132 °C) IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

*)

6.12

The products listed in table 3 are suitable lubricating greases for filling of adjacent cavities.

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

Supplier

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Tab. 5: Lubricating pastes free from molybdenum disulfide

7

For your information

Service addresses

For your information If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Headquarters) Industriestraße 1 D-44534 Lünen Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: infodbt@dbt.de

Great Britain

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

DBT GmbH, Lünen 2006

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: martin.daldrup@dbtgb.com DBT GB Limited Engineering Pioneer House 2 Renshaw Place Europoint Office Park Eurocentral Lanarkshire, ML1 4UF Scotland Phone: +44 / 16 98 83 5 - 000 Fax: +44 / 16 98 83 5 - 038 Poland

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48 / 32 31 70 - 500 Fax: +48 / 32 31 70 - 509 E-mail: dbtpolska@dbtpolska.com

Russia

DBT Office Moskau Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: dbt@co.ru

Doc. No.: 8154 118 000 BA 00

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7.3

Service addresses OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: office@dbtrus.ru

Northamerica, Canada, Southamerica USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@dbtamerica.com DBT America Inc. 4041 Wurno Road Pulaski, VA 24301

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+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Australia DBT Australia Pty Ltd / DBT Diesel Pty Ltd 537 Lake Road Argenton, New South Wales 2284 P.O. Box 102 Boolaroo, New South Wales 2284 Tel: +61 / 24 95 8 - 3133 Fax: +61 / 24 95 8 - 5754 E-mail: tim.clark@dbtaustralia.com DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

South Africa Südafrika

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: zelda.stephens@dbtafrica.com

7.4

DBT - Electrohydraulic Control Unit - 10 Functions

DBT GmbH, Lünen 2006

Tel: Fax:

Service addresses Asia China

DBT China Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@dbtchina.com DBT (Langfang) Mine Technik Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@dbtchina.com DBT Tangshan Machinery Ltd.

DBT GmbH, Lünen 2006

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@dbtchina.com Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209 Tel: +86 / 47 78 28 - 7245 (& 7514, 7290) Fax: +86 / 47 78 28 - 7431 E-mail: Info.shenhua@dbtchina.com India

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

Doc. No.: 8154 118 000 BA 00

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+91 / 33 24 2 - 0272 +91 / 33 24 2 - 8684

7.5

DBT GmbH, Lünen 2006

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Service addresses

7.6

DBT - Electrohydraulic Control Unit - 10 Functions

Operating Manual DBT - Water valve unit 4 functions Doc. No.: 8401 007 240 BA 00

DBT GmbH Industriestrasse 1 Telephone: +49 (0) 23 06 / 709 - 0 E-mail: infodbt@dbt.de D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Internet: www.dbt.de A Bucyrus International, Inc. company

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

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

We reserve the right to introduce modifications as a result of technical developments without previous notice!

DBT GmbH, Lünen 2007 E A Bucyrus International, Inc. company

Contents

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

1.3

Persons for whom this operating manual is intended . . . .

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

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

1.3 1.3 1.4

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

2.3

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

Repair and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

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

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

2.4 2.4

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

2.5

DBT GmbH, Lünen 2007

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

3.3

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

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.4

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

3.5

Transport boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3.5 3.5 3.5

4. Installation Installation of the control unit . . . . . . . . . . . . . . . . . . . .

4.3

Removing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of the control unit . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.4

5. Operation

Doc. no.: 8401 007 240 BA 00

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

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

5.4

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

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

5.4 5.4

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Contents 6. Technical Data Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

Main components+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.3 6.4 6.4 6.4 6.4 6.5

Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . .

6.6

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

6.7

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

6.7

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.8 6.11

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.13

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

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

North America, Canada, South America . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.4

DBT- Water valve unit - 4 functions

DBT GmbH, Lünen 2007

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7. For your information

1

About this manual

Before starting work

About this manual This chapter contains important information to make it easier for you to use this manual. It also provides you with information on the structure of the manual and the symbols used.

Before starting work use the correct manual

Using an operating manual that was not specifically written for the control unit concerned can result in a safety hazard for yourself and others. Ensure that the specifications on the control unit comply with the specifications in the operating manual.

This operating manual is designed for: Water valve unit - 4 functions device number 8401 007 240 00 00 and is only permitted to be used for control units of this type. Only use the operating manual which applies to the respective control unit. Failure to do so will pose a danger to yourself and others.

