CAT DBT shield 1143 3048-2X4113-1750 Operating Manual

Operating manual DBT Shield 1143/3048-2X4113-1750 Doc. No.: 7420 181 000 BA 00

DBT GmbH Industriestraße 1 Telephone: +49 (0) 23 06 / 709 - 0 D-44534 Lünen Fax: +49 (0) 23 06 / 709 -1421 A Bucyrus International, Inc. company

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

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

Its content is protected by copyright 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

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

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

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 equilibrium of the electronic control system . . . .

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

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

4.5 4.6 4.10

Requirements for the face hydraulic system . . . . . . . 4.11 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

4.12 4.13

Corrosion protection of hydraulic components . . . . . 4.14

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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 automatic dual backflush filter . . . . . . . . .

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

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

Shield variant functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.15 5.17 5.18 5.24 5.35 5.36 5.38 5.39 5.41 5.42 5.43 5.44 5.44 5.44

Remedying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 Troubleshooting tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

5.45 5.45 5.48 5.48 5.49 5.49 5.49

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

6.3

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

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

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

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

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

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

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

6.4 6.6 6.7 6.10 6.12 6.13 6.14

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

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

6.15 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42

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 6.27

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29 Shield control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic control unit PMC®-R . . . . . . . . . . . . . . . . . . . . . .

6.31 6.32

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.33 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.34 6.37

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.39

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7. For your information

Doc. No.: 7420 181 000 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 1143/3048-2X4113-1750

1

About this manual

Before starting work

About this manual This chapter provides you with important information making 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 is applicable 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 1143/3048-2X4113-1750 with the ID number 7420 181 000 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. If you don’t you will endanger yourself and others.

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Tab. 1: Type specification for DBT shield 1143/3048-2X4113-1750 Year of Application Device number Prop force manufacturing 7420 181 000 00 01 2 x 4113 kN availability of operating manual

2007

Endshield

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 economical 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 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 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.

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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 of the following: J of the mining company, J of the mines inspectorate, and

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J of the mining supervisory authorities.

DBT GmbH, Lünen 2007

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 specially tailored 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, J hydraulic, and 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 1143/3048-2X4113-1750

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 – advancing – aligning and – 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 regarded as 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 in this respect is given in the section “Operation” of this chapter and in Chapter 5 of this manual in the section “Operation of the shield”.

DBT does not accept any liability for any 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 signalling systems and safety equipment

Maintain the lighting systems in working condition.

Maintain the signalling 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 foreman 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 travelling 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.

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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. Moreover, this measure prevents 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 (both faceside and gobside). transporting

Connect the means of attachment only at the lifting 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 figures which are included in the spare parts catalogue.

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.

For round components, such as cylinders and props, which are not provided with lifting points, only use transport straps. 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, then these are pretensioned by spring force! Therefore, do not use force to remove the transport securing element 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 physical force.

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

travel way

Make sure that the minimum dimensions specified for the travel way with 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 not 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 1143/3048-2X4113-1750

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 travelling 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 device in the support unit currently operated.

Check to determine whether all safety equipment on the shield are 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 recognisable. This measure avoids faulty operation and any resulting accidents.

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 to 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 neighboring to the support, if necessary. This way you can prevent the conveyor from shifting to the side with respect 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 advancing the shields, always observe the specified sequence of steps to prevent the shields from colliding with the anchorage cylinders.

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2.9

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

The shields must be aligned at right angles with respect to the conveyor and parallel with respect to each another. 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 neighboring 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 J the stabilizing cylinder locks J the canopy will be loaded excessively in the longitudinal direc-

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

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 the entire 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 faceside.

Only use only 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.

2.10

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exceeded

Safety instructions 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.

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 lifting 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 safety equipment are included in the DBT scope of delivery, refer to Chapter 6 for their location.

DBT GmbH, Lünen 2007

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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.

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 catalogue provided for the equipment for 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 authorisation 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.

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2.11

Safety instructions 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, and 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.

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.

Hydraulics handling hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid which penetrates the skin can cause serious infections.

hydraulic system protective equipment

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 squirting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

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

maintenance, repair

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 in the whole system! Flush out the hydraulic lines thoroughly before connecting.

2.12

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DBT GmbH, Lünen 2007

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

E

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

Safety instructions Before removing staples to disconnect hydraulic hose lines, turn the hose at the coupling 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.

Secure the connectors of the hydraulic elements with the proper staples only. Always fasten the clips completely.

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 hose lines

Use only hydraulic hose lines 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

DBT GmbH, Lünen 2007

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2 1

6

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

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a hydraulic hose that is whipping 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.

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2.13

Safety instructions laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying hydraulic hoses, twisting WRONG

J are not bent directly behind the connections (distance min.

1.5 x nominal diameter), Fig. 5:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

2.14

Laying hydraulic hoses, crossing RIGHT

WRONG

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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RIGHT

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

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

When installing the hydraulic hoses, ensure that they cannot be: J torn out, J kinked, J crushed, J driven over or J twisting 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

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 context, their significance may not always be immediately obvious.

Chapter 3: Storage and 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.

Chapter 4: Installation Danger!

Damaged hose lines 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 hose lines can’t be damaged by movements of the support.

Lay the hydraulic hose lines correctly behind the brackets provided for them.

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.

Pressure may build up in the return line due to incorrect operation.

This must be relieved via the pressure release valve (see Fig. 16, Item 30) by screwing in vented cap screw a. 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!

2.16

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

For transporting, use the four lifting points S1 and S2. Use lifting points S3 to S6 only for aligning the shield - not for raising it.

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Caution!

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

Overview of the safety instructions The first start-up and test run may only be carried out by a welltrained 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.

Bent support canopies may not project into the mining area.

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.

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”.

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”.

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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 damage to property.

Take care to ensure that the pressure relief screw is released for the purpose of pressure equilibrium at the control system. The foil displays may become damaged if no pressure equilibrium is established.

Take care to ensure that the pressure relief screw is made handtight again after pressure equilibrium 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.

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.

Dangerous situations could arise as a result under unlucky circumstances, leading to accidents involving damage to property and/or injuries to personnel.

Implement for that reason all required measures in order to ensure that system pressure will not be able to fall below 180 bar at any place in the face hydraulics system.

Notice!

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

Make sure that all transport securing elements required for transport have been removed. See Chapter 3, Section “Transport”.

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2.17

Overview of the safety instructions Important!

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

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

Chapter 5: For Operating 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.

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.

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.

Do not put the filter into operation before making sure that all connections have been properly established. Be sure to observe the separate operating manual for the filter.

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. 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. If the control unit is included in the DBT scope of delivery, the respective operating manual will be included in the DBT documentation provided for the installation.

2.18

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

Warning!

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

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

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

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

Overview of the safety instructions You are only allowed to operate the controls of the electrohydraulic control unit if 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 incorrect operation. This could result in serious injury and even fatal accidents.

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 “pull 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.

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.

DBT GmbH, Lünen 2007

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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.

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.

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.

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

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.

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, hydrocylinders and their fastening elements, as well as to the part hinges.

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

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2.19

Overview of the safety instructions Do not exceed the permissible inclination!

Observe the value for minimum residual stroke!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke!

