CAT Roof Support Shield support 11432540-2x3973-1750 Operation Manual

BI622249

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI622249

Operating Manual Shield support 1143/2540-2x3973-1750 Doc. no.: 7420 214 000 BA 00

Bucyrus Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

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Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus declines any liability for direct or indirect consequences of printing errors.

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

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Contents

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

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

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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

3.3

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3 3.4

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

3.5

Load units; dimensions and weights . . . . . . . . . . . . . . . . . .

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.8

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

4.3

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

4.3

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

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

4.4 4.7

Requirements for the face hydraulic system . . . . . . . .

4.8

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

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

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

4.9 4.11

Anticorrosion protection of hydraulic components . 4.11

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

5.3

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

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

5.3 5.6

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

5.9

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

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

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

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

Retracting or extending the lift cylinder . . . . . . . . . . . . . . . .

Bleeder fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing canopy spray nozzles . . . . . . . . . . . . . . . . . . . . . . .

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

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

Operation and functions of the electrohydraulic control unit

5.15 5.17 5.18 5.23 5.29 5.30 5.32 5.33 5.34 5.36 5.40 5.41 5.42 5.42 5.42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

5.43 5.43 5.46 5.46 5.47 5.47 5.47

6. Technical data Shield description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

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

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

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

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

6.4 6.5 6.6 6.10 6.12 6.14

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-stage telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data, hydraulic cylinders . . . . . . . . . . . . . . . . . . .

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

6.15 6.17 6.19 6.21 6.23

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

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

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

Every six months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular, scheduled damage assessment . . . . . . . . . . . . . .

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40

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Contents Angles of inclination of the canopy . . . . . . . . . . . . . . . . 6.25 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quality of the process water . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.26 6.28 6.30

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.32

7. For your information 7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

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

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

7.6 7.6

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

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Contents

Shield support 1143/2540-2x3973-1750

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1

About this manual

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Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols used in it.

Before starting work applicable operating manual

shield type

Using an operating manual that is not written for the shield support at hand can result in a safety hazard for yourself and others.

Ensure that the data on the shield agrees with the data given in the operating manual.

This operating manual belongs to the: shield support 1143/2540-2x3973-1750 * ID no.:

7420 214 000 00 01

and is only permitted to be used for shields of this type!

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The operating manual must be accessible at all times to all persons working on or with the shield.

There should, if possible, always be an operating manual for the shield available at the place of operation. new operating manual

Send for a new operating manual immediately if the present operating 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.

All persons working on the face, at the edge of the face or at the entry must read this operating manual.

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

Supervisory personnel who: J initiate the activities named above and/or J supervise the activities named above.

*

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The shield support is referred to as the shield in the following text.

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1.3

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Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work economically and safely with our product. It contains important information on all the activities related to the shield support.

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

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our Service Department. Our service address can be found in chapter 7 “For your information”.

safety

Pay special attention to chapter 2, “Your safety”. This chapter contains important information indicating possible hazards.

Observe this information and follow the procedural instructions.

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

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

Notice!

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

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. It will help you carry out your work faster and, more importantly, more safely.

1.4

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Danger!

Points in the text marked with this symbol point out immediately impending danger. Possible consequences are very serious injury or even death.

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Try to memorize the symbols and their meanings.

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2

Your safety

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Personnel

Your safety This chapter provides important information for your safety.

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

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

You and others can nevertheless be exposed to dangerous situations, e.g., as a result of environmental influences, machine damage or operator errors.

Do not make any modifications or carry out conversions which could impair the safety of the shield support. All modifications and conversions must be approved by Bucyrus.

Use only original replacement parts from Bucyrus. Note that use of parts from other manufacturers will void the guarantee.

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

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Observe the safety and accident prevention regulations: J of the mine, J of the mines inspectorate and J of mining supervisory authorities. additional operating manuals

Please also read the operating manuals of the components required for operation, e.g. gearboxes, E-motors, etc. carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation The shield support may be operated only by trained personnel. training

The shield support may only be operated by qualified personnel who can provide proof of having been trained on the control system installed.

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

They must possess and furnish proof of adequate familiarity with the J mechanical system, J hydraulic system, and J control technology.

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Personnel Installation and repairs As a fundamental rule, installation and repair work may only be carried out by personnel who have been trained adequately for these particular requirements.

Installation and repair work on: J safety components (pressure relief valves, extinguishers, etc.), J electrical systems (control systems, signaling devices, etc.)

