CAT DBT − Shield 25505500−2×3176-1750 Operating Manual - PDF DOWNLOAD

Operating Manual DBT - Shield 2200/4500-2x3176-1750 Variants 01, 02, 03, 04 and 05

Doc. no.: 7420 066 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

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

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

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

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

DBT GmbH, Lünen 2002 E

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

1.3

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

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

1.4 1.5

2. Your Safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.3

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

2.4

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

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

2.4 2.4

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

2.5

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

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

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

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

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

2.5 2.6 2.7 2.8 2.10

Overview of the safety instructions . . . . . . . . . . . . . . . 2.14

3. Storage and Transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storage of new Equipment . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3 3.4

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

3.5

Load Units, Dimensions and Weights . . . . . . . . . . . . . . . . .

Before Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly level upon delivery . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.6

4. Installation

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

4.3

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

4.3

Power take-off connections . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4.4 4.5 4.6

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

4.6

First Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion-Protected Hydraulic Components . . . . . . . . . . .

4.6 4.7 4.7

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5. Operations and Maintenance Safety Measures to be Taken during Operation . . . . .

5.3

General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Guidelines for Operation . . . . . . . . . . . . . . . . . . . . .

5.3 5.5

Operating Shield Support . . . . . . . . . . . . . . . . . . . . . . . .

5.7

Safety Precautions for Shield Supports with ElectroHydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 Operation of the Shield Hydraulics . . . . . . . . . . . . . . . . 5.13 Location of hydraulic devices at the shield support . . . . . .

Repair and Emergency Operation . . . . . . . . . . . . . . . . . . . .

Operation and Functions of the Control Block . . . . . . . . . .

5.13 5.24 5.26

Maintenance of the shield hydraulic . . . . . . . . . . . . . . . 5.29 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Monthly record of damage . . . . . . . . . . . . . . . . . . . . . . . . . .

5.29 5.29 5.29 5.30

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31 Failure to operate the tip function . . . . . . . . . . . . . . . . . . . .

5.33

Fault Finding on Shield Support Hydraulic System . 5.34 By-passing or Sticking 3/2-Way Valve or Pilot Valve . . . . .

By-passing pilot operated check valve (POCV) . . . . . . . . .

Locked pilot operated check valve (POCV) . . . . . . . . . . . .

Internal by-pass in leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Faulty yield valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Faulty or blocked filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.34 5.35 5.35 5.35 5.35 5.36

6. Technical Description Shield Support Variants . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Main Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base with Lemniscatic Links and Central Shifting Unit . . .

Shield Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caving Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Side flipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data of Shield Support . . . . . . . . . . . . . . . . . . . . .

6.4 6.6 6.8 6.11 6.12 6.13 6.14

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 Shield Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double-Telescopic Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinder, double and single acting . . . . . . . . . . .

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

Technical Data of Hydraulic Cylinders . . . . . . . . . . . . . . . . .

Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 6.20 6.21 6.22 6.23 6.24 6.27

DBT - Shield 2200/4500-2x3176-1750

Electro-Hydraulic Control System . . . . . . . . . . . . . . . . . 6.28 PANZERMATIC ® PM-4/A . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.29

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31 Anchoring device canopy / canopy . . . . . . . . . . . . . . . . . . .

6.31

Angles of Inclination of the Canopy . . . . . . . . . . . . . . . 6.33 Recommended Lubricating Greases and Pastes . . . . 6.37 Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Pastes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating agents and lubricants with organic lubricating media . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.37 6.38 6.38

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39 Screws with Metric Coarse Thread DIN 13 . . . . . . . . . . . . .

6.39

7. For Your Information

Doc. no.: 7420 066 000 BA 00

Our Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

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

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

7.3 7.4

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DBT - Shield 2200/4500-2x3176-1750

1

About this manual

Before starting work

About this manual This section provides important information, which will simplify operation with this instruction manual. In addition, it contains information on the structure of the manual and on the symbols employed.

Before starting work Correct operating manual

Shield type

If you employ an operating manual which does not apply specifically to the present shield type, you endanger yourself and others.

Ensure that the type specifications on the shield agree with those of the operating manual.

This operating manual applies to the following shield types: DBT Shield Support Type 2200/4500-2x3716-1750 Identification no.: 7420 066 000 00 00 Variants :

01, 02, 03, 04 and 05

Its use is permissible only for shields of these types!

DBT GmbH, Lünen 2002

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New operating manual

An operating manual must always be available for the support at the site of operation. Request a new operating manual immediately, if the existing manual is no longer complete, or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields. Every person who works in the face or in the zone at the edge of the face must read this operating manual.

This includes persons who: J are in charge of transport,

– erect the rise heading, – perform assembly / disassembly work, – operate the shields, – correct malfunctions, – perform daily routine work in the face, – monitor / care for the hydraulic system, – perform maintenance work, – perform repair work; supervisory personnel who J initiate or J supervise

the activities just indicated, or both.

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1.3

Before starting work Purpose of this operating manual Economy

This operating manual is intended to help you in working economically and safely with our product. It provides important instructions for all activities which are associated with the shield support.

Read this operating manual completely and at ease. Pay special attention to the respective safety instructions. Become thoroughly familiar with the appearance and meaning of the safety and instruction symbols.

Service

If any details are not clearly understood, please contact our service department.

Safety

Read the section ”For your safety” with special attention. This section contains important information which indicates possible hazards.

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Familiarize yourself with the specifications and observe the procedural instructions.

1.4

DBT - Shield 2200/4500-2x3176-1750

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

Pay particular attention to these points.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

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

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

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

J

Items in lists are marked with bullets.

–

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

.

Points in the text marked in this way describe individual work steps.

Follow these instructions step-by-step.

They will help you carry out your work faster and, more importantly, safer.

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1.5

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DBT GmbH, Lünen 2002

1.6

DBT - Shield 2200/4500-2x3176-1750

2

Your safety

Personnel

Your Safety For your safety

This section provides vital information for your safety.

Read this section with special attention. The safety instructions and rules of procedure are intended to protect you against hazardous situations, and to help you in performing your work as safely as possible.

State of the art

The shield has been manufactured in accordance with the state of the art and with recognized safety regulations. Nevertheless, situations hazardous to you and third parties can occur, for instance, as a result of environmental effects, machine damage, or faulty operation.

In addition to this operating manual, also be sure to observe the respective legal specifications 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

DBT GmbH, Lünen 2002

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J of the miners’ accident insurance association.

Personnel Operation The shield shall be operated only by trained personnel.

Training

The electrohydraulic and hydraulic control systems shall be operated only by personnel who furnish proof of having been trained for operating the present control system. Reading of the operating manual, especially the section 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.

Repairs In general, repair work shall be performed only by persons who have been adequately trained for these special requirements. Repair work on, and servicing of: J the safety devices (pressure relief valves, etc.), J the long hydraulic devices (props and cylinders, etc.)

J the hydraulic system, and J the control systems

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

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2.3

Conditions for operation Conditions for 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!

Uses in conformance with specifications are: J propping the roof against the floor; J ensuring a sufficient carriage road; J the following shield operations:

– withdrawal, – drawing up, – alignment, and – setting; J the following conveyor operations:

– advancing, – retracting; J forming an abutment for:

– the conveyor and winning machine, – longwall, partial and block anchoring.

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 resetting of the shield in a fractured area, J raising of the conveyor by means of the hydraulic force of the

shield, J setting of the canopy bar in areas of roof fracture.

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

2.4

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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– raising, and

Safety instructions Safety instructions Basic principles General

Always concentrate on your work.

Become familiar 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.

Protective devices

Maintain the signalling and lighting systems in a functional condition.

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

EMERGENCY STOP

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.

Support blocking switch

Actuate the support blocking switch (repair switch) in the event of: J maintenance work, J inspection work, J repair work, J prolonged presence in the shield.

Moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: J pressure pads, J canopy bars, J guide bars (lemniscatic links and shifting system), J gap covers, J front cantilevers, J hydraulic props and cylinders.

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2.5

Safety instructions Storage and transport For this purpose, thoroughly read section 3, ”Concerning 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 carriage road or in your working area.

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

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

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

Securing for transport

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

J the advancing beam (front and rear sides).

Fastening devices

Attach the hoisting gear only at the fastening points provided for the purpose. Observe the different load limits of the fastening points.

Observe the instructions on the transport sheets.

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

Damage of this kind necessitates elaborate and expensive repair work.

Use only transport straps for hoisting of round components, such as cylinders and props. Never employ chains or steel cables for this purpose.

Use only fastening devices which are in good condition and have been designed for the loads concerned.

Fix the movable parts in place.

Observe the position of the center of gravity, especially during transport with gallery conveying devices. The center of gravity must be as low as possible, in order to prevent tipping of the transport unit.

2.6

DBT - Shield 2200/4500-2x3176-1750

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J the flipper,

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

Mechanically secure the shield against lowering during: J installation of the canopy bars, J installation of the longitudinal hydraulic system, J work on the open hydraulic system, J work in the shield.

For securing the shield, wooden wedges, for instance, can be placed between the guide bars.

Securing by means of wooden wedges

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Fig. 1:

Transport securing devices

Remove the transport securing device from the gap cover only with the use of a clamping device. The gap cover is prestressed by spring force.

Ensure that no one is present in the swivelling area of the coal face bar. It can swing downward as soon as the transport securing device is dismounted.

Carriage road

Ensure that the specified minimal dimensions of the carriage road of the shield are always maintained.

J Width: 600 mm J Height: 400 mm

Mechanical stops must be added to limit the shield lowering height if the minimum travelway height specified is reduced by any additional equipment installed (for example, anchorages between shield and conveyor).

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2.7

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

Operate the shield control system only if you are thoroughly familiar with the operating controls and operating principles. Previous instruction is necessary for operating the present control unit. Attentively read the instructions for operating the present control unit.

Operate the shield only from the adjacent shield.

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

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

Erect the shield until the full setting pressure has been attained, since good roof support can be ensured only in this manner.

Move the coal face interceptor against the coal face in such a way that no falling coal or barren rock can enter the carriage road.

Ensure that the water spray system responds during advancement.

Inclined deposits

Block and partial anchoring

Secure the conveyor by anchoring. This measure prevents lateral displacement of the conveyor, and thus jamming of the walking travel gear.

Also set the partial and block anchoring until attainment of the setting pressure, since this is the only way to ensure adequate anchoring between the roof and floor.

Always push shields from the bottom upward into coal faces with inclined bedding. This provides a better view of your working area.

Observe the correct advancing sequence, in order to avoid moving of the shields against the face anchoring cylinders when drawing up.

Shield alignment

Set the shields in such a way that the canopy bars and pressure pads are parallel with the adjacent shield.

Align the shields as soon as possible. Use the aligning device or the gap cover. Alignment in due time prevents the following: J moving under the canopy bar of the adjacent shields, J tilting of the shields, J slipping of the shields, J support lag.

Roof caving

Prevent roof caving by minimizing support lag as far as possible.

Never set the tip of the canopy bar in a caving roof. This can result in overloading of components if the maximal angles are exceeded.

2.8

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

Keep the hanging wall free of broken material. The walking travel gear can thus be extended without hindrance, and the conveyor can be pushed without difficulty.

E

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

Safety instructions During temporary support of a caving roof, ensure that the downward curved canopy bar does not hinder the passage of the winning machine.

Residual stroke

Withdrawal of conveyor

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.

Before withdrawing the conveyor, make sure that you are familiar with the circuit and wiring diagrams of the equipment.

Secure the entire winning machine against unauthorized starting.

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

Check to determine whether the shields are set sufficiently tightly 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.

Use only the fastening points intended for the purpose. Never employ the cylinder mounts for this purpose, since these have not been designed for withstanding tensile loads. The mounts may become detached, and the cylinders severely damaged.

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Raise the conveyor only in the area of shields which are connected with the conveyor by the advancing beam. Unhooked shields may tilt forward.

Reset all shields with which the conveyor is raised. Recheck the setting pressure. Never disengage the canopy bar from the roof. It must always be in contact over the entire length.