E

availability of operating manual

It is absolutely necessary to ensure that all persons working with or on the control unit always have unrestricted access to the contents of the current, applicable operating manuals.

DBT GmbH, Lünen 2007

Persons for whom this operating manual is intended This operating manual is intended for everyone concerned with J installing, J servicing, J repairing, J operating and J removing J the control unit.

The supervisors who ask initiate the above work or supervise it must also follow this operating manual.

Purpose of this operating manual efficiency

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

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

safety

Read chapter 2 “Your safety” closely. This chapter contains important information indicating potential hazards.

operating costs

Observe this information and follow the instructions in this operating manual. This is the only way that you can keep the operating costs down and retain your rights to make a claim under the warranty.

guarantee

Doc. no.: 8401 007 240 BA 00

SUVA / 01

1.3

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

Try to memorize the symbols and their meanings.

Danger!

Points in the text marked with this symbol point out 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

Items in lists are marked with bullets.

–

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

.

The hand symbol prompts you to take action.

Several successive paragraphs marked with the hand symbol represent a sequence of actions which must be executed in the order specified. Follow these instructions step-by-step in order to perform the work safely and efficiently.

DBT- Water valve unit - 4 functions

DBT GmbH, Lünen 2007

Notice!

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

E

Caution!

This symbol draws attention to dangerous situations. Possible consequences are: minor to moderately serious injuries and damage to the machine.

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 unit was manufactured in accordance with state of the art and generally recognized safety standards and regulations.

However, a residual risk still exists which may involve you getting into hazardous situations when working with or on the control unit.

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 mines inspectorate, and

E

J of the mining supervisory authorities.

DBT GmbH, Lünen 2007

Personnel Persons employed in the operation, repair and overhaul of hydraulic and/or electrohydraulic control components must be specially qualified. In addition to having had training in mining technology, the following minimum requirements must be met.

Operation and maintenance qualification

Operation and maintenance of the shield control system may only be performed by trained personnel.

The training must be specially tailored to the type of control unit actually being used.

The content of the operating manual, especially the chapter on safety, must constitute a part of this training.

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

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2.3

Operating conditions Repair and maintenance In general, repair work may only be performed by persons who have the 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 units, J working valves, J pilot valves, J safety components such as pressure relief valves etc.

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

Operating conditions Intended use

The water spraying system serves to actively counteract dust.

Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily depending on the operating state of the system, for example when pushing the shield and when the mining equipment passes the support.

The water spraying valves are controlled by the program of the electronic shield control or directly by means of the hydraulic shield control system.

Unauthorized use All use, which is not expressly declared as intended, is regarded as unauthorized use Unauthorized use can endanger yourself and others. You might be killed or seriously injured.

You should thus only use the electrohydraulic control unit as intended.

DBT will accept no responsibility for the consequences of unauthorized use.

2.4

DBT- Water valve unit - 4 functions

DBT GmbH, Lünen 2007

water spraying system

E

The water valve unit serves to control the water spraying system.

It is only used in conjunction with an electronic control system, for example a PMC®-R control system.

Only use the water valve unit as intended.

Safety instructions Safety instructions The following always applies: general

Always concentrate on your work.

It is also imperative that you follow the operating manual for the support and the control unit.

Always familiarize yourself with the working environment before starting work.

Always keep out of any shield which is not set.

Always wear your personal protective clothing and equipment.

Observe the acoustic and visual start-up warnings. Pay special attention to the start-up warnings for the conveyor and for the mining equipment.

requirements

Only use control units which are in a technically flawless condition.

EMERGENCY STOP

Press the EMERGENCY STOP switch immediately, in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, in order that necessary action can be taken immediately.

DBT GmbH, Lünen 2007

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support lock-out switch

If the shield is equipped with an electrohydraulic control unit, you must lock-out the shield by pressing the support lock-out switch (repair switch). This means the shield can not be controlled via the control unit.

Press the support lock-out switch when performing: J maintenance work, J inspection work, J repair work, J and during 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 skids, J relay bar assemblies, J lemniscatic links, J hydraulic props and cylinders, J canopies and J flippers.

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2.5

Safety instructions Storage and transport Never store materials of any kind in the travel way or in your working area.

To avoid hindering or endangering the face crew, immediately remove any faulty components from the face.

