CAT DBT − Shield 1800/3200-2x1596-1500 Operating Manual – PDF DOWNLOAD

Operating Manual DBT - Shield 1800/3200-2x1596-1500 Doc. no.: 7420 056 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

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

Email: infodbt@dbt.de Internet: www.dbt.de

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

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

DBT GmbH, Lünen 2001 E

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

1.3

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

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

1.4 1.5

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

2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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

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

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

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

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

2.6 2.7 2.8 2.9 2.11

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

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

3.3

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

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

3.3 3.4

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

3.5

4. Installation

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

4.3

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

4.3

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

4.4

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

4.5

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

4.5

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

4.6

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

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

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

4.6 4.8 4.8

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5. Operation and maintenance General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special guidelines for operation . . . . . . . . . . . . . . . . . . . . . .

5.3 5.5

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

5.8

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

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

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

5.14 5.18 5.21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5.28 5.28 5.28 5.29

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 Fault finding on shield hydraulic system . . . . . . . . . . . . . . .

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

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

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

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

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

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

5.29 5.29 5.33 5.33 5.33 5.34 5.34

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

6.3

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

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

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

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

6.5 6.8 6.11 6.14 6.17 6.19 6.21

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23

Telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 Hydraulic cylinder, double and single acting . . . . . . . . . . . .

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

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

6.30 6.31 6.33

Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.34 PANZERMATIC[ PM4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.35

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36 Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

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

6.36 6.39

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41 Screws with metric coarse thread DIN 13 . . . . . . . . . . . . . .

6.41

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7. For your information

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

7.3

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

7.3

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

7.3

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

7.4

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DBT - 1800/3200-2x1596-1500

1

About this manual

Before starting work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols used.

Before starting work applicable operating manual

Take care to ensure that the operating manual available to you is applicable for the shield support used. Compare the data given below with the data on the type plate of the shield. Where to find the type plate on the shield is described in chapter 7 of this operating manual.

This operating manual is designed for DBT shield 1800/3200-2x1596-1500 with the following type specification:

DBT Deutsche Bergbau-Technik GmbH, Lünen 2001

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Identification no.:

7420 056 000 00 01 7420 056 000 00 02 7420 056 000 00 03 7420 056 000 00 04

Year of construction: 2001 Prop force in kN: 2 x 1596 and is only permitted to be used for shields of this type. Only use the operating manual applicable to the respective shield. If you don’t you will endanger yourself and others. availability of operating manual

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

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

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

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

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1.3

Before starting work Purpose of this operating manual operating manual

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

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

questions

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

safety

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

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Observe the information given and follow the procedural instructions.

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

Try to memorize the symbols and their meanings.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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

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

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

J

Items in lists are marked with black squares.

–

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

.

The symbol of the hand asks you to do something. Several successive paragraphs marked with the symbol of the hand represent a string of actions which must be executed in the order specified. Follow the respective instructions step-by-step to perform the work safely and efficiently.

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1.5

1.6

DBT - 1800/3200-2x1596-1500 E DBT Deutsche Bergbau-Technik GmbH, Lünen 2001

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety.

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

supplementary regulations

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

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

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

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

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J of the miners’ accident insurance association.

DBT GmbH, Lünen 2001

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

Operation and maintenance Operation and maintenance of the shields is only allowed to be performed by trained personnel. qualification

The training shall be matched to the type of shield actually used.

The electrohydraulic and hydraulic control systems shall be operated only by personnel who have been adequately trained to operate the present control system. The content of the operating manual, especially the chapter on safety, shall constitute a part of this training.

They shall possess and furnish proof of adequate familiarity with the J mechanical, J hydraulic, and J control systems.

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2.3

Personnel Repair In general, repair work shall be performed only by persons who have the respective knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment. Repair work on and overhaul of J safety devices, J hydraulic props and cylinders J control blocks, valves, and filters

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

2.4

DBT - 1800/3200-2x1596-1500

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

Use the shield only in conformance with specifications!

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

– lowering, – pulling up, – alignment, and – setting; J the following conveyor operations:

– advancing, E

– retracting; DBT GmbH, Lünen 2001

J forming an abutment for:

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

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

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

shield, J setting of the canopy in areas of roof fracture. Detailed informa-

tion on this subject is given in chapter 5 “Operation” DBT assumes no liability for damages which result from use contrary to specifications.

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2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

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

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

EMERGENCY STOP

support lock-out switch

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

Only applicable for shields provided with electrohydraulic control systems.

Actuate the support lock-out switch (repair switch) before performing J maintenance work, J inspection work, J repair work, and before J prolonged presence in the shield.

moving parts

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

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signalling systems and protective devices

Maintain the lighting systems in a functional condition.

DBT GmbH, Lünen 2001

lighting

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

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

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

Moreover, this measure prevents inadvertent reinstallation of these components elsewhere. Dispatch these components for repair immediately.

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

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

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

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

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

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

Damage of this kind necessitates elaborate and expensive repair work.

For round components such as cylinders and props use transport straps, only. Never use chains or steel cables for this purpose.

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

Firmly secure all components which might start moving.

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

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2.7

Safety instructions Installation Employ appropriate loading equipment for safe transfer of the transport units.

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

For securing the shield, hardwood wedges, for instance, can be placed between the pairs of links.

Securing by means of hardwood wedges

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Fig. 1:

transport securing devices

The side seal is pretensioned by a spring. Therefore do not use force to remove the transport securing device of the side seals.

Use the hydraulic control system to adjust the side seal cylinders such that the locking pins either drop down or can be pulled out without the use of physical force.

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

travelway

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

J width: 600 mm J height: 400 mm

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

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Safety instructions Operation shield control

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

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

Carefully read the instructions for operating the control system used.

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

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

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

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

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

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

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

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

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

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

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

On inclined faces, always advance the shields from the bottom to the top. This gives you a better view of your working area.

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2.9

Safety instructions shield alignment

Set the shields in such a way that the canopies and the base skids are parallel with those of the adjacent shield.

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

roof falls

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

Never set the tip of the canopy into a roof fall-out. This could lead to excessive stress and strain on the components if the maximum angles of inclination are exceeded.

Ensure that sufficient residual stroke is still present in the props when the seam thickness decreases. This prevents the props from going solid between the roof and floor.

pulling back the conveyor

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

Secure the entire mining machine against unauthorized starting.

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

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

raising of conveyor

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

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

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

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

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

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

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

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DBT GmbH, Lünen 2001

residual stroke

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

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

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

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

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

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

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

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

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

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

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

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

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

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

pressure or mechanical stress.

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

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

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2.11

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

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

Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

maintenance, repair

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

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: J the hoses are not pinched or trapped.

J the hoses have no bubbles or blisters.

J the hoses or the outer sheathes of the hoses are not abnor-

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

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J the outer sheath of the hoses is not damaged.

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mally rigid or hard.

Safety instructions Fig. 2:

Example: 4SP hydraulic hose, designation date of manufacture 1st quarter 2000 hose type

manufacturer

nominal diameter flame-resistant and antistatic

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

Never try to repair damaged hydraulic hoses. Immediately replace damaged hydraulic hoses.

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

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so that they:

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J always have a little slack.

Fig. 3:

Laying of hydraulic hose lines, slack RIGHT

WRONG

J are not twisted.

Fig. 4:

Laying of hydraulic hose lines, twist RIGHT

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WRONG

2.13

Safety instructions J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter).

Fig. 5:

Laying of hydraulic hose lines, bend RIGHT

WRONG

J cannot chafe.

Fig. 6:

Laying of hydraulic hose lines, crossing WRONG

J are not kinked.

J do not have to withstand tensile strains.

J are protected against thermal radiation.

J are accessible at all times.

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

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

Fig. 7:

Laying of hydraulic hose lines, connections at movable parts RIGHT

2.14

WRONG

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RIGHT

Overview of the safety instructions Overview of the safety instructions This is a summary of all safety instructions given in the individual chapters of this operating manual.

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

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

Use only suitable load handling devices.

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

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

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

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

Lay the hoselines correctly behind the retainers provided for that purpose.

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

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

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

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

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

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

CAUTION! Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

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

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

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

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CAUTION! Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

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

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

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

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

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

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

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

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

WARNING! During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. If the control unit is part of the DBT scope of supply you will find the corresponding operating manual in the DBT documentation on the system.

WARNING! The control elements on the control block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose.

They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries. During normal operating mode, the shield is operated exclusively by means of the electrohydraulic control.

In this respect it is imperative that you observe the separate operating manual of the control unit. If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

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

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Overview of the safety instructions

CAUTION! Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

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

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

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

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

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

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

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CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

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

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

WARNING! When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior.

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

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

Overview of the safety instructions CAUTION! The hatch is only allowed to be opened when the shield is in close-up position, the chute is lowered and the chute extension has been pulled out!

CAUTION! Lowering the shield is only allowed with the chute extension pushed in and the chute retracted!

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

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

IMPORTANT! Please be sure to keep in mind that the functions of valves 13 to 16 differ for the different shield variants! Only the functions of valves 1 to 12 are the same for all shield variants!

