CAT DBT Shield 2400/5000−2x4319−1750 Operating Manual

Operating Manual DBT − Shield 2400/5000−2x4319−1750 Doc. no.: 7420 128 000 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

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

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

We reserve the right to introduce modifications obtained by technical development without previous notice!

DBT GmbH, Lünen 2004 E

Index

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

1.3

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

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

1.4 1.4

DBT GmbH, Lünen 2004

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

2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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

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

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

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

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

2.6 2.7 2.8 2.9 2.11

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

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

3.3

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

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

3.3 3.5

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

3.5

4. Installation

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Pre−assembly of the shield units . . . . . . . . . . . . . . . . . .

4.3

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

4.3

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

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

4.5 4.6

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

4.7

Start−up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8

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

Start−up of the shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.8 4.10 4.10

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

5.3

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

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

5.3 5.6

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

5.9

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

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

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

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

5.15 5.24 5.25 5.27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

To be done every six months . . . . . . . . . . . . . . . . . . . . . . . .

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

5.30 5.31 5.31 5.31 5.31 5.32 5.32 5.35 5.35 5.36 5.36 5.36

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

6.3

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

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

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

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

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

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

6.5 6.7 6.11 6.15 6.16 6.18

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 Double−telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Baselif t cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

6.24 6.25 6.26 6.27 6.27 6.28 6.29 6.32

Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.34 Electronic shield control . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.35

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.36 DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

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

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

Pilot−operated check valves . . . . . . . . . . . . . . . . . . . . . . . . .

Internal by−pass in props . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Index Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.37 Anti−topple device canopy − canopy" . . . . . . . . . . . . . . . . .

Anchoring device base − base . . . . . . . . . . . . . . . . . . . . . . .

6.37 6.39

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40 Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

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

6.40 6.43

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45 Screws with metric coarse thread DIN 13 . . . . . . . . . . . . . .

6.45

7. For your information 7.3

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

7.3

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

7.5

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

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

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

7.5 7.5 7.6

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

Doc. no.: 7420 128 000 BA 00

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DBT GmbH, Lünen 2004

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Index

DBT − Shield 2400/5000−2x4319−1750

1

About this manual

Before starting work

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

Before starting work applicable operating manual

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

This operating manual is designed for: DBT−shield 2400/5000−2x4319−1750 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.

DBT GmbH, Lünen 2004

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Tab. 1: Type specification for DBT−shield 2400/5000−2x4319−1750

availability of operating manual

identification no.

prop force

year of application construction

7420 128 000 00 01

2 x 4319 kN

2004

face shield

7420 128 000 00 02

2 x 4319 kN

2004

transition shield

7420 128 000 00 03 ...06

2 x 4319 kN

2004

face end shield

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.

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

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

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.

Observe the information given and follow the procedural instructions.

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.

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

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

1.4

J

Items in lists are marked with 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 .

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

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Characters and symbols used

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 2004

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 requirement s 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

DBT GmbH, Lünen 2004

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

2.4

DBT − Shield 2400/5000−2x4319−1750

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

Use the shield only in conformance with specifications!

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

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

— advancing, DBT GmbH, Lünen 2004

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— retracting; J forming an abutment for:

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

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

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

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

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

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

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2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

lighting signalling systems and protective devices

Maintain the lighting systems in a functional condition.

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

support lock−out switch

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

Only applicable for shields provided with electrohydraulic control systems.

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

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

moving parts

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

automatic mode

2.6

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

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

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

EMERGENCY STOP

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

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

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

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

Moreover, this measure prevents inadvertent reinstallation of these component s elsewhere.

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

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

DBT GmbH, Lünen 2004

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

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

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

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

Damage of this kind necessitates elaborate and expensive repair work.

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

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

Firmly secure all components which might start moving.

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

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2.7

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

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

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

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

Securing by means of hardwood wedges

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Fig. 1:

transport securing devices

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

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

travelway

Make sure that the minimum dimensions specified for the travelway within the shield are maintained under any circumstances. The minimum dimensions are: J width: 600 mm J height: 400 mm

Any devices added to the shield later such as for example steering devices are not allowed to reduce the minimum travelway. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travelway is maintained.

2.8

DBT − Shield 2400/5000−2x4319−1750

Safety instructions Operation

DBT GmbH, Lünen 2004

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shield control

inclined faces

Doc. no.: 7420 128 000 BA 00

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

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

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

Carefully read the instructions for operating the control system used.

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

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

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

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

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

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

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

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

Ensure that the water spray system responds during advancement.

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

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

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

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

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

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2.9

Safety instructions shield alignment

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

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

roof falls

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

Never set the tip of the canopy into a roof fall−out such that — the max. admissible angle of inclination of the canopy is exceeded — the stabilizing cylinder locks

residual stroke

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

pulling back the conveyor

If possible, pull the conveyor back by operating the respective functions of the electronic shield control unit. If this is not possible, do as specified in the respective operating instructions of the mine.

Secure the entire mining machine against unauthorized starting.

Isolate your place of work such as to prevent any unauthorized persons entering this area.

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

raising of conveyor

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

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

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

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

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

For raising the conveyor, only use: J high−strength undamaged round link steel chains, J the fastening points provided for the purpose. Check that the fastening points are undamaged before attaching a load, J lifting gear with sufficient permissible load−bearing capacity.

2.10

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

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— the canopy will be loaded excessively in longitudinal direction as this may cause damage due to excessive stress and strain on the components.

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

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

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

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

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

DBT GmbH, Lünen 2004

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Use only spare parts which conform with the specified technical requirement s. 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.

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

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

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

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

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

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

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

pressure or mechanical stress.

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

When performing any work which might entail the risk of the support retracting automatically secure the shield mechanically to prevent it lowering by itself.

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2.11

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

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

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

Hydraulics handling of hydraulic fluids

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

Never use hydraulic fluids for rinsing or cleaning.

maintenance, repair

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

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

J the hoses have no bubbles or blisters.

J the hoses or the outer sheathes of the hoses are not abnorJ the outer sheath of the hoses is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak−tight.

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

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

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

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

After completion of any repair work, check the depressurized system first to make sure all connections are correct. Next, apply pressure to the hydraulic system and check that the installation is leak− proof and functioning properly. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage. Never install hydraulic hoses which are more than 2 years old, even if they don’t show any visible signs of damage.

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mally rigid or hard.

Safety instructions

Fig. 2:

Example: 4SP hydraulic hose, designation

3

2 1

6 5

4 1 hose type 2 nominal diameter 3 date of manufacture

4 manufacturer 5 flame−resist ant and antistatic 6 standard

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

DBT GmbH, Lünen 2004

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

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

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

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

Fig. 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

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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RIGHT

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

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

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

Use only suitable load handling devices.

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

DBT GmbH, Lünen 2004

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

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

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

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

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

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

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2.15

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

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

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

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

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

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

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

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

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

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

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DBT GmbH, Lünen 2004

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".

E

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

Overview of the safety instructions NOTICE! Take care to ensure that all transport safety devices required for transport have been removed. See chapter 3, section "Transport".

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

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

Chapter 5: Operation and maintenance

DBT GmbH, Lünen 2004

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

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

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

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

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

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

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

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

WARNING The control elements on the control valve block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose. They are not allowed to be used for normal op-

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2.17

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

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

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

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

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DBT GmbH, Lünen 2004

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.

E

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

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 fall− outs 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.

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

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

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

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

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

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

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

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2.19

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

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

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

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

CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy − caving shield) will not be exceeded.

CAUTION! The pressure setting must not be changed.

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

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

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DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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.

E

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.

Overview of the safety instructions NOTICE! New seals must be fitted whenever a pressure relief valve is replaced.

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

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

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

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

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

IMPORTANT! Further information is contained in DIN 24320.

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

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

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

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

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

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DBT GmbH, Lünen 2004

2.22

DBT − Shield 2400/5000−2x4319−1750

3

Storage and transport

Storage

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

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

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

Storage Storage of new equipment corrosion protection

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

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

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

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

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

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

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

long−term storage

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

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

Doc. no.: 7420 128 000 BA 00

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

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3.3

Storage storage outdoors

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

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

electrical equipment, rubber and plastic parts

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

natural ageing

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

moisture and dirt

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

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

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

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

random sample inspection

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

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

HFA fluids

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

Supplement ary information is given in the section "Pressure fluids of group HFA" in this manual.

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

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plastic deformation

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

Transport 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

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.

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 km/h for truck transport.

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3.5

Transport electrical and electronic components

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.

transport units

A shield can be transported as a completely assembled unit or divided into transport units. If dismantling into transport units is necessary, this is planned and laid down in close cooperation with the costumer .

Tab. 2: Transport units Transport position

Remarks

as for normal use

without electronic control unit

side canopy

hydraulic cylinders on top

E

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: Tab. 3: Transport safety devices Part

Transport safety device

flipper

chain

1

side seal, moveable side

pin and retaining clip

4

shifting unit, faceside

transport rod

1

shifting unit, gobside

chain

1

hydraulics

hydraulic ports not used are closed with protection plugs

−

Quant.