J the hydraulic system,

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may only be carried out by Bucyrus service engineers or by specially trained personnel of the mining company.

2.4

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

Use the shield only as intended.

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

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

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– retracting J forming a thrust bearing for:

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

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

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

shield J setting of the canopy in roof falls.

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

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

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Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

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

EMERGENCY STOP

support lock-out switch

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

- Only applies for version with the electrohydraulic shield control system: Actuate the support lock-out switch (repair switch) before: J maintenance work, J inspection work, J repair work, J and during prolonged presence in the shield.

moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: J bases and relay bar assemblies, J canopies, J lemniscatic links, J side seals, J front cantilevers, J hydraulic props and cylinders, J steering devices.

automatic mode

2.6

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals sent by the electronic control unit in the shield currently operated.

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signaling systems and safety equipment

Maintain the lighting systems in a functional condition.

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lighting system

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

Never stand under unsecured or suspended loads.

Observe the specified storage periods and the storage instructions.

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

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

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

Make sure the transport safety devices have been installed properly. In particular, ensure that the following are secured for transport: J side seals,

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J flippers, J relay bars (both face side and gobside). transporting

Connect the means of attachment only at the lifting points provided for this purpose. Observe the different load limits of the lifting points. Also observe the instructions for transport given on the replacement part drawings which are included in the replacement parts catalog. Non-standard transport units are shown in special drawings, which are included in the appendix of the operating manual, if required.

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

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

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

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

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

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

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

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

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

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

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Fig. 1:

transport safety devices

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

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

travel way

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

Any devices added to the shield later, such as steering devices, must not reduce the minimum travel way. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travel way is maintained.

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Safety instructions Operation shield control

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield units may move automatically. Therefore, it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the shield unit currently operated.

Check whether all protective devices are present on the shield and capable of functioning, see also chapter 6 “Technical data”.

You may only operate the shield control system if you have extensive knowledge of the control elements and their functions.

You must have been trained on the respective control and know the contents of the respective operating manual for that control.

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

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

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

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

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

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

Keep the floor as clean as possible. Keep the mine floor free of debris. This way you will be able to extend the relay bar assembly without obstacles and to advance the conveyor without problems.

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

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

Hydraulic anchorages must always be charged to the specified working pressure since this is the only way sufficient anchorage between the support and conveyor is ensured.

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

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

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Safety instructions shield alignment

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

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

Early alignment prevents: J getting under the canopy of the adjacent shield, J canting of the shields, J slipping of the shields, J delays in supporting the newly mined roof.

roof falls

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

Never set the tip of the canopy into a roof fall so that J the maximum admissible angle of inclination of the canopy is

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

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

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

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

retracting the conveyor

If possible, pull the conveyor back by operating the respective functions of the electronic shield control system. If this isn't possible, do as specified in the applicable work instructions of the mine.

Secure all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the points of attachment intended for that purpose.

Never attach loads to hydraulic cylinders or to their points of attachment.

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

Check the setting pressure again. Do not under any circumstances loosen the canopy from the roof; it must be in place the entire length.

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tion,

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

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

Check that the points of attachment are undamaged before attaching a load.

J lifting tackle of adequate load-carrying capacity.

Maintenance Make sure that all safety and protective equipment of the shield support units are complete and functional. If the safety and protective equipment is included in the Bucyrus scope of delivery, refer to chapter 6, “Technical data”, for its location.

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

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

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

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

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

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

Please refer to the replacement parts catalog provided for the equipment for the order nos. for the required replacement parts.

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

Any modifications carried out without authorization invalidate the Bucyrus declaration of conformity and a new conformity test will be required.

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

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

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

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

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

pressure or mechanical stress.

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

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

Hydraulic system handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

protective devices - hydraulic system

Note that when dismantling protective devices that include hydraulic components, those components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repair

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

pressure relief valves

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

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

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

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

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

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Safety instructions Make sure no dirt enters the hydraulics system during repair work.

Dirt in the hydraulic system can cause serious damage to the whole system. Backflush the hydraulic lines thoroughly before installing them.

Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the coupling socket to check whether the line is pressurized. The line is still under pressure if the hose is difficult to turn or does not turn at all. Make sure the line is depressurized.

Secure the plug connectors of the hydraulic elements with the proper staples only. Always fasten the staples completely with both sides.

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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Observe the date of manufacture stamped on the hose fitting of the hydraulic hose. Never use hydraulic hoses which are more than 2 years old, even if they show no visible signs of damage.