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

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

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

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

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

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

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

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

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

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

CAUTION! Before putting the shield unit into operation, remove the transport safety devices of the movable side seal.

The movable side seals are retracted for transport and locked mechanically by means of pins. The pins are secured with coupling clamps.

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

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

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

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

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

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

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

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

IMPORTANT! Further information is contained in DIN 24320.

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CAUTION! The pressure setting must not be changed.

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

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

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

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

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

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3

Storage and transport

Storage

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

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

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

Storage Storage of new equipment corrosion protection

Prior to delivery the hydraulically operated equipment will be tested and operated at the DBT site using the anti corrosive and anti freezing fluid HYDROCOR® CV50*. This fluid remains in the hydraulic system for transport and a following short-time storage period.

HYDROCOR ® CV50 is freeze-proof down to - 40 degrees Celsius and protects inside metallic materials against corrosion.

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

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

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

exposure to sunlight

Protect the equipment against direct exposure to sunlight.

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

natural ageing

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

moisture and dirt

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

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

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

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During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must, however, be particularly protected against environmental influences, including high temperatures, for example by suitable covers or sheathings for the controls and by additionally covering the equipment.

long-term storage

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

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

plastic deformation

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

random sample inspection

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

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

HFA fluids

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

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

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

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

3.4

In case the hydraulic system is to be put out of operation temporarily the complete system has to be flushed thoroughly and filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50). If this is not done, considerable damage to the hydraulic components may be caused within a short time since the properties of the medium used may change very fast and negatively, e.g. due to microbial attack.

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short-term storage

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Storage

Transport Transport WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices.

In consultation with the customer and taking into consideration the local conditions prevailing at the site transport units were specified as follows: The shields are delivered as completely pre-assembled units.

points of attachment

As far as technically possible, the load units are provided with suitable and fixed points of attachment for transport and assembly. If not, adequate threaded holes or other provisions are available for the temporary attachment of parts. Details on the arrangement and load-carrying capacity of the attachment points are given in the spare parts catalog or on the special drawings for transport assemblies which are added in the annex to this manual, if required.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with a medium sensitive to frost, for example, an oil-in-water emulsion (HFAE) have to be completely drained and then filled with a frost-proof preserving fluid, e.g.

HYDROCOR® CV 50. If, for technical reasons, the fluid cannot be drained completely choose a preserving fluid which can be mixed with the medium originally used and ensure that the media are adequately mixed.

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transport units

Transport of equipment at temperatures between -21°C and -40° C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and are only loaded statically or quasi-statically. External forces are only allowed to be introduced via the points of attachment and absorption surfaces indicated on separate drawings, if any.

The equipment is not allowed to be transported at temperatures below -40 °C. During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to max. 25 kph for truck transport. electrical and electronic components

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Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

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Transport transport safety devices and transport units

For the purpose of ensuring safety during transport, the movable parts of each transport unit must be fastened such as to prevent their changing their position inadvertently, if required in addition to the standard securing devices, e.g. on side seals and flipper. The following transport safety devices are provided on the transport units: J Support unit(s):

complete Transport position: as for normal use Transport safety devices are requiered at the - moveable side of the caving shield side seal - shifting unit - sliding canopy - flipper - chute

J Hydraulic system:

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

Fig. 8:

Transport of shields as complete unit

S3 H S2

W S1 S2 S3 So

3.6

S1

L

slot hole, 2 x on base faceside, load-bearing capacity: 8000 kg attaching eye, 2 x on base gobside, load-bearing capacity: 8000 kg attaching eye, 2 x on caving shield, load-bearing capacity: 8000 kg center of gravity

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

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

Transport Tab. 1: Shield support 7420 056 000 00 .. , dimensions and weights of variants Variant

Order no.

Length in mm

Width in mm

Height in mm

Sx/Sy in mm

Weight in kg

01 7420 056 000 00 01

4305

1450

1800

12430

02 7420 056 000 00 02

4305

1450

1800

12460 15460

04 7420 056 000 00 04

16130

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03 7420 056 000 00 03

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4

Installation

Pre-assembly of the shield units

Installation This chapter contains information on the installation of the shield units. Please pay particular attention to the warnings and tips.

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

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

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

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CAUTION! Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

Pre-assembly of the shield units The shields are delivered as completely pre-assembled units.

Hence, no further pre-assembly is required for the mechanical and hydraulic systems of the shields.

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

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

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

identification for installation in the face

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To facilitate identification for assembly and installation in the face the shields or the transport units should be provided with consecutive numbers. This numbering should, for example, correspond to the order in which the shields are to be arranged in the face. The numbers should be written on the surface of the components with a clearly visible color.

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

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each shield unit. This pipe provides the hydraulic supply to the individual shield unit. The manifold pipes of adjacent shield units are connected with the use of two hose lines: A pressure line (DN 20) and a return line (DN 25). See the hydraulic block diagram in chapter 6.

control unit

The shield units are equipped with an electronic control unit of type PM-4. The connection between the control unit and the electrohydraulic control block is provided by a solenoid driver module. The connecting cables required for this purpose are included in the scope of supply of the PM-4 control system. How to connect the control unit is described in the separate operating manual for the PM-4 control system. An overview of the design of the control is also given in chapter 6 of this operating manual in the section titled ”shield control”.

additional equipment

Provision is made on the shield units to allow the attachment of additional equipment which is not included in DBT’s scope of supply, as for example: – two-way intercom system For information on the installation of the additional equipment, please refer to the pertinent operating manual of the respective manufacturer.

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– lighting system

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

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

Purity class 18 / 14 to ISO 4406 nominal pressure

310 bar

admissible tolerance

10 % of nominal pressure

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CAUTION! Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

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

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

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

Please observe the following items: J Mechanics

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

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

J Hydraulic system

. Test the entire hydraulic system for leaks. Seal any conneccould cause damage to hoses.

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

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

Lay the hoselines correctly behind the retainers provided for that purpose.

. Check the hydraulic supply pressure. . Check supporting power of the props (observe pressure gauge reading)

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

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. Check whether shield movements, particularly in the links,

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tions that are leaking.

Start-up J Signalling and lighting systems

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

. Check all signalling systems. . Check that the face is illuminated sufficiently. . Check that the face area, especially the travelway, is provided with all signs required. It is imperative that you observe the regulations of the responsible mining authority.

J Emergency stop systems

. Check that all emergency stop systems function properly.

J Mining and conveying

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

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

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

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

. Check all lines by means of the line plans.

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

. Check the function of the hydraulic supply system for the face. . Check all functions of the shield control system.

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

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

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

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

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Corrosion protection of hydraulic components

5

Operation

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

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

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

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

General guidelines face crew

The face crew must be informed about possible danger situations.

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

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

face equipment

The face must be illuminated sufficiently.

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

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

conveyor overload

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

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

5.3

travel way

The minimum dimensions for the travelway specified must be maintained.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travelway: Width: 600 mm Height: 400 mm If the support is used in countries other than the Federal Republic of Germany the respective regulations applicable in those countries must be observed.

Debris or objects lying in the travelway must be removed immediately. This does especially apply for low seam heights.

If crawl pans are used whose length is adjustable, care has to be taken that a safe travelway of adequate width remains.

roof supporting work

Care must be taken that the filling section of the face conveyor remains unobstructed. This means that the canopies of the shields must be set against the roof immediately after the shields have been lowered and advanced.

work in the mining track

Work in the mining track may only be carried out from a safe position. The conveyor and the mining machine must be at a standstill and locked-out to prevent restarting.

The conveyor and the space above the conveyor may only be entered if there is a protection against fall of rock from the roof.

In thick seams the coal face must also be protected against slabbing in these places. On faces equipped with shields this is best done by using flippers.

Care must be taken that the flippers are always extended towards the coal face far enough to achieve the desired protection. This does not apply during shield advance.

If flippers are not used, some other kind of protection must be applied to shield the mining track from the rest of the face, e.g. extrahigh spill plates, wire mesh, nets, etc. or the like.

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

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

5.4

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

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

E

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

repair work

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

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

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

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

DBT GmbH, Lünen 2001

E

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

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

anchorage device

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

This measure is required to prevent the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid.

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

When pulling up the shields, always observe the specified sequence of steps. If not, the anchorage device might be damaged and become unfit for use.

Special guidelines for operation shield operation

A shield must always be operated from a safe position and from within an adjacent shield.

Never ever stay under a shield which has not been set.

Take care that no part of your body ever gets between the canopy and the roof, the base and the floor or between the side seals of adjacent shields.

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5.5

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

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

You are not allowed to lower or advance a shield as long as a person is in the immediate vicinity of the support unit or in the support unit.

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

On inclined faces, shield advance should be started in the lower section. Since the shields are to be operated by adjacent control, the operator can operate and observe the unit to be advanced from a safe position within the adjacent shield.

The props of the shields must always be set until the setting pressure has been reached to ensure good roof support and in case of shields with special functions, e.g. shields serving as abutments for conveyor alignment systems, sufficient anchoring between roof and floor.

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

DBT GmbH, Lünen 2001

Fig. 9:

E

The shields must be advanced as soon as possible to prevent the potential danger of roof fall-outs.