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

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

1) end shield variants 03 and 06: side canopy detached

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transport safety devices

Designation support unit complete 1)

Transport Fig. 8:

Transport of shields as complete unit W X5 X4 X3 Y

H

S 0

SY

X4

X1 S3

X2 S4

Sx L

S3 slot hole, 2 x on the coal face end of the base, load−bearing capacity: 15000 kg S4 slot hole, 2 x on the gob side end of the base, load−bearing capacity: 15000 kg X1, X2 securing elements to fix the relay bar during transport, faceside and gobside X3 securing elements to fix the flipper X4 securing elements to fix the moveable side seals X5 transport safety devices at the side canopy Y transport safety device between canopy and base not included in the scope of delivery So center of gravity

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Tab. 4: Shield support 7420 128 000 00 .. , Dimensions and weights of variants Variant

Order no.

Length in mm

Width in mm

Height in mm

Sx/Sy in mm

Weight approx. in kg

01 7420 128 000 00 01

7215

1650

2400

1552 / 1423

02 7420 128 000 00 02

7725

1650

2400

1411 / 1459

27940

03 7420 128 000 00 03

8225

1650 1)

2400

1320 / 1431

294101)

04 7420 128 000 00 04

8225

1650

2400

1320 / 1431

29410

05 7420 128 000 00 05

8225

1650

2400

1320 / 1431

29410

8225

1650 1)

2400

1320 / 1431

294101)

06 7420 128 000 00 06

27190

1) Side canopy detached

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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

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

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

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4.3

Installation of the shield units

4.4

Shield no.

Order no.

Application

5 .... 147

7420 128 000 00 01

face shield

4

7420 128 000 00 02

transition shield

1

7420 128 000 00 03

end shield

2 and 3

7420 128 000 00 04

end shield

148 and 149

7420 128 000 00 05

end shield

150

7420 128 000 00 06

end shield

DBT − Shield 2400/5000−2x4319−1750

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Shield number, example

DBT GmbH, Lünen 2004

Fig. 9:

Installation of the shield units Supply connections During first start−up as well as during normal operation the supply to the support shield unit proceeds exclusively by means of the manifold pipe.

Fig. 10: View on the manifold pipe b

21a

21b P R W

16

a

DBT GmbH, Lünen 2004

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16 manifold pipe 21a high−pressure ball valve, auxiliary water line 21b high−pressure ball valve, supply to the water spray system

a protective cover for electrohydraulic control unit b protective cover for dual filter R return line, DN 50 P pressure supply line, DN 40 W water supply line, DN25

Fig. 11: View on the rear manifold pipe and the dual filter, protective cover removed

21c

20 23

16 16 manifold pipe 20 dual filter, back flush type 21c high pressure ball valve, serves to isolate the water supply to the

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rear nozzle row at the canopy tip, open as shown 23 high−pressure ball valve, serves to isolate the shield hydraulics from pressure supply, open as shown

4.5

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

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each shield unit. This pipe provides the hydraulic supply to the individual shield unit. The manifold pipes of adjacent shield units are connected with the use of three hose lines: A pressure line (DN 40), a return line (DN 50) and a water line DN 25. See the hydraulic block diagram in chapter 6.

control unit

The shield units are equipped with an electronic control unit of type PM4. The connection between the control unit and the electrohydraulic control block is provided by a solenoid driver module. The connecting cables required for this purpose are included in the scope of supply of the PM4 control system. How to connect the control unit is described in the separate operating manual for the PM4 control system. An overview of the design of the control is also given in chapter 6 of this operating manual in the section titled "shield control".

additional equipment

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

4.6

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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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

315 bar

admissible tolerance

"10 % of nominal pressure

DBT GmbH, Lünen 2004

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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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4.7

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

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

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

Please observe the following items:

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 connections that are leaking.

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

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

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

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

. Check the hydraulic supply pressure. . Check supporting power of the props. (observe pressure gauge reading)The actual pressure under the piston of a prop can be read off the PM4 control unit. You can either read off the pressure of an adjacent support or of the support where you are currently located. The pressure gauge at the prop check valve indicates the pressure direct..

4.8

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

E

J Mechanics

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

function is executed when actuating the respective operating element.

J Signalling and lighting systems

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

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

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

J Emergency stop systems

. Check that all emergency stop systems function properly.

J Mining and conveying

. Check all functions of the longwall system before start−up.

DBT GmbH, Lünen 2004

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. Check correct interaction of the complete longwall system (mining machine, conveyor system, shields).

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

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4.9

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

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

. Check all line connections made during the installation of the

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

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

. Check the function of the hydraulic and water supply systems

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

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

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

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

4.10

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

. Check all functions of the shield control system.

E

for the face.

5

Operation

Basic requirements

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

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

DBT GmbH, Lünen 2004

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

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

Basic requirements Conditions for operation face crew

The face crew must be informed about possible danger situations.

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

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

face equipment

The face must be illuminated sufficiently .

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

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

conveyor overload

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

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

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5.3

Basic requirements travel way

The minimum dimensions for the travelway specified must be maintained.

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

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

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

roof supporting work

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

work in the mining track

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

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

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

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

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

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

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

5.4

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

E

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

Basic requirements repair work

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

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

Component s 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 2004

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

conveyor steering devices

On inclined faces, the conveyor has to be secured by anchorages, if required. This measure is required to prevent the conveyor offset ting 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.

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5.5

Basic requirements Safety requirements automatic mode

Exercise special care and caution when travelling a face that is operated automatically. Be sure to observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be prepared for the shield which you are in being addressed by the automatic system. Therefore it is vital that you observe the acoustic and optical warning signals sent by the control unit of a shield which is just being operated.

Operate the "support lock−out switch" when you have to stay in a shield for a longer period of time.

shield operation

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

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

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

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

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

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

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

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

5.6

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

E

When operating the shield manually the operator has to always watch the area of movement of the shield before and while operating the shield in order to prevent potential hazards by cautious behavior.

Basic requirements Fig. 12: W r o n g , shields have not been advanced in the right time

DBT GmbH, Lünen 2004

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Fig. 13: C o r r e c t, shields have been advanced in time

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

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

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

hydraulics, controls

Take care to avoid misoperation of the shield control.

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

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

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

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5.7

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

Shut−of f 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.

DBT GmbH, Lünen 2004

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

5.8

DBT − Shield 2400/5000−2x4319−1750

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

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

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

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

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

DBT GmbH, Lünen 2004

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canopy adjustment

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

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

Fig. 14: Shield in the normal position

α=0 M

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

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5.9

Operation of the shield CAUTION! Never extend or retract the stabilizing cylinders of the shield completely. 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. 15: Shield with extremely inclined canopy

s

1

α

1

α2

s2

M

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

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

This applies especially if the shield control unit is equipped with an automatic positive setting function. Under unfavorable conditions − for example, soft floor and in addition, perhaps a tendency to roof fall−out s − 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.

5.10

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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M

Operation of the shield CAUTION! Avoid an excessive inclination of the canopy by filling roof fall− outs 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.

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.

DBT GmbH, Lünen 2004

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Never set the tip of the canopy of two−leg shields with stabilizing cylinder in a cavity (figure 16) 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.

Fig. 16: 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. 17) or by leveling off the canopy.

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

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5.11

Operation of the shield Fig. 17: 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.

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 component s.

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.

5.12

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

range of adjustment / changing seam thickness

E

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.

Operation of the shield inclined faces

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

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

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

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

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

DBT GmbH, Lünen 2004

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

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

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

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

draulically by retracting a prop.

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

usually applied in mines.

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

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5.13

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

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

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

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

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

Always observe these safety rules :

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

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

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

5.14

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

E

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

Operation of the shield hydraulics Operation of the shield hydraulics WARNING! During normal operation, the shield−type support is operated only by means of the control unit of the electrohydraulic adjacent control system. Pay attention to the separate manual of the electronic control system.

Location of hydraulic components at the shield Tab. 5: Hydraulic components Item 1

Qty. 1 1) 1 2)

DBT GmbH, Lünen 2004

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2 3 5 6 7 8 11

2 1 2 2 1 1 2) 3

Description electrohydraulic control, 14 functions electrohydraulic control 16 functions

Location at holder, between the two front links at holder, between the two front links

prop check valve NG 20 pilot−operated check valve pressure relief valve 462 bar pressure relief valve 470 bar check valve NW 25 pilot operated check valve twin check valve

at prop rear side at the R.H. front lemniscatic link gobside at the prop at the link cylinder at the manifold pipe at the gobeside side canopy cyl. a) at the link cylinder b) under the front canopy c) at the flipper cylinder at prop check valve, L.H.