Fig. 2:

Example hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

Never try to hold a hydraulic hose that is thrashing about. Immediately depressurize the section in concern.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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Safety instructions laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying a hydraulic hose, twisted WRONG

J are not bent directly behind the connectors (distance minimum

1.5 x nominal diameter), Fig. 5:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

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Laying hydraulic hoses, crossing RIGHT

WRONG

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RIGHT

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

Insert 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, make sure they cannot be: J torn out J kinked, J crushed, J driven over J twisted (Fig.: 7).

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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Safety instructions

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3

Storage and transport

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Storage

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

Following the instructions and the manuals will increase the service life of the shield. You will be able to carry out transport work more safely and quickly.

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

Storage Storage of the equipment anticorrosion protection

Components with a temporary anticorrosion coating are protected for about six months.

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, replacement parts made out of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15C to 25C.

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moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, for example with tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs.

short-term storage

long-term storage

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

During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

An inspection must be conducted to determine whether the measures taken and the method of storage have prevented damage after a storage period of approximately two years.

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. Do not use these components if they have been stored for more than two years.

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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

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

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

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Water-bearing parts, such as the parts for the water spraying system of a shield, must be completely emptied, and possibly also filled with an antifreeze fluid if required.

*

3.4

HYDROCOR® CV 50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

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Transport Transport Load units; dimensions and weights It is imperative that you observe the transport sheets. It includes information on: J dimensions, J weight, J lifting points and J centers of gravity.

The load units are provided with suitable lifting points for transport and installation as far as technically possible.

Warning!

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

Falling components can cause serious injury and death.

Use only suitable load handling devices.

freezing temperature

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Before transport Before transporting the equipment at temperatures below freezing, all hydraulic components operated with by emulsion (HFAE and HFAS) must be completely drained and filled with a corrosion inhibitor (e.g. CV 50).

It is only permitted to transport equipment at temperatures of -21C to -40C if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

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

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

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

If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.

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Transport transport units

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

Tab. 1: Transport units

transport safety devices

Designation

Transport position

support unit complete

as for normal use

Remarks

For the purpose of ensuring safety during transport, the movable parts of each transport unit must be fastened such as to prevent their changing their position inadvertently, if required in addition to the standard securing devices, e.g. on side seals and flipper. The following transport safety devices are provided on the transport units: Tab. 2: Transport safety devices Part

Transport safety device

relay bar, faceside

transport rod chain

1 1

relay bar, gobside

chain

1

hydraulics

hydraulic ports not used are closed with protection caps or plugs

-

Caution!

If the assembled shield unit is to be transported, then the canopy and base must first be mechanically connected to each other using an additional transport safety device so that they cannot move apart. A wooden block is to be placed between the rear lemniscatic link and the caving shield in order to ensure that the transport height is attained.

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Caution!

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

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Quant.

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Transport Fig. 8:

Transport of shields as complete unit S1 H

So

Sy

Y

Sx L

S2 S3

S1

1300

S4

890

4303

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S3

S1

S2 S1 lifting eye, 2x on the caving shield, load-bearing capacity: 8 000 kg S2 slot hole, 2x on the coal face end of the canopy, load-bearing capacity: 15 000 kg S3 lifting eye, 2x on the gob side end of the base, load-bearing capacity: 8 000 kg S4 slot hole, 2x on the gob side end of the base, load-bearing capacity: 15 000 kg Y transport safety device between canopy and base e.g. turn buckle not included in the scope of delivery So center of gravity

Important!

For transportation use the four lifting eyes S1 and S3.

Tab. 3: Shield support 7420 214 000 00 01, dimensions and weights

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Order no.

Length L in mm

Width B in mm

HeightH in mm

Sx/Sy retract in mm

Weight approx in kg

7420 214 000 00 01

6 606

1 700

1 143

1 550/647

20 650

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Transport Transport safety device Transport safety device, relay bar assembly Fig. 9:

Relay bar assembly, gobside

1

3

1 chain 6x42 2 hex. head screw M 12x40-8.8

3 hex. nut M 12-8

Transport safety device, lifting cylinder Caution!

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

Fig. 10: Lifting cylinder with bracket folded in for transport

Z4 Z4

1

2

2 1

1 spring clip 2x 2 transport rod

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Z4 lifting cylinder

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Transport Supply hoses Fig. 11: Arrangement of the supply hoses

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

Shield transport Fig. 12: Shield in transport position

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Transport

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4

Installation

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Pre-assembly of the shield units

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

Warning!