Notice!

It is important that the control system symbols are easily legible.

This prevents the risk of operational errors and any resulting accidents.

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.

Chapter 6: Technical data

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.

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!

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.

2.20

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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.

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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.

Overview of the safety instructions 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.

The setting pressure of pressure relief valves should not be changed! Only use pressure relief valves which have been factoryset 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.

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.

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.

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Notice!

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

The lifting points in the canopy (see Fig. 62) 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.

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

The technical data for the cylinders can be found in the “Technical Data, Hydraulic Cylinders” section for the support unit used.

Always fit new seals when replacing a pressure relief valve. Failure to comply with these instructions can lead to leaky plug connections and impair the operational safety of the hydraulics.

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

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.

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2.21

Overview of the safety instructions Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases 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.

The instructions for mixing lubricating greases also basically apply to the lubricating pastes.

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The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

2.22

DBT shield 1143/3048-2X4113-1750

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 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 anticorrosion 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 need not be removed. They do however still need to be protected, particularly against environmental influences, 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.

*

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

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3.3

3.4

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 separately stored.

storage outdoors

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 ageing

Even with proper storage, seals and hose lines are subject to natural ageing. 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.

plastic deformation

When storing subassemblies, such as props and cylinders, which contain sealed contact joints, sealing elements can be plastically deformed since they are constantly subjected to unilateral loads due to the weight of the parts. This can render the sealing element useless or reduce its service life considerably. This effect is mainly influenced by the size and duration of the acting force and the temperature at the time.

For this reason, only store the props, cylinders and similar parts in an upright position. This especially applies when the parts are to be stored for a relatively long period of time.

If you want to store a machine which contains the above-named parts, you might have to dismantle such parts for the purpose of proper storage.

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 request of the mine. The mining company will bear the cost for this.

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DBT GmbH, Lünen 2007

long-term storage

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Storage

Storage 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 stocks 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.

If the hydraulics system is to be temporarily put out of operation, the entire hydraulic 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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anticorrosion 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 catalogue 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, the external forces are only to be applied to the lifting points and retainer 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

degree of disassembly

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 safety devices, e.g. on side seals and flipper, so that their positions cannot shift inadvertently. Specifically, the following listed transport securing elements are provided on the transport units.

Tab. 3: Transport securing devices Part

Transport securing device

Quantity

Relay bar Faceside

Transport rod, chain

1

Gobside

Chain

1

Hydraulic connections not used are protected by protective caps or plugs

-

Hydraulics

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Caution!

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

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3.7

Transport Shield transport Fig. 8:

Transporting the endshield as a complete unit

Sy

H

SO

S3 Sx

X1

S4 X2

L

S1

S2

S6

B

S5

4566 S1

S2

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S5

S1 slot, 2x faceside on the base, load capacity: 15,000 kg S2 transport ring, 2x on the caving shield, load capacity 8000 kg S3 transport ring, 2x on the base, load capacity 8000 kg S4 transport ring, 2x on the base, load capacity 8000 kg S5 slot, 2x on the canopy, load capacity: 15,000 kg S6 transport ring, 2x on the base, load capacity 15,000 kg X1, X2 transport securing device for relay bar, faceside and gobside So center of gravity

Caution!

For transporting, use the four lifting points S1 and S2.

Use lifting points S3 to S6 only for aligning the shield - not for raising it.

Tab. 4: Shield support 7420 181 000 00 01, dimensions and weight Device number 7420 181 000 00 01

3.8

L Length in mm

B Width in mm

H Height in mm

So Sx/Sy in mm

Weight in kg

8063

1700

1270

1423/658

23 070

DBT shield 1143/3048-2X4113-1750

Transport Transport securing devices Fig. 9:

Relay bar assembly (gobside)

132

133

134

DBT GmbH, Lünen 2007

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

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3.9

Transport 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.

Fig. 10: Relay bar assembly, faceside

131

130

130 transport rod 131 spring clip 6 132 chain 6x42

3.10

133 hex. head screw M 12x45-8.8 (not shown) 134 hex. nut M 12-8 (not shown)

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132

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”.

DBT GmbH, Lünen 2007

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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 damage to property. 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 provided 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 stickers displaying the respective shield number are to be found on the left-hand base of the shield, faceside, left of the load hook.

Shield number on the base, example

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Fig. 11:

Tab. 5: Allocation of the shield numbers

4.4

Shield number

Device number

42A01 to 42A10

7420 181 000 00 01 endshield

Use

DBT shield 1143/3048-2X4113-1750

Installation of the support units Pressure equilibrium 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 pressure relief screw in order to enable pressure equilibrium 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 with several rotations.

Pressure equilibrium will be signalled by an audible hissing.

Caution!

Take care to ensure that the pressure relief screw is released for the purpose of pressure equilibrium at the control system.

The foil displays may become damaged if no pressure equilibrium is established.

Fig. 12: Example of a pressure relief screw on an electronic control system

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a

c

b a pressure relief screw b bracket for the control system

c electronic control system

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

Caution!

Take care to ensure that the pressure relief screw is made hand-tight again after pressure equilibrium 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 is equipped with two auxiliary supplies, one each on the left-hand and on the right-hand sides underneath the canopy.

The respective auxiliary supply must be connected by means of connectors a and b (Fig. 14 and/or Fig. 15).

Fig. 13: View of the supply block and the auxiliary connections, left and right (supply lines short-circuited for transport)

30

16 a

24

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22 1

1 electrohydraulic control unit 4 water valve unit 16 supply block 22 HP ball valve DN 12, for auxiliary supply

DBT GmbH, Lünen 2007

22

4.6

X

4

X

24 HP ball valve DN 25, in the pressure supply line to the shield 30 plug DN 10 with pressure relief a PMC®-R control unit X auxiliary supply

DBT shield 1143/3048-2X4113-1750

Installation of the support units Fig. 14: View of auxiliary supply on the right, connected and equipped with plugs a

b

c b

a

22 22

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22 HP ball valve DN 12, for auxiliary supply, on the right a pressure line auxiliary supply

b return line auxiliary supply c plug for auxiliary supply

Fig. 15: View of auxiliary supply on the left, connected and equipped with plugs b

a

b

c a

22

21b

22

4 4

4 water valve unit 21b HP ball valve DN 10, for lifting cylinder 22 HP ball valve DN 12, for auxiliary supply, on the left

a pressure line auxiliary supply b return line auxiliary supply c plug for auxiliary supply

Notice!

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

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4.7

Installation of the support units Fig. 16: Plug on the supply block 30 32 a

16

26

31

26 PRV, 80 bar 30 plug DN 10 with pressure relief

31 HP ball valve DN 10, blue, in the spray line 32 HP ball valve DN 20, blue, in the water circuit 35b pressure gauge for supply block a vented cap screw

To operate the shield with the help of one of the two auxiliary supplies, the shield functions must be activated via an additional external PMC®-R control unit. This is connected to the internal PMC®-R control unit via a corresponding cable (see separate operating manual for the PMC®-R control unit).