Remark for shield variants 01, 02,04 and 05 only for shield variants 03 to 06 only, end shields with side canopy or auxiliary functions in shift cylinder circuit high flow rate type return line

b) flipper extension cyl. circuit

12 13 14 15 16 17 18

1 1 1 1 1 1 6 / 72)

glycerine pressure gauge hose lines water spray system retainers and accessories manifold pipe accumulator cartridge pressure relief valve 380 bar

19 20 21

1 1 4

water spray valve dual filter, back flush high−pressure ball valve

22

2

high−pressure ball valve

23

1

high−pressure ball valve

a) L.H. prop check valve b) R.H. prop check valve at the manifold pipe, P−line

24 25 26

1 2 1 3)

in−line−filter screwed socket high−pressure ball valve

at the manifold pipe, in W−line at the prop head at holder beyond the PM4 SCU

27 28 30 32 33 34

3 1 1 1 3) 1 2) 2 4)

manifold L.H. under the rear canopy connecting plate symbol plate at the electrohydraulic control unit beyond the pilot valves hose lines for pusher cyl. see separate parts list hose lines for side canopy see separate parts list plug DN10 at the electrohydraulic control unit port 15 and 16 1) for shield variants 01 and 02 only 2) for shield variants 03 and 06 only, face end shields with side canopy 3) for end shield variants 03 to 06 only 4) for end shield variants 04 and 05 only

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see separate parts list see separate parts list see separate parts list between the front lemniscatic links at the electrohydraulic control unit a) lower seal cyl. at caving shield b) at shift cyl. check valve c) at twin check valve 11b (2 x) d) at twin check valve 11c (2 x) e) at the front side canopy cyl. at the R.H. front lemniscatic link between the front lemniscatic links a) at the manifold pipe b) at the manifold pipe c) at the water spray valve (19) d) L.H. under the rear canopy

port SP"

a) auxiliary water line b) water supply to the spray system c) in supply line to the rear nozzle row d) in supply line to the seal cyl. annulus side serves to isolate the prop piston chamber from pressure supply serves to isolate the shield hydraulic from pressure supply

serves to activate / deactivate the pusher cylinder

5.15

Operation of the shield hydraulics Shield hydraulics Fig. 18: Shield hydraulics 18d

18c

11b

28

22 27 21d 18a

1 3

16

25 11c 18d 14

22

18e

12

33

8

16

25

11a 23

E

7 DBT GmbH, Lünen 2004

21b 24 21a 20 21c 19 3

15 26 30 32 5

2

18b 17

1 electrohydraulic control 2 prop check valve 3 pilot−operated check valve

14 water spray system 15 retainer and accessories 16 manifold pipe

5 pressure relief valve, 462 bar 6 pressure relief valve, 470 bar

17 accumulator cartridge 18 pressure relief valve, 380 bar

7 check valve 8 pilot−operated check valve 11 twin check valve

19 water spray valve 20 dual filter, back flush 21 high−pressure ball valve

12 pressure gauge 13 hose lines

22 high−pressure ball valve 23 high−pressure ball valve

24 in−line−filter 25 screwed socket 26 ball valve 27 manifold 28 connecting plate 30 symbol plate 32 accessories pusher cyl.

33 accessories side canopy 34 plug DN10 please, refer also to the spare parts catalog

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02

5.16

DBT − Shield 2400/5000−2x4319−1750

Operation of the shield hydraulics Fig. 19: Hydraulic circuit diagram, overview Please, refer also to the spare parts catalog.

control valve block functions: 1 extend stabilizing cylinder 2 retract stabilizing cylinder

1 16

3 extend props 4 extend seal cylinders

21a

23

21b 7

24

5 retract props 6 retract seal cylinders 7 advance shield 8 push conveyor 9 extend flipper cylinder

20

(34)

10 retract flipper cylinder 11 retract flipper extension cyl.

12 extend flipper extension cyl.

17

27

19

21d

13 extend lift cylinder 14 activate water spray system 15 retract side canopy cylinder 16 extend side canopy cylinder

21c Z4

component s: 1 electrohydraulic control 2 prop check valve

6 33 Z4 DBT GmbH, Lünen 2004

E

Z3 Z8

8 11a

Z4

6 Z2

18a

32

26

18e

3

18b Z4 Z5

22

22

5

Z9

12 13

Z1

Z1

2

2 25

25

28

14

18d Z6

11c

18 pressure relief valve, 380 bar 19 water spray valve 20 dual filter, back flush type

23 high−pressure ball valve 24 in−line−filter 25 screwed socket

33 accessories side canopy 34 plug Z7

hydraulic cylinders: Z1 prop Z2 shift cylinder Z3 stabilizing cylinder

16 manifold pipe 17 accumulator cartridge

27 manifold 32 accessories pusher cylinder

18d

Z7

13 hose lines 14 water spray system 15 retainer and accessories

21 high−pressure ball valve 22 high−pressure ball valve

11b 18c

6 pressure relief valve, 470 bar 7 check valve 8 pilot−operated check valve 11 twin check valve 12 pressure gauge

Z8

5

3 pilot−operated check valve 5 pressure relief valve, 462 bar

Z4 seal cylinder Z5 base lift cylinder Z6 flipper cylinder

S1 pressure sensor

Z7 flipper extension cylinder Z8 side canopy cylinder Z9 pusher cylinder

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.17

Operation of the shield hydraulics Fig. 20: Hydraulic lines, overview key, see Fig. 19 18a

Z4

20 16

21c

7

23

P T W

21a

21b 24

19

17

Z4

1 34

3

18b 11

DBT GmbH, Lünen 2004

E

6

Z3 Z4

6 Z2

21d 27

27

Z5

Z1

Z1 5 2

12

S1

22

5 2

22

Z6 25

25

11c Z7

Z4 18d

Z7

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02.

5.18

DBT − Shield 2400/5000−2x4319−1750

Operation of the shield hydraulics Fig. 21: Pusher cylinder, hose lines and fittings key, see Fig. 19

32

26

B

A

Z9

DBT GmbH, Lünen 2004

E

A retract pusher cylinder B extend pusher cylinder NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02.

Fig. 22: Side canopy, hose lines and fittings key, see Fig. 19

18e Z8

8

Z8

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02.

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.19

Operation of the shield hydraulics Fig. 23: Shield

2

3

1

DBT GmbH, Lünen 2004

E

1 manifold pipe 2 PM 4 control unit 3 control valve block

Fig. 24: View on the manifold pipe 21a

21b

b

P R W

16

a

16 manifold pipe 21a high−pressure ball valve, auxiliary water line 21b high−pressure ball valve, supply to the water spray system

5.20

a protective cover for electrohydraulic control unit b protective cover for dual filter R return line, DN 50 P pressure supply line, DN 40 W water supply line, DN25

DBT − Shield 2400/5000−2x4319−1750

Operation of the shield hydraulics Fig. 25: View on the dual filter and the rear manifold pipe, protective cover removed

21c

20 23

16 at the canopy tip, open as shown 23 high−pressure ball valve, serves to isolate the shield hydraulics from pressure supply, open as shown

16 manifold pipe 20 dual filter, back flush type DBT GmbH, Lünen 2004

E

21c high pressure ball valve, serves to isolate the water supply to the rear nozzle row

Fig. 26: PM4 control unit fitted at adjustable holder

a

b

c

a PM4 control unit b holder for PM4 control unit c control valve block

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.21

Operation of the shield hydraulics Fig. 27: Adjustable holder for electronic control unit PM4

B 6, 9

6, 9

11

A

11 securing spring A height adjustable link B adjustable hinge fitted link

Prior to putting the shield unit into operation, the retainer for the PM4 control unit must be fitted in suitable working position.

. Fix height of the retainer (A) at both sides in working position using the securing springs (11).

. Adjust angle (B) in working position and retighten bolts (6) with the recommended tightening torque.

Fig. 28: High−pressure ball valve (26) to operate the pusher cylinder

a A C

26

B

26 high−pressure ball valve not available at shield variants 01 and 02 a holder C height adjustable link A extend pusher cylinder B retract pusher cylinder

5.22

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

6 hex. head bolt M16x35 − 8.8, recommended tightening torque 195 Nm 9 washer

Operation of the shield hydraulics Fig. 29: L.H. prop, gobside view

2

22

12 5

2 prop check valve

22 high−pressure ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown

DBT GmbH, Lünen 2004

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5 pressure relief valve 12 pressure gauge

Fig. 30: R.H. prop, gobside view

22 2 S1

5

2 prop check valve 5 pressure relief valve S1 pressure sensor

Doc. no.: 7420 128 000 BA 00

VEVE / 01

22 high−pressure ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown

5.23

Operation of the shield hydraulics Operation of the dual backflush filter WARNING! Do not put the filter into operation, prior making sure that all connections have been made properly. operation

The filter works, if both backflush levers are in parallel position. The filter needs to be backflushed after contamination accumulates to the point of increased pressure drop and restricted flow.

flushing

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

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

Only one filter element must be backflushed at a time by simply turning the lever 90 degrees for about two seconds and then returning the lever to the working position. Repeat procedure for the other filter element.

Fig. 31: View on the dual filter and the rear manifold pipe, protective cover removed

20

B

B

A

20 dual filter, back flush type A normal operation: both levers in position A"

5.24

A

B back−flushing: one of the levers in position B"

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

Effective backflushing requires flow in excess of 70 I/min (19 GPM).

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−of f valves are open as for normal operation.

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

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

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

DBT GmbH, Lünen 2004

E

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

Fig. 32: Control devices

a

b

a PM4 control unit b electrohydraulic control

Figure 32 above shows the arrangement of the PM4 control unit and the control valve block.

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

See separate manual for the PM4 control unit.