If you raise the conveyor with several shields, make sure that these are not in direct proximity to one another.

For raising the conveyor, employ only: J undamaged, high-strength round link chains, J the fastening points provided for the purpose (Check the fasten-

ing points for cracks at the welds and damage to the load-supporting rings.), J hoisting gear with sufficient permissible load-bearing capacity.

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2.9

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

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

Inform the supervisory personnel and 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 immediately. Immediately shut down the shield concerned, if immediate repair is not possible. Secure this area and notify the entire coal face crew and the responsible foremen without delay.

Do not perform any conversions or modifications which impair the safety of the shield. All conversions and modifications require approval by DBT. During work on the walking travel gear, isolate the working area for the winning 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 running out, and J the winning machine and conveyor have been shut down and

secured against restarting.

Before disconnecting the shield from the conveyor, you must: J stop production, and J relieve the load on the components which are under hydraulic

pressure or mechanical stress.

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

Secure the shield before all work: J mechanically against inadvertent yield, for instance with the use

of: – wooden wedges between the lemniscatic links, – and safety chains between the gob shield and roof.

In coal faces with inclined stratification, secure the components to be replaced with the use of chains or hoisting gear, for instance.

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

2.10

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Use only spare parts which conform with the specified technical requirements. This is ensured only by the use of original spare parts from DBT. The catalogue numbers are indicated in the spare parts lists.

DBT GmbH, Lünen 2002

Original spare parts

Safety instructions Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

maintenance, repair

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

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

J The hoses have no bubbles or blisters.

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

mally rigid or hard.

J The outer sheath of the hoses is not damaged.

J The connectors are securely inserted into the sockets.

J The connections are leak-tight.

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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 depressurized the line before disconnecting couplers.

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

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2.11

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-resistant and antistatic 6 standard

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

installation of hydraulic tubing

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 WRONG

RIGHT

J are not twisted.

Fig. 4:

Laying of hydraulic hose lines, twist RIGHT

2.12

WRONG

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

Replace hydraulic hoses at the first suspicion of damage.

E

Never try to repair damaged hydraulic hoses.

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

DBT GmbH, Lünen 2002

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RIGHT

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

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WRONG

2.13

Overview of the safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and Transport DANGER! If the shield is raised above fastening points S1 and S2, the base may swing downward. This could result in serious injury or death. Join the base and canopy, for instance, with the use of turnbuckles, or lift the shield only by means of fastening points S3 and S4 with the use of a cross beam.

Hoisting and hauling equipment with which the complete support shield unit is to be moved must be attached exclusively at the fastening points indicated in detail in the following figure!

Any other fastening points additionally present on the support shield unit are not suited for this purpose!

Take care that all transport safety devices are fitted properly.

These are the fixing elements for the relay bar at face and gob side and the turnbuckles between canopy and base.

IMPORTANT! Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

Chapter 4: Installation WARNING! First start-up and executing the test-run must only be performed by a well trained crew of skilled personnel which is very familiar with working in underground mining and the special safety regulations. The personnel must also be very familiar with the equipment and the appertaining operating instructions.

CAUTION! Hoisting and haulage equipment with which the complete support shield unit is to be moved must be attached exclusively at the fastening points indicated in detail in the following figure!

Any other fastening points additionally present on the support shield unit are not suited for this purpose!

2.14

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

CAUTION! There is a highly danger of hardly damaging or destroying the hydraulic components, if you do not replace the emulsion by an suitable anti-corrosive fluid. The emulsion possibly will change its properties within short time - caused e.g. by microbial attack - to an aggressive acting fluid.

Flush the hydraulic components respectively system carefully and replace the emulsion completely by an suitable anti-corrosive agent.

E

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

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

Use only suitable load handling devices.

Overview of the safety instructions Prior to assembly, sockets and nipples of the plug-in O-couplers must be treated with a type B3 lubricating paste according to EWN 7068, which is free of molybdenum disulfide. See chapter 6, section “Recommended Lubricating Greases and Pastes”.

Temporarily pressure drop may occur during operation, if your pressure supply equipment for the face hydraulic is not amply dimensioned or instable caused by other reasons.

In case the pressure drops down to 180 bar or less, there is a highly danger of malfunction of the hydraulic control system.

Valve functions possibly will not be executed. Under certain circumstances valves possibly get a tendency to oscillate. This may be the cause for damages at valves.

Under bad conditions this possibly results in dangerous situations and may be the cause of accidents within people may be hurt seriously. For this reason You must take all measures to secure, that the system pressure cannot drop down to 180 bar or less at any location of the face hydraulic system.

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

DBT GmbH, Lünen 2002

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IMPORTANT! The shields are numbered consecutively. Be certain to observe the shield number.

Chapter 5: Operations and Maintenance DANGER! Jammed or blocked push-buttons can result in uncontrolled movements of the shield. This can then result in very serious personal injury or even death!

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 to the individual safety regulations of your mine.

In all cases, always remain clear of all possible movements of a shield being advanced.

Unusual occurrences (such as a shield becoming lodged) can result in unpredictable shield movement and should be treated with extreme caution.

Failure to comply with this warning may result in serious bodily injury or death.

During normal operation, the shield-type support is operated only with the electronic controller. Observe the separate operating manual for the control unit. If the control unit forms part of the DBT scope of supply, you will find the corresponding operating manual in the DBT documentation on the system.

The control elements on the control block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for such operations. They must not be used during normal operation, as otherwise dangerous situations may arise resulting in very serious injury or even death!

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2.15

Overview of the safety instructions

Never drive the stabilizing cylinders of the support shield to block! Stabilizing cylinders must always have sufficient residual stroke!

Guide value: at least 20 mm!

The same applies as appropriate to the adjusting cylinders of the front cantilever.

Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of tendency toward roof caving, or extremely soft floor, or both!

Avoid excessive inclination of the canopy, for instance, by lining of roof caving or by supporting of minor roof caving with the shield in the horizontal position! In this conjunction, we must emphasize once again that any possible damage due to noncompliance with these instructions is not covered by the guarantee.

Do not exceed the maximal angles of inclination specified in the ”Technical data” section. If the maximal angles of inclination are exceeded, this will cause damage to props and cylinders, their arresting elements, as well as the articulations.

The tappets of the electromagnetic valves must not be damaged. Jammed tappets possibly will cause malfunction of the valve which may result an accident.

Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

Always take care when investigating a hydraulic leak to protect against high pressure fluid being forced into the skin. Wear gloves or use other protective equipment.

2.16

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

CAUTION! Maximum angles of inclination stated in the section ”Technical Data” must not be exceeded.

If the maximum angles of inclination will be exceeded, this will cause damage to props and cylinders and their arresting elements as well as to the articulations.

E

You may only operate the control elements on the control block when you have been thoroughly informed about the method of operation of the functions in relation to the shield-type support. You must therefore have undergone appropriate training.

There is otherwise a danger of incorrect operation which may lead to very serious personal injury or even death!

Manual operation of a push-button on one of the pilot control valves causes the corresponding function to be performed directly. Interrelationships between the individual functions are ignored. This can result in dangerous situations if sequences of functions are triggered in the wrong order. For example, the function ”Retract shield” can be initiated without the function ”Actively retract support” having been previously initiated.

This can lead to dangerous situations which may result in very serious personal injury or even death!

Damaged components must be replaced immediately. If this is not possible, the shield must be shut down and secured immediately. Notify the entire coal face crew and your superior immediately.

Never conduct any maintenance work while the system pressure is on.

Overview of the safety instructions NOTICE! Legibility of the control symbols is vital for avoiding faulty operation and accidents.

IMPORTANT! Both cases require knowledge of the flow plan and instruction by trained 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 support.

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

DBT GmbH, Lünen 2002

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You must not operate the valve functions by pressing the elastic cap at the solenoid during normal operation. Doing this may lead to unexpected, dangerous situations and accidents because of interlocked functions may be bypassed or kept out of function.

Direct operation by pressing the elastic cap is only allowed under certain conditions, e.g. for repair and maintenance. The special safety precautions must be observed strictly.

Never close the connections for lowering double-acting props pressure-tight. Risk of serious bodily injuries caused by unexpected break down of hydraulic components.

Irregular pressure build up, up to several times of the setting pressure, will occur if the connections for lowering double-acting props will be closed pressure tight.

Observe the warning plate at the cylinder surface.

Never block the port to the annulus of a cylinder.

Risk of serious bodily injuries caused by unexpected break down of hydraulic components.

Irregular pressure build up, up to several times of the setting pressure, will occur if the port to the annulus of a cylinder will be closed pressure tight.

During normal operation you must not operate the valve functions by pressing the elastic cap at the solenoid. Doing this may lead to unexpected, dangerous situations and accidents because of interlocked functions may be bypassed or kept out of function.

Direct operation by pressing the elastic cap is only allowed under certain conditions, e.g. for repair and maintenance. The special safety precautions must be observed strictly.

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

The pressure setting must not be changed.

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! When the piston rod is being extended no excess pressure must build up in the annulus.

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2.17

Overview of the safety instructions New seals must be fitted whenever a pressure relief valve is replaced. Failure to do so may cause malfunction resulting in serious bodily injury or death.

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

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

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

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

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

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

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

2.18

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

The greases listed in the same table, 1 or 2, 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.

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Further information is contained in DIN 24320.

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 and availability of the shield. 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 corrosion protection

Components coated with temporary corrosion inhibitor are protected for around six months.

The hydraulically operated equipment is operated before delivery with a test medium and then drained as far as possible before delivery. The medium remaining in the equipment also protects all the internal parts against corrosion for at least six months.

Storage of new Equipment Protect the equipment against direct exposure to sunlight.

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

moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.

DBT GmbH, Lünen 2002

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no direct exposure to sunlight

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied. short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components must not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the hydraulic components are to be stored for more than six months, they must be completely filled with a corrosion inhibiting/ frost-proofing fluid such as e.g. HYDROCOR CV 50*.

Fill cylinder piston and ring sides in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room – not outdoors.

plastic deformation

random sample inspection

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders, e.g. the corner cylinders, must be removed so that they can be stored upright.

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. * HYDROCOR CV50 is a trade name of Theunissen, Chemische Fabrik GmbH, Wuppertal / Germany

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3.3

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.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in section ”Barely flammable hydraulic fluids of Group HFA” in this operating manual.

IMPORTANT! Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

Used equipment If there is any need to store hydraulic equipment that has been in use before, you have to apply the measures mentioned above in the section ”storage of new equipment” also except of the paragraph ”corrosion protection”. Regarding corrosion protection apply the following: Corrosion protection

In case the hydraulic system will be put out of operation temporarily or used hydraulic components will be stored, special measures regarding corrosion protection are to be taken:

CAUTION! There is a highly danger of hardly damaging or destroying the hydraulic components, if you do not replace the emulsion by an suitable anti-corrosive fluid. The emulsion possibly will change its properties within short time - caused e.g. by microbial attack - to an aggressive acting fluid.

Flush the hydraulic components respectively system carefully and replace the emulsion completely by an suitable anti-corrosive agent.

3.4

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

– The emulsion must be replaced completely by an anti corrosive fluid e.g. Hydrocor CV50.

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– Flush the hydraulic components / system carefully.

Transport Transport Load Units, Dimensions and Weights Observe the transport sheets for the various transport units.

They contain information on: J Dimensions J Weight J Lifting points J Center of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and erection.

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

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

Use only suitable load handling devices.

Before Transport DBT GmbH, Lünen 2002

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temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a a corrosion inhibiting/ frost-proofing fluid (e.g. HYDROCOR CV 50).

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.

During transport of this equipment with floor conveyors at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

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

electrical and electronic components

Doc. no.: 7420 066 000 BA 00

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 a suitable packaging.

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

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3.5

Transport Disassembly level upon delivery The individual support shield units are transported as a complete unit. Disassembly into smaller subassemblies is not planned. However, if disassembly is necessary, the procedure is subject to agreement with the authorized agencies of DBT. CAUTION! Hoisting and hauling equipment with which the complete support shield unit is to be moved must be attached exclusively at the fastening points indicated in detail in the following figure!