When one of the auxiliary supplies is used, the connections P, R and W (see Chapter 5 and Fig. 32, and Fig. 33) on the supply block must be short-circuited with the hose lines which will be used later to establish the connection to the neighboring shield - this is usually the condition at the time of delivery (see Fig. 13). If the supply hose lines can’t be short-circuited this way, then the connections must be sealed with corresponding plugs.

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

. shut off the two HP ball valves at Item 22*) as with the HP ball valve Item 24 (see Fig. 13).

. remove the plugs c from connections a and b (see Fig. 14, 15) of the auxiliary supply to be used.

. connect the auxiliary supply to the pressure and return lines of the pump.

. then open the HP ball valve, Item 22, again. *) shut off the HP ball valve on the right underneath the canopy when you are using the right-hand auxiliary supply. Proceed accordingly when using the left-hand auxiliary supply.

4.8

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DBT GmbH, Lünen 2007

16 supply block

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35b

Installation of the support units Make sure that the HP ball valves, Item 23 (see Chapter 5, Fig. 45 and 46), 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 22, 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 (see Fig. 16, Item 30) by screwing in vented cap screw a.

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 DBT GmbH, Lünen 2007

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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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4.9

Installation of the support units Establish a link between the connections The hydraulic connections on the support units are designed as plug connections in accordance with DIN 20043, which is standard for German mining.

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 Chapter 5, Fig. 32, 33 and the hydraulic circuit diagrams in Chapter 6 of this manual.

electrical shield control system

The support units are equipped with a model PMC®-R electronic control unit. 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 PMC®-R control system.

For more details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R 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: 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.

4.10

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hydraulic system

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.

pressure, permissible

Nominal pressure

320 bar

Admissible tolerance

¦ 10% of nominal pressure

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Caution!

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.

Dangerous situations could arise as a result under unlucky circumstances, leading to accidents involving damage to property and/or injuries to personnel.

Implement for that reason all required measures in order to ensure that system pressure will not be able to fall below 180 bar at any place in the face hydraulics system.

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4.11

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 elements 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:

moved.

. 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 hose lines can be damaged due to movements of the support.

Danger!

Damaged hose lines 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 hose lines can’t be damaged by movements of the support.

Lay the hydraulic hose lines correctly behind the brackets provided for them.

1) maximum possible plugging.

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DBT GmbH, Lünen 2007

. make sure that all transport securing elements have been re-

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J Mechanics:

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 PMC®-R control unit. 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 signalling and lighting systems, information plates

Important!

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

. check all signalling systems. . make sure that the face lighting is sufficient. . check whether the face area, especially the travel way, has sufDBT GmbH, Lünen 2007

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

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.

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4.13

Corrosion protection of hydraulic components 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

4.14

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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.

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

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.

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Warning!

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

The regulations about safe operation of your mine must be followed strictly. 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 remains.

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 1143/3048-2X4113-1750

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 remains.

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 fight against the 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 neighboring 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.

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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 travelling a face that is 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 start 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.

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DBT GmbH, Lünen 2007

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

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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.

Requirements Fig. 17: W r o n g , support advanced too late

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Fig. 18: 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 hose lines 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 props 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.

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

5.8

DBT shield 1143/3048-2X4113-1750

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 before attempting to operating this support.

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.

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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. 19: 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. 20: 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!

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M

Operation of the shield This is especially true if the shield control system is equipped with a 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 setting.

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.

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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.

Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in roof falls (see Fig. 21), 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. 21: 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. 22) 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. 22: 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 buildup 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 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

range of adjustment of the support/ 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 advance 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 implementation 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

E

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. 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 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.

5.14

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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

E

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 device. 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.

DBT GmbH, Lünen 2007

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Tab. 6: Hydraulic components Item 01

Pcs. 1

02 03 04 05

1 1 1 1

Designation electrohydraulic control unit, 12-way prop CV, NG 20 compact prop CV, NG 20 compact water valve unit CV DN 13, hydraulically piloted

06

1

accumulator cartridge

07 08 09 10

2 1 1 1

PRV, 460 bar CV, NW 25 CV, NW 20 CV, DN 10

11 13 14

1 1 1

15 16

1 1

twin CV, NG 4 hose lines water spraying system accessories brackets and accessories supply block

17

2

PRV, 380 bar

18

2

PRV

20

1

21

2

dual filter, can be backflushed automatically HP ball valve, DN 10 red handle

22

2

HP ball valve, DN 12 red handle

23

2

24

1

26 29 30 31

1 2 1 1

32

1

HP ball valve, DN 20 red handle HP ball valve, DN 25 red handle PRV, 80 bar pressure gauge port plug DN 10 with pressure relief HP ball valve DN 10, blue handle HP ball valve DN 20, blue handle

Arrangement behind the props underneath the canopy on the left prop, faceside on the right-hand prop, faceside on the left underneath the canopy underneath the canopy behind the left-hand prop next to the PRV (17a) on the electrohydraulic control unit (1) respectively on the prop, faceside on the supply block (16) on the left underneath the canopy on the left underneath the canopy on the stabilizing cylinder (Z3)

centred under the canopy in front of the two props a) on the CV, hydr. piloted (5) b) underneath the canopy next to the HP ball valve (21b) on the stabilizing cylinder underneath the canopy behind the right prop a) on the right prop on the compensating valve for the stabilizing cylinder b)next to PRV (17b) to the left under the canopy to the right and to the left underneath the canopy in front of the props respectively on the prop, faceside on the supply block (16) before the supply block (16) respectively on the prop, faceside on the supply block (16) on the right, next to the supply block (16) underneath the canopy next to the supply block (16) in front of the water filter (34)

Note on a support without compensating valve with compensating valve for shifting rams (Z2)

in the piston space in the return line in the water supply in the line for backflushing the water spraying system for stabilizing cylinders (Z3) subassembly subassembly subassembly on a bracket a) for shifting rams (Z2) b) for baselift cylinders (Z4) for piston space side and annular space side

a) for stabilizing cylinders (Z3) b) for baselift cylinders (Z4) for auxiliary supply, on the left and on the right in the pressure supply line to the prop in the pressure supply line to the shield in the return line

in the spray line in the water circuit

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

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5.15

Operation of the shield hydraulics Pcs. 1

Designation water filter DN 20

35

3

glycerine pressure gauge

S1 Z1 Z2 Z3 Z4

2 2 1 1 1

pressure sensor prop shifting ram stabilizing cylinder baselift cylinder (lifting)

Arrangement to the right in the vicinity of the supply block (16) a) on each prop CV (2, 3), faceside b) on the supply block (16) respectively on the prop, faceside

Note in the water feed line

DBT GmbH, Lünen 2007

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Item 34

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

5.16

DBT shield 1143/3048-2X4113-1750

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 21a, 21b, 23, 24, 32

The following ball valves are closed during normal operation: J 22, 31

DBT GmbH, Lünen 2007

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Tab. 7: HP ball valves Item

Color

Designation

21a

red

HP ball valve, DN 10

21b

red

HP ball valve, DN 10

22

red

HP ball valve, DN 12

23

red

HP ball valve, DN 20

24

red

HP ball valve, DN 25

31

blue

HP ball valve, DN 10

32

blue

HP ball valve, DN 20

Function interrupts the connection of the stabilizing cylinder/compensating valve used for shutting-off the pressure supply to the baselift (lifting) cylinder