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.25

Operation of the shield hydraulics Fig. 33: Control valve block (14 functions) fitted at holder between the front lemniscatic links

e

d 1

c

a

c pilot valve d connecting cable e solenoid driver

Fig. 34: Symbol plate for 14 function control valve block

Fig. 35: Symbol plate for 16 function control valve block

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

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

5.26

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

1 electrohydraulic control a push button b symbol plate, hidden by the pilot valves

E

b

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

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

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

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

DBT GmbH, Lünen 2004

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.

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.27

Operation of the shield hydraulics

1

Extend stabilizing cylinder CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

This function causes the canopy tip to raise and serves to correct the attitude of the canopy. It is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

After the attitude of the canopy has been corrected the props will have to be set again.

2

Retract stabilizing cylinder

Set both props 3

Before this function is initiated the canopy must be aligned correctly. The lift cylinder will be retracted automatically.

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

Extend seal cylinders

4

5

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

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

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

6

5.28

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

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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

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

E

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Operation of the shield hydraulics Advance shield 7

8

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

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

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

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

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

Retract flipper cylinder

9

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

DBT GmbH, Lünen 2004

E

Extend flipper cylinder 10

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

Retract flipper extension cylinder

11

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

Extend flipper extension cylinder

12

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

Extend base lift cylinder

13

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

Activate water spray system at canopy and caving shield

14

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

Retract side canopy cylinders

15

Not applicable to shield variants 01, 02, 04 and 05.

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

Extend side canopy cylinders

16

Doc. no.: 7420 128 000 BA 00

Not applicable to shield variants 01, 02, 04 and 06.

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

VEVE / 01

5.29

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

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

Special measures

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

All shields equipped with a water spraying system require the piston rods of those cylinders which are usually only rarely extended or retracted completely, for example, props and and stabilizing cylinders, to be thoroughly cleaned approximately every 6 months. A suitable preservative should be applied afterwards.

filter cartridges

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

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

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

pressure relief valve

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

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

5.30

DBT − Shield 2400/5000−2x4319−1750

E

One week after start−up, at the latest, the filter cartridges of the electrohydraulic control valve blocks of the shield control units on the complete longwall must be checked for dirt on a random basis.

If this inspection reveals that there is a high probability of failures due to dirty filters all filter cartridges on the face must be replaced.

DBT GmbH, Lünen 2004

One week after start−up

Maintenance hydraulic high−pressure hoses

dual back flush filter

For reasons of safety and to maintain the installation operative all hydraulic high−pressure hoses must be replaced regularly at least after two years of operation, irrespective of whether they show any signs of damage. If this deadline cannot be met because the end of the section planned to be mined will only be reached shortly after the deadline, the hoses can by way of exception be replaced after the respective section has been completed.

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

Daily inspection hydraulics

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

. Check pressure gauges at the props for any visible signs of

DBT GmbH, Lünen 2004

E

damage and correct functioning.

steel structure

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

Weekly inspection control unit

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

. Clean the control units, especially the control panel.

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

To be done every six months

. Apply a preservative to the piston rods of the hydraulic cylin-

ders. Details are given in this chapter under the heading "special measures".

Assessment of damage according to schedule We recommend to keep records of the damages found. These records should be evaluated regularly, say once a month, and summarized in a damage report. Frequently recurring failures can thus be detected early and the source of the failure eliminated. This will improve the availability of the installation and help to reduce operating cost.

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.31

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

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

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

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

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

5.32

possible cause

check / measure required

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

Open shut−off valve.

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

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

Open shut−off valve.

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

Canopy is trapped by adjacent shields.

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

Pilot piston in the prop check valve is not operating.

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

Prop check valve may be faulty.

Damaged or trapped hoses.

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

Props are damaged.

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

No pressure at control valve block output.

Disconnect hose at lowering port of prop.

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

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

failure to lower the shield

E

Fault localization

Trouble shooting failure to set the shield

Possible cause

Check / measure required

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

Open shut−off valve.

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

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

Open shut−off valve.

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

Canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that − hydraulic system works correctly. − all shut−off valves are open − system pressure is sufficient.

DBT GmbH, Lünen 2004

E

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

Prop check valve may be faulty.

failure to advance the shield

Damaged or trapped hoses.

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

Props are damaged.

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

Possible cause

Check / measure required

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

Open shut−off valve.

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

Canopy is trapped by adjacent shields.

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

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

Doc. no.: 7420 128 000 BA 00

System pressure is too low for operation.

Check that − hydraulic system works correctly. − all shut−off valves are open − system pressure is sufficient.

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

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

Prop check valve may be faulty.

Damaged or trapped hoses.

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

Shifting ram is defective.

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

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

VEVE / 01

5.33

failure to operate the tip up function

failure to operate the tip down function

5.34

Possible cause

Check / measure required

Faulty prop check valve.

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

Props are damaged.

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

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

Faulty pressure relief valve.

Check pressure gauge reading. Is pressure relief valve weeping?

If so, replace pressure relief valve and check functions.

Possible cause

Check / measure required

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

Open shut−off valve.

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

Shield canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that − hydraulic system works correctly. − all shut−off valves are open − system pressure is sufficient.

Pilot−operated check valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

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

Possible cause

Check / measure required

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

Open shut−off valve.

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

Shield canopy is trapped by adjacent shields.

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

System pressure is too low for operation.

Check that − hydraulic system works correctly. − all shut−off valves are open − system pressure is sufficient.

Pilot−operated check valve is not operating.

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

POCV may be faulty.

Damaged or trapped hoses.

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

Stabilizing cylinder is damaged.

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

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

failure to maintain the prop pressure after setting the support

E

Trouble shooting

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

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

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

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

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

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

internal leakage

. Try to locate the defective valve by operating the individual

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 2004

manifold pipe.

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

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

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

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

. Check valve and replace, if defective.

Doc. no.: 7420 128 000 BA 00

VEVE / 01

5.35

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

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

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

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

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

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

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

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

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

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

. Check the filters in the hydraulic system. Backflush filters may

be cleaned by backflushing. On fine−mesh filters which are, for example, used on the control valve blocks, the filter elements must be replaced.

5.36

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

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.

E

Faulty pressure relief valve

6

Technical data

Shield variants

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

Shield variants Type 2400/5000−2x4319−1750 The two−leg shield units basically comprise the following main component s: J base with lemniscatic links, shifting unit and baselift cylinder J canopy with flipper J caving shield J side seal, moveable at R.H. side only J hydraulic props J hydraulic equipment with hose lines and controls

Six different versions of the same type of shield will be supplied:

DBT GmbH, Lünen 2004

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Tab. 6: Variants of the shield (1) Variant

Application

Order−no.

01

face shield

7420 128 000 00 01

6000 x 18501) x 5000 7255 x 1650 x 2400

27190

02

transition shield

7420 128 000 00 02

6500 x 18501) x 5000 7725 x 1650 x 2400

27940

04 , 05

end shield

7420 128 000 00 04 7420 128 000 00 05

7000 x 18501) x 5000 8225 x 1650 x 2400

27940

03 , 06

end shield

7420 128 000 00 03 7420 128 000 00 06

7000 x 27501)3) x 5000 8225 x 22152) x 2400

30185

Dimensions max. / min. in mm LxWxH

Weight approx. in kg

Tab. 7: Variants of the shield (2)

Doc. no.: 7420 128 000 BA 00

Variant

Application

Shield no.

Special features

01

face shield

5 .... 147

shifting ram dia. 150 mm, short relay bar, short canopy (4075 mm)

02

transition shield

4

shifting ram dia. 150 mm, short relay bar, prolonged canopy (4575 mm)

03

end shield

1

shifting ram dia. 200 mm, long relay bar, long canopy (5075 mm), side canopy R.H., pusher L.H.

04

end shield

2 and 3

like variant 03, but side canopy optional applicable

05

end shield

148 and 149

like variant 04, but pusher R.H.

06

end shield

150

like variant 05, but side canopy fitted L.H.

1

side seal fully extended

2.

side canopy fully retracted

3.

side canopy fully extended

VEVE / 01

6.3

Shield variants The shield is provided with a solid base which has the two inter− connected skids separated by a tunnel. The bases are equipped with different shifting cylinders depending on their use. See table 7 above.

The caving shield is a solid steel structure and connected to the base via the lemniscatic links. The caving shields of all variants are identical.

The canopy transmits the support load of the two hydraulic props into the roof. Connection to the caving shield is via pins and a stabilizing cylinder. All the canopies are equipped with a flipper. The canopy of the transition shield (variant 02) is 500 mm longer than the canopy of the face shield (variant 01). The canopies of the end shields (variants 03 ... 06) are 1000 mm longer than those of the face shields (variant 01).

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

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

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

The electrohydraulic control unit for shield variants 01 and 02 is the same and includes fourteen functions. The electrohydraulic control unit for the shield variants 03 to 06 has sixteen functions as it has two additional functions for the operation of the side canopy or auxiliary functions.

6.4

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

Unlike the face shields, transition and end shields can be equipped with a side canopy. This can be fitted optionally at the righthand or at the lefthand side. For shield variants 03 and 06, the side canopy is included in the scope of supply and is attached at the righthand (03) / lefthand (06) side at the side seal of the canopy.