Never store faulty parts with good parts. This way you can avoid inadvertent reinstallation of these faulty components somewhere else. Have these faulty components repaired.

Observe the specified storage periods and the storage instructions.

Installation Mechanically secure all moving parts before you depressurize the hydraulic system.

As a matter of principle, only work on depressurized hydraulic systems.

Make sure that no dirt or impurities can get into the hydraulic system.

Only remove the protective caps from the connections immediately before installing the control unit.

Only work in repair mode if it is absolutely necessary. If possible control the shields from the control unit of the neighboring shield.

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

Make sure that no one is in the area of the shield being actuated.

Watch the shield’s range of motion so that potential hazards can be recognized in time and preventative action can be taken.

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

Keep your working area clear to avoid danger to yourself and other persons.

Block off the working area for the mining equipment or stop the equipment and the conveyor and lock the system, to prevent it from being turned on again.

Before performing work, mechanically secure the shield to prevent it from accidentally sinking into the floor, e.g. by: J propping up or supporting the canopy, J placing wooden wedges between the lemniscatic links.

2.6

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Operation

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

Immediately after completing work, refit any removed protective devices and check that they work properly.

Make sure that the prescribed maintenance and inspection intervals are observed. original parts

Use only spare parts which conform to the specified technical requirements. This is best ensured by using original DBT spare parts.

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

Do not make any modifications or changes. All modifications and changes must be approved by DBT. Never use the control unit without a filter cartridge. If the filter is missing or if it is not fine enough, this can lead to malfunctions and damage to the control unit.

Hydraulic system

handling hydraulic fluids

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

E DBT GmbH, Lünen 2007

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

protective devices hydraulic system

Note that when dismantling protective equipment that includes hydraulic components, that they can be pressurized. You could be severely injured by hydraulic fluid jetting out wildly. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

maintenance, repair

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

pressure relief valves

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace defective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: J the hoses are not pinched or trapped J the hoses have no bubbles or blisters J the hoses or the outer sheaths of the hoses are not abnormally

rigid or hard J the outer sheath of the hose is not damaged J the connectors are securely inserted into the coupling sockets J the connections are leak-tight.

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2.7

Safety instructions 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.

Before removing the coupling clips for disconnecting the hydraulic hose lines, turn the hose at the coupling socket to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the line.

If coupling clips are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Do not fail to depressurize the line.

Only secure the coupling sockets of the hydraulic elements with the proper coupling clips. Always fasten the clips completely with both sides.

Never use nails, wire or similar materials to secure the connectors.

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.

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, identification 3 2 1

5

6

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

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a hydraulic hose that is thrashing about. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged.

2.8

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

E

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

Safety instructions laying hydraulic hoses

Lay the hydraulic hoses correctly behind the brackets and clips provided for them.

Always lay hydraulic hoses so that they: J always have a little slack, Fig. 2:

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted Fig. 3:

Laying hydraulic hoses, twisting WRONG

DBT GmbH, Lünen 2007

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RIGHT

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter) Fig. 4:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe Fig. 5:

Laying hydraulic hoses, crossing RIGHT

WRONG

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

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2.9

Safety instructions Only push hydraulic hoses into the connectors 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 equipment (Fig. 6).

Fig. 6:

Laying hydraulic hoses, connections on moving parts WRONG

DBT GmbH, Lünen 2007

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RIGHT

2.10

DBT- Water valve unit - 4 functions

3

Storage and transport

Storage

Storage and transport This chapter contains important information concerning the proper storage and transport of the electrohydraulic control unit.

Observance of the instructions and tips will prolong the service life of the control unit. You will also find instructions on how to transport safely and efficiently.

Reading this chapter carefully will help you to simplify your day-today work.

Storage Storage of new equipment corrosion protection

Prior to delivery, hydraulically operated equipment is filled with the anticorrosion and antifreeze fluid HYDROCOR® CV50*) and tested.

The fluid remains in the hydraulics system for the purpose of transport and (if required) subsequent storage.

HYDROCOR® CV50 is frost-free down to -40 °C and protects the used metallic materials from corrosion. It contains a color indicator which reacts when the pH value drops. The color of the medium changes from “red” to “yellow” here. The yellow coloration indicates that the anticorrosion protection is no longer adequate.

E DBT GmbH, Lünen 2007

The surfaces of the equipment are coated with temporary corrosion protection. If stored properly, the equipment parts will be protected for a period of six months, starting from the date of delivery.