Use in order to deactivate the compensating function of the stabilizing cylinder used for holding the baselift cylinder in a certain position and for deactivating the lift function for moving the shield during start-up and for connecting pressure supply during start-up hydraulically operated auxiliary and for auxiliary devices devices is used for shutting-off the presduring maintenance work on the sure supply to the prop piston prop and any possible disasspace sembly is used for shutting-off the presduring maintenance and repair sure supply line to the shield work on the shield used for shutting-off the spray line for cleaning soiled components used for shutting-off the water sup- in order to deactivate the funcply tion of the water spraying system

Fig. 23: 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. 24: Shield hydraulics, face shield, arrangement (1) Image caption: see Table 6 Z

Y

DBT GmbH, Lünen 2007

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X

View X 7 35a

21a

29 23

View Z

3

View Y 7 13

23 35a

2

5.18

29

DBT shield 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 25: Shield hydraulics, face shield, arrangement (2) Image caption: see Table 6

14

DBT GmbH, Lünen 2007

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26 35b 30 17b

31 32

21b

34 16 24

22 8

22 6 1

4 10 9

15

5 17a

20

11

18

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5.19

Operation of the shield hydraulics

DBT GmbH, Lünen 2007

E

Fig. 26: Functions of the electrohydraulic control unit, instruction plate

12 functions shield advance

1

conveyor push

4

2 legs raise

canopy tip up

3

extending lift-cyl

back flush

sprays clean

5

7

1

9

8

2

10

6 canopy tip down

back flush

open POCV D.A. ram

12 legs lower

Tab. 8: Electrohydraulic control units with 12 functions, allocation of functions Function, designation

Function No. for

advance shield

1

set props

2

slide conveyor

3

extend baselift cylinder

4

extend stabilizing cylinder

5

retract stabilizing cylinder

6

backflush filter

7

backflush filter

8

water spraying system

9

conveyor pull back

10 11

lowering props

5.20

12

DBT shield 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 27: Functions of the water valve unit, instruction plate water curtain

side plate sprays

W4

W2

W3

W1

water curtain

water spray canopy

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

Function No. W1

not assigned

W2

water spraying system, faceside

W3

water spraying system, faceside

W4

DBT GmbH, Lünen 2007

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canopy, water spraying system

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5.21

Operation of the shield hydraulics Fig. 28: Shield hydraulics, face shield Image caption: see Table 6

22

6 22 1

8 24 DN40SS DN50 DN50

20 30 26

35b

16

31

32

34 9

10

18

Z3

DBT GmbH, Lünen 2007

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4

11

23

29

13

18

35a

7

S1

35a

Z2

29

S1

5 3

23

7

21a

2 Z4

17a Z1

Z1

21b

17b 14

waterspray lemniscate

waterspray canopy

watercurtain

5.22

watercurtain

DBT shield 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 29: Hydraulic lines (1), overview for face shield Image caption: see Table 6 18

18 11

Z2

Z3

17a

Z1

20

Z1 10 7

S1

21a

A

9 Z A

DBT GmbH, Lünen 2007

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5

Z4

29

1

29 S1

6

2

3 7 23

35a 23 21b

35a

4

17b

24

22

16 8

22

DN40SS P

34

DN50

R

DN50

W

35b 31 32

26 30 14

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5.23

Operation of the shield hydraulics Shield components Shield support Fig. 30: Face shield, side view

11

51 31

a

c b 41

61

1

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

61 hydraulics a PMC®-R control unit b electrohydraulic control unit c supply block d baselift cylinder (lifting)

Fig. 31: Face shield, rear view

71

71 caving flap

5.24

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

E

d

Operation of the shield hydraulics Supply block Fig. 32: View of the supply block from the front 26

30 32 b

31

16

35b

a 6

4 1 24 P R

Z3 W

DBT GmbH, Lünen 2007

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18

11

1 electrohydraulic control unit 4 water valve unit 6 accumulator cartridge 11 twin CV 16 supply block 18 PRV 24 HP ball valve DN 25, in the pressure supply line to the shield 26 PRV, 80 bar 30 plug DN 10 with pressure relief

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31 HP ball valve DN 10, blue, for spray line 32 HP ball valve DN 20, blue, for water spraying system 35b pressure gauge P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a PMC®-R control unit b solenoid driver module Z3 stabilizing cylinder

5.25

Operation of the shield hydraulics Fig. 33: View of the supply block from below 30

26 31

32 W

R

P

16

8 CV, NW 25, in the return line

31 HP ball valve DN 10, blue, for spray line 32 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

16 supply block 24 HP ball valve DN 25, in the pressure supply line 26 PRV, 80 bar 30 plug DN 10 with pressure relief

Fig. 34: Lateral view of the supply block and the water filter

a

34

16

P 16 supply block 34 water filter P pressure line, DN 40SS

5.26

R

W

R return line, DN 50 W water line, DN 50 a solenoid driver module

DBT shield 1143/3048-2X4113-1750

E

8

DBT GmbH, Lünen 2007

24

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

5 1

17a

DBT GmbH, Lünen 2007

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1 electrohydr. control unit (from below)

5 CV, hydraul. piloted, for shifting ram 17a PRV, 380 bar, for shifting rams

Control units Fig. 36: View of the control units from the front 30

26 21b 32

31

b

35b

16 a

6

P R

22 4

W 1

24

1 electrohydraulic control unit 4 water valve unit 6 accumulator cartridge 16 supply block 21b HP ball valve DN 10, for lifting cylinder 22 HP ball valve DN 12, for auxiliary supply 24 HP ball valve DN 25, in the pressure supply line to the shield 26 PRV, 80 bar

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VTVA / 01

30 plug DN 10 with pressure relief 31 HP ball valve DN 10, blue, for spray line 32 HP ball valve DN 20, blue, for water spraying system 35b pressure gauge P pressure line, DN 40SS R return line, DN 50 W water line, DN 50 a PMC®-R control unit b solenoid driver module

5.27

Operation of the shield hydraulics Fig. 37: View of the electrohydr. control unit

c d

2

a 1 b

2 double 3/2 way magnetic pilot solenoid valve

a pushbutton b instruction plate c accumulator cartridge

6 filter cartridge

d bracket

Fig. 38: View of the solenoid driver module

a

P

a solenoid driver module P pressure line, DN 40SS

5.28

R

W

R return line, DN 50 W water line, DN 50

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

1 distributor block

E

6

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

22

DBT GmbH, Lünen 2007

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4

4 water valve unit 22 HP ball valve DN 12, for auxiliary supply, on the left Fig. 40: View of the dual filter

20

20 dual filter, can be backflushed automatically

Doc. No.: 7420 181 000 BA 00

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5.29

Operation of the shield hydraulics Brackets Fig. 41: Bracket for control unit

b,12

2

a

1

6 hex. head screw M10x25-A 2-70 10 washer 10 12 spring cotter 4 a chain b pin

1 support 2 support 3 angle for instruction plate 4 instruction plate 5 hex. head screw M6x8-A 2-70