Fig. 10: C o r r e c t, shields have been advanced in time

5.6

DBT - 1800/3200-2x1596-1500

A canopy which is sloping downwards at a step in the roof must not obstruct the passing of the mining machine.

The flipper must be folded back completely prior to advancing the shield unit. Never advance a shield against the coal face with a folded-out flipper. Otherwise the flipper cylinders and the link joints of the flipper will be damaged seriously.

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

hydraulics, controls

Take care to avoid misoperation of the shield control.

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

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

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

DBT GmbH, Lünen 2001

E

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

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

To prevent damage in case the return line is closed safety valves of nominal diameter 32 relieving to atmosphere should be installed additionally into the return line, spaced about 40 m apart. Relief pressure 25 bar. damages, spare parts

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

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

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SSVS / 03

5.7

Operation of the shield Operation of the shield A good training of the operating personnel, knowledge and observance of the safety regulations and of the operating instructions listed afterwards largely help to prevent the occurrence of hazardous situations. Moreover, they are good prerequisites for a reliable interaction of shield and mining machine within the longwall system.

If the shield is equipped with an electrohydraulic control system, a profound knowledge of the separate operating manual for this control system is absolutely necessary for shield operation.

The shields must be set until the setting pressure has been reached to ensure good roof support and, in case of shields with special functions, e.g. shields serving as abutments for anchorages, sufficient anchoring between roof and floor.

It is a general rule that the shields should be advanced as soon as possible to achieve an early support of the newly mined roof.

CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

Fig. 11:

Shield in the normal position

a=0 M

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

5.8

DBT - 1800/3200-2x1596-1500

E

The shields must always be set in such a way that the canopies and the bases are as parallel as possible. Within the maximum angles given in the technical data sheet it is possible, however, to adapt the canopy to steps in the roof and to overcome steps in the floor, if required by geological or operational conditions.

DBT GmbH, Lünen 2001

canopy adjustment

Operation of the shield CAUTION! Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

This is the only way of cushioning high peak loads, which may occur suddenly, by the hydraulic securing action of the stabilizing cylinders. If the residual stroke is not sufficient, this may result in serious damage to the shield under unfavorable leverage conditions.

Fig. 12: Shield with extremely inclined canopy

s

1

a

1

DBT GmbH, Lünen 2001

E

M

a2

s2

M

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

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

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

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5.9

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

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

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

Fig. 13: W r o n g, by no means must the tip of the canopy be set in a cavity, if the stabilizing cylinder is fully extended.

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 14) or by leveling off the canopy.

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

5.10

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 13) if the stabilizing cylinder is fully extended. There must always be sufficient stroke available for decreasing dynamic loads from the roof by the hydraulically protected stabilizing cylinder.

E

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

Operation of the shield Fig. 14: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

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

Accumulation of dirt on the canopies can be avoided by advancing the shields under roof contact. In some cases it is possible to let the dirt fall onto the conveyor or to clear it away after lowering the tips of the canopies for a short time.

DBT GmbH, Lünen 2001

E

range of adjustment / changing seam thickness

The closed height of the shields must be suitable for the lowest seam height.

The shield must be operated such as to ensure that there is always sufficient residual stroke available for lowering. If not, the shield might get jammed between the roof and the floor and may be heavily damaged by sudden load peaks - for example caused by a mountain bump. Load peaks cannot be cushioned hydraulically when there is not enough hydraulic fluid under the piston of the prop or the piston already has reached its bottom dead center position.

The minimum residual stroke required for lowering the shield can be maintained by J keeping the seam opening sufficiently large by means of the

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

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

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

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

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5.11

Operation of the shield inclined faces

Particularly in inclined workings sliding and canting of the shields must be avoided by correcting their attitude in time by means of the side seals and steering devices. This is to prevent a shield from getting under the canopy of its adjacent shield, often causing considerable damage.

Since in inclined workings shield advance starts as a rule in the lower section of the face, a correct attitude of the end shields is of importance. For correcting the attitude, hydraulically operated guide beam assemblies and steering devices at the canopy and the base or between canopy and base are used.

The side seals can be used with automatic controls to prevent tilting of a lowered shield during advance. Any corrections in the attitude becoming necessary can be carried out by means of manual control only.

The side seal of the caving shield is only allowed to be used for alignment with respect to the adjacent shield if the two shields have been advanced to the same extent.

unfavorable floor conditions

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

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

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

draulically by retracting a prop.

J shields with solid bases must be lifted and underlaid by means

usually applied in mines.

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

5.12

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

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

E

On inclined faces, the conveyor has to be secured with anchorages. This measure prevents the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid which would make shield advance difficult.

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

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

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

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

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

Always observe these safety rules : Keep all parts of your body under the canopy of a set shield and away from the shield in motion or about to be advanced.

DBT GmbH, Lünen 2001

E

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

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

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

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

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5.13

Operation of the shield hydraulics Operation of the shield hydraulics WARNING! During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. If the control unit is part of the DBT scope of supply you will find the corresponding operating manual in the DBT documentation on the system.

Location of hydraulic components at the shield Hydraulics of the shield

DBT GmbH, Lünen 2001

E

Fig. 15: Shield hydraulics

A

view “A” 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve 9 block ball valve 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve

5.14

DBT - 1800/3200-2x1596-1500

Operation of the shield hydraulics Fig. 16: Hydraulic flow plan for shield variants 01 and 02, overview components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve, 420 bar 9 block ball valve 11 pressure gauge

14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve C1 PM4 control C2 solenoid driver please refer also to the spare parts catalog

DBT GmbH, Lünen 2001

E

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant.

control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder V13 retract seal cylinders V14 extend seal cylinders V15 retract flipper cylinder V16 extend flipper cylinder

Z8

Z7

Z6

Z10 Z5

Z5

Z9

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z8 flipper cylinder Z9 pusher cylinder Z10 seal cylinder

Z4

Z3

Z2

Z1

Z1

C2 C1

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5.15

Operation of the shield hydraulics Fig. 17: Hydraulic flow plan for shield variant 03, overview

22 pilot operated check valve 25 hose lines and accessories 26 symbol plate for functions 15 and 16 27 symbol plate for functions 13 and 14 C1 PM4 control C2 solenoid driver please refer also to the spare parts catalog

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant.

Z11 Z12

V13 V14 V15 V16

Z7

Z5

Z5

Z3

Z4

retract faceside prop extend faceside prop retract front swivel canopy cylinder extend front swivel canopy cylinder

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z11 faceside prop Z12 swivel canopy cylinder

Z6

E

control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder

Z12

Z2

Z1

Z1

C2 C1

5.16

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve, 420 bar 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve

Operation of the shield hydraulics Fig. 18: Hydraulic flow plan for shield variant 04, overview components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve, 420 bar 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve

21 control unit, 4 functions 22 pilot operated check valve 25 hoses lines and fittings 26 symbol plate for functions 15 u. 16 28 symbol plate for functions HV1 u. HV2 29 symbol plate for functions HV3 u. HV4 please refer also to the spare parts catalog

DBT GmbH, Lünen 2001

E

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant. control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder V13 V14 V15 V16

Z12

Z11

Z11

Z7 Z10

retract seal cylinder extend seal cylinder retract front swivel canopy cylinder extend front swivel canopy cylinder

Z5

Z5 Z6

Z13

HV1 retract chute cylinder (lower), side box HV2 extend chute cylinder (lift up), side box HV3 lower faceside prop HV4 set faceside prop

Z4

Z3 Z2

Z1

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z10 seal cylinder Z11 faceside prop Z12 swivel canopy cylinder Z13 chute cylinder, side box

Z1

C2 C1

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SSVS / 03

5.17

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

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

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

5.18

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

WARNING! The control elements on the control block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose.

They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries. During normal operating mode, the shield is operated exclusively by means of the electrohydraulic control.

In this respect it is imperative that you observe the separate operating manual of the control unit. If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

E

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

Operation of the shield hydraulics Fig. 19: Arrangement of control valve block and PM4 control, example

e

a

d

b

E

c

DBT GmbH, Lünen 2001

a symbol plates b pilot valve c control valve block

d retainer e PM4 control

Figure 19 above shows the arrangement of the PM4 control unit and the control valve block on the shield.

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

See separate manual for the PM4 control unit.

The symbol plates are located at the control block above the pilot control valves. The symbols on the plates correspond directly to the functions activated by the respective push buttons. The meaning of the symbols and the functions is described in the following.

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5.19

Operation of the shield hydraulics Fig. 20: Control functions of shield variants 01 to 04, overview Note: The functions of valves 1 to 12 are the same for all shield variants. Valves 13 to 16 control varying functions, depending on the shield variant.