E

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

Shield variants Main subassemblies Fig. 36: Variants of the shield, dimensions face shield, variant 01

DBT GmbH, Lünen 2004

E

transition shield, variant 02

end shield, variants 03 to 06

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.5

Shield variants Fig. 37: Variants of the shield, main components face shield, variants 01 and 02

DBT GmbH, Lünen 2004

E

end shield, variants 03 to 06

6.6

1 base of shield variants 01, 02 3 base of shield variants 03 ... 06 11 canopy of shield variant 01

23 side seal of shield variants 02 ... 06

62 electrohydraulic shield control of shield variants 03 and 06

31 caving shield

12 canopy of shield variant 02 13 canopy of shield variants 03 ... 06 21 side seal of shield variant 01

41 prop

63 ,electrohydraulic shield control of shield variants 04 and 05

51 stabilizing cylinder 61 electrohydraulic shield control of shield variants 01 and 02

71 protective wall 81 side canopy

DBT − Shield 2400/5000−2x4319−1750

Shield variants Tab. 8: DBT−shield 7420 128 000 00 .. , variants, components item

description

0001

base

variants

order no.

01 02 03 04 05 06 x

−

−

−

−

7420.128.300.00.01

8017 shift cyl. 8241 233 000 00 00 lift cyl.

8241 189 000 00 00 shifting unit 7420 118 330 00 01 pusher: none

−

−

x

x

x

x

7420.128.300.00.03

9188 shift cyl. 8241 234 000 00 00 lift cyl.

8241 189 000 00 00 shifting unit 7420 118 340 00 01 pusher: 8241 046 000 00 00

x

−

−

−

−

−

7420.128.400.00.01

6532 flipper

7420 128 420 00 00

0012

−

x

−

−

−

−

7420.128.400.00.02

7935 flipper

7420 128 420 00 00

0013

−

−

x

x

x

x

7420.128.400.00.03

8648 flipper

7420 128 420 00 00

x

−

−

−

−

−

7420.128.700.00.01

2878

−

x

x

x

x

x

7420.128.700.00.03

3026

0011

0021

canopy

side seal

0023

E

remarks

x

0003

DBT GmbH, Lünen 2004

weight approx approx. in kg

0031

caving shield

x

x

x

x

x

x

7420.128.800.00.00

4421

0041

prop

x

x

x

x

x

x

8250.101.000.00.00

1717

0051

stabilizing cylinder

x

x

x

x

x

x

8241.212.000.00.00

225

0061

electrohydraulic control

x

x

−

−

−

−

8112.161.000.00.00

140

0062

−

−

x

−

−

x

8112.162.000.00.00

150

0063

−

−

−

x

x

−

8112.167.000.00.00

160

0071

protective wall

−

−

−

−

−

x

7421.001.860.00.00

661

0081

side canopy

−

−

−

−

−

x

7420.078.450.00.00

772

Base with lemniscatic links and central shifting unit The solid base transmits the shield load of the hydraulic props into the floor. The props are supported in an articulated manner in ball socket s welded to the base and secured by bolted prop retainers.

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

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

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

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.7

Shield variants

DBT GmbH, Lünen 2004

E

Fig. 38: base

1 baselift cylinder ZE−125/90−240 2 shift cylinder ZE−150/100−960 (shield variants 01 and 02 only)

3 shift cylinder ZE−200/140−960 (shield variants 03 ... 06 only) 4 pusher cylinder ZE−135/120−300 (shield variants 03 ... 06 only)

7 shifting unit (shield variants 01 and 02 only) 8 shifting unit (shield variants 03 ... 06 only) 11 base (variants 01 and 02 only)

6.8

12 13 14 15 16 17 18 19 20 30 31

base (shield variants 03 to 06 only) front lemniscatic link R.H. front lemniscatic link L.H. rear lemniscatic link R.H. rear lemniscatic link L.H. base lift cylinder bearing prop retainer R.H. prop retainer L.H. travel path retainer pin

32 pin dia. 50x100 33 bolt M24x90 34 staple DN10 35 staple DN40 36 lemniscatic pin dia. 139,3x525 38 staple DN20 (shield variants 03 ... 06 only)

40 locking plate 41 collared pin dia29x57 46 pin dia.30/40x180 (shield variants 03 ... 06 only)

DBT − Shield 2400/5000−2x4319−1750

Shield variants Shifting unit Fig. 39: Shifting unit 3

6

11

12

H1

1

L1

8

2

4

10

9

5

7

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

DBT GmbH, Lünen 2004

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Tab. 9: Shifting units, differences shield

shifting g unit,

dimensions

variant

order−no.

L1

H1

01 and 02

7420 118 330 00 00

3422

230

03 .... 06

7420 118 340 00 00

3527

230

The variants of the shield are equipped with different types of shifting units. See table 9 above.

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

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

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

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

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.9

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

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

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

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

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

DBT GmbH, Lünen 2004

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

6.10

DBT − Shield 2400/5000−2x4319−1750

Shield variants Shield canopy The canopy of a shield has the hydraulic props connected in an articulated manner. It transmits the support load of the props into the roof. The canopy is connected with the caving shield by a locking hinge. Stability for the articulation is provided by a stabilizing cylinder.

CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy − caving shield) will not be exceeded.

The canopies of all shield variants are equipped with an an adjustable side seal at the R.H. side and a flipper.

DBT GmbH, Lünen 2004

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Tab. 10: Canopy, differences shield

canopy, py

variant

order−no.

01

7420 128 400 00 01 total length : 4230 mm 1)

02

7420 128 400 00 02 total length : 4730 mm 1)

03 ... 06

7420 128 400 00 03 slot holes to attache − anti−topple device canopy − canopy"

features

Fig. 40: Canopy of the face shield, variant 01

1 canopy, subassembly 4 flipper 5 prop head retainer

7 pin dia. 53x155 8 staple DN40 9 retaining clip 5x32

6 pin dia. 24.3x156

10 pin dia.138.5x540

1)

Doc. no.: 7420 128 000 BA 00

11 retainer 12 pin 13 retaining clip

with the flipper folded back to the canopy

VEVE / 01

6.11

Shield variants

2 canopy, subassembly 4 flipper 5 prop head retainer

7 pin dia. 53x155 8 staple DN40 9 retaining clip 5x32

6 pin dia. 24.3x156

10 pin dia. 138.5x540

11 retainer 12 pin 13 locking clip

Fig. 42: Canopy of the end shield, variants 03 ... 06

3 canopy, subassembly 4 flipper 5 prop head retainer 6 pin dia. 24.3x156

6.12

7 retaining clip 5x32 8 pin dia. 53x155 9 staple DN40 10 pin dia. 138.5x540

11 retainer 12 pin 13 retaining clip

DBT − Shield 2400/5000−2x4319−1750

E

Canopy of the transition shield, variant 02

DBT GmbH, Lünen 2004

Fig. 41:

Shield variants Fig. 43: Prop head retaining components

6, 7 5 6, 7

7 retaining clip 5x32

12 crossbar

23 pin dia. 43.5x141 24 fork 25 locking device

Flipper

DBT GmbH, Lünen 2004

E

Fig. 44:

5 prop head retainer 6 pin dia. 24.3x156

1 hydraulic cylinder ZE165/100−500 2 Hydraulic cylinder ZE80/63−215 6 flipper extension, subassembly 7 flipper, subassembly 9 fork link 11 link

Doc. no.: 7420 128 000 BA 00

13 pin dia. 58.5x 300 14 pin dia. 58.5x240 15 pin dia. 58.5x170 16 pin dia. 38.5x115 17 pin dia. 28.5x152

VEVE / 01

26 bolt dia. 34.5x150 others: fastening elements please, refer also to the spare parts catalog

6.13

Shield variants

2 side canopy, subassembly

others: fastening and securing elements please, refer also to the spare parts catalog

3 console

Fig. 46: Protective wall, R.H. design

x

1 protective wall 2 holder 3 collared pin 4 locking clip x position of items 2, 3 and 4 for L.H. design please, refer also to the spare parts catalog

6.14

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

1 hydraulic cylinder

E

Fig. 45: Side canopy, applicable only to shield variants 03 ... 06

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

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

DBT GmbH, Lünen 2004

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Fig. 47: Caving shield

S2

S2 1 caving shield, subassembly 2 lemniscatic pin dia. 139.3x525 3 pin dia. 53x155

S1

4 locking plate 5 pin dia. 12x120/115 6 staple DN40 7 retaining clip S1 lifting eye, load−carrying capacity: 3000 kg

S1

S2 lifting eye, load−carrying capacity: 8000 kg

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.15

Shield variants Side seal

DBT GmbH, Lünen 2004

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Fig. 48: Side seal of the face shield variant 01

All sliding surfaces and joints coated with lubricating paste B6 to EWN 7068

Attention!

Remove transport securing devices, items 24, 38 and 45, 37 at moveable side before putting the shield into operation.