Any other fastening points additionally present on the support shield unit are not suited for this purpose!

CAUTION! Take care that all transport safety devices are fitted properly.

These are the fixing elements for the relay bar at face and gob side and the turnbuckles between canopy and base.

Fig. 8:

DBT GmbH, Lünen 2002

DANGER! If the shield is raised above fastening points S1 and S2, the base may swing downward. This could result in serious injury or death. Join the base and canopy, for instance, with the use of turnbuckles, or lift the shield only by means of fastening points S3 and S4 with the use of a cross beam.

Transport of the shield support units W

S2

S1 Y

H

S 0

SY

X1 S3

X2 S4

Sx L S1 S2 S3 S4 X1, X2 Y So

Attaching eye, 2 pieces on caving shield, load-bearing capacity: 8000 kg Slot hole, 2 pieces on the coal face end of the canopy, load-bearing capacity: 8000 kg Slot hole, 2 pieces on the coal face end of the base, load-bearing capacity: 8000 kg Slot hole, 2 pieces on the gob side end of the base, load-bearing capacity: 8000 kg Securing elements to fix the relay bar during transport Transport safety device: e.g. turnbuckles between canopy and base (not included in the extent of delivery) Position of the center of gravity Tab. 1: Shield support 7420 066 000 00 .. , Dimensions and weight of variants Variant

3.6

Width in mm

Height in mm

Sx/Sy in mm

E

Transport securing devices are to be found at : Side seals, Flipper and Shifting ram (face and gob side)

Order no.

Length in mm

Weight in kg

01 7420 066 000 00 01

7020

1650

2200

1494/1315

23340

02 7420 066 000 00 02

7020

1650

2200

1494/1305

23410

03 7420 066 000 00 03

7520

1650

2200

1365/1329

24580

04 7420 066 000 00 04

7520

1650

2200

1366/1326

24200

05 7420 066 000 00 05

7520

1650+561

2200

1321/1342

25050

DBT - Shield 2200/4500-2x3176-1750

4

Installation

Pre-assembly of the support shield units

Installation The individual support shields are transported as complete units.

Disassembly into smaller subassemblies is not planned. However, if disassembly is necessary, the procedure is subject to agreement with the responsible agencies of DBT. CAUTION! Hoisting and haulage equipment with which the complete support shield unit is to be moved must be attached exclusively at the fastening points indicated in detail in figure 8, see chapter “Transport”. Any other fastening points additionally present on the support shield unit are not suited for this purpose!

CAUTION! Prior to assembly, sockets and nipples of the plug-in O-couplers must be treated with a type B3 lubricating paste according to EWN 7068, which is free of molybdenum disulfide. See chapter 6, section “Recommended Lubricating Greases and Pastes”.

Pre-assembly of the support shield units

DBT GmbH, Lünen 2002

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The support shield units are delivered in the completely pre-assembled condition. Hence, no further pre-assembly is necessary for the mechanical and hydraulic systems of the support shield frame.

Installation of the support shield units The support shield units are installed in the coal face in correspondence with the installation plan of the shaft plant.

IMPORTANT! The shields are numbered consecutively. Be certain to observe the shield number.

The sign plate with the shield number is placed at the base. The shield units are numbered from 1 to 140.

Fig. 9:

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Shield number sign plate at the base

4.3

Installation of the support shield units Power take-off connections Fig. 10: View into the support unit from face side Supply hoses short circuited as ready for transport and power take off.

2

4 3

Fig. 11:

Shut-off tap pressure supply for shield hydraulic, open as shown Manifold pipe Return line (R) Pressure supply line (P) PTO connections at the manifold pipe Hoses connected as ready for power take off

T 1

P

1 T P

4.4

Shut-off tap, pressure supply for shield hydraulic, open as shown PTO return line PTO pressure supply line

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

1 2 3 4

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1

Installation of the support shield units

The Power Take-Off (PTO) nipples are located at the manifold pipe.

See also circuit diagrams in chapter 6, section ”Hydraulic System”. The PTO connections are provided for connecting the shield to a hydraulic supply unit when the shield is set for the first time.

The pressure line to the shield hydraulic can be shut off using the shut-off tap at the manifold pipe.

In case of supply by way of the PTO connections, the connections on the manifold pipe are short-circuited with the use of hose lines, which later serve as connection with the manifold pipe of the adjacent shield. See fig. 10, above.

During normal operation the supply to the support shield unit proceeds exclusively by means of the manifold pipe. The PTO connections are then closed by plugs.

Coupling between the connections The hydraulic connectors are of plug-in coupler design according to DIN 20043.

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each support shield unit. This pipe provides the hydraulic supply to the individual support shield unit. The manifold pipes of adjacent support shield units are connected with the use of two hose lines: A pressure line (DN 32) and a return line (DN 50). See the hydraulic block diagram in chapter 6.

Control unit

The electrohydraulic control unit PM 4 of the support shield is connected with the pilot control valves by means of plug-in connectors.

Please refer to the separate operating manual for exact PM 4 connecting data.

DBT GmbH, Lünen 2002

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Hydraulic system

Electrical system

Electrical devices, such as the lighting and intercom systems, are not included in the scope of supply of the DBT. Information about the correct connection of the electrical devices installed on the support shield, such as the lighting and intercom systems, are to be taken from the corresponding, separate operating manual of the supplier.

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4.5

Test-Run 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

315bar

admissible tolerance

10 % of nominal pressure

Test-Run WARNING! First start-up and executing the test-run must only be performed by a well trained crew of skilled personnel which is very familiar with working in underground mining and the special safety regulations. The personnel must also be very familiar with the equipment and the appertaining operating instructions.

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

First Start-Up Safety measures to be taken prior the first start-up Check on the hydraulic system J Test the entire hydraulic system for leaks.

J Check the supporting power of the props at the pressure

gauge.

J Check whether the pressure required is available in the different

hydraulic feed lines.

Check on the signaling and lighting systems J After the function test of all components of the installation, check once more the signaling devices and the face lighting system.

Check on the mining machine and the conveyor Before the face system is put into operation, check functioning of the mining machine and the conveyor; check whether the face conveyor and the track for the mining machine have been cleared.

4.6

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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CAUTION! Temporarily pressure drop may occur during operation, if your pressure supply equipment for the face hydraulic is not amply dimensioned or instable caused by other reasons.

In case the pressure drops down to 180 bar or less, there is a highly danger of malfunction of the hydraulic control system.

Valve functions possibly will not be executed. Under certain circumstances valves possibly get a tendency to oscillate. This may be the cause for damages at valves.

Under bad conditions this possibly results in dangerous situations and may be the cause of accidents within people may be hurt seriously. For this reason You must take all measures to secure, that the system pressure cannot drop down to 180 bar or less at any location of the face hydraulic system.

Test-Run Check on the electro-hydraulic support control system J How to check the electro-hydraulic control system is described

in the separate operating manual for the PM4 control system.

J Canopies must not be sloping downwards and reach into the

track for the mining machine.

J The safest area on the face is the travelway. In practice, it has

proved useful to identify the travelway by a sign.

Start-Up J First, the support units must be properly aligned following instal-

lation.

J Then, tests for leaks and for isolation must follow, also func-

tional checking of the auxiliary and monitoring switches, the power pack and the pressure control members.

J The supports should only be put into operation by trained per-

sonnel. If it is the first time that the mine uses the shield support, the DBT service team should be present when the support is put into operation.

J Shut-off valves must not be installed in the return lines. All hose

connections have to be checked for leaks.

DBT GmbH, Lünen 2002

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J Any leakage should be eliminated.

J Check the control functions.

J Check laying of the hose lines.

Keep sure, that hose lines will not be damaged by support movement.

J Check quantity, temperature, pressure and condition of the

emulsion and correct, if necessary.

J Check the pump according to the respective operating instruc-

tions.

Corrosion-Protected Hydraulic Components Putting into Operation Before delivery DBT hydraulic components are provided with a corrosion preventing medium for testing purposes.

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

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

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4.7

E

DBT GmbH, Lünen 2002

4.8

DBT - Shield 2200/4500-2x3176-1750

5

Operation

Safety Measures to be Taken during Operation

Operations and Maintenance This chapter gives information about operations and maintenance of the shield support.

Safety Measures to be Taken during Operation A very important pre-requisite for safe operation of shield supports is a good state of training of the operating and maintenance crew.

This means that the operating and maintenance crew must be familiar with the operating instructions and safety guidelines and must have proper command of the control functions.

The DBT training department will be glad to provide detailed instructions.

DBT GmbH, Lünen 2002

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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 to the individual safety regulations of your mine.

General Guidelines Face crew

The face crew must be informed about possible danger situations.

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

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

Face equipment

The face must be illuminated sufficiently.

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

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

Conveyor overload

Large layers of coal and rock must be broken up to prevent spillage and jamming under support 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 sufficiently, they may only be transported after the face crew has been informed. In this case support operations and work on the face conveyor have to be stopped until the rock and coal have been transported off.

Travel way

It is absolutely necessary that the minimum dimensions of the travel way, which depend on the type of support used, are maintained.

Debris or any objects must be removed from the travel way immediately. This applies in particular in case of low seam heights.

If crawl pans are used whose length is adjustable, care has to be taken that an adequate and safe travel way remains.

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5.3

Safety Measures to be Taken during Operation In the Federal Republic of Germany, the requirement is for a minimum travel way width of 600 mm.

If the height of the travel way is restricted by the use of additional equipment, e.g. anchorages between support and conveyor, care has to be taken that a safe travel way of adequate height remains.

In the Federal Republic of Germany, the requirement is for a minimum travel way height of 400 mm.

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

Roof supporting works

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 by setting the props 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.

Care must be taken that the face guards are always extended towards the coal face far enough to achieve the desired protection.

This does not apply during support advance.

If face guards 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.).

Work which has to be performed in the immediate vicinity of the face conveyor, e.g. at or above the spill plates, may also only be carried out from a safe position, i.e. the place where the work is to be carried out must be protected against fall of rock and falling coal layers.

On inclined faces the conveyor must additionally be provided with barriers which have to be fitted above the place where the work has to be carried out. If necessary, barriers (e.g. air cushions) must also be provided in other places for further protection. Their number and height depends on the gradient and other conditions.

Repair works

If supports are to be disconnected from the conveyor, mining must be stopped in the respective section.

When work has to be carried out on supports, components or individual elements which are under hydraulic tension or mechanical stress may only be loosened or removed after they have been relieved of their tension or stress, e.g. by lifting, aligning or lowering.

Before hydraulic components are opened, the respective area of the hydraulic system must be depressurized.

If in certain cases it is not possible to relieve the tension or stress, care must be taken to use suitable means, e.g. chains or locking bars, for absorbing the stress or tension when it is released. Any work of this kind may only be performed from a safe position.

5.4

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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

E

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

Safety Measures to be Taken during Operation

Water spray system

Anchorage device

The protective equipment increases the safety and must, therefore, not be removed.

Dust suppression systems are used to suppress the dust in the canopy/caving shield area. Care must be taken that the systems start to operate during support advance.

The arrangement of the spray nozzles depends on the conditions at the place of installation and must be discussed with the safety engineers of the mine.

Safe anchorage of the conveyor prevents lateral displacement between conveyor and supports.

Displacement may cause jamming of the shifting units and lead to damage and dangerous deformation of flexible components.

Special Guidelines for Operation

DBT GmbH, Lünen 2002

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Shield operation

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

Hands and feet respectively must never get between the canopy and the roof or between the base and the floor.

Nobody should ever stay under a support which has not been set.

Parts of the body must not get between the side seals.

The operator must generally observe the section where a support is to be operated. He must never lower or advance a support if another person is in its immediate vicinity, close to it or even under it, or if the mining machine is moving towards his position.

Everyone traveling through the face has to stay away from a support which is being operated.

On inclined faces, support advance should be started in the lower section. Since the supports 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 support.

The supports 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.