Shield variants 01 and 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder retract seal cylinders extend seal cylinders retract flipper cylinder extend flipper cylinder

15 16

13 14

11 12

9 10

7 8

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

Shield variant 03

13 14 15 16

retract faceside prop extend faceside prop retract front swivel canopy cylinder extend front swivel canopy cylinder

15 16

13 14

11 12

9 10

7 8

5 6

1 2

3 4

E

retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

13 14

11 12

9 10

Shield variant 04 1 2 3 4 5 6 7 8 9 10 11 12

retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder

13 14 15 16

retract seal cylinder extend seal cylinder retract front swivel canopy cylinder extend front swivel canopy cylinder

15 16

7 8

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

HV1 retract chute cylinder (lower), side box HV2 extend chute cylinder (lift up), side box HV3 set faceside prop HV4 lower faceside prop

5.20

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DBT GmbH, Lünen 2001

1 2 3 4 5 6 7 8 9 10 11 12

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

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

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

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

DBT GmbH, Lünen 2001

E

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

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

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

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

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

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

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5.21

Operation of the shield hydraulics Control functions The following is a short description of the functions of the electrohydraulic control unit. The lefthand column shows the symbols for the respective functions which are also given on the control block.

The numbers in brackets are the numbers identifying the ports on the control block.

IMPORTANT! Please be sure to keep in mind that the functions of valves 13 to 16 differ for the different shield variants! Only the functions of valves 1 to 12 are the same for all shield variants!

Control functions of shield variants 01 and 02 Fig. 21: Control valve block of shield variants 01 and 02, front view retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder

13 14 15 16

retract faceside prop extend faceside prop retract front swivel canopy cylinder extend front swivel canopy cylinder

15 16

13 14

11 12

9 10

7 8

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

CAUTION! The hatch is only allowed to be opened when the shield is in close-up position, the chute is lowered and the chute extension has been pulled out!

Retract hatch cylinder (1) Opens the hatch in the caving shield.

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

Extend hatch cylinder (2) Closes the hatch in the caving shield.

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

Retract chute cylinder (3) Lowers the chute.

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

Extend chute cylinder (4) Lifts the chute.

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

5.22

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

E

1 2 3 4 5 6 7 8 9 10 11 12

Operation of the shield hydraulics CAUTION! Lowering the shield is only allowed with the chute extension pushed in and the chute retracted!

Lower props (5) Before this function is initiated, ensure that the neighboring shields have been set completely.

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

Set props (6) Before this function is initiated, the canopy must be aligned to the roof. The lift cylinders will be retracted automatically.

The function is performed as long as the button is held depressed, until the setting pressure is reached or until the end position is reached.

Advance conveyor (7) Before initiating this function, ensure that the shield has been set completely.

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

E

Advance shield (8) DBT GmbH, Lünen 2001

Before this function is initiated, the functions “lower props” and “retract seal cylinders” must have been executed. The adjacent shields must be set completely.

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

As long as this function is active the piston side of the baselift cylinders is pressurized causing them to extend. The baselift cylinders retract automatically as soon as the function is deactivated.

Retract forepole canopy (9) Before executing this function the canopy should be released from the roof. Next, the swivel canopy must be realigned and the shield set again.

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

Extend forepole canopy (10) Before executing this function the canopy should be released from the roof. Next, the swivel canopy must be realigned and the shield set again.

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

Retract swivel canopy cylinders (11) Before executing this function make sure that the adjacent shield units are set against the roof.

Executing this function causes the canopy to be lowered.

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

After executing the function the shield unit has to be set again.

Doc. no.: 7420 056 000 BA 00

SSVS / 03

5.23

Operation of the shield hydraulics Extend swivel canopy cylinders (12) Before this function is initiated, the functions “lower props” and “retract seal cylinders” must have been executed. The adjacent shields must be set completely.

The function is used to correct the attitude of the canopy. Executing the function causes the canopy to be raised.

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

After execution of this function, the shield must be set again.

Retract seal cylinders (13) The function is performed as long as the button is held depressed or until the end position is reached.

Extend seal cylinders (14) The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position is reached.

Extend flipper cylinders (16) Extends the flipper.

Before this function is initiated, the canopy must be aligned to the roof and the shield must be set completely.

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

Extend pusher cylinder The pusher cylinder is designed to correct the attitude of the shield base skids, if required. It is actuated manually by means of the three-way ball valve (9, see flow plan) which is located behind the props under the caving shield. When not activated, the piston side of the pusher cylinder is connected with the return of the shield hydraulics.

5.24

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DBT GmbH, Lünen 2001

Retracts the flipper.

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

E

Retract flipper cylinders (15)

Operation of the shield hydraulics Control functions of shield variant 03 The functions of valves V1 to V12 are the same for all shield variants. The respective description is given under ”Functions of shield variants 01 and 02”.

Fig. 22: Control valve block of shield variant 03, front view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder retract faceside prop extend faceside prop retract front swivel canopy cylinder extend front swivel canopy cylinder

15 16

13 14

11 12

9 10

7 8

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

Lower faceside prop (13) The auxiliary prop retracts.

DBT GmbH, Lünen 2001

E

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

Set faceside prop (14) The auxiliary prop extends.

This function is only allowed to be executed after correcting the attitude of main canopy and swivel canopy and after the main props have been completely set.

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

Retract front swivel canopy cylinder (15) This function is used to correct the attitude of the swivel canopy.

The swivel canopy is lowered.

This function is only allowed to be executed after the auxiliary prop has been lowered.

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

Extend front swivel canopy cylinder (16) This function is used to correct the attitude of the swivel canopy.

The swivel canopy is raised.

After executing this function, the auxiliary prop must be set again.

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

5.25

Operation of the shield hydraulics Functions of shield variants 04 The functions of valves V1 to V12 are the same for all shield variants. The respective description is given under ”Functions of shield variants 01 and 02”.

Fig. 23: Control valve block and additional control unit of shield variant 04, front view 1 2 3 4 5 6 7 8 9 10 11 12

retract hatch cylinder open) extend hatch cylinder (close) retract chute cylinder (lower) extend chute cylinder (lift up) lower props set props advance conveyor advance shield retract forepole canopy extend forepole canopy retract swivel canopy cylinder extend swivel canopy cylinder

13 14 15 16

retract seal cylinder extend seal cylinder retract front swivel canopy cylinder extend front swivel canopy cylinder

15 16

13 14

11 12

9 10

7 8

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

Retract seal cylinders (13) The function is performed as long as the button is held depressed or until the end position is reached.

Extend seal cylinders (14) The function is performed as long as the button is held depressed or until the end position is reached.

Retract front swivel canopy cylinder (15) This function is used to correct the attitude of the swivel canopy.

The swivel canopy is lowered.

This function is only allowed to be executed after the auxiliary prop has been lowered.

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

Extend front swivel canopy cylinder (16) This function is used to correct the attitude of the swivel canopy.

The swivel canopy is raised.

After executing this function, the auxiliary prop must be set again.

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

5.26

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DBT GmbH, Lünen 2001

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HV1 retract chute cylinder (lower), side box HV2 extend chute cylinder (lift up), side box HV3 set faceside prop HV4 lower faceside prop

Operation of the shield hydraulics Retract chute cylinder at the side box (V1) The chute at the side box is lowered.

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

Extend chute cylinder at the side box (V2) The chute at the side box is raised.

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

Set faceside prop (V3) The auxiliary prop extends.

This function is only allowed to be executed after correcting the attitude of main canopy and swivel canopy and after the main props have been completely set.

DBT GmbH, Lünen 2001

E

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

Lower faceside prop (V4) The faceside prop retracts.

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

5.27

Maintenance Maintenance WARNING! When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior. electronic control

. See separate original operating instructions for the PM4 control unit.

hydraulic control

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

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

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

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

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

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

hydraulics

. Check all shield units by visual inspection for hydraulic fluid es-

DBT GmbH, Lünen 2001

caping on the: J hose lines, J control valve blocks, J valves J props, J shifting ram and lift cylinder J stabilizing cylinder, seal and flipper cylinders.

. Check pressure gauges at the props. steel structure

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

Weekly inspection control unit

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

. Clean the control units, especially the control panel.

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

5.28

E

Daily inspection

DBT - 1800/3200-2x1596-1500

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

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

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

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

DBT GmbH, Lünen 2001

E

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

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

Fault localization failure to lower the shield

Doc. no.: 7420 056 000 BA 00

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

Check required Open shut-off valve.

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

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

Open shut-off valve.

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

Canopy is trapped by adjacent shields.

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

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses

Check for damaged or kinked hoses in prop circuit.

Props are damaged.

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

Lack of fluid from control valves

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

SSVS / 03

5.29

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

Check required Open shut-off valve.

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

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

Open shut-off valve.

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

Canopy is trapped by or under adjacent shields.

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

System pressure is too low for operation.

Check pumps are ‘ON’.

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

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Props are damaged.

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

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

Check required Open shut-off valve.

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

Shield is trapped by adjacent shields.

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

failure to advance the shield

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

System pressure is too low for operation.

Check pumps are ‘ON’.

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

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

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

Shifting ram is faulty.

Check cylinder for damage.

Check for POCV (load lock) malfunction.

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

POCV = pilot operated check valve

5.30

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E

failure to set the shield

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

DBT GmbH, Lünen 2001

E

failure to operate the tip up function

Doc. no.: 7420 056 000 BA 00

Possible cause Faulty POCV.

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

Props are damaged.

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

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

Faulty pressure relief valve.

Check pressure gauge for reading.

Is pressure relief valve weeping?

Replace pressure relief valve and check functions.