1 hydraulic cylinder ZE−119−63/50−215 2 side seal, canopy R.H. 3 side seal, canopy L.H. 4 side seal, caving shield R.H. 5 side seal, caving shield L.H. 8 guide pin dia. 90 9 pin dia. 34x329 10,11 guide pin 12 cover

6.16

13 guide pin 14, 16 compression spring 15 guide pin 17 torque support 18 bush 20...23 pin 24 transport safety device 25, 26 pin 27 torque support 28 retainer

29 pin 37 clip pin 38 staple 42 washer 43 locking clip 45 pin others fastening and securing elements please, refer also to the spare parts catalog

DBT − Shield 2400/5000−2x4319−1750

Shield variants

DBT GmbH, Lünen 2004

E

Fig. 49: Side seal of transition shield variant 02 and end shield variants 03 ... 06

All sliding surfaces and joints coated with lubricating paste B6 to EWN 7068

Attention!

Remove transport securing devices, items 24, 38 and 45, 37 at moveable side before putting the shield into operation.

1 hydraulic cylinder ZE−119−63/50−215 2 side seal, canopy R.H. 3 side seal, canopy L.H. 4 side seal, caving shield R.H. 5 side seal, caving shield L.H. 8 guide pin dia. 90 9 pin dia. 34x329 10,11 guide pin 12 cover

Doc. no.: 7420 128 000 BA 00

13 guide pin 14, 16 compression spring 15 guide pin 17 torque support 18 bush 20...23 pin 24 transport safety device 25, 26 pin 27 torque support 28 retainer

VEVE / 01

29 pin 37 clip pin 38 staple 42 washer 43 locking clip 45 pin others fastening and securing elements please, refer also to the spare parts catalog

6.17

Shield variants Technical data of the shield, steel structure face shield, variant 01

deg

15

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

2400

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

5000

hydraulic height adjustment of shield . . mm

2600

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

865 960

distance of prop centers (inclination) . . . mm

900

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

2910

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

1165

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

1650

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

4075

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

14.0 56.8

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

1650

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

1610

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

33776

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

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4200 5847 8575

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 4200 a) at 315 bar setting pressure . . . . . . . . kN/m2 720 b) at 462 bar yield pressure 890 / 1056 (distance canopy tip to face low / high) . kN/m 2

6.18

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

permissible inclination, omnidirectional up to

E

operating mode . . . . . . . . . . . . . . . . . . . . immediate forward system

Shield variants transition shield, variant 02 operating mode . . . . . . . . . . . . . . . . . . . . immediate forward system

DBT GmbH, Lünen 2004

E

permissible inclination, omnidirectional up to

Doc. no.: 7420 128 000 BA 00

deg

15

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

2400

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

5000

hydraulic height adjustment of shield . . mm

2600

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

865 960

distance of prop centers (inclination) . . . mm

900

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

3410

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

1165

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

1650

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

4575

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

14.0 56.8

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

1650

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

1610

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

33776

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

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4200 5847 8575

VEVE / 01

6.19

Shield variants end shield, variants 03 ... 06

6.20

deg

15

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

2400

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

5000

hydraulic height adjustment of shield . . mm

2600

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

865 960

distance of prop centers (inclination) . . . mm

900

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

3910

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

1165

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

1650

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

5075

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

14.0 56.8

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

1650

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

1610

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

33776

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

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4200 5847 8575

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

permissible inclination, omnidirectional up to

E

operating mode . . . . . . . . . . . . . . . . . . . . immediate forward system

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

normal and exceptional operation

The electrohydraulic control unit for shield variants 01, 02, 04 and 05 is the same and includes fourteen functions. The electrohydraulic control unit for shield variants 03 and 06 has sixteen functions as it has two additional functions for the operation of the side canopy.

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

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

DBT GmbH, Lünen 2004

E

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

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

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.21

Hydraulic system Shield hydraulics Fig. 50: Shield hydraulics 18d

18c

11b

28

22 27 21d 18a

1 3

16

25 11c 18d 14

22

18e

12

33

8

16

25

11a 23

E

7 DBT GmbH, Lünen 2004

21b 24 21a 20 21c 19 3

15 26 30 32 5

2

18b 17

1 electrohydraulic control 2 prop check valve 3 pilot−operated check valve

14 water spray system 15 retainer and accessories 16 manifold pipe

24 in−line−filter

5 pressure relief valve, 462 bar 6 pressure relief valve, 470 bar

17 accumulator cartridge 18 pressure relief valve, 380 bar

27 manifold

7 check valve 8 pilot−operated check valve 11 twin check valve

19 water spray valve 20 dual filter, back flush 21 high−pressure ball valve

30 symbol plate

12 pressure gauge 13 hose lines

22 high−pressure ball valve 23 high−pressure ball valve

25 screwed socket 26 ball valve 28 connecting plate 32 accessories pusher cyl.

34 plug DN10 please, refer also to the spare parts catalog

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02

6.22

DBT − Shield 2400/5000−2x4319−1750

Hydraulic system Fig. 51: Hydraulic circuit diagram, overview Please, refer also to the spare parts catalog.

control valve block functions: 1 extend stabilizing cylinder 2 retract stabilizing cylinder

1 16

3 extend props 4 extend seal cylinders

21a

23

21b 7

24

5 retract props 6 retract seal cylinders 7 advance shield 8 push conveyor 9 extend flipper cylinder

20

(34)

10 retract flipper cylinder 11 retract flipper extension cyl.

12 extend flipper extension cyl.

17

27

19

21d

13 extend lift cylinder 14 activate water spray system 15 retract side canopy cylinder 16 extend side canopy cylinder

21c Z4

component s: 1 electrohydraulic control 2 prop check valve

6 33 Z4 DBT GmbH, Lünen 2004

E

Z3 Z8

8 11a

Z4

6 Z2

18a

32

26

18e

3

18b Z4 Z5

22

22

5

Z9

12 13

Z1

Z1

2

2 25

25

28

14

18d Z6

11c

18 pressure relief valve, 380 bar 19 water spray valve 20 dual filter, back flush type

23 high−pressure ball valve 24 in−line−filter 25 screwed socket

33 acessories, side canopy 34 plug Z7

hydraulic cylinders: Z1 prop Z2 shift cylinder Z3 stabilizing cylinder

16 manifold pipe 17 accumulator cartridge

27 manifold 32 acessories, pusher cylinder

18d

Z7

13 hose lines 14 water spray system 15 retainer and accessories

21 high−pressure ball valve 22 high−pressure ball valve

11b 18c

6 pressure relief valve, 470 bar 7 check valve 8 pilot−operated check valve 11 twin check valve 12 pressure gauge

Z8

5

3 pilot−operated check valve 5 pressure relief valve, 462 bar

Z4 seal cylinder Z5 base lift cylinder Z6 flipper cylinder

S1 pressure sensor

Z7 flipper extension cylinder Z8 side canopy cylinder Z9 pusher cylinder

NOTE: The components marked in blue" are not included in the scope of supply of the face shield variants 01 and 02

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.23

Hydraulic system Double−telescopic prop The prop described is a double−telescopic prop with equal load− bearing capacity at both stages. Equal load−bearing capacity of the two stages is ensured by a pilot−operated check valve which is installed in the piston pipe.

Bottom and top end of the prop are designed as a globe joint. This allows to join the prop to the base and the canopy with angular articulation. The cams at the bottom end of the prop will be fixed at the base using bolted arresting devices.

The prop head is fastened to the canopy using special securing elements.

The technical data of the hydraulic prop are to be found in section Technical data, hydraulic cylinders".

Fig. 52: Double telescopic prop, type SD4300−345−1820/4375−CR

DBT GmbH, Lünen 2004

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retracted 1820 / extended 4375 stroke: upper stage 1250, lower stage 1305

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

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

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

6.24

DBT − Shield 2400/5000−2x4319−1750

Hydraulic system Function prop setting

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

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

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

DBT GmbH, Lünen 2004

E

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

Doc. no.: 7420 128 000 BA 00

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

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

VEVE / 01

6.25

Hydraulic system Hydraulic cylinder, double and single acting design

The following figure shows the main components of a hydraulic cylinder. The cylinders differ mainly by the arrangement of the connections. They can be roughly divided into two groups: a) arrangement of connections at the outer cylinder b) arrangement of connections at the piston rod Fig. 53:

Hydraulic cylinder, typical example

Type a)

2

1

3

5

4

2

3

Type a): Connection at the outer cylinder Type b): Connection at the piston rod 1 outer cylinder 2 cylinder bottom

1

4

6

3 piston rod 4 guide bush 5 connection 6 connection

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.