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

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

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5.5

Safety Measures to be Taken during Operation Fig. 13: C o r r e c t, Supports 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.

Hydraulics, controls

Proper command of the control functions is an important prerequisite for the prevention of accidents.

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

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

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

To prevent damage in case the return line is closed accidentally 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 to the supervisor so that the defects can be eliminated as quickly as possible and necessary repair work can be carried out.

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

5.6

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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

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The operating symbols at the control units rule out misunderstandings and help to avoid mistakes. They must not be removed or damaged.

Operating Shield Support Operating Shield Support A good state of training of the operating crew and observance of the instructions stated below are most important for safe and proper operation of the supports and the mining machine.

If the shield support is equipped with an electro-hydraulic support control system please observe the instructions given in the separate manual ”Electro-hydraulic support control system.”

The supports 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.

Canopy adjustment

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

DBT GmbH, Lünen 2002

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CAUTION! Maximum angles of inclination stated in the section ”Technical Data” must not be exceeded.

If the maximum angles of inclination will be exceeded, this will cause damage to props and cylinders and their arresting elements as well as to the articulations.

Fig. 14: Shield support in the normal position

M = Height of the set shield support a = Inclination angle of the canopy

CAUTION! Never drive the stabilizing cylinders of the support shield to block! Stabilizing cylinders must always have sufficient residual stroke!

Guide value: at least 20 mm!

The same applies as appropriate to the adjusting cylinders of the front cantilever.

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

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5.7

Operating Shield Support

DBT GmbH, Lünen 2002

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Fig. 15: Shield support with extremely inclined canopy

M = Height of the set shield support a = Inclination angle of the canopy S = Residual stroke of the stabilizing cylinder

CAUTION! Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of tendency toward roof caving, or extremely soft floor, or both!

This applies especially if the shield control unit is equipped with an automatic resetting function. Under unfavorable conditions - for instance, soft floor and, in addition, perhaps a tendency toward roof caving - there is a danger that the residual stroke of the corner cylinders is no longer sufficient, or the cylinders are driven to block, as a result of the automatic resetting function. In these or similar cases, therefore, operate the shield support without the automatic resetting function.

CAUTION! Avoid excessive inclination of the canopy, for instance, by lining of roof caving or by supporting of minor roof caving with the shield in the horizontal position! In this conjunction, we must emphasize once again that any possible damage due to noncompliance with these instructions is not covered by the guarantee.

5.8

DBT - Shield 2200/4500-2x3176-1750

Operating Shield Support CAUTION! Do not exceed the maximal angles of inclination specified in the ”Technical data” section. If the maximal angles of inclination are exceeded, this will cause damage to props and cylinders, their arresting elements, as well as the articulations.

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.

Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 14) if the stabilizing cylinder is fully extended. There must always be sufficient stroke available for decreasing dynamic loads from the roof by the hydraulically protected stabilizing cylinder.

DBT GmbH, Lünen 2002

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Fig. 16: W r o n g, by no means the tip of the canopy must be set in a cavity, if the stabilizing cylinder is extended fully.

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.

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.

Accumulation of dirt on the canopies can be avoided by advancing the supports 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.

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5.9

Operating Shield Support Support adjustability / unsteady seam thickness

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

Care should be taken in case of a decreasing seam opening that the residual stroke of the props is always sufficient to avoid that the props go solid during convergence of the roof, as this would result in overloading the entire support.

Countermeasures: J Avoiding the accumulation of debris and fine coal on the floor J Removing accumulated dirt from the canopies J If necessary, producing a larger face opening by means of the

mining machine.

Inclined faces

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

Since in inclined workings support 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 support during advance. Any corrections in the attitude becoming necessary can be carried out by means of manual control only.

Safe anchorage of the conveyor prevents lateral displacement between conveyor and supports. Displacement may cause jamming of the shifting units and lead to damage and dangerous deformation of flexible components. It also impedes advance of the conveyor.

When using block anchorages on the face, it is most important to advance the supports in the correct sequence to avoid damage to the cylinders of the anchorage when the supports are advanced.

First, advance the support unit to which the cylinder is attached and, then, the adjacent unit(s) along which the anchorage is run towards the conveyor.

bad floor conditions

If the bases sink in too much, e.g. because of very bad floor conditions, the shifting unit may get jammed. In such a case the bases have to be raised out of the floor.

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

5.10

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

If the seam height increases considerably and the hydraulic stroke is not sufficient, the props have to be extended in time, either hydro mechanically or by using the inner prop extension. For extending the props mechanically or for retracting the extensions, the canopy must be secured in position. Make sure that the prop which has been separated from the canopy cannot turn over.

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Before the supports are advanced, the floor must be clear of coarse debris so that the supports 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.

Operating Shield Support Supports without a hydraulic base lifting device can be raised out in different cases: J Individual skids of two-leg shields can, as a rule, be lifted hy-

draulically by retracting a prop.

J Supports with solid bases must be lifted and underlaid by

means usually applied in mines.

DBT GmbH, Lünen 2002

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

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5.11

Safety Precautions for Shield Supports with Electro-Hydraulic Controls Safety Precautions for Shield Supports with Electro-Hydraulic Controls For safety of the operator the shields are provided with adjacent controls; e.g. each shield is operated using the controls located in the shield left or right adjacent to the unit to be advanced, or by automated remote batch control.

WARNING! In all cases, always remain clear of all possible movements of a shield being advanced.

Unusual occurrences (such as a shield becoming lodged) can result in unpredictable shield movement and should be treated with extreme caution.

Failure to comply with this warning may result in serious bodily injury or death.

CAUTION! The tappets of the electromagnetic valves must not be damaged. Jammed tappets possibly will cause malfunction of the valve which may result an accident.

When shields are advanced in automated batch cycles no person is allowed to locate in the area between shield in motion and the operator controlling the batch.

Follow these steps if a shield has failed to advance : 1. Determine reason for failure to advance, there may be: J Malfunctioning of electric 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 PM4 control panel of the adjacent shield unit. See separated manual of the PM4 control.

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

5.12

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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.

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Always observe these safety rules :

Operation of the Shield Hydraulics Operation of the Shield Hydraulics WARNING! During normal operation, the shield-type support is operated only with the electronic controller. Observe the separate operating manual for the control unit. If the control unit forms part of the DBT scope of supply, you will find the corresponding operating manual in the DBT documentation on the system.

Location of hydraulic devices at the shield support The following table is valid for all variants of the shield support.

DBT GmbH, Lünen 2002

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Tab. 2: Hydraulic components Item

Qty.

Description

Location

1

1

control valve block

2

2

prop check valve

between the front lemniscatic links, at holder one at each prop

3

1

check valve

4

2 (3)*

piloted check valve

5

2

pressure relief valve, 462 bar

6

6 (7)*

pressure relief valve,462 bar

7

1

check valve

one piece each at: - check valve item 3, - ball valve item 16 two pieces each at: - piloted check valves item 4, - piloted check valves item 11 at manifold pipe, in return line

8

1

filter

at manifold pipe, in supply line

9

1

block ball valve, NW10

at the block ball valve item 16

10

3

block ball valve, NW20

at manifold pipe

Remark

between the front lemniscatic links, at holder for the manifold pipe under the canopy, between the props one at each prop

one at each prop check valve port “PA”

serves to isolate alining cylinder ring side from pressure supply serves to isolate shield hydraulics from pressure supply serves to isolate the prop piston side port from pressure supply

11

1

piloted check valve

at the link cylinder

12

1

pressure gauge

at the prop check valve port “A”; at left side prop only

13

1

hose lines

14

1

retainer and accessories

15

1

manifold pipe

between the front lemniscatic links

subassembly

16

1

Block ball valve

at the left side front lemniscatic link

serves to change between the functions retracting / extending aligning cylinders

17

1

accumulator cartridge

at control valve block

subassembly subassembly

* Deviating quantities of the variant 05 are given in brackets.

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5.13

Operation of the Shield Hydraulics Hydraulic of the shield support variants 01, 02, 03 and 04 Fig. 18: Hydraulic of the shield support variants 01, 02, 03 and 04 view “B”

4 4

B A

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

1 (17) view “A” (enlarged view)

3

5.14

6

9

7

8

6

16

10

2(12)

15

14

10

5

2 10 5 13

DBT - Shield 2200/4500-2x3176-1750

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1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar DBT GmbH, Lünen 2002

6 6

6 6 11

Operation of the Shield Hydraulics Fig. 19: Hydraulic Flow Plan for shield support variants 01, 02 ,03 and 04, overview.

Please refer also to the spare parts book.

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar 6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe

DBT GmbH, Lünen 2002

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16 Block ball valve 17 Accumulator cartridge Z1 Prop Z2 D.A ram Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder

Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract

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5.15

Operation of the Shield Hydraulics Fig. 20: Hydraulic lines of the shield support variants 01, 02 ,03 and 04, overview

1 Control valve block 2 Prop check valve 3 Check valve

Z4

11 6

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm

6

Z3

view “A”

4 Piloted check valve 5 Pressure relief valve, 462 bar

9 Block ball valve, NW10 10 Block ball valve, NW20

16 7

6

14 Retainer and accessories 15 Manifold pipe

10

8

3

6

11 Piloted check valve 12 Pressure gauge 13 Hose lines

16 Block ball valve 17 Accumulator cartridge

2 Z1

Z6

Z4

6

4

Z5

5.16

6

Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

12 10

Z2

10 5

Z1

2

5

E

1

17

Z1 Prop Z2 D.A ram Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder

Operation of the Shield Hydraulics Hydraulic of the shield support variant 05 Fig. 21: Hydraulic of the shield support variant 05 view “B”

DBT GmbH, Lünen 2002

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(enlarged view)

A

B

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar 6 Pressure relief valve, 462 bar 7 Check valve 8 Filter 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

view “A” (enlarged view)

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5.17

Operation of the Shield Hydraulics Fig. 22: Hydraulic Flow Plan for shield support variant 05, overview.

Please refer also to the spare parts book.

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar 6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

DBT GmbH, Lünen 2002

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Z1 Prop Z2 D.A ram Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder Z7 Side flipper cylinder

Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract 11 side flipper cylinder, retract 12 side flipper cylinder, extend

5.18

DBT - Shield 2200/4500-2x3176-1750

Operation of the Shield Hydraulics Fig. 23: Hydraulic lines of the shield support, overview

7

10

8

3

9 16 6

6

9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines

6

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm

6

4 Piloted check valve 5 Pressure relief valve, 462 bar

Z4

view “A”

1 Control valve block 2 Prop check valve 3 Check valve

5 2

12

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Z6

Z7 Z4

6

4

Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract 11 side flipper cylinder, extend 12 side flipper cylinder, retract

6

Z5

Z1

Z1

10

10

2

Z2

5

DBT GmbH, Lünen 2002

6 4

E

Z7

1 1

17

Z4

14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

Z1 Prop Z2 D.A ram Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder Z7 Side flipper cylinder

5.19

Operation of the Shield Hydraulics Fig. 24: Single shield support unit, view from face-side 1 Manifold pipe 2 PM 4 control unit 3 Control valve block

1

2

DBT GmbH, Lünen 2002

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3

Fig. 25: View to the manifold pipe, supply hoses connected as ready for transport

PTO (R) R

P

PTO (P) 10

R Return line, DN 50 P Pressure line, DN 32 PTO Power take off ports (P and R), plugged as shown 10 Shut-off tap for pressure supply of the shield hydraulic

5.20

DBT - Shield 2200/4500-2x3176-1750

Operation of the Shield Hydraulics Fig. 26: Manifold pipe, auxiliary hose lines connected ready for power take off

PTO

R PTO

P

R

DBT GmbH, Lünen 2002

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P

10

15

10 Shut-off tap for pressure supply of the shield hydraulic, open as shown 15 Manifold pipe P Pressure supply port PTO Power take off ports (P and R), connected to auxiliary pressure supply as shown R Return port For power take off the pressure supply ports and the return ports of the manifold pipe must be short circuited.