Additional information concerning the characteristics of the HYDROCOR® CV50 can be obtained as needed from the respective manufacturer’s data sheet. sunlight

Electrical equipment, electronic components, spare parts made of rubber or plastic - such as seals and hoses - and hydraulic fluids must be stored in closed rooms at 15 °C to 25 °C, and protected from direct sunlight.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. A storage period of approximately two years is therefore specified for these parts as a guide value.

moisture and dirt

All hydraulic elements must be appropriately protected against the penetration of dirt and moisture during storage. The connection surfaces of the hydraulics components that remain in the device must be protected against corrosion and sealed with blind plates. Hydraulic plug connections and electrical cables must be sealed with suitable caps or plugs.

*)

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HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal / Germany

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During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. They do however still need to be specially protected against environmental influences, and also against high temperatures, e.g. by suitable protective plates and/or sheathings for the control systems and by supplementary covering of the equipment.

long-term storage

If storage is expected to last longer than six months, then all of the cavities in the hydraulic components must be filled completely with a corrosion inhibitor and antifreeze liquid, such as HYDROCOR® CV50. The fluid must have corrosion protection properties and be frost-proof within the temperature range intended for the application. All connections must be sealed with durable and suitable plugs.

It is highly recommended that the equipment not be stored outdoors. It should be stored in a dry, well-ventilated room. If this is not possible for the entire support unit, for example, then the hydraulic and electronic components might have to be dismantled and stored separately.

random sample inspection

Random sample inspections must be carried out after a storage period of approximately two years. This will make it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

This can be checked by DBT upon request of the mine. The mining company will bear the cost for this.

HFA fluids

The regulations stipulated by the manufacturer or of the supplier take precedence in every instance involving the storage of HFA fluids and/or concentrates for the production of HFA fluids. Additional information can also be found in chapter 6, in the section “Permissible media”.

When removing stock from storage or when placing it there, take care to ensure that any new supplies are stored separately from existing stock in such a way that old stock is always taken first when supplies are required for use. Label the containers accordingly.

Storing used equipment The points listed above, with the exception of the one concerning anticorrosion protection, can be applied analogously for the storage of hydraulic components that have already been in use. corrosion protection

3.4

If the hydraulics system is to be put out of operation temporarily, the entire hydraulics system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor and antifreeze liquid (e.g. HYDROCOR® CV50). If this is not done, the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, negative changes, e.g. due to microbial infestation.

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Storage

Transport Transport Transport boxes The control units are packed in several transport boxes. They should stay in these boxes until they reach their final operating location. This protects them from external damage.

Make sure that the boxes are not damaged during transport. During transport, make sure that they are not: J dropped, J broken open.

Protect the transport boxes from moisture. avoid frost damage

Before transporting the equipment at temperatures below freezing, all of the hydraulic components must be completely emptied and then completely filled with a corrosion inhibitor (e.g. HYDROCOR® CV50).

If, during transport, the control unit is exposed to temperatures below -20 °C, then special measures may have to be taken. In this case, before starting transport, contact DBT’s service department to clarify the necessary measures.

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Dimensions and weight Depth: . . . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . .

207 mm 102 mm 103 mm 8.8 kg

Plugs The connections for the individual control units are closed off with plastic plugs. This protects them from moisture, dirt and damage.

Notice!

Impurities in the hydraulic system can lead to the failure of the entire system, making expensive repairs necessary.

For this reason, you should only remove the plugs just before the control unit is connected.

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Transport

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Installation

Installation of the control unit

Installation This chapter contains information on the installation and deinstallation of electrohydraulic control units. Please pay special attention to the warnings and tips.

Warning!

Improper or faulty installation can endanger yourself and others.

You may only carry out the installation if you can demonstrate that you have the requisite, special knowledge.

Installation of the control unit Removing the control unit Before you can start with the installation or exchange of the control unit, you must take safety precautions: safety

. Seal off your working area to keep all other personnel out. . Have mining stopped in this area. . Inform your colleagues about the nature and duration of the

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repair work and about your exact location. switch hydraulic pressure off

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

removing control unit

If everything is OK so far, then you can continue with the next step.

. Label the connecting cables and hydraulic hoses to avoid mixups later on.

. Pull off the connecting cable from the cover of the pilot valve.

Danger!