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

Check required Open shut-off valve.

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

Shield canopy is trapped by adjacent shields.

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

Canopy is trapped by adjacent side seals.

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

System pressure is too low for operation.

Check pumps are ‘ON’.

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

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

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

SSVS / 03

5.31

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

Check required Open shut-off valve.

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

Canopy is trapped by adjacent shields.

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

Canopy is trapped by adjacent side seals.

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

System pressure is too low for operation.

Check pumps are ‘ON’.

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

Check pressure delivered by pumps is correct.

Pilot piston in the POCV valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

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

Possible cause The shut-off valve on the shield is closed.

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

System pressure is too low for operation.

Check pumps are ‘ON’.

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

Check pressure delivered by pumps is correct.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit

Baselift cylinder is damaged.

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

Shield is not lowered from roof.

Lower shield to attempt to operate baselift.

Wait until shield is advanced and attempt function again.

failure to operate baselift function

5.32

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

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failure to operate the tip down function

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

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

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

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

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

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

internal leakage

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

E

valve replacement

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

DBT GmbH, Lünen 2001

manifold pipe.

. Operate the functions manually to depressurize the system. . Replace the 3/2-way valve or the pilot valve.

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

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

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

. Check valve and replace, if defective.

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

. Pump props up to roof at set pressure. . Isolate the annulus side of the prop. To this end, detach the control line at the pilot-operated check valve (item 11, see hydraulic flow plan) temporarily and admit pressure to the control port of the POCV.

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

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

5.33

Trouble shooting If there is an internal by-pass in the prop, for example due to damaged piston packings, fluid will flow out of the prop lower port. If this happens, the prop must be replaced.

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

Pressure relief or pressure relief valves of various types are used in the hydraulic circuit of a shield. pressure relief valves used on props, for example, have a high flow rate while the pressure relief valves used on shifting rams, stabilizing cylinders etc. are designed for a lesser flow rate.

Defective or blocked filter Operation of the shield is slow although pressure is known to be normal operating pressure. Contamination is assumed to have occurred in the hydraulic system, e.g. after repair work.

. Check the filters in the hydraulic system. Backflush filters may be cleaned by backflushing. On fine-mesh filters which are, for example, used on the control blocks, the filter elements must be replaced.

5.34

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DBT GmbH, Lünen 2001

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The pressure relief valves for different cylinders or for the piston and ring sides of a cylinder may have different max. value settings.

Please observe the information given in the hydraulic flow plans or in the spare parts catalog.

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

6

Technical data

Description

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

Description Type 1800/3200-2x1596-1500 The two leg shields basically comprise the following main components: J base with lemniscatic links J shifting unit J baselift unit J aligning device J canopy with

- forepole canopy and flipper, variants 01, 02 - swivel canopy and forepole canopy with side box, variants 03,04 J caving shield with hatch and chute, variants 03 and 04 with DBT GmbH, Lünen 2001

E

additional side box J side seal J hydraulic props J shield control shield

The shield is equipped with a solid base. The shifting unit is arranged in the center of the base. The shifting ram is reverse-mounted.

The caving shield consists of one part and is connected to the base by means of the links. A hydraulically operated hatch cover in the caving shield permits to discharge any caved material into the chute provided at the caving shield.

The chute can be lifted or lowered hydraulically. A chute extension permits to directly transfer the material onto the conveyor.

The caving shield is equipped with a movable side seal on the R.H. side and a fixed side seal.

The shield canopy is used to support the roof. The articulation between caving shield and canopy is stabilized by means of two cylinders. The supporting force is transmitted via the stabilizing cylinders to the caving shield and from there via the props and the base to the floor.

The shield canopy is provided with a forepole extension and a flipper. Connection to the caving shield is by means of pins.

The shield is equipped with two single-stage props of type SE-1600-180-1115/1990.

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.3

Description variants

Four different variants of the same type are available. The two face shield variants, 01 and 02, differ only in the design of the shifting unit. Unlike shield variant 02, the shifting unit of variant 01 is not equipped with a control cylinder.

The two end shield variants 03 and 04 differ from the face shield variants in that they have caving shield and canopy equipped with side boxes. And, they are provided with a swivel canopy with forepole extension. The main canopy of these two variants is additionally supported in the front area by an auxiliary prop.

Application

Order number

Weight in kg

Special features

01

face shield

7420 056 000 00 01

12430

- shifting unit without steering cyl.

- forepole canopy with flipper

02

face shield

7420 056 000 00 02

12460

- shifting unit with steering cylinder, - forepole canopy with flipper

03

end shield

7420 056 000 00 03

15460

- caving shield with side box R.H. - swivel canopy, forepole canopy with side box R.H. - auxiliary prop

04

end shield

7420 056 000 00 04

16130

- caving shield with side box L.H. - swivel canopy, forepole canopy with side box L.H. - auxiliary prop

The shield has a solid base which transmits the supporting forces of the hydraulic props into the floor. Ball sockets located in the side parts of the base serve as abutments for the props.

The props are secured in position at both sides by means of socalled prop retainers which are fastened to the base by bolts.

The two pairs of links are connected to the base in an articulated manner by means of bolts. They provide the connection to the caving shield.

An open duct accommodating the pushing and shifting unit is provided in the center of the base. In the travelway area this duct is covered by a footboard.

The base comes equipped with a baselift device for raising the tips of the base when pulling up the shield.

The relay bar consists of two leaf spring elements interconnected at the gobside and at the faceside. It runs in the duct for the shifting unit of the base. The shifting ram connecting base and relay bar mechanically is reverse-mounted. The shifting ram stroke is 800 mm.

Provision is made on the shield units for the operation of an electrohydraulic adjacent control using the PM4 electronic control unit.

6.4

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

base

Variant

E

Tab. 2: Variants of shields

Description Main subassemblies Tab. 3: Main subassemblies of shield type 1800/3200-2x1596-1500 with order number 7420 056 000 00 ..

DBT GmbH, Lünen 2001

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Item

Doc. no.: 7420 056 000 BA 00

Description

Variants

Order number

Weight approx approx. in kg

01

02

03

04

1 base

x

x

x

x

7420 056 000 00 00

3040

2 shifting unit without steering cylinder

x

-

x

x

7420 056 330 00 01

780

3 shifting unit with steering cylinder

-

x

-

-

7420 056 330 00 02

822

4 aligning device

x

x

-

-

7420 056 340 00 00

182

5 canopy

x

x

-

-

7420 056 400 00 03

3338

6

-

-

-

x

7420 056 400 00 02

6095

7

-

-

x

-

7420 056 400 00 01

5910

8 baselift unit

x

x

x

x

7420 056 350 00 00

159

10 side seal

x

x

-

-

7420 056 700 00 00

908

11

-

-

x

-

7420 056 720 00 00

444

12

-

-

-

x

7420 056 730 00 00

930

15 caving shield

x

x

7420 056 800 00 03

3345

16

-

-

x

-

7420 056 800 00 01

4060

17

-

-

-

x

7420 056 800 00 02

4060

20 prop, type SE 1600

x

x

x

x

8250 038 000 00 00

413

21 protective covering

x

x

x

x

0000 000 727 09 99

26 prop, type SE 1000

-

-

x

x

9551 100 200 00 00

391

27 articulated skid

-

-

x

x

6852 833 050 00 00

109

30 hydraulic shield control

x

x

-

-

8112 118 000 00 00

31

-

-

-

x

8112 119 000 00 00

32

-

-

x

-

8112 120 000 00 00

SSVS / 03

6.5

Description

extended

Fig. 24: Main subassemblies of shield variants 01 and 02

DBT GmbH, Lünen 2001

E

retracted

A

view A

1 2 3 4 5 8 10 15 20 21 30

base shifting unit without steering cylinder shifting unit with steering cylinder aligning device canopy baselift device side seal caving shield prop, type SE 1600 protective covering hydraulic shield control

see also spare parts catalog

6.6

DBT - 1800/3200-2x1596-1500

Description

A

DBT GmbH, Lünen 2001

E

retracted

extended

Fig. 25: Main subassemblies of shield variant 03 and 04

1 2 3 4 6 7 8 11 12 16 17 20 21 26 27 31 32

base shifting unit without steering cylinder shifting unit with steering cylinder aligning device canopy of shield variant 04 canopy of shield variant 03 baselift device side seal of shield variant 03 side seal of shield variant 04 caving shield of shield variant 03 caving shield of shield variant 04 prop, type SE 1600 protective covering prop, type SE 1000 articulated skid shield control of shield variant 04 shield control of shield variant 03

see also spare parts catalog

Doc. no.: 7420 056 000 BA 00

view A

shield variant 04

SSVS / 03

shield variant 03

6.7

Description Base with lemniscatic links and shifting unit

DBT GmbH, Lünen 2001

E

Fig. 26: Base

1/2

lemniscatic link front / rear

5

base

base

shifting unit

6.8

6,7,8,9 others

prop retainer L.H. / R.H. fastening elements see also spare parts catalog

The solid base transmits the supporting forces of the hydraulic props into the floor. Ball sockets located in the side parts of the base accommodate the props which are secured in position at both sides by means of prop retainers. The two pairs of links are connected to the base in an articulated manner by means of bolts. Typical of this base is that is has the shifting unit arranged in the center.