Fig. 27: PM4 control unit fitted at adjustable holder

a PM4 control unit b Holder for PM4 control unit c Control valve block

a

b

c

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5.21

Operation of the Shield Hydraulics Fig. 28: Adjustable holder for electronic control unit PM4

B

6 6

A Height adjustable link B Adjustable hinge fitted link 6 Hex. head bolt M16x35 - 8.8, recommended tightening torque 195 Nm 11 Securing spring

11

A

Prior putting the support unit into operation, the holder for the PM4 control unit must be fitted in suitable working position.

. Fix height of the holder (A) at both sides in working position usthe recommended tightening torque again.

Fig. 29: View to the left side front lemniscatic link

6 Pressure relief valve 9 Block ball valve Closed as shown 16 Block ball valve A: Retract aligning cyl.

B: Extend aligning cyl.

9 A

B

16 6

5.22

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

. Adjust angle (B) in working position and retighten bolts (6) with

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ing the securing springs (11).

Operation of the Shield Hydraulics Fig. 30: View to the left side prop from gob side

2 Prop check valve 5 Pressure relief valve 10 Block ball valve, isolates the prop piston chamber from pressure supply; open as shown 12 Pressure gauge

10

DBT GmbH, Lünen 2002

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2

5

12

Fig. 31: View to the right side prop from gob side 2 Prop check valve 5 Pressure relief valve 10 Block ball valve, isolates the prop piston chamber from pressure supply; open as shown a Pressure sensor

10 2

a 5

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5.23

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

Operation of the control unit for the electronic controller is not described here. For information, please refer to the separate operating manual for the control unit. If the control unit forms 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 support unit and the shield controller is described in chapter 6, ”Technical Description”, of this manual.

During normal operation, the shield-type support is operated only with the electronic controller. Observe the separate operating manual for the control unit. If the control unit forms part of the DBT scope of supply, you will find the corresponding operating manual in the DBT documentation on the system.

Fig. 32: Control devices a PM4 control unit b Control valve block

a

b

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 content of this manual. See separate manual for the PM4 control unit.

5.24

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

WARNING! The control elements on the control block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for such operations. They must not be used during normal operation, as otherwise dangerous situations may arise resulting in very serious injury or even death!

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

Operation of the Shield Hydraulics Fig. 33: Control valve block (10 functions) fitted at holder between the front lemniscatic links 1 Control valve block a Push button b Symbol plate c Pilot valve d Connecting cable e Solenoid driver

e a d

1

c b

DBT GmbH, Lünen 2002

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Fig. 34: Symbol plate for 10 function control block

Fig. 35: Symbol plate for 12 function control block

The symbol plate is located at the control block underneath the pilot control valves. The symbols on the plate correspond directly to the function of the particular push-button on the pilot control valve. The meaning of the symbols is explained in the following text.

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5.25

Operation of the Shield Hydraulics Operation and Functions of the Control Block This section contains information on the functions of the control block. Please be sure also to observe the operating instructions for the hydraulic control block and the electronic control unit.

WARNING! You may only operate the control elements on the control block when you have been thoroughly informed about the method of operation of the functions in relation to the shield-type support. You must therefore have undergone appropriate training.

There is otherwise a danger of incorrect operation which may lead to very serious personal injury or even death!

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

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

DANGER! Jammed or blocked push-buttons can result in uncontrolled movements of the shield. This can then result in very serious personal injury or even death!

Therefore never block the push-buttons and ensure that any damaged pilot control valves are replaced immediately.

WARNING! Manual operation of a push-button on one of the pilot control valves causes the corresponding function to be performed directly. Interrelationships between the individual functions are ignored. This can result in dangerous situations if sequences of functions are triggered in the wrong order. For example, the function ”Retract shield” can be initiated without the function ”Actively retract support” having been previously initiated.

This can lead to dangerous situations which may result in very serious personal injury or even death!

5.26

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

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.

E

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

Operation of the Shield Hydraulics Extend link cylinder 1 CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

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

The function serves to raise the canopy tip and for alignment of the canopy bar. The function is performed as long as the button is held depressed or until the end position is reached.

Retract link cylinder 2 CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

DBT GmbH, Lünen 2002

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Before this function is initiated, ensure that the neighboring shields have been completely set.

The function serves to lower the canopy tip and for alignment of the canopy. The function is performed as long as the button is held depressed or until the end position is reached.

3

4

Set both props Before this function is initiated, the canopy must be aligned to the roof. The lift cylinder will be retracted automatically.

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

Extend / retract aligning cylinders This button serves to perform both functions ”extending” and ”retracting” the aligning cylinders depending on the position of the lever at the block ball valve (16), see figure 36.

The function is performed as long as the button is held depressed or until the end position is reached. Both functions are disabled, if the block ball valve (9) is closed, which is arranged between the block ball valve (16) and the aligning cylinder ring side.

Fig. 36: Block ball valves located at the left side front lemniscatic link 9 Block ball valve; serves to isolate the pressure supply from the aligning cylinders, closed as shown 16 Block ball valve serves to change between functions “retract” and “extend aligning cylinders” A: Retract aligning cyl.

B: Extend aligning cyl.

9 A B

16

Doc. no.: 7420 066 000 BA 00

VLVU / 02

5.27

Operation of the Shield Hydraulics Actively lower both props 5

Before this function is initiated, ensure that the neighboring shields have been set completely .

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

Extend lift cylinders

6

Before this function is initiated, the function ”Actively lower both props” must have been executed.

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

If the function is not operated, the piston chamber is connected to the return line. Therefore the lift cylinder retracts automatically because of the weight of the support unit or actively during the props will be set again.

Advance support

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

As long as the function is activated, the hydraulically lockable nonreturn valve which seals off the ring chamber of the shifting ram is automatically held open.

8

Advance conveyor Before initiating this function, ensure that the support unit has been set.

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

9

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

10

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

11

Retract side flipper cylinder Not available at shield support variants 01, 02, 03 and 04.

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

12

Extend side flipper cylinder Not available at shield support variants 01, 02, 03 and 04.

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

5.28

DBT - Shield 2200/4500-2x3176-1750

E

Before this function is initiated, the functions ”Actively lower both props” and “Retract aligning cylinders” must have been executed.

DBT GmbH, Lünen 2002

7

Maintenance of the shield hydraulic Maintenance of the shield hydraulic WARNING! Damaged components must be replaced immediately, if safe operation of the support unit is impossible furthermore. If this is not possible, the shield must be shut down and secured immediately. Notify the entire coal face crew and your superior immediately.

Electronic control

. See separated original operating instructions of the PM4 control.

Hydraulic control

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

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

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

least once annually, and in any case after every relocation in the coal face.

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

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

DBT GmbH, Lünen 2002

E

Daily inspection Hydraulics

. Check all shield support units by visual inspection for escaping hydraulic fluid on the: J hose lines, J control units, J props, J valves J D.A. ram and lift cylinder J link cylinder, aligning and flipper cylinders.

Steel structure

. Check pressure gauges at the props. . Check all shield support units by visual inspection for damage to the steel structure, for instance: J on the D.A ram system, J on the side seals, J on holders, etc.

Weekly inspection Control unit

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

. Clean the control units, especially the control panel.

NOTICE! Legibility of the control symbols is vital for avoiding faulty operation and accidents.

Doc. no.: 7420 066 000 BA 00

VLVU / 02

5.29

Maintenance of the shield hydraulic Monthly record of damage

DBT GmbH, Lünen 2002

E

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

5.30

DBT - Shield 2200/4500-2x3176-1750

Trouble shooting Trouble shooting Possible Cause The isolating valve for pressure supply at the manifold pipe of the support is closed.

Check Required Open isolating valve.

Feed line must be open to allow pressure to the support.

Check leg isolating valve (if fitted) is closed.

Open isolating valve.

Lines to leg and return must be open.

Support canopy is trapped by adjacent supports

Check the support is not ‘iron-bound’ and if necessary, operate or lower adjacent supports to free

Pilot piston in the POCV valve is not operating

Check if there is enough pressure to operate the piston (minimum 80 bar) POCV may be faulty

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Legs are damaged

Check cylinder for damage (if damaged, replace cylinder)

Lack of fluid from control valves

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

Possible Cause The isolating valve for pressure supply at the manifold pipe of the support is closed.

Check Required Open isolating valve.

Feed line must be open to allow pressure to the support.

Support is trapped by adjacent supports

Check the support is not ‘iron-bound’ and if necessary, operate or lower adjacent supports to free

Step on roof or floor preventing advance

Lower support sufficiently to clear the step or put base-lift function ‘ON’

System pressure is too low for operation

Check pumps are ‘ON’ Check all ‘shut-off’ valves are ‘OPEN’ Check pressure delivered by pumps is correct

Pilot piston in the POCV valve is not operating

Check if there is enough pressure to operate the piston (minimum 80 bar) POCV faulty and leg has not lowered

Damaged or trapped hoses

Check for damaged or kinked hoses in supply line to face

Advancing cylinder is faulty

Check cylinder for damage Check for POCV (load lock) malfunction Operate ‘Bankpush’ with hose disconnected on piston side, if fluid flows without ram operating, change ram

DBT GmbH, Lünen 2002

E

Failure to lower the support

Failure to advance the support

POCV = pilot operated check valve

Doc. no.: 7420 066 000 BA 00

VLVU / 02

5.31

Trouble shooting Possible Cause The isolating valve for pressure supply at the manifold pipe of the support is closed.

Check Required Open isolating valve.

Feed line must be open to allow pressure to the support.

Check leg isolating valve (if fitted) is closed.

Open isolating valve.

Lines to leg and return must be open.

Support canopy is trapped by or under adjacent supports

Check the support is not ‘iron-bound’ and if necessary, operate or lower adjacent supports to free

System pressure is too low for operation

Check pumps are ‘ON’ Check all ‘shut-off’ valves are ‘OPEN’ Check pressure delivered by pumps is correct

Pilot piston in the POCV valve is not operating

Check if there is enough pressure to operate the piston (minimum 80 bar) POCV may be faulty

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Legs are damaged

Check cylinder for damage (if damaged, replace cylinder)

Possible Cause Faulty POCV

Check Required Check the POCV by replacing unit

Legs are damaged

Check cylinder for damage (if damaged, replace cylinder) Check if fluid is flowing from leg lower port/hose without large leg movement

Faulty Yield valve

Check pressure gauge for reading Is yield valve weeping?

Replace yield valve and check functions

Failure to maintain the leg pressure after setting the support

5.32

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

Failure to set the support

Trouble shooting Failure to operate the tip function Possible Cause The isolating valve for pressure supply at the manifold pipe of the support is closed.

Check Required Open isolating valve.

Feed line must be open to allow pressure to the support.

Support canopy is trapped by adjacent supports

Check the support is not ‘iron-bound’ and if necessary, operate or lower adjacent supports to free

Support canopy is trapped by adjacent side seals

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

System pressure is too low for operation

Check pumps are ‘ON’ Check all ‘shut-off’ valves are ‘OPEN’ Check pressure delivered by pumps is correct

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Stabilising cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

Possible Cause The isolating valve for pressure supply at the manifold pipe of the support is closed.

Check Required Open isolating valve.

Feed line must be open to allow pressure to the support.

Support canopy is trapped by adjacent supports

Check the support is not ‘iron-bound’ and if necessary, operate or lower adjacent supports to free

Support canopy is trapped by adjacent side seals

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

System pressure is too low for operation

Check pumps are ‘ON’ Check all ‘shut-off’ valves are ‘OPEN’ Check pressure delivered by pumps is correct

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Stabilising cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

DBT GmbH, Lünen 2002

E

Failure to operate the tip up function

Failure to operate the tip down function

Doc. no.: 7420 066 000 BA 00

VLVU / 02

5.33

Fault Finding on Shield Support Hydraulic System Failure to operate baselift function

Possible Cause The isolating valve on the support is closed

Check Required Feed line must be open to allow pressure to the support

System pressure is too low for operation

Check pumps are ‘ON’ Check all ‘shut-off’ valves are ‘OPEN’ Check pressure delivered by pumps is correct

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Baselift cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

Shield is not lowered from roof

Lower support to attempt to operate baselift Wait until support is advanced and attempt function again.