6.26

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

Type b)

Hydraulic system Stabilizing cylinder

DBT GmbH, Lünen 2004

E

Fig. 54: Hydraulic cylinder, type ZE−200/140−520−EC−CR

1 cylinder pipe 11 piston rod

13 piston others: see spare parts catalog

Baselift cylinder Fig. 55: Hydraulic cylinder, type ZE−125/90−240−LI−CR

1 cylinder pipe 2 wear pad

Doc. no.: 7420 128 000 BA 00

3 piston rod 5 piston

VEVE / 01

others: see spare parts catalog

6.27

Hydraulic system Shifting cylinder Fig. 56: Hydraulic cylinder type ZE−150/100−960−SC−W−CR, in use with face shield (variant 01) and transition shield (variant 02) only

stroke: 960 retracted 1299 / extended 2259

23 piston 25 annular magnet see spare parts catalog

Fig. 57: Hydraulic cylinder type ZE−200/140−960−SC−W−CR in use with the end shield variants 03 ... 06 only retracted 1404 / extended 2364 stroke 960

1 cylinder pipe 2 reed rod 3 piston pipe

6.28

5 piston 7 annular magnet see spare parts catalog

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

1 cylinder pipe 2 reed rod 21 piston rod

E

view Z"

Hydraulic system Technical data of hydraulic cylinders

DBT GmbH, Lünen 2004

E

double telescopic prop, double−acting − 2 stages

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

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

Doc. no.: 7420 128 000 BA 00

Type SD−4300−345−1820/4375, drawing no. 8250 101 000 00 00 prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1820

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

4375

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

2555

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

345/ 250

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

320/ 230

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

934.8/490/9

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

130.6/75.4

prop force at 315 bar setting pressure . kN

2944

prop force at 462 bar yield pressure . . . kN

4319

retracting force at 315 bar . . . . . . . . . . . . kN

411

Type ZE−150/100−960−SC−W−CR, drawing no. 8241 233 000 00 00, equipped with reed contact rod, in use with base variant 01 and 02 only stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

960

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

150

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

100

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

176.7

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

98.2

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

556

pulling force at 315 / 380 bar . . . . . . . . . kN

309/ 373

Type ZE−200/140−960−SC−W−CR, drawing no. 8241 234 000 00 00, equipped with reed contact rod, in use with base variants 03 ... 06 only stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

960

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

200

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

140

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

314.2

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

160.2

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

989

pulling force at 315 / 380 bar . . . . . . . . . kN

504/ 609

VEVE / 01

6.29

Hydraulic system stabilizing cylinder, double−acting

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

520

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

200

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

140

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

314.2

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

160.2

thrust at 315 / 470 bar . . . . . . . . . . . . . . . kN

990/1477

pulling force at 315 / 470 bar . . . . . . . . . kN

504/753

Type ZE−125/90−240−LI, drawing no. 8241 189 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

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

125

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

90

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

122.7

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

59.1

thrust at 315 / −−− bar . . . . . . . . . . . . . . . . kN

386 / −−−

pulling force at 315 / −−− bar . . . . . . . . . . . kN

186 / −−−

side seal cylinder, double−acting

flipper cylinder, double−acting

6.30

Type ZE−119−63/50−215−N, drawing no. 9571 191 200 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

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

63

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

50

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

31.2

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

11.5

thrust at 315 / −−− bar . . . . . . . . . . . . . . . . kN

98 / −−−

pulling force at 315 / 380 bar . . . . . . . . . kN

36 / 44

Type ZE−165/100−500−KO−CR, drawing no. 8241 232 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

500

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

165

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

100

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

213.8

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

135.5

thrust at 315 / 380 bar . . . . . . . . . . . . . . . kN

673 / 812

pulling force at 315 / 380 bar . . . . . . . . . kN

426 / 514

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

baselift cylinder, double−acting

Type ZE−200/140−520−EC−CR, drawing no. 8241 212 000 00 00

Hydraulic system flipper extension cylinder, double−acting

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

215

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

80

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

63

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

50.3

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

19.1

thrust at 315 / 380 bar . . . . . . . . . . . . . . . kN

158.5 / 191.2

pulling force at 315 / 380 bar . . . . . . . . . kN

60 / −−

Type ZE−90/60−280, drawing no. 7370 953 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

280

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

90

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

60

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

63.6

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

35.3

thrust at 315 / 380 bar . . . . . . . . . . . . . . . kN

200 / 242

pulling force at 315 / 380 bar . . . . . . . . . kN

111 /−−−

DBT GmbH, Lünen 2004

E

side canopy cylinder, double−acting

Type ZE−80/63−215−KO−CR, drawing no. 8241 235 000 00 00

pusher cylinder, double−acting

hydraulic cylinder of anti−topple device double−acting

Doc. no.: 7420 128 000 BA 00

Type ZE−90/60−280, drawing no. 7370 953 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

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

135

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

120

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

143,1

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

30

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

450,8

pulling force at 315 bar . . . . . . . . . . . . . . kN

94,5

Type ZE−80/50−600, drawing no. 8241 066 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

600

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

80

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

50

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

50.3

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

30.6

thrust at 315 / −−− bar . . . . . . . . . . . . . . . . kN

158 /−−−

pulling force at 315 / −−− bar . . . . . . . . . . . kN

96 /−−−

VEVE / 01

6.31

Hydraulic system

hydraulic cylinder of anchoring device base − base double−acting

Type ZE−100/70−900−AB−CR, drawing no. 8241 192 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

900

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

110

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

70

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

95

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

56.5

thrust at 315 / −−− bar . . . . . . . . . . . . . . . . kN

299/−−−

pulling force at 315 / −−− bar . . . . . . . . . . . kN

178/−−−

Pressure relief valves Pressure relief valves protect the hydraulic equipment, such as props and cylinders, connected with them from overload. When the set pressure is reached, the valve opens and the 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.

application

type

set pressure in bar

order−no.

general application

spring−loaded

380

7337 486 380 00 00

only at stabilizing cylinder

spring−loaded

470

8220 027 470 00 00

only at props

gas−pressure operated

462

7337 611 462 00 00

CAUTION! Do not change the pressure setting of pressure relief valves!

Only use pressure relief valves which have been factory−set to the required value and are provided with the relevant color code.

Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

CAUTION! Always replace pressure relief valves with valves which are as new and have the same properties. Refer to the hydraulic flow plan in this respect. Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

NOTICE! Always fit new seals when replacing a pressure relief valve.

Failure to comply may result in leakages at the plug−type connection and impair the operational safety of the hydraulic system.

6.32

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

Tab. 11: Pressure relief valves, use of different types

Hydraulic system code system

Pressure relief valves are color and letter coded according to DIN 21557.

The letter code includes the following details: J Set pressure, target value J Week setting was made J Year setting was made J Last setting made by Tab. 12: Typical letter code 420 od. 42 1)

09

03

xy

set pressure

week

year

made by last

The color code may consist of one or two colors. It characterizes the setting pressure range. The following figure 41 shows a pressure relief valve provided with a blue−white color code. This color code corresponds to the pressure range of 350 to 399 bar.

DBT GmbH, Lünen 2004

E

Fig. 58: Typical pressure relief valve

a color code b protection cap b

a

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

Tab. 13: Color codes for pressure relief valves, overview color

1)

Doc. no.: 7420 128 000 BA 00

pressure range (bar)

black

0 − 49

black / white

50 − 99

brown

100 − 149

brown / white

150 − 199

green

200 − 249

green / white

250 − 299

blue

300 − 349

blue / white

350 − 399

red

400 − 449

red / white

450 − 499

yellow

500 − 549

yellow /white

550 − 599

orange

600 − 649

orange / white

650 − 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, "42" equals 420 bar, "08" equals 80 bar

VEVE / 01

6.33

Electrohydraulic control system Electrohydraulic control system Fig. 59: Electrohydraulic control, 14 functions

1

2

4

3

3 push−button for manual operation 4 plug contact, electrical connection to the control unit DBT GmbH, Lünen 2004

E

1 control valve block 2 pilot control valve for electromagnetic operation

Fig. 60: Electrohydraulic control, 16 functions

4

1 2

3 1 control valve block 2 pilot control valve for electromagnetic operation

3 push−button for manual operation 4 plug contact, electrical connection to the control unit

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

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

6.34

DBT − Shield 2400/5000−2x4319−1750

Electrohydraulic control system Electronic shield control NOTICE! How to operate the electronic shield control unit type is not subject of this manual. See separate operating instructions.

Fig. 61: Electronic shield control unit type Panzermatic® PM4, schematic diagram NOTE: The components marked in "blue" are only included in the scope of supply of the end shield variants 03 and 06. a 1

A

b c d 3

E

6

DBT GmbH, Lünen 2004

5

e A electronic shield control, components B support with power adapter (PA) C support with isolation adaptor (IA) 1 single control unit (SCU)

B

3 solenoid driver 5 pressure sensor 6 infrared receiver other: see spare parts catalog a SCU, rear view b SCU, front view c to R.H. adjacent support, port A1

b

d to L.H. adjacent support, port F1 e reed rod, shifting cylinder c

C

b c

ports in use at the SCU rear side : A1, F1 adjacent support B1 infrared receiver C1 pressure sensor D2 reed rod F2 solenoid driver

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.35

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

DBT GmbH, Lünen 2004

E

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

Angle α2 measured with retracted stabilizing cylinder Inclination a at height M

Shield Order−no.

Variant

7420 118 000 00 ..

01 ... 06

a1 in ° 14

M in mm 2400

a2 in ° 13.5

M in mm 5000

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.