The shifting unit is reverse-mounted. This means, the force of the piston surface area of the shifting ram is utilized to advance the shield. The smaller force of the ring surface area is used to advance the panline. Connection to the conveyor is provided by the hinge piece of the shifting unit.

baselift device

The baselift device permits to raise the shield during advance.

aligning device

The aligning device serves for correcting the lateral attitude of the shield with respect to the base of an adjacent shield. Seen in direction of advance, the aligning device is arranged at the L.H. side.

DBT - 1800/3200-2x1596-1500

Description Shifting unit Fig. 27: Shifting unit variant 01 variant 02

1 shifting ram 2 steering cylinder 10 retainer, gobside 11 retainer, faceside 12 link 36 leaf spring others: fastening elements, see spare parts catalog

DBT GmbH, Lünen 2001

E

The shifting unit is arranged in the middle of the base. It consists mainly of the relay bar, formed by the two leaf springs with the gobside and faceside retainer, the shifting ram and the necessary fastening elements. It serves to advance conveyor and shield.

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

The baselifting device serves for raising the base during shield advance.

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

2. Advancing the shield When advancing the shield, the base skid is automatically raised by means of the baselift device.

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

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

3. Setting the shield When setting the shield, the baselift device is automatically retracted again.

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.9

Description Fig. 28: Aligning device

DBT GmbH, Lünen 2001

E

1 hydraulic cylinder 2 bridge 3 flap 4 end cover others: fastening elements, see also spare parts catalog Fig. 29: baselift device

1 hydraulic cylinder 3 cover 4 lifter 5 retainer others: fastening elements, see spare parts catalog

6.10

DBT - 1800/3200-2x1596-1500

Description Caving shield The caving shield shields the face area towards the gob. It is connected to the main canopy by a hinge link and to the base by the front and rear lemniscatic links. The forces required to support the roof are transmitted via the caving shield into the prop heads. Stability for the articulation between caving shield and canopy is provided by two cylinders.

Located in the caving shield is a hydraulically operated hatch cover (hatch) which permits to discharge the debris into the chute also provided at the caving shield. The chute can be raised and lowered hydraulically. A chute extension permits to transfer the debris directly onto the conveyor.

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

The design of the caving shield is the same for face shield variants 01 and 02. Although the caving shields for end shield variants 03 and 04 are similar they differ in that they come equipped with a side box and have a modified side seal.

DBT GmbH, Lünen 2001

E

Fig. 30: Caving shield of shield variants 01 and 02

shown without items 8 and 9

1 hydraulic cylinder, chute 2 hydraulic cylinder, hatch 5 caving shield 6 hatch 7 bar 8 chute 9 chute extension others: fastening elements, see also spare parts catalog

Doc. no.: 7420 056 000 BA 00

tightening torques for bolts of property class 8.8 according to EWN 6003: 380 Nm for M20 item 30 655 Nm for M24 item 31

treat all joints according specification EWN 416, paragraph 9

SSVS / 03

6.11

Description Fig. 31: Caving shield of shield variant 03

shown without items 8 and 9

C

DBT GmbH, Lünen 2001

E

D

A-B 1 hydraulic cylinder, chute 2 hydraulic cylinder, hatch 6 hatch 7 bar 8 chute 9 chute extension 50 caving shield R.H. 52 side box 54 guide plate R.H. 55 guide plate L.H. 57 chute plate 58 bar 59 apron others: fastening elements, see also spare parts catalog

6.12

C-D

tightening torques for bolts of property class 8.8 according to EWN 6003: 380 Nm for M20 item 30 655 Nm for M24 item 31

treat all joints according specification EWN 416, paragraph 9

DBT - 1800/3200-2x1596-1500

Description Fig. 32: Caving shield of shield variant 04

DBT GmbH, Lünen 2001

E

shown without items 8 and 9

view ”X”

1 hydraulic cylinder, chute 2 hydraulic cylinder, hatch 6 hatch 7 bare 8 chute 9 chute extension 51 caving shield L.H. 53 side box with hatch not DBT scope of supply 54 guide plate R.H. 55 guide plate L.H. 57 chute plate 58 bar 59 apron others: fastening elements, see also spare parts catalog Doc. no.: 7420 056 000 BA 00

SSVS / 03

tightening torques for bolts of property class 8.8 according to EWN 6003: 380 Nm for M20 item 30 655 Nm for M24 item 31

treat all joints according specification EWN 416, paragraph 9

6.13

Description Canopy The shield canopy is connected with the caving shield in an articulated manner. Two cylinders are attached to provide stability for this articulation. The angle of inclination of the canopy relative to the floor level is approx. ±15° unless limited by the closed or extended condition of props or stabilizing cylinders or by the closed locking hinge. See chapter ”Technical data”, section ”Angles of inclination of the canopy”.

Different types of canopies are available for the different shield variants.

The canopy design is the same for face shield variants 01 and 02.

Although the canopies for end shield variants 03 and 04 are similar they differ in that they come equipped with a swivel canopy and a side box at the left or at the right.

All shield canopies are equipped with a forepole canopy.

DBT GmbH, Lünen 2001

E

Fig. 33: Canopy of shield variants 01 and 02

2 stabilizing cylinder 4 forepole canopy cylinder 11 flipper 16 swivel canopy

6.14

21 forepole canopy 25 telescoping bar others: fastening elements, see also spare parts catalog

DBT - 1800/3200-2x1596-1500

Description Fig. 34: Canopy of shield variant 03

2 stabilizing cylinder 4 forepole canopy cylinder

DBT GmbH, Lünen 2001

E

16 swivel canopy 19 side box for forepole canopy 22 forepole canopy

24 beam 55 canopy 57 side box for canopy

view ”X”

others: fastening elements, see also spare parts catalog

Fig. 35: Canopy of shield variant 04

2 stabilizing cylinder 4 forepole canopy cylinder 16 swivel canopy 20 side box for forepole canopy 23 forepole canopy

Doc. no.: 7420 056 000 BA 00

SSVS / 03

24 beam 56 canopy 58 side box for canopy

view ”X”

others: fastening elements, see spare parts catalog

6.15

Description

6.16

2

hydraulic cylinder

6

flipper

10

guide rod I, L.H.

11

guide rod I, R.H.

12 16,18-20 17 others:

guide rod II pin forked pin fastening elements, see also spare parts catalog

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

E

Fig. 36: Flipper

Description Side seal side seal

The side seals seal the gap between two adjacent support units.

They are also used to correct the attitude with respect to the adjacent shields.

Depending on the shield variant, side seals may be fitted on one or both sides of the caving shield. Face shield variants 01 and 02 have one movable and one fixed side seal fitted. If required, the movable and fixed side seals can be interchanged quite easily.

The movable side seal is fastened with guide pins and is extended and retracted by means of hydraulic cylinders.

The fixed side seal is locked mechanically by means of detachable connecting elements.

CAUTION! Before putting the shield unit into operation, remove the transport safety devices of the movable side seal.

The movable side seals are retracted for transport and locked mechanically by means of pins. The pins are secured with coupling clamps.

CAUTION !

Remove securing elements and devices for transport, items 9, 12 at moveable side before start-up.

stroke

DBT GmbH, Lünen 2001

E

Fig. 37: Side seal of shield variants 01 and 02

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

1 4, 5 7, 13

Doc. no.: 7420 056 000 BA 00

hydraulic cylinder side seal fastening elements for item 10

SSVS / 03

8, 13 9, 12 10

fastening elements for item 1 securing elements for transport guide rod

6.17

Description

4 7, 13

side seal fastening elements for item 10

9, 12 10

fastening elements for transport guide rod

Fig. 39: Side seal of shield variant 04

CAUTION !

Remove securing elements and devices for transport, items 9, 12 at moveable side before start-up.