Fault Finding on Shield Support Hydraulic System

It is possible that faults can occur on any of the components, normally in the form of a hydraulic by-pass, audible to the operator.

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

WARNING! Always take care when investigating a hydraulic leak to protect against high pressure fluid being forced into the skin. Wear gloves or use other protective equipment.

By-passing or Sticking 3/2-Way Valve or Pilot Valve The valve on the control module can usually be heard hissing and the control module or solenoid valve may be slightly warm due to the passage of fluid.

By-passing pilot valve No pilot valve drain on this valve bank. Therefore if pilot valve is by-passing then no indication (i.e. drain to atmosphere) It could be a problem with the 3/2-way or pilot valve Operate the electrical function or manual control buttons several times to attempt to release the problem.

When the function with the problem is operated, the noise should stop. It may be necessary to keep your finger on the button for several seconds before the noise stops.

J this indicates it is the 3/2-way valve or pilot valve J shut off the main isolation valve to the support and operate the

manual functions to depressurize the system

5.34

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

The hydraulic circuit of the supports contain a number of modules and components, identified in the schematic drawings, to be found in this chapter, see “operating the shield hydraulics”.

Fault Finding on Shield Support Hydraulic System J change the 3/2-way valve or pilot valve

By-passing pilot operated check valve (POCV) To be recognized by pressure drop at the pressure Operate the electrical function or manual control buttons several times to attempt to release the problem.

If the problem still exists: J this indicates it is a bypass J check/change the POCV

Locked pilot operated check valve (POCV) The support is operating correctly but the leg will not release.

The pressure is locked in the leg and must be released before the valve can be changed.

DBT GmbH, Lünen 2002

E

Operate the prop check valve on the leg to release pressure.

Internal by-pass in leg If an internal bypass in the leg is suspected, this procedure should be followed: J pump legs up to roof to set pressure J isolate the support at the main isolation handle J depressurize the control unit J remove the leg lower hose from the top of the leg and cap the

hose J turn on the isolation valve J operate the leg raise function from adjacent support

If there is an internal by-pass, fluid will flow out of the leg lower port of the leg.

Faulty yield valve The valve can usually be seen to be weeping and a check on the pressure gauge may reveal it is not holding pressure or if the unit is still weeping at setting pressure may indicate a problem.

There are a number of yield valves on the support, ie., legs (special rapid flow units), advancing, baselift and stabilizing cylinders.

The yield valves may be of different values for each cylinder or on each side of the cylinder. Observe the information given in the parts book.

The permissible pressure for the yield valves in use here is 462 bar and is indicated by a red and white color code.

Doc. no.: 7420 066 000 BA 00

VLVU / 02

5.35

Fault Finding on Shield Support Hydraulic System Faulty or blocked filter

DBT GmbH, Lünen 2002

E

If the operation of the shield is slow, and pressure is known to be normal operating pressure, or if contamination is known to have occurred in the hydraulic emulsion circuit, the filters need to be checked.

5.36

DBT - Shield 2200/4500-2x3176-1750

6

Technical data

Shield Support Variants

Technical Description This chapter contains important and useful information on the design and a technical description of the shield support and it’s main components.

Shield Support Variants Type 2200/4500-2x3176-1750 Face shield (variant 01), transition shield (variant 03) and gate end shields (variants 02, 04 and 05) The two-leg shield support units basically comprises the following main components: J base with lemniscatic links, shifting unit and

base lift cylinder J canopy with flipper J caving shield J side seal, moveable at right side only J hydraulic props J hydraulic equipment with hose lines and controls DBT GmbH, Lünen 2002

E

J side flipper (variant 05 only)

There will be delivered five different versions of the same type shield support: Tab. 3: Variants of shield support (1) variant

application

Order-no.

Weight in kg

01

face shield

7420 066 000 00 01

23,340

02

end shield, head gate

7420 066 000 00 02

23,410

03

transition shield, tail gate

7420 066 000 00 03

24,580

04

end shield, tail gate

7420 066 000 00 04

24,200

05

end shield, tail gate

7420 066 000 00 05

25,050

Tab. 4: Variants of shield support (2)

Doc. no.: 7420 066 000 BA 00

variant

application

shield no. special features

01

face shield

4 - 136

none

02

end shield, head gate

1-3

- shifting ram Ø 165 / 100 - canopy with slot holes for anchoring device

03

transition shield, tail gate

137

- canopy length 4690 - canopy with slot holes for anchoring device

04

end shield, tail gate

138, 139

- canopy length 4690 - shifting ram Ø 165 / 100 - canopy with slot holes for anchoring device

05

end shield, tail gate

140

- canopy length 4690 - shifting ram Ø 165 / 100 - canopy with slot holes for anchoring device - side flipper - 12 functions hydr. control block

VLVU / 02

6.3

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

The caving shield is a solid structure and connected to the base via the lemniscatic links.

The shield canopy transmits the support load of the two hydraulic props into the roof. Connection to the caving shield is via pins and a stabilizing cylinder. All the canopies are equipped with a flipper.

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

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

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

Main Subassemblies Tab. 5: Components of the shield support type 2200/4500-2x3176-1750 according to drawing no. 7420 066 000 00 ..

Item

6.4

Description

Variant

Order-no.

weight approx approx. in kg

01

02

03

04

05

1 Base

x

-

x

-

-

7420 066 300 00 01

7,310

2

-

x

-

x

x

7420 066 300 00 02

7,365

11 Canopy

x

-

-

-

-

7420 066 400 00 01

6,514

12

-

-

x

x

x

7420 066 400 00 02

7,204

13

-

x

-

-

-

7420 066 400 00 03

6,514

15 Side flipper

-

-

-

-

x

7420 066 450 00 00

825

21 Side seal

x

x

-

-

-

7420 066 700 00 01

1,560

22

-

-

x

x

x

7420 066 700 00 02

1,631

31 Caving shield

x

x

x

x

x

7420 066 800 00 00

4,160

41 Prop

x

x

x

x

x

8250 046 000 00 00

1,240

51 Stabilizing cyl.

x

x

x

x

x

8241 138 000 00 00

184

61 Hydr. control

x

x

x

x

-

8112 084 000 00 00

114

62

-

-

-

-

x

8112 091 000 00 00

122

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

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

Shield Support Variants Fig. 37: Components of the shield support, variants 01, 02, 03 and 04

11, 12 ,13

21, 22 W

31

51

H 41

DBT GmbH, Lünen 2002

E

61

1, 2 L Fig. 38: Components of the shield support, variant 05

15

W

L

31 51 12 H

22 41

62

2

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.5

Shield Support Variants Base with Lemniscatic Links and Central Shifting Unit Fig. 39: Base 32 35 17 33 55 41 61 50 51 36 40 60

7

11

1

19 18 30 3134

20

2 or 3

13

14

15

16

1 Lift cylinder 2 D.A ram cylinder ZE-150/100-960 (only at variants 01 and 03) DBT GmbH, Lünen 2002

E

3 D.A ram cylinder ZE-165/100-960 (only at variants 02, 04 and 05)

7 Shifting unit 11 Base frame 13 Lemniscatic link, R.H. front 14 Lemniscatic link, L.H. front 15 Lemniscatic link, R.H. rear 16 Lemniscatic link, L.H. rear 17 Lift cylinder bearing 18 Prop retainer, R.H. 19 Prop retainer, L.H. 20 Travel path 30 Holder others are fastening elements, see spare parts book

The solid base transmits the support load of the hydraulic props into the floor. The props are supported in an articulated manner in ball sockets welded to the base and secured by bolted prop retainers.

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

The type of base described is characterized by having the shifting unit and its guiding device arranged between the skids. The shifting unit is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reverse-mounted shifting unit, the force of the piston surface area is utilized to advance the support 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 base lift cylinder serves for raising the base out of a soft floor during support advance.

6.6

DBT - Shield 2200/4500-2x3176-1750

Shield Support Variants Shifting unit Fig. 40: Shifting unit 3

8

2

4

10

9

5

1

6

11

12

7

1 Relay bar 2 Clevis assembly for conveyor others: Fastening elements, see spare parts book

DBT GmbH, Lünen 2002

E

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

The D.A. ram cylinder is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reverse-mounted D.A. ram cylinder, the force of the piston surface area is utilized to advance the support 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 support advance.

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

Functional Description 1. Initial Position of Support The shifting cylinder of the support unit is retracted.

2. Advancing the Support During support 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 support.

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

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

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

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.7

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

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

The variants of the shield support units are provided with different performed canopies depending on their use. See tables 4 and 5 above. The canopy of the transition shield (variant 03) and the gate end shields (variant 04 and 05) is about 500 mm longer than the others. All end and transition shield canopies are equipped with slot holes to attache the anchoring device “canopy / canopy”.

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

Tab. 6: Variants of the Canopy Variant

6.8

In use at shield support variant

Features

Order-no.

01

02

03

04

05

01

x

-

-

-

-

total length: 4385 mm

7420 066 400 00 01

02

-

-

x

x

x

- total length: 4885 mm - slot holes to attache an anchoring device “canopy / canopy”

7420 066 400 00 02

03

-

x

-

-

-

- total length: 4385 mm, - slot holes to attach an anchoring device “canopy / canopy”

7420 066 400 00 03

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

The canopy of shield support variant 05 is equipped with an additional side flipper.

Shield Support Variants Fig. 41: Canopy for shield variant 01, face shield

6 9 5 7 8

3

1

13

12

11 10

DBT GmbH, Lünen 2002

E

1 Canopy M.B.F. 2 Flipper 5, 6, 9 Securing and fastening elements for the prop head 7, 8 Securing and fastening elements for the link cylinder 10 .. 13 Securing and fastening elements for the hinged link to the caving shield Fig. 42: Canopy for shield variant 03, 04 and 05

X

X

6 9 5 7 8

3

2

13

12

11

10

2 Canopy M.B.F. 3 Flipper 5, 6, 9 Securing and fastening elements for the prop head 7, 8 Securing and fastening elements for the link cylinder 10 .. 13 Securing and fastening elements for the hinged link to the caving shield X Slot holes to attache an anchorage device “canopy / canopy”

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.9

Shield Support Variants Fig. 43: Canopy for shield variant 02

X

X

8

7

5

6 9

3

4

13

12

1

9 , 11

1 Canopy M.B.F. 3 Flipper 5, 6, 9 Securing and fastening elements for the prop head 7, 8 Securing and fastening elements for the link cylinder 10 .. 13 Securing and fastening elements for the hinged link to the caving shield

11

10

DBT GmbH, Lünen 2002

E

X Slot holes to attache an anchorage device “canopy / canopy” Fig. 44: Flipper

1 Hydraulic cylinder 2 Flipper 3 Fork link 4 Fork 5 Connecting rod others: Fastening and securing elements

6,11

6.10

2

9 , 11

5

8,11

3

4

7,11

10,11

DBT - Shield 2200/4500-2x3176-1750

Shield Support 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.

The caving shield is equipped with an welded on side seal at the right side. The side seal at the left side is adjustable.

Fig. 45: Caving shield

DBT GmbH, Lünen 2002

E

1

1 Caving shield M.B.F. 2 Lemniscatic pin 3 Pin

3

6

2

5 4

4 Locking plate 5 Spring dowel sleeve 6 Staple

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.11

Shield Support Variants Side seal The following shown two variants of the side seal are applicable for the different canopies of the shield support units. They are of same design, but the canopy side seal differs in length depending on the length of the canopy .

Fig. 46: Side seal for shield variant 01 and 02 15 26 40 1 18 35 9 39

15 26 40 3518 9 39 1

36 20 39 35 18 1 22

8

14 13

1 Hydraulic cylinder 4 Side seal, canopy 6 Side seal, caving shield 8 Guide pin 9 Pin 10,11,13 Guide pin 14,16 Compression spring 15,17 Guide pin

38 23 16 10 37 21 9* 39* 16 10 21 37 37 2127 9* 39* 1114 25 37 25 37 38* 24* 37 25 38* 24* 24*38* 27 21 37 4 17 38* 24* 6

18 Bush others Fastening and securing elements see spare parts book

E

DBT GmbH, Lünen 2002

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

17

CAUTION! Remove securing elements and devices for transport, items 9, 24, 38, 39, at moveable side before putting into operation.