Never work on a hydraulic line, if you are not sure that the line is completely depressurized.

If loose hydraulic hoses are thrashing about and hydraulic fluid is escaping under pressure, you could be seriously injured or even killed.

It is thus vital that you depressurize hydraulic components before you start to dismantle them.

If a coupling clip can’t be pulled out, or is very stiff, then you should be very careful. It is possible that the hydraulic line is still under pressure.

. Undo all of the hydraulic connections on the rear side of the control unit and make sure that the connections are not damaged or soiled when doing this.

. Undo the screws on the mounting of the control unit. . Pull the control unit out of the mounting.

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Installation of the control unit Installation of the control unit To install the control unit,

. place the control unit in the mounting and tighten the screws (M10) by hand.

Fig. 7:

Example

2

A

1

4

Caution!

Before the hydraulic connections are made, the sockets and nipples of the connectors must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, section “Lubricating greases and pastes”.

. Connect the hydraulic hoses. Ensure that you do not mix up the connections.

Follow the hose plan and the labeling of the hoses.

Danger!

You could be seriously injured or even killed by a hydraulic hose that is thrashing about!

Only use the correct size of coupling clip to secure connectors. Push the clips on completely, using both sides of the clip.

Never use nails, wire or similar materials. safety

. Check the hose connections again. The hose nipples must be firmly seated in the connector and must be locked in place with a coupling clip. Both arms of the clip must fit in the connector.

Ensure that the connections don’t leak.

. After you have connected and checked the hoses, plug in the connecting cable from the electrohydraulic control unit into the connection on the pilot valve. Follow the circuit diagram and the labeling of the cables.

. Check all of the connections again using the wiring plan.

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4 hex nut M10-A 2-70 a water valve unit

DBT GmbH, Lünen 2007

1 clip 2 cylinder head screw M10x20-1.4571 3 hex. head screw M10x25-A 2-70

3

Installation of the control unit . Test all of the control unit functions and remove all of the safety measures used.

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Warning!

Only release the control unit for use once you have checked that it works properly and did not find any malfunctions.

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Installation of the control unit

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Operation

Main components

Operation This chapter provides you with information on the operation of the water valve unit.

Main components Fig. 8:

Water valve unit, 4 functions 4

22

1

5

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3

12, 13 1 double 3/2-way magnetic pilot solenoid valve 3 connection plate 4 intermediate plate 5 valve cartridge

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12 screw fitting M10x1-A 2-70 13 sealing ring A 10x14 22 cylinder head screw M6x30-A 4-80 components not listed can be found in the spare parts catalog supplied.

5.3

Operation and function of the pilot valves Operation and function of the pilot valves Operation There are two pushbuttons on the cover of each pilot valve. If you push one of these buttons, the corresponding valve is immediately operated.

As soon as you release the button, the function is ended.

Pushbutton

Function variable functions

5.4

The function of each pilot valve is variable and depends on the external circuitry of the control unit. A symbol strip shows the function of the buttons.

The symbol strip is mounted near the pilot valve.

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Fig. 9:

Technical description

Technical Data This chapter contains important and useful information about the type of construction of the control unit and the materials used. At the end of this chapter, you will find information about permissible hydraulic fluids and recommendations on lubricants.

Important!

Please refer to the corresponding spare parts catalogue for the details necessary to order spare parts.

Technical description Functions Four functions can be controlled independently of one another using the water valve unit. The control unit’s working valves are driven via electromagnetic pilot valves. An electronic control unit is required to control the pilot valves, for example a PMC®-R, type control unit.

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Fig. 10: View of the water valve unit, example

a

b

a control unit b water valve unit

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Technical description Main components+ The main parts of the electrohydraulic control unit are: J Distribution block with

– working valves, – connection socket J pilot valves.

Fig. 11:

Water valve unit, 4 functions c

5 1

3

a 2

1 double 3/2-way magnetic pilot solenoid valve 3 connection plate

a pushbutton

4 intermediate plate 5 valve cartridge

c connection socket on the rear side

b connecting sockets for control unit

Materials used The control unit is made of corrosion resistant materials such as stainless steel, brass, bronze, etc.

The seal materials are designed for operation with HFA hydraulic fluids (oil in water emulsions).

Dimensions and weight Depth: . . . . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . .

207 mm 102 mm 103 mm 8.8 kg

Pressures Permissible working pressure: 350 bar Test pressure: . . . . . . . . . . . . . . 400 bar

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b

Technical description Valves Working valves: J 4 x 2/2-directional control valves (UG)

They are driven via pilot valves.

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

The pilot valves are driven by a control unit (e.g. PMC®-R). In an emergency, or for repairs, they can also be operated directly. For this, two pushbuttons are fitted in the valve cover.

The power supply to the pilot valve comes from the electronic control unit. In the housing cover of each pilot valve there are 4 contacts, which serve to attach a suitable connecting cable.

Double 3/2-directional control valve parameters

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Classification according to guidelines 94/9/EC (ATEX): . . . . . . . . . . . . . . . . . . . .

Protection class: . . . . . . . . . . . . . . . . . . . .

Connector type: . . . . . . . . . . . . . . . . . . . .

Type of magnet: . . . . . . . . . . . . . . . . . . . .

Nominal voltage: . . . . . . . . . . . . . . . . . . .

Perm. variation: . . . . . . . . . . . . . . . . . . . .

Switching current: . . . . . . . . . . . . . . . . . .

Lowest current: . . . . . . . . . . . . . . . . . . . . .

Group I, category M2 EExib l OS4 Electromagnet, around 57 Ohm Type: DMA3-1 12 V, DC -2%/+10% approximately 190 mA at most, down to 40 mA

Warning!

As soon as the current falls to a level below 40 mA, the switch settings will become unstable. This can lead to malfunctions or to the failure of the control unit.

Tab. 1: Mining approvals

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Apply in

Approval authority

Approval no.

Europe

INERIS, ATEX

05 ATEX 0049

USA

MSHA

18-ISA050002-0

Australia

Testsafe, ANZEx

05.4015X

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Hydraulic circuit diagram Hydraulic circuit diagram Fig. 12: Water valve, 4 functions W

P

W4 W4

W3 W3 W2 W2

W1 W1

W (input) = DN 20 P, W1, W2, W3, W4 and leakage = DN 10

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leakage

Connections Connections The connection sockets for the hydraulic lines are on the rear side of the control unit.

Fig. 13: Control block, rear view

W3

W1

P

W4

W2

W L

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W input L leakage P pressure

Hydraulic connections consumer of medium quantities

Connections: . . . . . . . . . . . . 4 x DN 10, socket, Steck-0 Identification: . . . . . . . . . . . . DN 10: W1, W2, W3, W4 Flow rate: . . . . . . . . . . . . . . . max. 180 l/min at ∆p = 100 bar Use: . . . . . . . . . . . . . . . . . . . . Consumer of medium quantities

connections for water supply

Connections: . . . . . . . . . . . . 1 x DN 20 socket, Steck-0 Identification: . . . . . . . . . . . . W Flow rate: . . . . . . . . . . . . . . . max. 340 l/min at ∆p = 100 bar Use: . . . . . . . . . . . . . . . . . . . . Water supply

connections for pressure feed

Connections: . . . . . . . . . . . . 1 x DN 10 socket, Steck-0 Identification: . . . . . . . . . . . . P Flow rate: . . . . . . . . . . . . . . . max. 180 l/min at ∆p = 100 bar Use: . . . . . . . . . . . . . . . . . . . . Pressure feed

leakage connection

Connections: . . . . . . . . . . . . 1 x DN 10 socket, Steck-0 Identification: . . . . . . . . . . . . L Use: . . . . . . . . . . . . . . . . . . . . Leakage Important!

The Leakage connection must not be connected to the return, it must be arranged so that it can discharge freely.

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by DBT GmbH. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

For the operation of hydraulic components from DBT GmbH, generally only such hydraulic fluids may be used for which there is a valid certificate in accordance with EWN 8350 or an exemption permit from DBT GmbH is available to the respective operator. DBT GmbH will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

Suitability test Before the certificate of DBT GmbH is issued for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by DBT GmbH. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

In addition, a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

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

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If a mine only uses individual hydraulic components without using DBT shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by DBT. The same applies, for example, to hydraulic chain tensioners, hydraulically tensionable drive units, etc.

The respective exemption permit will be issued by DBT GmbH on request.

E

In addition, when operating this equipment national and sometimes also regional health and safety at work regulations and any environmental regulations must be observed.