1 4 7, 13

6.18

hydraulic cylinder side seal fastening elements for item 10

8, 13 9, 12 10

fastening elements for item 1 securing elements for transport guide rod

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

E

Fig. 38: Side seal of shield variant 03

Description Technical data, steel structure Shield variants 01 and 02 height ,extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3200 height, retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1800 range of hydraulic height adjustment . . . . . . . . . . . . . mm . . 1400 advance stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 800

base

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3150 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1320 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 695

front lemniscatic link

two parts length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1200 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 255 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 190

rear lemniscatic link

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1180 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1210 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 310

caving shield

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 2862 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1450 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 800

canopy

swivel canopy with forepole canopy liftable, at M = 2,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . gon . . 18 lowerable, at M = 2,8 m . . . . . . . . . . . . . . . . . . . . . . . . gon . . 38 forepole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1400 rear projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 150 total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1675 supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1550 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1450 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 490 force at the canopy tip at 420 bar yield pressure of the stabilizing cylinders and M = 2,8 m . . . . . . . . . . . . . . kN . . . 778

swivel canopy

forepole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1295 rear projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 150 total length, retracted . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1445 supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1445 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1402 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 490

DBT GmbH, Lünen 2001

E

main dimensions

forepole canopy

flipper

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

length, projecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 950 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1420

shifting unit

reverse mounted shifting ram, relay bar

side seal

only at the caving shield, R.H. moveable, L.H. mechanical locked

Doc. no.: 7420 056 000 BA 00

mm . . 800 mm . . 1645 mm . . 1645 mm . . 1450 mm . . 365

SSVS / 03

6.19

Description

height ,extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3200 height, retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1800 range of hydraulic height adjustment . . . . . . . . . . . . . mm . . 1400 advance stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 800

base

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3150 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1320 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 695

front lemniscatic link

two parts length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1200 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 255 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 190

rear lemniscatic link

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1180 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1210 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 310

caving shield

one part length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 2862 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1450 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 800

canopy

swivel canopy with forepole canopy liftable, at M = 2,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . gon . . 18 lowerable, at M = 2,8 m . . . . . . . . . . . . . . . . . . . . . . . . gon . . 38 forepole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3710 rear projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 150 total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3970 supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3860 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1450 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 490 force at the canopy tip at 420 bar yield pressure of the stabilizing cylinders and M = 2,8 m . . . . . . . . . . . . . . kN . . . 290

swivel canopy

forepole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 2695 rear projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 150 total length, retracted . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3845 supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 3845 width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1402 height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 490

forepole canopy

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . supporting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

shifting unit

reverse mounted shifting ram, relay bar

side seal

at the caving shield of shield variant 03: L.H. mechanical locked, R.H. side box

mm . . 800 mm . . 2445 mm . . 2445 mm . . 1450 mm . . 335

at the canopy of shield variant 03: R.H. side box at the caving shield of shield variant 04: L.H. side box with hatch, R.H. moveable at the canopy of shield variant 04: L.H. side box

6.20

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

main dimensions

E

Shield variant 03 and 04

Description Support resistance of shield variants 01 and 02 after the advance step

at M = 3,2 m and setting pressure 310 bar . . . . . . . . kN/m2 431 at M = 3,2 m and yield pressure 420 bar . . . . . . . . . kN/m2 584

unsupported roof area

before the advance step, at M = 3,2 m . . . . . . . . . . m2 . . . 4.535 after the advance step, at M = 3,2 m . . . . . . . . . . . . m2 . . . 3.335

Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 13.5 gon (15 degree) unless limited by the closed or extended condition of props or stabilizing cylinders or by the limited articulation of the hinged joint between canopy and caving shield.

DBT GmbH, Lünen 2001

E

a1 = 18 gon at M = 2,8 m and with the hinged joint articulated up to the limit

a2 = 38 gon at M= 2,8 m and with retracted link cylinder

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.21

Hydraulic system Hydraulic system The following section gives an overview of the hydraulic system installed on the shield units. For additional information please refer to the spare parts catalog. variants, differences

normal and exceptional operation

The hydraulic system is the same for shield variants 01 and 02. As shield variants 03 and 04 are provided with special functions, the hydraulic system for these shields in some aspects differs from that of variants 01 and 02. This refers to the functions 13 to 16 and the additional functions V1 to V4 (shield variant 4, only).

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

6.22

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

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

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

E

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

Hydraulic system Shield hydraulics Fig. 40: Shield hydraulics

DBT GmbH, Lünen 2001

E

A

view “A”

1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve 9 block ball valve 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.23

Hydraulic system Fig. 41: Hydraulic flow plan for shield variants 01 and 02, overview components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve, 420 bar 9 block ball valve 11 pressure gauge

14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve C1 PM4 control C2 solenoid driver please refer also to the spare parts catalog

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant.

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z8 flipper cylinder Z9 pusher cylinder Z10 seal cylinder

Z8

Z7

E

Z6

Z10 Z5

Z5

Z9

Z4

Z3

Z2

Z1

Z1

C2 C1

6.24

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder V13 retract seal cylinders V14 extend seal cylinders V15 retract flipper cylinder V16 extend flipper cylinder

Hydraulic system Fig. 42: Hydraulic flow plan for shield variant 03, overview components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve 5 pilot operated check valve 8 pressure relief valve, 420 bar 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories 18 manifold block DN 20/12 with isolating valve and filter 19 manifold block DN 25/12 with check valve

DBT GmbH, Lünen 2001

E

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant. control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder V13 V14 V15 V16

22 pilot operated check valve 25 hose lines and accessories 26 symbol plate for functions 15 and 16 27 symbol plate for functions 13 and 14 C1 PM4 control C2 solenoid driver please refer also to the spare parts catalog

Z11 Z12

Z12

Z7

Z6

Z5

Z5

Z3

Z4

retract faceside prop extend faceside prop retract front swivel canopy cylinder extend front swivel canopy cylinder

hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z11 faceside prop Z12 swivel canopy cylinder

Z2

Z1

Z1

C2 C1

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.25

Hydraulic system Fig. 43: Hydraulic flow plan for shield variant 04, overview 19 manifold block DN 25/12 with check valve

components: 1 control block, 16 functions 2 pilot operated check valve 3 pilot operated check valve 4 pilot operated check valve

21 control unit, 4 functions

5 pilot operated check valve 8 pressure relief valve, 420 bar 11 pressure gauge 14 hose lines and fittings 15 retainer and accesories

25 hoses lines and fittings

22 pilot operated check valve 26 symbol plate for functions 15 u. 16 28 symbol plate for functions HV1 u. HV2 29 symbol plate for functions HV3 u. HV4 please refer also to the spare parts catalog

18 manifold block DN 20/12 with isolating valve and filter

Note: The functions of valves V1 to V12 are the same for all shield variants. Valves V13 to V16 control varying functions, depending on the shield variant.

V13 V14 V15 V16

retract seal cylinder extend seal cylinder retract front swivel canopy cylinder extend front swivel canopy cylinder

Z11

Z11

Z7 Z10 Z5

Z5 Z6

Z13

HV1 retract chute cylinder (lower), side box HV2 extend chute cylinder (lift up), side box HV3 lower faceside prop HV4 set faceside prop hydraulic cylinders: Z1 prop Z2 shifting ram Z3 lift cylinder Z4 chute cylinder Z5 swivel canopy cylinder Z6 hatch cylinder Z7 forepole canopy cylinder Z10 seal cylinder Z11 faceside prop Z12 swivel canopy cylinder Z13 chute cylinder, side box

E

Z12

Z4

Z3 Z2

Z1

Z1

C2 C1

6.26

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

control functions: V1 retract hatch cylinder open) V2 extend hatch cylinder (close) V3 retract chute cylinder (lower) V4 extend chute cylinder (lift up) V5 lower props V6 set props V7 advance conveyor V8 advance shield V9 retract forepole canopy V10 extend forepole canopy V11 retract swivel canopy cylinder V12 extend swivel canopy cylinder

Telescopic prop Telescopic prop The single-stage telescopic prop is double-acting.

Bottom and top end of the prop are designed as a globe joint. this allows to join the prop to the base and the canopy with angular articulation. The prop head is fastened to the caving shield by a pin connection. The cams at the bottom end of the prop are fixed to the base using bolted arresting devices.

The technical data of the hydraulic prop are to be found in section “Technical data of hydraulic cylinders”.

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

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

Fig. 44: Prop, type SE-1600-180-1115/1990

stroke

DBT GmbH, Lünen 2001

E

retracted extended

applicable only for transport and storage

view ”X” 2 prop base 3 piston rod 4 piston 5 sleeve holder 6 protective plate see also spare parts catalog

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.27

Telescopic prop Fig. 45: Prop retainer at the base 1, 2

3, 4

E

1- 4 prop retainer R.h. / L.H. see also spare parts catalog DBT GmbH, Lünen 2001

Fig. 46: Fastening of the prop head at the caving shield

4

1

2

1 pin 2 locking clip

6.28

3

3 prop head 4 caving shield

DBT - 1800/3200-2x1596-1500

Telescopic prop

DBT GmbH, Lünen 2001

E

Fig. 47: Prop, type SE-1000-170-1560/2760 only applicable at shield variants 03 and 04

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.29

Telescopic prop Hydraulic cylinder, double and single acting design

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

Fig. 48:

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

2

1

3

5

4

2

3

1

4

6

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

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

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

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

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

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

6.30

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

E

Type b)

Telescopic prop Technical data of hydraulic cylinders Single-stage prop SE-1600-180-1115/1990 active piston surface area . . . . . . . . . . . . . . . . . . . . . . cm2 . . 380.1 active ring surface area . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 125.6 stroke, total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 875 prop force at setting pressure of 310 bar . . . . . . . . . . . . . . . . . . . . . kN . . . 1178.3 yield pressure of 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 1596 retracting force at 310 bar . . . . . . . . . . . . . . . . . . . . . . kN . . . 389.4

auxiliary prop only applicable for the shield variants 03 and 04

Einfachhubstempel SE-1000-170-1560/2760 active piston surface area . . . . . . . . . . . . . . . . . . . . . . cm2 . . 268.8 active ring surface area . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 41.8 stroke, total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 1200 prop force at setting pressure of 310 bar . . . . . . . . . . . . . . . . . . . . . kN . . . 833 yield pressure of 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 1129 retracting force at 310 bar . . . . . . . . . . . . . . . . . . . . . . kN . . . 129

shifting ram

double-acting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 850 force to advance the conveyor at 310 bar . . . . . . . . kN . . . 419 force to advance the shield at 310 bar . . . . . . . . . . . kN . . . 663 active piston surface area . . . . . . . . . . . . . . . . . . . . . . cm2 . . 213.8 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 135.3

pusher cylinder

double-acting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . 200 thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 96.7 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 131 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 57.7 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 31.2 active ring surface area . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 18.6