Fig. 42: View behind the bracket for control unit

7,10 a

2

3

b 24 2 support 3 angle for instruction plate 7 hex. head screw M10x35-A 2-70

24 HP ball valve DN 25, in the pressure supply line a chain b solenoid driver module

10 washer 10

5.30

DBT shield 1143/3048-2X4113-1750

E

3

DBT GmbH, Lünen 2007

4

5

6,10

Operation of the shield hydraulics Fig. 43: Bracket for PMC®-R 5 a

b

c

1

6,7

a PMC®-R b emergency stop switch c support lock-out switch

1 angle 5 hex. head screw M12x25-A 2-70 6 cyl. screw M12x90-1.4301 DBT GmbH, Lünen 2007

E

7 hex. nut M12-1.4571

Fig. 44: Bracket for PMC®-R, rear view

22 17b

21b 3 1 6,7

2

1 angle 2 angle 3 tube 6 cyl. screw M12x90-1.4301 7 hex. nut M12-1.4571

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17b PRV, 380 bar, for baselift cylinder 21b HP ball valve, DN 10, for stabilizing cylinder 22 HP ball valve, DN 12, for auxiliary supply

5.31

Operation of the shield hydraulics Prop Fig. 45: Left-hand prop, with and without cover, view from the faceside 7

35a

S1

a

23

29

29 pressure gauge port 35a pressure gauge S1 pressure sensor a cover

DBT GmbH, Lünen 2007

2 prop control valve 7 PRV, 460 bar 23 HP ball valve DN 20, in the pressure supply line to the prop

E

2

Fig. 46: Right prop, with and without cover, view from the faceside 35a

b

S1 21a 7

a 23 29

3

3 prop control valve 7 PRV, 460 bar 21a HP ball valve DN 10, on the compensating valve for the stabilizing cylinder 23 HP ball valve DN 20, in the pressure supply line

5.32

29 pressure gauge port 35a pressure gauge S1 pressure sensor a compensating valve b cover

DBT shield 1143/3048-2X4113-1750

Operation of the shield hydraulics Fig. 47: Prop, view from the gob side

a

a

a annular space on the prop pipe

Plug with pressure relief

DBT GmbH, Lünen 2007

E

The shield is equipped with a plug DN 10 with vented cap screw on the supply block (16).

The plug with pressure relief aligned 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. 48: Plug on the supply block 30 32 a

16

26

31

35b

16 supply block 26 PRV, 80 bar 30 plug DN 10 with pressure relief

32 HP ball valve DN 20, blue, in the water circuit 35b pressure gauge a vented cap screw

31 HP ball valve DN 10, blue, in the spray line

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5.33

Operation of the shield hydraulics Stabilizing cylinder Fig. 49: View of the stabilizing cylinder

18

18 11 Z3

Z3 stabilizing cylinder

DBT GmbH, Lünen 2007

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11 dual check valve 18 PRV, for piston space side and annular space side

5.34

DBT shield 1143/3048-2X4113-1750

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

Do not put the filter into operation before making sure that all connections have been properly established. Be sure to observe the separate operating manual for the filter. backflushing

The filter must be backflushed when contamination of the filter elements leads to reduced flow or pressure loss.

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 the dual backflush filters regularly once per shift.

The filter elements are backflushed in turn by pressing function keys 7 and 8 on the electrohydraulic control unit.

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

DBT GmbH, Lünen 2007

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Fig. 50: View of the dual filter, automatic backflush

20

20 dual filter, can be backflushed automatically

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5.35

Operation of the shield hydraulics Repair and emergency operation

The drawings Fig. 51 and 52 show the arrangement of the PMC®-R control device and the electrohydraulic control unit on the support.

Operation of the PMC®-R control unit is not described in this operating manual. For information on this, please refer to the separate operating manual for the PMC®-R control unit.

5.36

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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.

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. If the control unit is included in the DBT scope of delivery, the respective operating manual will be included in the DBT documentation provided for the installation.

E

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. If the control unit is included in the DBT scope of delivery, you will find the corresponding operating manual in the DBT documentation of the system.

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

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

Operation of the shield hydraulics Fig. 51: View of the control units from the front a

30

16

4

24 1

DBT GmbH, Lünen 2007

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1 electrohydraulic control unit 4 water valve unit 16 supply block 24 HP ball valve DN 25, in the pressure supply line

30 plug DN 10 with pressure relief a PMC®-R control unit

Fig. 52: View of the electrohydr. control unit

c d

2 a 1

b

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

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a pushbutton b instruction plate c accumulator cartridge d bracket

5.37

Operation of the shield hydraulics The symbol plate is located on the electrohydraulic control unit underneath the pilot solenoid valves. 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. 53: Functions of the electrohydraulic control unit, instruction plates 12 fuctions shield advance

1

2 legs raise

conveyor push

3

4 extending lift-cyl

canopy tip up

sprays clean

back flush

5

7

1

8

2

6 canopy tip down

back flush

9 10

open POCV D.A. ram

12

legs lower

Operation and functions of the electrohydraulic control unit

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 incorrect operation. 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 which you are at the moment 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 pushbuttons 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. Which could seriously injure or kill you.

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

5.38

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

E

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.

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 “pull 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 variant functions (12 functions) 1

Advance shield

DBT GmbH, Lünen 2007

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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.

2

Setting props Before this function is actuated, the shield canopy must be correctly aligned. The baselift 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

The compensating valve (Fig. 46, Item a) and the associated shutoff valve (Fig. 46, Item 21a) 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.

3

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.

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VTVA / 01

5.39

Operation of the shield hydraulics 4

Extend baselift 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

Extending 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!

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.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke!

Backflush filter 7

The function is executed as long as the button remains pressed.

Backflush filter 8

10

The function is executed as long as the button remains pressed.

Conveyor pull back 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.

Function 11 is not assigned.

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Retracting stabilizing cylinder

DBT GmbH, Lünen 2007

6

Operation of the shield hydraulics 12

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.

Functions of the water valve unit Fig. 54: Functions of the water valve unit, instruction plate Water curtain

side plate sprays

W4

W2

W3

W1

Water curtain

water spray canopy

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

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W1

W2

Function W2 is not assigned.

Water spraying system, faceside W3

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

Water spraying system, faceside W4

Doc. No.: 7420 181 000 BA 00

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

VTVA / 01

5.41

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.

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.

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.

5.42

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.

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Refer to the separate original operating manual for the PMC®-R control unit.

DBT GmbH, Lünen 2007

electronic control system

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

DBT GmbH, Lünen 2007

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high-pressure hydraulics hoses

Daily maintenance hydraulics

. 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.

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VTVA / 01

5.43

Maintenance . lubricate the dirt strippers of both telescope stages via the lubri-

hydraulic prop

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

Fig. 55: Lubricating nipples on the hydraulic props

b

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.

5.44

DBT shield 1143/3048-2X4113-1750

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a

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 catalogue.

Functional errors can, in principle, occur in all components. The majority of faults on hydraulic valves is, however, cause 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.

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.

Fault localisation support cannot be lowered

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

Doc. No.: 7420 181 000 BA 00

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.