6.36

DBT − Shield 2400/5000−2x4319−1750

Accessories Accessories Anti−topple device canopy − canopy" The anti−topple device canopy − canopy" according to drawing number 7420 066 470 00 00 is only applicable for the following listed shield support variants: Tab. 14: Anti−topple device canopy − canopy" order no. 7420 066 470 00 00, suitable shield supports Application of shield support

Order−no.

end shield

7420 118 000 00 03

end shield

7420 118 000 00 04

end shield

7420 118 000 00 05

end shield

7420 118 000 00 06

DBT GmbH, Lünen 2004

E

Fig. 62: Anti−topple device canopy − canopy"

27

28

5 26

19

24 10

6

1

25 16

17

15 18

1 hydraulic cylinder 5 chain shackle 6 chain connector

18, 19 pin 16, 17 universal joint 24 chain

10 anchoring bracket 15 pin

29 control unit other fastening and securing elements

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.37

Accessories Fig. 63: Hydraulic control for anti−topple device canopy − canopy"

piston area

ring area

14 14

3, 7 R

R 5, 7, 8

5, 7, 8 14

4, 7 P R

3, 7 13 7

1, 10 1 hydraulic control unit 3, 4 plug−in socket

6.38

5 plug−in reducer 7, 8 staple

10 bolt 13 ... 15hose

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

E

5, 7, 8

15

13

Accessories Anchoring device base − base Fig. 64:

Anchoring device L. H. (tail gate)

R. H. (head gate)

sequence for advancing the shields must be: 149 − 150 − 148 or 149 − 148 − 150

DBT GmbH, Lünen 2004

E

sequence for advancing the shields must be: 2 − 3 − 1 or 2 − 1 − 3

section A − A"

section B − B"

1 hydraulic cylinder 10 pin dia. 40x125 11 chain shackle

15 pin 16 bush 17 locking device

12 washer 13 cylinder protection

40 cylinder bracket R.H. 41 cylinder bracket L.H.

14 protective plate

42 chain guide

Doc. no.: 7420 128 000 BA 00

VEVE / 01

section C − C"

43 chain guide 44 chain attachment 70 chain 71 chain connector other: fastening and securing elements

6.39

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. 15: Approval list (Part 1)

type X test water

type Y test water

type Z test water

ARAL Lubricant s

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%

not tested

1.5 %

not tested

not tested

not tested

2%

not tested

1.5 %

2%

not tested not tested not tested

5% 3% 5%

not tested

not tested

3%

not tested

not tested

5%

not tested

Fuchs/Century

Solcenic Ecosyn 3050 Solcenic Ecosyn 3060 Renolin Ecubsol BOA ||

6.40

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

Mobil Oil

Mobilmet S−122

Quaker LTD

Quintolubric 812−01 Quintolubric 814−01 Quintolubric N 807 Al Shell Tellina Q

not tested not tested

DBT − Shield 2400/5000−2x4319−1750

E

Product designation

DBT GmbH, Lünen 2004

Manufacturer

Operating media Tab. 16: 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 Isosynth VX 110 BF 5 Hydrocor TS 100 N

not tested

1.5 %

2%

not tested

not tested

1.5 %

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. Stuart− Th 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 2004

E

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

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

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

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

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

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

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

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

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

Doc. no.: 7420 128 000 BA 00

VEVE / 01

6.41

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: v 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.

6.42

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

type X test water (NCB 18 to Luxembourg Report)

E

Tab. 17: Chemical composition of the test water samples used

Operating media Lubricating greases and pastes IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

Lubricating greases general properties

lubricating greases A1

base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non−soluble in water

temperature of application :

−20 to +120 °C

flash point:

y 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN *) 7068

DBT GmbH, Lünen 2004

E

Tab. 18: Lubricating greases for general application

lubricating greases A2

Flash point in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

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

Tab. 19: Lubricating greases for general application Flash point in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

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

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

*)

Doc. no.: 7420 128 000 BA 00

EWN = DBT standard

VEVE / 01

6.43

Operating media Lubricating pastes lubricating pastes B3

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

Tab. 20: Lubricating pastes free from molybdenum disulfide

Supplier

Type

Base

NLGI class

flash point °C

gleitmolybdän

gleitmo 805 *)

Li

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän "gleitmo 805"

Behavior in the presence of water:

non−soluble in water

Temperature of application:

−34 to +120° C

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent & lubricant 785 (flash point 132 °C) IMPORTANT! The instructions for the use of the lubricating greases given under "important" also apply to the lubricating pastes.

*)

6.44

The products listed in table 18 are suitable lubricating greases for filling of adjacent cavities.

DBT − Shield 2400/5000−2x4319−1750

E

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.

DBT GmbH, Lünen 2004

lubricating pastes B6

Tightening torques Tightening torques Screws with metric coarse thread DIN 13

DBT GmbH, Lünen 2004

E

Tab. 21: Recommended tightening torques at mges. = 0.14 Thread 1)

Pitch

Tightening torque 4)

(mm)

(mm)

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

455 640

MA (Nm)

M 20

2,5

380

535

(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

−

− 2215

M 30

3,5

1310

1845

M 30 3)

2

−

1450

−

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

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

1) 2) 3) 4)

Doc. no.: 7420 128 000 BA 00

dimensions in brackets in exceptional cases only according to works standard (EWN 6110), February 1985 edition only for expansion screws having a reduced shaft cross−section of 24.2 mm the tightening torques comply with EWN 6003 works standard.

VEVE / 01

6.45

E

DBT GmbH, Lünen 2004

6.46

DBT − Shield 2400/5000−2x4319−1750

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 addresses Germany

DBT GmbH Industriestraße 1 D−44534 Lünen Tel:

+49 / 23 06 70 9 − 0

Fax:

+49 / 23 06 70 9 − 4 21

E−mail: infodbt@dbt.de Internet: http://www.dbt.de Great Britain

DBT GB Ltd. Hallam Fields Road

DBT GmbH, Lünen 2004

E

Ilkeston, Derbyshire DE7 4BS Tel:

+44 / 11 59 51 − 2500

Fax:

+44 / 11 59 32 − 9683

E−mail: info@dbtgb.com Internet: http://www.dbt.de USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 − 1010 Tel:

+ 001 / 72 47 43 12 − 00

Fax:

+ 001 / 72 47 43 12 − 01

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

DBT Australia Pty. Ltd. 10−14 Kellogg Road P.O. Box 41 Rooty Hill, NSW 2766 Tel:

+ 61 / 2 98 30 − 9500

Fax:

+ 61 / 2 98 30 − 9555

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

Doc. no.: 7420 128 000 BA 00

VEVE / 01

7.3

Our service China

DBT China Beijing Representative Office Room 502, Prime Tower No. 22 Chaowai Street Beijing 100020 Tel:

+86 / 10 65 88 − 2998

Fax:

+86 / 10 65 88 − 6570

E−mail: Info.beijing@dbtchina.com Internet: http://www.dbt.de DBT Langfang Co. Ltd. Jinyua. Road − Langfang Economic and Technical Development Zone − 065001 Hebei Province P.R. Tel:

+ 86 / 3 16 60 86 − 840 (& 841, 842, 843)

Fax:

+ 86 / 3 16 60 86 − 845

DBT GmbH, Lünen 2004

E

E−mail: Info.langfang@dbtchina.com Internet: http://www.dbt.de South Africa

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston, 1401 Tel:

+ 27 / 11 82 58 21 2

Fax:

+ 27 / 11 82 57 38 9

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

DBT France S.A.R.L. 1, rue d‘Annecy, BP 144 57150 Creutzwald Tel:

+ 33 / 38 72 92 08 0

Fax:

+ 33 / 38 79 02 30 9

E−mail: info@dbt france.com Internet: http://www.dbt.de

7.4

DBT − Shield 2400/5000−2x4319−1750

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

Fig. 65: Identification plate, example

1

DBT GmbH 2 5

6

7

2

12345

E

04/04

4

678

7420 128 311 00 00 4319 kN

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

3 month and year of manufacture 4 current component no.

DBT GmbH, Lünen 2004

3

5 drawing no.

6 number of props 7 rated yield force of props

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

Fig. 66: Shield number, example

Tab. 22: Shield numbers

Doc. no.: 7420 128 000 BA 00

shield number

order number

application

5 .... 147

7420 128 000 00 01

face shield

4

7420 128 000 00 02

transision shield

1

7420 128 000 00 03

end shield

2, 3

7420 128 000 00 04

end shield

148,149

7420 128 000 00 05

end shield

150

7420 128 000 00 06

end shield

VEVE / 01

7.5

Identification of shields Referenced standards and guidelines Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery Safety of machinery− Safety requirements for fluid power systems and their components

DIN EN 982 DIN EN 60445

Identification of Connections

DIN EN 62079

Erstellen von Anleitungen

DIN 6789

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

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self−Advancing Supports

DIN 2000

DIN 24320 DIN 24343 DIN 24346 *EWN 6003

Fire Resistant Hydraulic Fluids Hydraulic fluid power systems and component s; list for attendance inspection of hydraulic equipments Hydraulic Systems; Design Principles Pretensioning forces and tightening torques

*EWN 7068 *EWN 7069

Lubricants Nonmetallic surface protection

ISO 4406

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

*)EWN = DBT standard

7.6

DBT − Shield 2400/5000−2x4319−1750

DBT GmbH, Lünen 2004

Designation

E

Tab. 23: Referenced standards and guidelines