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of DBT GmbH hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can respectively be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information,please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

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Fig. 14: Typical certificate

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Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator must draw up a maintenance concept for the hydraulic fluid that relates to the respective conditions of use. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: see certificate – Target value: ≤ 105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following Table (Tab. 2) contains limit values for the essential properties and components of the water.

If the limits shown are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not met this should be taken into consideration when selecting a concentrate. Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to allow the tests required for the issue of the certificate to be performed.

Changes in the composition of the water will also lead to the loss of the certificate, even if they are within the limit values mentioned.

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J Microbial load

Permissible media Tab. 2: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 µS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

Ratio of solid foreign matter at 1.2 µm -filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

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Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

Basis of grease: . . . . . . . . . . . . . . . lithium soap NLGI class: . . . . . . . . . . . . . . . . . . . 2 Worked penetration: . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: practically insoluble in water Temperature of application: . . . . . . -20 to +120 °C Flashpoint : . . . . . . . . . . . . . . . . . . . ≧ 200 °C

lubricating grease A1

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *) 7068).

Tab. 3: Lubricating greases for general application

lubricating grease A2

Flashpoint in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load Tab. 4: Lubricating greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*) EWN = DBT works standard

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Permissible 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 that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

Lubricating pastes lubricating paste B3

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

Type

Base

Gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 is used in accordance with the DBT works standard EWN 7068: Gleitmolybdän “gleitmo 805” lubricating paste B6

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support Behavior in the presence of water: . . . non-soluble in water Temperature range for use: . . . . . . . . . -34 to +120 °C When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B 6 in accordance with the DBT works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flash point 132 °C) Important!

The instructions for mixing lubricating greases also naturally apply to the lubricating pastes.

*) The products listed in table 3 are suitable lubricating greases for filling of adjacent cavities.

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Tab. 5: Lubricating pastes free from molybdenum disulfide

Tightening torques Tightening torques Screws with ISO metric thread Tab. 6: Tightening torques at µtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

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Tightening torque 4)

Pitch P

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

36 m

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

1) 2) 3) 4)

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The dimensions listed in brackets are used in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

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

The tightening torques comply with the DBT works standard (EWN 6003).

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Tightening torques

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For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact out after-sales service personnel or contact us directly (Homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Head office) Industriestrasse 1 D-44534 Lünen, Germany Tel: +49/23 06 70 9 - 0 Fax: +49/23 06 70 9 - 1421 E-mail: infodbt@dbt.de

Great Britain

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

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Tel: +44 /11 59 51 - 2500 Fax: +44/ 11 59 32 - 9683 E-mail: martin.daldrup@dbtgb.com DBT GB Limited Engineering 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44/16 98 83 5 - 000 +44/16 98 83 5 - 038

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48 / 32 31 70 - 500 Fax: +48 / 32 31 70 - 509 E-mail: dbtpolska@dbtpolska.com

Russia

DBT Moscow office Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7/49 56 23 - 5396 Fax: +7/49 59 24 - 8363 E-mail: dbt@co.ru OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7/38 43 35 - 3441 Fax: +7/38 43 35 - 3442 E-mail: office@dbtrus.ru

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Service addresses North America, Canada, South America USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@dbtamerica.com DBT America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia DBT Australia Pty. Ltd.

DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: zelda.stephens@dbtafrica.com

Asia China

DBT China Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@dbtchina.com

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DBT- Water valve unit - 4 functions

DBT GmbH, Lünen 2007

Tel: +61/24 91 4 - 7144 Fax: +61/24 91 4 - 7169 E-mail. Ron.Spencer@dbtaustralia.com Internet: http://www.dbt.de

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Customer Service 20 Killara Close, Beresfield, New South Wales 2322

Service addresses DBT (Langfang) Mine Technik Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@dbtchina.com DBT Tangshan Machinery Ltd. No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86/31 53 20 - 3117 (& 3445, 3404) Fax: +86/31 53 20 - 3438 E-mail: Info.tangshan@dbtchina.com Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209

DBT GmbH, Lünen 2007

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Tel: +86/47 78 28 - 7245 (& 7514, 7290) Fax: +86/47 78 28 - 7431 E-mail: Info.shenhua@dbtchina.com India

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

Doc. no.: 8401 007 240 BA 00

SUVA / 01

+91/33 24 2 - 0272 +91/33 24 2 - 8684

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DBT GmbH, Lünen 2007

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Service addresses

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DBT- Water valve unit - 4 functions