VTVA / 01

5.45

Remedying faults support cannot be set

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 open the shut-off valve! to the piston space of the prop is Lines to the piston and annular space of the closed. prop must be open. the shield canopy is stuck between find the cause. If required, lower neighboring the neighboring supports. supports and align them in order to free the canopy. 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 approx. 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

support cannot be advanced

the shut-off valve for the pressure open the shut-off valve! feed line on the supply block is clo- Valves can only be switched when the supply line is open. sed.

5.46

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 approx. 80 bar.

The pilot operated check 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 shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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the pressure of the hydraulic supply is too low.

Remedying faults set pressure is not reached/ prop pressure drops again aftersetting

canopy cannot be positioned

Possible cause

Remedy

prop control valve is defective.

replace prop control valve. Continue trouble shooting 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 open the shut-off valve! feed line on the supply block is clo- Valves can only be switched when the supply line is open. sed.

DBT GmbH, Lünen 2007

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the shield canopy is stuck between find the cause. If required, lower neighboring the neighboring supports. supports and align them in order to free the canopy.

canopy cannot be lowered

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 approx. 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 open the shut-off valve! feed line on the supply block is clo- Valves can only be switched when the supply line is open. sed. the shield canopy is stuck between find the cause. If required, lower neighboring the neighboring supports. supports and align them in order to free the canopy.

Doc. No.: 7420 181 000 BA 00

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 approx. 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.

VTVA / 01

5.47

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 device or the electrohydraulic control unit.

internal leakage

. locate the faulty valve by initiating the functions individually one

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

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DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

valve replacement

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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.

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.

Pressure relief valve defective

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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.

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 and 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 catalogue.

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.

Doc. No.: 7420 181 000 BA 00

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5.49

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Remedying faults

5.50

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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 Model 1143/3048-2X4113-1750 Endshield 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 stabilizing cylinders, J hydraulic equipment with hose lines and controlsystem.

DBT GmbH, Lünen 2007

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Tab. 10: Shield variants (1) Shield variants

Application

Device number

Dimensions, LxWxH max./min. in mm

Approximate weight in kg

01

endshield

7420 181 000 00 01

7389 x 1700 x 3048 8064 x 1700 x 1270

24,060

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.

hydraulics

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 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 shield units are equipped with all components required for realizing an electrohydraulic neighboring control with the electronic PMC®-R control system.

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6.3

Description Main subassemblies Shield support Fig. 56: Face shield, side view

11

51 31

a

c b

41

61

1

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

61 hydraulics a PMC®-R control unit b electrohydraulic control unit c supply block d baselift cylinder (lifting)

Fig. 57: Face shield, rear view

71

71 caving plate

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d

Description Tab. 11: DBT shield 7420 181 000 00 01, subassemblies used Approximate weight in kg

Item

Designation

ID No. No

Remarks

0001

base frame/base

7420 181 300 00 01

7867 shifting ram baselift (lifting) cylinder relay bar assembly

0011

canopy

7420 181 400 00 01

7424

0031

caving shield

7420 096 800 00 00

3850

0041

hydraulic prop

8250 145 000 00 00

1160

0051

stabilizing cylinder

8241 355 000 00 00

140

0061

Shield control system - 12 functions -

8112 257 000 00 00

0071

caving flap

7420 181 890 00 00

electrohydr. control unit lines water spraying system brackets

8241 357 000 00 00 8241 224 000 00 00 7420 181 330 00 01

8154 120 000 00 00 8112 257 010 00 00 8112 257 020 00 00 8112 257 030 00 00

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53

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6.5

Description Main dimensions Fig. 58: Endshield, dimensions

130

5775 4500

3702

1981

1270

3048

1275

80 8064

1750 shield clearance

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1700 890

340

shield number

1680

6.6

DBT shield 1143/3048-2X4113-1750

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 in hinged position 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 forward with the smaller force which is generated via the annular 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.

210

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Fig. 59: Base frame (base) face shield, dimensions and positions

300 1680

3831.5 4

2

5

20 10 6 a

19 11 1 b

8

1 base 2 lemniscatic link, front 4 lemniscatic link, at the rear on the right 5 lemniscatic link, at the rear on the left

6 cylinder bearing 8 relay bar assembly 10 shifting ram, ZE-180/100-1130 11 lifting cylinder ZE-135/90-240 19 protective flap

20 prop retainer, right a load ring 15,000 kg b load ring 8,000 kg For parts not listed here, please referto the spare parts list supplied.

Notice!

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

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6.7

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. 60: Relay bar assembly, face shield 3745 3530

3

280

DBT GmbH, Lünen 2007

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230

300

105

E

210

240 370

215

1 a

c

5, 4, 13

1 relay bar 2 clevis assembly for conveyor 3 pin 80/50x290 4 retaining ring

6.8

5 pin 12/20X95 13 locking clip 2.5 a load ring 3000 kg For parts not listed here, please referto the spare parts list supplied.

DBT shield 1143/3048-2X4113-1750

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 shield, the baselift cylinder retracts again automatically.

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4. Advancing the conveyor The shifting ram is retracted.

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6.9

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. 62) 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.

994

480

195

0 130

240

1275

5775

890 1700

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Fig. 61: Canopy, dimensions

6.10

DBT shield 1143/3048-2X4113-1750

Description Fig. 62: Canopy, positions a

b

1

8, 9

5, 6, 7

c

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1 canopy 5 pawl R90 6 pin 30/24x136 7 spring clip 5x32 8 pin Ø 53x155

a load ring Load capacity 1000 kg b load ring Load capacity 3000 kg c lifting point (clip) Load capacity 8000 kg

9 locking element with connector

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6.11

Description Prop head with pawl Fig. 63: Prop head attachment

DBT GmbH, Lünen 2007

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6, 7

5

5

7

5 pawl R90 6 pin 30/24.5x136

6.12

7 spring clip 5x32

DBT shield 1143/3048-2X4113-1750

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. 64: Caving shield, dimensions and positions

DBT GmbH, Lünen 2007

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2426

1654 975

950

1698 6

7, 21 15, 32

5

33

S2

17 1

S2 S1

10

S1 16

1 caving shield 5 lemniscatic link pin Ø155x533 6 lemniscatic link pin Ø130x533 7 pin Ø53x155 10 joint pin Ø133.5x328

15 pin 15/12x120 16 securing device 17 securing device 21 locking element with connector 32 locking clip 2.5

33 spring cotter 5 S1 load ring, Load capacity: 3000 kg S2 load ring, Load capacity: 8000 kg

Notice!

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

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6.13

Description Technical data, steel structure Face shield, device number 7420 181 000 00 01

6.14

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

1270 (1143)

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

3048

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

1905

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

1067

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

1130

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

890

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

4500

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

1405

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

1700

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

5905

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

3.97

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

49.78

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

1700

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

1680

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

39550

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

1750

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

2000

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

4946

b) with 400 bar nominal pressure

kN

7020

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

2000

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

478

b) with 440 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

575/679

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DBT GmbH, Lünen 2007

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

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.

normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

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.

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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.