DBT GmbH, Lünen 2001

E

prop

stabilizing cylinder / swivel canopy cylinder

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 789 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 1068.9 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 545,6 at 420 bar . . . . . . . . . . . . . . . . . . . . . . kN . . . 739.2 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 254.5 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 176

forepole canopy cylinder

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 156 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 211 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 59.2 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 50.3 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 19.1

hatch cylinder

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 220.1 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 298 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 133.3 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 71 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 43

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.31

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 220.1 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 298 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 133.3 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 71 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 43

flipper cylinder

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 155,6 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 211 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 59.2 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 50.3 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 19.1

pusher cylinder

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 219.8 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 297.8 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 132 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 70.9 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 42,6

lift cylinder, only shield variant 02

6.32

double-acting thrust force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 220 at 420 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 298 pulling force at 310 bar . . . . . . . . . . . . . . . . . . . . . . . kN . . . 133 piston surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 71 ring surface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm2 . . 43

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

chute cylinder

E

Telescopic prop

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

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

Tab. 4: Pressure relief valves, use of different types Application

Type

Pre-setting in bar

Order-no.

general use

pre-loaded by pressure spring

462

7337 486 462 00 00

CAUTION! The pressure setting must not be changed.

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

DBT GmbH, Lünen 2001

E

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

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

Color Identification of Pressure Relief Valves

Doc. no.: 7420 056 000 BA 00

Color

Pressure range (bar)

black

0 - 49

black-and-white

50 - 99

brown

100 - 149

brown-and-white

150 - 199

green

200 - 249

green-and-white

250 - 299

blue

300 - 349

blue-and-white

350 - 399

red

400 - 449

red-and-white

450 - 499

yellow

500 - 549

yellow-and-white

550 - 599

orange

600 - 649

orange-and-white

650 - 699

SSVS / 03

6.33

Electrohydraulic control system Electrohydraulic control system Fig. 49: Control valve block, 16 functions b 1 15 16

13 14

11 12

7 8

9 10

5 6

1 2

3 4

15

13

11

9

7

5

3

1

16

14

12

10

8

6

4

2

A

view “A” 15 (3)

11, 12 19 a b

E

supply module housing pilot control valve, electromagnetic operation 3/2- valve capsule cover plate with filter filter insert symbol plate

DBT GmbH, Lünen 2001

1 3 7

see also spare parts catalog 7 11 oder 12

a 19

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

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

6.34

DBT - 1800/3200-2x1596-1500

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

DBT GmbH, Lünen 2001

E

Fig. 50: PanzermaticÒ PM4, schematic diagram

1 control unit 2 solenoid driver 4 covering pane 5 connecting cable 6 keyboard foil 7 sealing plug 8 bar 23 cable 24 hose cable see also spare parts catalog

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.35

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

Hydraulic fluid concentrates List of approved water-miscible hydraulic fluid concentrates for the production of fire-resistant hydraulic fluids of Group HFA. Tab. 5: Approval list (Part 1)

type X test water

type Y test water

type Z test water

P 87 AF

not tested

1.5 %

3%

Carl Bechem

Fimitol P 87 AF

not tested

1.5 %

3%

Castrol

Anvol C 18

not tested

5%

not tested

Anvol C 19

not tested

5%

not tested

Anvol SF 2000

not tested

2.5 %

not tested

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

5%

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1.5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1.5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

not tested

Quintolubric 814-01

not tested

5%

not tested

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

DBT - 1800/3200-2x1596-1500

E

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

ARAL Lubricants

Fuchs/Century

6.36

Product designation

DBT GmbH, Lünen 2001

Manufacturer

Operating media Tab. 6: Approval list (Part 2) Manufacturer

Product designation

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

type Y test water

type Z test water

GS 460 N

not tested

1.5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1.5 %

Hydrocor TS 100 N

not tested

2%

not tested

Isosynth VX 110 BF 1) 2)

not tested

1.5 %

1.5 %

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTh Theunissen i

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

2) Only permissible is the variant manufactured in Germany.

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

DBT GmbH, Lünen 2001

E

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

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

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

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

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

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

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

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

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.37

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

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

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

type Y test water (DIN 24320 resp.

Luxembourg Report)

type Z test water (NCB 19 to Luxembourg Report)

pH value

6.5 - 8.5

6.5 - 8.5

6.5 - 8.5

hardness mmol/l

2.5 (=14°d)**

3.58 (= 20°d)**

7.5 (= 42°d)**

chloride

200 mg/l

200 mg/l

200 mg/l

sulfate

240 mg/l

150 mg/l

720 mg/l

nitrate

0 mg/l

20 mg/l

0 mg/l

magnesium

30 mg/l

50 mg/l

90 mg/l

sodium

130 mg/l

115 mg/l

130 mg/l

calcium

50 mg/l

61 mg/l

150 mg/l

iron, max.

0.3 mg/l*

0.3 mg/l*

0.3 mg/l*

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

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

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

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

test method: by agreement with the concentrate manufacturer J the microbial load

test method: dip slides IMPORTANT! Further information is contained in DIN 24320.

6.38

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

type X test water (NCB 18 to Luxembourg Report)

E

Tab. 7: Chemical composition of the test water samples used

Operating media Recommended lubricating greases and pastes Lubricating greases general properties

lubricating greases for general application

base:

lithium soap

NLGI class:

2

penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble in water

temperature of application :

-20 to +120° C

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

Tab. 8: Lubricating greases for general application Type

ARAL

Aralub HL 2

BP

BP Energrease LS 2

ESSO

BEACON 2

MOBIL

MOBILUX 2

SHELL

Shell Alvania Grease R 2

TEXACO

MULTIFAK 20

CALYPSOL

Multipurpose grease 20

DBT GmbH, Lünen 2001

E

Supplier

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

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

Tab. 9: Lubricating greases containing additives Supplier

Type

ARAL

Aralub HLP 2

BP

BP Energrease LS-EP 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

SHELL

Shell Alvania E.P. Grease 2

TEXACO

MULTIFAK EP 2

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.39

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

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

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

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

Tab. 10: Lubricating pastes free from molybdenum disulfide Type

Base

NLGI class

gleitmolybdän

gleitmo 805 1)

Li

2

Klüber Lubrication

Altemp Q NB 50 2)

Ba-complex

2/3

Liqui Moly

LM 841 1)

Li

2

1) If necessary, neighboring cavities must be filled using a lubricating grease according to table 8 above.

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

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän ”gleitmo 805” Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water: Temperature of application:

non-soluble in water -34 to +120° C

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent and lubricant 785 IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

6.40

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

E

Supplier

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

DBT GmbH, Lünen 2001

E

Tab. 11:

Thread 1)

Pitch

Tightening torque 4)

(mm)

(mm)

MA (Nm)

d

P

8.8

10.9

12.9

M8

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

DM 27 2)

3

580

-

-

M 30

3,5

1310

1845

2215

M 32 3)

2

-

1450

-

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

1) dimensions in brackets in exceptional cases only 2) according to works standard (EWN 6110), February 1985 edition 3) only for expansion screws having a reduced shaft cross-section of 24.2 mm 4) The tightening torques comply with EWN 6003 works standard.

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

Doc. no.: 7420 056 000 BA 00

SSVS / 03

6.41

E

DBT GmbH, Lünen 2001

6.42

DBT - 1800/3200-2x1596-1500

7

For your information

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Germany

DBT GmbH Mail:

DBT GmbH Verkauf / Service Industriestraße 1 44534 Lünen GERMANY

DBT GmbH, Lünen 2001

E

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

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

Fig. 51: Type plate, example

1

DBT 2 3

7420.056.000.00.00

2

1596

kN

4 1 manufacturer 2 order number

3 number of props 4 prop force

The shields are numbered consecutively. A plate showing the shield number is fitted to the main canopy, the base and the caving shield.

Doc. no.: 7420 056 000 BA 00

SSVS / 03

7.3

Identification of shields

7.4

Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery

DIN EN 982

Safety of machinerySafety requirements for fluid power systems and their components

DIN EN 60445

Identification of Connections

DIN 2000

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

DIN 6789

Documentation System

DIN 8418

Information for Users

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self-Advancing Supports

DIN 24320

Fire Resistant Hydraulic Fluids

DIN 24343

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

DIN 24346

Hydraulic Systems; Design Principles

EWN 6003

Pretensioning forces and tightening torques

EWN 7068

Lubricants

EWN 7069

Nonmetallic surface protection

ISO 4406

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

DBT - 1800/3200-2x1596-1500

DBT GmbH, Lünen 2001

Designation

E

Referenced standards and guidelines