Fig. 47: Side seal for shield variant 03, 04 and 05 15 26 40 1 1835 9 39

15 26 4035 18 9 39 1

36 2039 35 18 1 22 8

14 13 38

1 Hydraulic cylinder 4 Side seal, canopy 6 Side seal, caving shield 8 Guide pin 9 Pin 10,11,13 Guide pin 14,16 Compression spring 15,17 Guide pin 18 Bush others Fastening and securing elements see spare parts book R. H. side moveable design as shown. L.H. side moveable design mirror inverted.

6.12

23 16 10 3721 9* 39* 24*38*27 2137

25 37 16 10 21 37 372127 9* 39* 11 14 5 38* 24 37 25 38* 24* 17 38 24

25 37

6 17

CAUTION! Remove securing elements and devices for transport, items 9, 24, 38, 39, at moveable side before putting into operation.

DBT - Shield 2200/4500-2x3176-1750

Shield Support Variants Side flipper Fig. 48: Side flipper for shield variant 05 only

1 Hydraulic cylinder 2 Side flipper 3 Console others: Fastening and securing elements.

DBT GmbH, Lünen 2002

E

see spare parts catalog.

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.13

Shield Support Variants Technical Data of Shield Support 2200

Extended height . . . . . . . . . . . . . . . . . . . . mm

4500

Hydraulic height adjustment of shield . . mm

2300

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm Ram stroke . . . . . . . . . . . . . . . . . . . . . . . . mm

865 960

Distance of prop centers (inclination) . . mm

870

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

3140 / 3940

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

1050

Width of canopy incl. side seals . . . . . . . mm

1650

Length of canopy . . . . . . . . . . . . . . . . . . . mm

4190 / 4690

Inclination of caving shield, support closed . . . . . . . . . . . . . . . . . . . . . . deg. support extended . . . . . . . . . . . . . . . . . . . deg.

13.1 55.8

Width of caving shield, incl. side seals . mm

1650

Width of base . . . . . . . . . . . . . . . . . . . . . . mm

1610

Total area of base . . . . . . . . . . . . . . . . . . . cm2

34022

Support 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

4000 5016 7357

Specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . mm 4000 a) at 320 bar setting pressure . . . . . . . . kN/m2 621 b) at 410 bar yield pressure (distance canopy tip to face low / high) . kN/m2 797 / 908

6.14

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

Closed height . . . . . . . . . . . . . . . . . . . . . . mm

E

applicable to face shield and transition shield.

Hydraulic System Hydraulic System The following part gives an overview about the hydraulic installed at the shield units. For additional information please refer to the spare parts book. differences in design

The hydraulic at all variants of the shield support except of variant 05 is the same. Because of the additional side flipper, the hydraulic of shield variant 05 is provided with two extra functions and a 12 function control valve block.

normal and exceptional operation

DBT GmbH, Lünen 2002

E

Tab. 7: Hydraulics of shield support 7420 066 000 00 0x Shield variant

Application

01

face shield

02

end shield, head gate

03

transition shield, tail gate

04

end shield, tail gate

05

end shield, tail gate

Hydraulic Order-no.

8112 084 000 00 00

8112 091 000 00 00

Remark

10 fu functions ctio s co control trol valve block

12 functions control valve block because of additional side flipper

During normal operation the functions of the shield support units are to be operated by use of the PanzermaticÒ control panel only.

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

WARNING! You must not operate the valve functions by pressing the elastic cap at the solenoid during normal operation. Doing this may lead to unexpected, dangerous situations and accidents because of interlocked functions may be bypassed or kept out of function.

Direct operation by pressing the elastic cap is only allowed under certain conditions, e.g. for repair and maintenance. The special safety precautions must be observed strictly.

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.15

Hydraulic System Shield Hydraulics Hydraulic of the shield support variants 01, 02, 03 and 04 Fig. 49: Hydraulic of the shield support variants 01, 02, 03 and 04 view “B”

4 4

B A

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

1 (17) view “A”

6

9

7

8

6

16

2(12)

(enlarged view)

3

6.16

10

15

10

5

14 2 10 5 13

DBT - Shield 2200/4500-2x3176-1750

E

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar DBT GmbH, Lünen 2002

6 6

6 6 11

Hydraulic System

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar

P

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm

R

9 Block ball valve, NW10 10 Block ball valve, NW20

working pressure 315 bar

Fig. 50: Hydraulic Flow Plan of shield support variants 01, 02 ,03 and 04, overview Please refer also to the spare parts book.

11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe

DBT GmbH, Lünen 2002

E

16 Block ball valve 17 Accumulator cartridge Z1 Prop Z2 D.A ram

Z7

Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder

Z6

Z5

Z1

Z1

Z2 Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract

Doc. no.: 7420 066 000 BA 00

Z4

Z3

VLVU / 02

6.17

Hydraulic System Hydraulic of the shield support variant 05 Fig. 51: Hydraulic of the shield support variant 05 view “B”

6 Pressure relief valve, 462 bar 7 Check valve 8 Filter 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines 14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge

view “A” (enlarged view)

6.18

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

A

B

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar

E

(enlarged view)

Hydraulic System Fig. 52: Hydraulic Flow Plan of shield support variant 05, overview Please refer also to the spare parts book.

1 Control valve block 2 Prop check valve 3 Check valve 4 Piloted check valve 5 Pressure relief valve, 462 bar 6 Pressure relief valve, 462 bar 7 Check valve 8 Filter, 40 mm 9 Block ball valve, NW10 10 Block ball valve, NW20 11 Piloted check valve 12 Pressure gauge 13 Hose lines

DBT GmbH, Lünen 2002

E

14 Retainer and accessories 15 Manifold pipe 16 Block ball valve 17 Accumulator cartridge Z1 Prop Z2 D.A ram Z3 Stabilizing cylinder Z4 Aligning cylinder Z5 Lift cylinder Z6 Flipper cylinder Z7 Side flipper cylinder

Control valve block functions: 1 link cylinder, extend 2 link cylinder, retract 3 props, extend 4 aligning cylinders retract / extend 5 props, retract 6 lift cylinder, extend 7 advance shield 8 push conveyor 9 flipper cylinder, extend 10 flipper cylinder, retract 11 side flipper cylinder, retract 12 side flipper cylinder, extend

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.19

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

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

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

The technical data of the hydraulic prop are to be found in section “Technical Data of Hydraulic Cylinders”.

Fig. 53: Double telescopic prop type SD 3600/2 retracted 1595 extended 3865

stroke, lower stage 1170 stroke, upper stage 1100 38

DBT GmbH, Lünen 2002

E

39 40

29 30 31 32 33 34 24 25 23 22

1

2

21

26

27 28 35 36

4

3 37

1 Prop base 2 Piston pipe 3 Bottom valve 21 Piston rod see also spare parts book

WARNING! Never close the connections for lowering double-acting props pressure-tight. Risk of serious bodily injuries caused by unexpected break down of hydraulic components.

Irregular pressure build up, up to several times of the setting pressure, will occur if the connections for lowering double-acting props will be closed pressure tight.

Observe the warning plate at the cylinder surface.

6.20

DBT - Shield 2200/4500-2x3176-1750

Hydraulic System Operating props 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. a) Center Prop Extended Only

load acceptance (resistance)

Load is transmitted mechanically from the canopy to the inner prop via the prop head and, then, to the valve housing installed in the center prop. 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; it is important to note, however, that this yield of the prop will occur without a decrease in the rated prop resistance. b) Center Prop and Inner Prop Extended

DBT GmbH, Lünen 2002

E

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. If load in excess of the rated load is applied, the center prop will gradually lower, as fluid escapes through the pressure relief valve. Just before the piston of the center prop reaches its lowest position, the tappet of the check valve strikes against the bottom of the outer prop and the check valve opens. As fluid escapes now from the piston surface area of the inner prop through the check valve, the fluid will raise the piston of the center prop and the check valve closes again. This process is repeated several times until the entire stroke has been used up. lowering

Doc. no.: 7420 066 000 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.

VLVU / 02

6.21

Hydraulic System Hydraulic Cylinder, double and single acting Design

The following figure shows the main components of a hydraulic cylinder Fig. 54:

Hydraulic cylinder, example main components

Type a)

2

1

3

5

4

Type b)

2

3

1

4

6

DBT GmbH, Lünen 2002

E

Type a): Connection at the outer cylinder Type b): Connection at the piston rod 1Outer cylinder 2Cylinder bottom 3Piston rod 4Guide bush 5Connection 6Connection

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).

NOTICE! When the piston rod is being extended no excess pressure must build up in the annulus.

WARNING! Never block the port to the annulus of a cylinder.

Risk of serious bodily injuries caused by unexpected break down of hydraulic components.

Irregular pressure build up, up to several times of the setting pressure, will occur if the port to the annulus of a cylinder will be closed pressure tight.

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.

6.22

DBT - Shield 2200/4500-2x3176-1750

Hydraulic System Shifting cylinder Fig. 55: Shifting cylinder

Types of shifting cylinders in use at the different shield variants: Fig. 56: Shifting cylinder type ZE-150/100-960-SC-W-CR in use at the shield variants 01 and 03

31 30

21 2 1

22 28 33 27 46 35 41 29

DBT GmbH, Lünen 2002

E

24 3 48 32 25 34

26 47

stroke 960

373623

4038 39

retracted 1299, extended 2259

1 cylinder tube 2 reed rod 21 piston rod

23 piston 25 toric magnet please refer also to the spare parts book

Fig. 57: Shifting cylinder type ZE-165/100-960-SC-W-CR in use at the shield variants 02, 04 and 05

7 27 3 8 9 11 12 13 14 10 6 15 16

1 2

17 18 19 5 20 21 22 26 23 24 25 4

stroke 960 retracted 1299, extended 2259

1 cylinder tube 2 reed rod 4 piston rod

Doc. no.: 7420 066 000 BA 00

6 piston 10 toric magnet please refer also to the spare parts book

VLVU / 02

6.23

Hydraulic System Technical Data of Hydraulic Cylinders Type SD 3600/2, drawing no. 8250 046 000 00 00 Prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1595

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

3865

Hydraulic stroke . . . . . . . . . . . . . . . . . . . . mm

2270

Piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

320 / 230

Piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

295 / 210

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

804.2 / 415.5

Ring surface area . . . . . . . . . . . . . . . . . . . cm2

120.8 / 69.1

Prop force at 315 bar setting pressure . . . . . . . . . . . . . . . . . . . . kN

2533

Prop force at 462 bar yield pressure . . . . . . . . . . . . . . . . . . . . . . kN

3715

Retracting force at 315 bar . . . . . . . . . . . kN

380

Shifting ram double acting, el. connection, reverse mounted

Shifting ram double acting, el. connection, reverse mounted

6.24

Drawing No. 8241 148 000 00 00, equipped with reed contact rod, in use only at the shield variants 01 and 03 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 / 462 bar . . . . . . . . . . . . . . . . . . . . . . . kN

309 / 453

Drawing No. 8241 149 000 00 00, equipped with reed contact rod, in use only at shield variants 02, 04 and 05 Equipped with distance bush at the piston side Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

960

Piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

100

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

213.8

Ring surface area . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust at 315 bar . . . . . . . . . . . . . . . . . . . kN

673

Pulling force at 315 / 462 bar . . . . . . . . . . . . . . . . . . . . . . . kN

426 / 625

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

Double telescopic prop, doubleacting - 2 stages

Hydraulic System Stabilizing cylinder, double acting

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

520

Piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

180

Piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

125

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

254.5

Ring surface area . . . . . . . . . . . . . . . . . . . cm2

131.8

Thrust at 315 / 462 bar . . . . . . . . . . . . . . kN

801 / 1175

Pulling force at 315 / 462 bar . . . . . . . . . kN

415 / 608

Drawing No. 8241 147 000 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 /---

DBT GmbH, Lünen 2002

E

Base lift cylinder, double acting

Drawing No. 8241 138 000 00 00

Side seal cylinder, double acting

Flipper cylinder, double acting

Doc. no.: 7420 066 000 BA 00

Drawing No. 9571 191 100 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 / 462 bar . . . . . . . . . kN

36 / 53

Drawing No. 8241 142 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

485

Piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

125

Piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

80

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

122.7

Ring surface area . . . . . . . . . . . . . . . . . . . cm2

72.5

Thrust at 315 / --- bar . . . . . . . . . . . . . . . . kN

389 / 571

Pulling force at 315 / 462 bar . . . . . . . . . kN

228 / 335

VLVU / 02

6.25

Hydraulic System 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 / --- bar . . . . . . . . . . . . . . . . kN

200 / 293

Pulling force at 315 / 462 bar . . . . . . . . . kN

111 / ---

DBT GmbH, Lünen 2002

E

Side flipper cylinder, double acting

6.26

DBT - Shield 2200/4500-2x3176-1750

Hydraulic System Pressure Relief Valves Pressure relief valves protect the hydraulic equipment (e.g. props or cylinders) connected with them from overload. When the opening pressure is reached, pressure fluid is discharged to atmosphere.