Tab. 12: Hydraulic components Item 01

Pcs. 1

02 03 04 05

1 1 1 1

Designation electrohydraulic control unit, 12-way prop CV, NG 20 compact prop CV, NG 20 compact water valve unit CV DN 13, hydraulically piloted

06

1

accumulator cartridge

07 08 09 10

2 1 1 1

PRV, 460 bar CV, NW 25 CV, NW 20 CV, DN 10

11 13 14

1 1 1

15 16

1 1

twin CV, NG 4 hose lines water spraying system accessories brackets and accessories supply block

17

2

PRV, 380 bar

18

2

PRV

Arrangement behind the props underneath the canopy on the left prop, faceside on the right-hand prop, faceside on the left underneath the canopy underneath the canopy behind the left-hand prop next to the PRV (17a) on the electrohydraulic control unit (1) respectively on the prop, faceside on the supply block (16) on the left underneath the canopy on the left underneath the canopy on the stabilizing cylinder (Z3)

centred under the canopy in front of the two props a) on the CV, hydr. piloted (5) b) under the canopy next to the HP ball valve (21b) on the stabilizing cylinder

Note on a support without compensating valve with compensating valve for shifting rams (Z2)

in the piston space in the return line in the water supply in the line for backflushing the water spraying system for stabilizing cylinders (Z3) subassembly subassembly subassembly on a bracket a) for shifting rams (Z2) b) for baselift cylinders (Z4) for piston space side and annular space side

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

Doc. No.: 7420 181 000 BA 00

VTVA / 01

6.15

Hydraulic system

21

2

Designation dual filter, can be backflushed automatically HP ball valve, DN 10 red handle

22

2

HP ball valve, DN 12 red handle

23

2

24

1

26 29 30 31

1 2 1 1

32

1

34

1

HP ball valve, DN 20 red handle HP ball valve, DN 25 red handle PRV, 80 bar pressure gauge port plug DN 10 with pressure relief HP ball valve DN 10, blue handle HP ball valve DN 20, blue handle water filter DN 20

35

3

glycerine pressure gauge

S1 Z1 Z2 Z3 Z4

2 2 1 1 1

pressure sensors prop shifting ram stabilizing cylinder baselift cylinder (lifting)

Arrangement underneath the canopy behind the right prop a) on the right prop on the compensating valve for the stabilizing cylinder b)next to PRV (17b) to the left under the canopy to the right and to the left underneath the canopy in front of the props respectively on the prop, faceside on the supply block (16)

Note

a) for stabilizing cylinders (Z3) b) for baselift cylinders (Z4) for auxiliary supply, on the left and on the right in the pressure supply line to the prop in the pressure supply line to the shield in the return line

before the supply block (16) respectively on the prop, faceside on the supply block (16) on the right, next to the supply in the spray line block (16) underneath the canopy next to the supply block (16) in in the water circuit front of the water filter (34) to the right in the vicinity of the in the water feed line supply block (16) a) on each prop CV (2, 3), faceside b) on the supply block (16) respectively on the prop, faceside

E

Pcs. 1

DBT GmbH, Lünen 2007

Item 20

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

6.16

DBT shield 1143/3048-2X4113-1750

Hydraulic system Shield hydraulics Fig. 65: Shield hydraulics, face shield, arrangement (1) Image caption: see Table 6 Z

Y

DBT GmbH, Lünen 2007

E

X

View X 7 35a

21a

29 23

View Z

3

View Y 7 13

23 35a

2

Doc. No.: 7420 181 000 BA 00

29

VTVA / 01

6.17

Hydraulic system Fig. 66: Shield hydraulics, face shield, arrangement (2) Image caption: see Table 6

35b 30 31 32

17b 21b

34 16 24 22 6 1 15 20

22 8 4 10 9 5 17a 11

18

6.18

18

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

26

E

14

Hydraulic system

DBT GmbH, Lünen 2007

E

Fig. 67: Functions of the electrohydraulic control unit, instruction plate

12 functions shield advance

1

conveyor push

4

2 legs raise

canopy tip up

3

extending lift-cyl

sprays clean

back flush

5

7

1

9

8

2

10

6 canopy tip down

back flush

open POCV D.A. ram

12 legs lower

Tab. 13: Electrohydraulic control units with 12 functions, allocation of functions Function, designation

Function No. for

advance shield

1

setting props

2

slide conveyor

3

extend baselift cylinder

4

extend stabilizing cylinder

5

retract stabilizing cylinder

6

backflush filter

7

backflush filter

8

water spraying system

9

conveyor pull back

10

lowering props

12

11

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6.19

Hydraulic system Fig. 68: Functions of the water valve unit, instruction plate water curtain

side plate sprays

W4

W2

W3

W1

water curtain

water spray canopy

Tab. 14: Water valve unit with 3 functions, allocation of functions Function, designation

Function No. W1

not assigned

W2

Water spraying system, faceside

W3

Water spraying system, faceside

W4

DBT GmbH, Lünen 2007

E

canopy, water spraying system

6.20

DBT shield 1143/3048-2X4113-1750

Hydraulic system Fig. 69: Shield hydraulics, face shield Image caption: see Table 6

22

6 22 1

8 24 DN40SS DN50 DN50

20 30 26

32

35b

16

31 34 9

10

18

Z3

DBT GmbH, Lünen 2007

E

4

11

23

29

13

18

35a

S1

35a

Z2

7

29

S1

5 3

23

7

21a 2 Z4

17a Z1

Z1

21b

17b 14

waterspray lemniscate

waterspray canopy

watercurtain

Doc. No.: 7420 181 000 BA 00

watercurtain

VTVA / 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 head is fastened using two pegs each that are inserted into the bore holes in the mounting device before the prop head is installed.

The pegs are secured in the second groove by a pin and spring clip. After the prop head is installed, the pegs are pushed into the bore holes of the prop head and secured in the first groove with a pin and spring clip.

The technical data can be found in the section “Technical data, Hydraulic Cylinders”.

Fig. 70: Hydraulic prop, 2-stage,

44

21

a DBT GmbH, Lünen 2007

E

2

1

1 prop base 2 piston pipe 21 piston rod

b

44 lubricating nipple a valve connection plate b load ring 3000 kg

Tab. 15: Hydraulic prop of the shield variants Length in mm ID No. Hydraulic prop 8250 145 000 000 00

6.22

Stroke in mm

Retracted

Extended

Upper stage

Lower stage

1195

2775

785

795

DBT shield 1143/3048-2X4113-1750

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

E

setting props

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated control 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.

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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. 71: 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 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

Model b)

E

2

Hydraulic cylinder Stabilizing cylinder Fig. 72: Hydraulic cylinder ZE-165/100-420,

55

55 L a b

21

1

DBT GmbH, Lünen 2007

E

1 cylinder tube 21 piston rod a valve connection plate

b load ring 1000 kg L retracted 860 - extended 1280 stroke: 420

Shifting ram Fig. 73: Shifting ram model ZE-180/100-1130

62

70 L

d

b c 24

2

21 a

1

e 1 cylinder tube 2 reed rod 21 piston rod 24 screw fitting a annular space connection b piston space connection

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c reed rod adaptor d load ring 1000 kg e bearing pin L retracted 1493 - extended 2623 stroke: 1130

6.25

Hydraulic cylinder Baselift cylinder (lifting) Fig. 74: Hydraulic cylinder ZE-135/90-240

335

c

2

a

b 1 L

1 cylinder tube 2 piston rod 3 wearing bottom a piston space connection

6.26

b annular space connection c load ring 1000 kg L retracted 525 - extended 765 stroke: 240

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

E

3

Hydraulic cylinder Technical data, hydraulic cylinder

DBT GmbH, Lünen 2007

E

hydraulic prop, double-acting, 2-stage

stabilizing cylinder, double-acting

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

Doc. No.: 7420 181 000 BA 00

Model SD-4100-345-1195/2775-CR, Device No. 8250 145 000 00 00 Length a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1195

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

2775

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1580

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, 440 bar setting pressure . . . . . . . . . . . . . . . . . . . . kN

4113

Retracting force at 310 bar . . . . . . . . . . . kN

405

Model ZE-165/100-420

Device No. 8241 355 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

420

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 310/420 bar . . . . . . . . . . . kN

663/898

Pulling force at 310/420 bar . . . . . . . . . . kN

419/568

Model ZE-180/100-1130 version with reed rod

Device No. 8241 357 000 00 00

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1 130

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

180

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

Piston surface . . . . . . . . . . . . . . . . . . . . . . cm2

78.5

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

176

Thrust force at 310 bar . . . . . . . . . . . . . . kN

243

Pulling force at 310 bar . . . . . . . . . . . . . . kN

546

VTVA / 01

6.27

Hydraulic cylinder Model 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

444

Pulling force at 310 bar . . . . . . . . . . . . . . kN

246

DBT GmbH, Lünen 2007

E

baselift cylinder, double-acting

6.28

DBT shield 1143/3048-2X4113-1750

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.

Tab. 16: Pressure relief valves, use of the various models Application

Model

Setting pressure in bar

Device No.

for return line

spring-loaded

80

8220 042 080 00 00

for shifting rams and lifting cylinders

spring-loaded

380

7337 486 380 00 00

for proponly

spring-loaded

460

8220 027 460 00 00

for stabilizing cylinder spring-loaded

470

7337 493 470 00 00

DBT GmbH, Lünen 2007

E

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!

Always fit new seals when replacing a pressure relief valve.

Failure to comply with these instructions can lead to leaky plug connections and impair the operational safety of the hydraulics. 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.

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VTVA / 01

6.29

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. 75 shows a pressure relief valve provided with a blue/white color code.

This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 75: Pressure relief valve, example

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

Tab. 18: Color codes for pressure relief valves, overview

1)

6.30

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

DBT shield 1143/3048-2X4113-1750

E

a

DBT GmbH, Lünen 2007

b

a color code b protective cap

Shield control unit Shield control unit Electrohydraulic control unit The electrohydraulic control unit has 12 functions.

DBT GmbH, Lünen 2007

E

Fig. 76: Electrohydraulic control unit, 12 functions

a

1

2

a connection (DN 20) for accumulator cartridge 1 distributor block

3

4 2 pilot valve actuated electromagnetically 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.

Doc. No.: 7420 181 000 BA 00

VTVA / 01

6.31

Shield control unit Electronic control unit PMC®-R Fig. 77: Control unit PMC®-R, input allocation PMC®-R inputs A1 = neighboring unit to the left A2 = not assigned

Front view

B1 = not assigned B2 = not assigned

Rear view A2

A1

B2

B1

C2 D2

C1 D1

E2

E1

F2

F1

C1 = pressure sensor, right C2 = pressure sensor, to the left D1 = shifting ram sensor D2 = not assigned E1 = not assigned E2 = not assigned F1 = right hand, neighboring unit F2 = solenoid driver module

E

Notice!

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

DBT GmbH, Lünen 2007

Fig. 78: Control unit PMC®-R, diagram 1 A2 B2 C2 D2 E2 F2

A1 B1 C1 D1 E1 F1 F1

A1

4

P2

P1

5

5

1 shield control device (SCU) 4 solenoid driver module

6.32

5 pressure sensor Other components: see spare parts catalogue

DBT shield 1143/3048-2X4113-1750

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15 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. 79: Angles α1/ α2

α1 α2

DBT GmbH, Lünen 2007

E

M

Tab. 19: Angles α1/ α2 at height M Inclination α at height M

Shield ID No. 7420 181 000 00 01

α1 in °

α2 in °

M in mm

3º

10º

1143 to 1626

15º

15º

1626 to 2235

15º

15º

2235 to 3048

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.

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6.33

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 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 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.

6.34

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

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.

E

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

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. 80: Typical certificate

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VTVA / 01

6.35

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 co-operation 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 (Table 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.

6.36

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

E

J microbial load

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 smell, 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

proportion of solid foreign matter at 1.2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination Class pursuant to ISO 4406: 1999

-/18/14

DBT GmbH, Lünen 2007

E

Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

lubricating grease A1

Base:

Lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behaviour in the presence of water:

practically non-soluble in water

Temperature 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

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VTVA / 01

6.37

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 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 props, 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.

6.38

DBT shield 1143/3048-2X4113-1750

DBT GmbH, Lünen 2007

lubricating paste B3

E

Lubricating pastes

Tightening torques Tightening torques Screws with ISO metric thread Tab. 24: Recommended 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

DBT GmbH, Lünen 2007

Tightening torque 4)

Pitch P

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

1) 2) 3) 4)

Doc. No.: 7420 181 000 BA 00

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).

VTVA / 01

6.39

DBT GmbH, Lünen 2007

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Tightening torques

6.40

DBT shield 1143/3048-2X4113-1750

7

For your information

Service addresses

For your information If you happen to require spare 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 181 000 BA 00

VTVA / 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 1143/3048-2X4113-1750

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 181 000 BA 00

VTVA / 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. 81: 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 181 000 00 01

7

4113 kN

5 device number 6 number of props 7 prop force E

2

4

DBT GmbH, Lünen 2007

6

12345 3 07/07

DBT shield 1143/3048-2X4113-1750

Identification of the shields Shield number The shields are numbered consecutively. Stickers with the shield number are located on the base frame, faceside, to the left of the load hook

DBT GmbH, Lünen 2007

E

Fig. 82: Shield number on the base, example

Tab. 25: Allocation of the shield numbers

Doc. No.: 7420 181 000 BA 00

Use

Shield number

Device number

42A01 to 42A10

7420 181 000 00 01 endshield

VTVA / 01

7.7

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 26: National standards and directives, extract

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation system Hydraulic system plug connections Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for bolts T-head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) 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 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

Directive of the European Parliament and the 1998-06-22 Council on the approximation of the laws of the member states relating to machinery EC directive of the approximation of the laws of the Member States concerning equipment and protective 1994-03-23 systems intended for use in potentially explosive atmospheres Safety of machinery 2004-04 Safety of machinery 2004-04 Non-electrical equipment for use in potentially explosive at2002-04 mospheres - 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 2000-08 interface Creating manuals 2001-11 - Structure, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water content - Distillation method Equipment and component for use in areas susceptible 2006-01 to firedamp in underground mines Mobile extraction machines on the face - safety require2003-09 ments for shearers and plane systems 1)

7.8

EWN = DBT works standard

DBT shield 1143/3048-2X4113-1750

E

Title

DBT GmbH, Lünen 2007

Designation