For the type of valve used please see the following table, the hydraulic flow plan or the spare parts book.

Tab. 8: Pressure relief valves, use of different types Application

Type

Pre-setting in bar

Order-no.

general use except of props

pre-loaded by pressure spring

462

7337 493 462 00 00

only at props

pre-loaded by gas pressure

462

7337 611 462 00 00

CAUTION! The pressure setting must not be changed.

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

DBT GmbH, Lünen 2002

E

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

The pressure to which a valve is preset is stamped on. Furthermore, pressure relief valves are painted in different colors to identify the different pressure ranges.

Color Identification of Pressure Relief Valves

Doc. no.: 7420 066 000 BA 00

Color

Pressure range (bar)

black

0 - 49

black-and-white

50 - 99

brown

100 - 149

brown-and-white

150 - 199

green

200 - 249

green-and-white

250 - 299

blue

300 - 349

blue-and-white

350 - 399

red

400 - 449

red-and-white

450 - 499

yellow

500 - 549

yellow-and-white

550 - 599

orange

600 - 649

orange-and-white

650 - 699

VLVU / 02

6.27

Electro-Hydraulic Control System Electro-Hydraulic Control System Fig. 58: Control valve block, 10 functions

1

4

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

2 3

DBT GmbH, Lünen 2002

E

Fig. 59: Control valve block, 12 functions

1

4

2 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

3

WARNING! During normal operation you must not operate the valve functions by pressing the elastic cap at the solenoid. Doing this may lead to unexpected, dangerous situations and accidents because of interlocked functions may be bypassed or kept out of function.

Direct operation by pressing the elastic cap is only allowed under certain conditions, e.g. for repair and maintenance. The special safety precautions must be observed strictly.

6.28

DBT - Shield 2200/4500-2x3176-1750

Electro-Hydraulic Control System PANZERMATIC® PM-4/A NOTICE! How to operate the PANZERMATICÒ control unit is not subject of this manual. See separate operating instructions.

Fig. 60: PanzermaticÒ PM-4 applicable for shield support variants 01, 02, 03 and 04 1

3

5

DBT GmbH, Lünen 2002

E

6

1 Control unit 3 Solenoid driver 5 Pressure sensor 6 Infrared receiver

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.29

Electro-Hydraulic Control System Fig. 61: PanzermaticÒ PM-4 applicable for shield support variant 05 1

3

5

DBT GmbH, Lünen 2002

E

6

1 Control unit 3 Solenoid driver 5 Pressure sensor 6 Infrared receiver

6.30

DBT - Shield 2200/4500-2x3176-1750

Accessories Accessories Anchoring device canopy / canopy The anchoring device canopy / canopy according to drawing number 7420 066 470 00 00 is only applicable for the following listed shield support variants: Tab. 9: Anchoring device canopy / canopy order no. 7420 066 470 00 00, suitable shield supports Application of shield support

Order-no.

end shield, head gate

7420 066 000 00 02

transition shield, tail gate

7420 066 000 00 03

end shield, tail gate

7420 066 000 00 04

end shield, tail gate

7420 066 000 00 05

DBT GmbH, Lünen 2002

E

Fig. 62: Anchoring device canopy / canopy

27

28

5 26

1 Hydraulic cylinder 5 chain shackle 6 chain connector 10 Anchoring bracket 15, 18, 19 Pin

Doc. no.: 7420 066 000 BA 00

VLVU / 02

19

24 10

6

1

25 16

17

15 18

16, 17 Universal joint 24 Chain 29 Control unit others Fastening and securing elements

6.31

Accessories Fig. 63: Hydraulic control for anchoring 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 5 Plug-in reducer

6.32

7, 8 Staple 10 Bolt 13, 14, 15 Hose

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

E

5, 7, 8

15

13

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

DBT GmbH, Lünen 2002

E

a1 µ 13 ° at M = 2200 mm , articulation limited by the hinged joint between canopy and caving shield.

a2 µ 10° at M = 4500 mm, angle a2 measured with retracted stabilizing cylinder

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

Doc. no.: 7420 066 000 BA 00

VLVU / 02

6.33

Angles of Inclination of the Canopy 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 barely inflammable hydraulic fluids of Group HFA. Approval list (Part 1) Recommended concentration for use with process water according to the chemical composition.

Test water Type: X

Test water Type: Y

Test water Type: Z

ARAL Lubricants

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

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 3 A

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

5%

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1,5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1,5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

not tested

Quintolubric 814-01

not tested

5%

not tested

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

Fuchs/Century

GS 460 N

not tested

1,5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1,5 %

Hydrocor TS 100 N

not tested

2%

not tested

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTh Theunissen i

6.34

Product designation

DBT - Shield 2200/4500-2x3176-1750

E

Manufacturer

DBT GmbH, Lünen 2002

Tab. 10:

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

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

Storage of the Hydraulic Fluid Concentrate Do not store the hydraulic fluid at temperatures below 5° C. Avoid excessive heating of the fluids. Protect the concentrate against direct exposure to sunlight.

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

Preconditions for Use Underground The approval of the responsible Mines Inspectorate is required for use underground.

The approval presupposes an examination by the RW TÜV/Essen and of the Hygiene Institute of the Ruhr/Gelsenkirchen (Germany).

DBT GmbH, Lünen 2002

E

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.

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 contain no 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.

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Angles of Inclination of the Canopy Tab. 11:

Chemical Composition of the Test Water Samples Used Test water Type: X (NCB 18 to Luxemburger report)

Test water Type: Y (DIN 24320 resp.

Luxemburger report)

Test water Type: Z (NCB 19 to Luxemburger 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

Sulphate:

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 Luxemburger Report.

Emulsion Values pH value: 7.5 - 9.5 Permissible bacteria in the emulsion: < 105 Kol/ml The maximum permissible temperature is max. 55° C; normally 45°C should not be exceeded. A higher working temperature will reduce the consistency of the emulsion and shorten the service life of the seal material.

Checking of the Emulsion Values At least once per week, check: J the pH value.

J the concentration.

– Test method: by agreement with the concentrate manufacturer J the microbial load.

– Test method: dip slides IMPORTANT! Further information is contained in DIN 24320.

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DBT GmbH, Lünen 2002

If the process water available does not have the demanded quality, the special approval of DBT must be obtained before use.

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** °d = degree German hardness (is no longer permissible in accordance with the applicable legal regulations. The information given is intended only for orientation.

Recommended Lubricating Greases and Pastes Recommended Lubricating Greases and Pastes Lubricating Greases General Properties

Base:

Lithium soap

NLGI class:

2

Penetration:

265 to 295 (0.1 mm)

Behavior in the presence of water: practically non-soluble in water Temperature of application : Lubricating greases for general application

-20 to +120

C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly.

Tab. 12:

Lubricating greases for general application Type

ARAL

Aralub HL 2

BP

BP Energrease LS 2

ESSO

BEACON 2

MOBIL

MOBILUX 2

SHELL

Shell Alvania Grease R 2

TEXACO

MULTIFAK 20

CALYPSOL

Multipurpose grease 20

DBT GmbH, Lünen 2002

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Supplier

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating grease A 1 according to the DBT works standard EWN 7068 is: Calypsol multipurpose grease 20 Lubricating greases for application under high pressure

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 13:

Lubricating greases containing additives

Supplier

Type

ARAL

Aralub HLP 2

BP

BP Energrease LS-EP 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

SHELL

Shell Alvania E.P. Grease 2

TEXACO

MULTIFAK EP 2

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating grease A 2 according to the DBT works standard EWN 7068 is: Shell Alvania E.P. Grease 2

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Recommended Lubricating Greases and Pastes IMPORTANT! The greases listed in the same table, 1 or 2, can be mixed.

Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases having the same saponification base but different origins.

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

Lubricating Pastes Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Tab. 14:

Lubricating pastes free from molybdenum disulfide Type

Base

NLGI class

gleitmolybdän

gleitmo 805 1)

Li

2

Klüber Lubrication

Altemp Q NB 50 2)

Ba-complex

2/3

Liqui Moly

LM 841 1)

Li

2

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

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

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän ”gleitmo 805”

Separating agents and lubricants with organic lubricating media Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water: non-soluble in water Temperature of application: -34 to +120 C When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent and lubricant 785 IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

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Supplier

Tightening Torques Tightening Torques Screws with Metric Coarse Thread DIN 13 Recommended Tightening Torques at mtotal = 0.14

DBT GmbH, Lünen 2002

E

Tab. 15:

Thread 1)

Pitch

Tightening torque 4)

(mm)

(mm)

MA (Nm)

d

P

8.8

10.9

12.9

M8

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

DM 27 2)

3

580

-

-

M 30

3,5

1310

1845

2215

M 32 3)

2

-

1450

-

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

1) Dimensions in brackets in exceptional cases only 2) According to works standard (EWN 6110), February 1985 edition 3) Only for expansion screws having a reduced shaft cross-section of 24.2 mm.

4) The tightening torques comply with EWN 6003 works standard.

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

Doc. no.: 7420 066 000 BA 00

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6.39

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DBT GmbH, Lünen 2002

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DBT - Shield 2200/4500-2x3176-1750

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 directly.

Service address Germany

DBT Deutsche Bergbau-Technik GmbH Mail:

DBT Deutsche Bergbau-Technik Verkauf / Service Industriestraße 1 44534 Lünen GERMANY

DBT GmbH, Lünen 2002

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

China

DBT Langfang Mail:

Langfang Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone 065001 Hebei Province P.R.

Phone: + 86 / 31 66 08 68 40 Fax: + 86 / 31 66 08 68 45

Doc. no.: 7420 066 000 BA 00

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7.3

Our Service Referenced Standards and Guidelines

7.4

Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery

DIN EN 982

Safety of machinerySafety requirements for fluid power systems and their components

DIN EN 60445

Identification of Connections

DIN 2000

Central drinking water supply Guidelines regarding requirements for drinking water, planing, construction operation and maintenance of plants

DIN 6789

Documentation System

DIN 8418

Information for Users

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self-Advancing Supports

DIN 24320

Fire Resistant Hydraulic Fluids

DIN 24343

Hydraulic fluid power systems and components; list for attendance inspection of hydraulic equipments

DIN 24346

Hydraulic Systems; Design Principles

EWN 6003

Pretensioning forces and tightening torques

EWN 7068

Lubricants

EWN 7069

Nonmetallic surface protection

ISO 4406

Hydraulic fluid power - fluids method for coding the level of contamination by solid particles

DBT - Shield 2200/4500-2x3176-1750

DBT GmbH, Lünen 2002

Designation

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