When performing any work, observe the safety instructions given in this manual and also the special safety instructions and operating manuals provided by the mine management. Failure to comply can lead to most serious accidents which might even result in death.

Caution!

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

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Caution!

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

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

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

Installation of the shield units Caution!

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

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

Important!

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

identification for installation in the face

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

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Installation of the shield units shield number

The shield number is an identification feature. All shields are numbered consecutively. Firmly attached plaques showing the respective shield number are provided at the base skid.

Supply connections During installation, the individual shields can be supplied with pressure and operated using the socalled auxiliary supply line. The auxiliary supply line must be connected to ports a and b (fig. 14) Fig. 14: View on the auxiliary ports of the face shield b 23

a

c

a pressure line b return line c plug

23 bleeder fitting (detail see: fig.15)

Notice!

Connections a, b of the auxiliary supply must be sealed with plugs c during normal operation.

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Fig. 13: Shield number at the base, example

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Installation of the shield units When using the auxiliary supply line, the shield functions must be operated via an additional external PM4 control unit connected to the internal PM4 control unit by a cable (see separate operating manual for the PM4 control unit).

The ports for the auxiliary supply line are located at the L.H. side under the canopy (see fig. 14 and in chapter 5, Hydraulic flow plan, fig. 28).

Fig. 15: View on the auxiliary ports of the face shield

23

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a

23 bleeder fitting

a vented cap screw

When using the auxiliary supply line, ports P, R, and W (see fig. 16) of the manifold block must be closed by connecting the hoses which later provide the connection with the adjacent shield (as a rule, this is the as-supplied condition). Should it not be possible to connect the hoses to these ports the latter must be closed by plugs.

To interconnect the shields please proceed as follows:

. Close the high-pressure ball valves items 10, 12c, and 29d, (see fig. 16 and in chapter 5, Hydraulic flow plan, fig. 28).

. Remove all sealing plugs from ports a and b (see fig. 14) of the auxiliary supply line.

. Connect the auxiliary supply line with the pressure and return lines of the pump.

The high-pressure ball valves item 9 (see chapter 5, figs. 37 and 38) at the prop check valves must be open. The shield can now be operated via the external control unit.

. Move the shield to the desired position. . Operate the function ”advance conveyor” for a short time until the pressure hose is depressurized (shield support not yet connected to the conveyor).

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Installation of the shield units Warning!

Incorrect operation can cause pressure to build up in the return line (for example: closed return line). Such pressure has to be relieved via the bleeder fitting (item 23, see fig. 15) by turning in the vented cap screw. After pressure has been relieved turn the screw back as far as it will go.

Take care to make sure that all hoses are depressurized before you start loosening the connecting lines at the manifold block!

. Pressure-relieve the ports of the auxiliary supply line. . Remove the connecting lines of the auxiliary supply line and close the ports with the sealing plugs.

. Detach the three connecting lines P, R, and W from the manifold block and connect them with the adjacent shields.

Fig. 16: View on the manifold block of the face shield b

10

a

P

R

19 W

30 29d 10 high pressure ball valve DN 25 (to isolate pressure to shield) 12c high pressure ball valve DN 10 (to isolate canopy nozzle flushing function) 19 supply block 29d high pressure ball valve DN 10 (to isolate washdown hose

4.6

30 high pressure ball valve DN 20 (to isolate water spray system) a pressure line (auxiliary supply) b return line (auxiliary supply) P pressure line DN 40 R return line DN 50 W water line DN 50

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12c

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Installation of the shield units Fig. 17: View of the dual filter of the face shield

4 a

b 8

c

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4 shifting ram check valve 8 dual filter, backflush type

b side plate spray c lemniscate spray

a side plate spray

Coupling between the connections The hydraulic connectors are plug-type connectors according to DIN 20043. hydraulic system

A manifold supply block for the shield hydraulic system is located underneath the canopy and between the legs of each shield unit.

The manifold of adjacent shield units are connected with the use of three hose lines: a pressure line (DN 40), a return line (DN 50) and a water line (DN 50). See the hydraulic block diagram in chapter 6.

control unit

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

additional equipment

Provision is made on the shield units to allow the attachment of additional equipment which is not included in Bucyrus scope of supply, as for example: J lighting system, J two-way intercom system.

For information on the installation of the additional equipment, please refer to the pertinent operating manual of the respective manufacturer.

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

The hydraulic medium must meet the following conditions for all hydraulics components included in the Bucyrus scope of delivery: Contamination Class 18/14 pursuant to ISO 4406.

Pressure fluids in accordance with the section “Permissible media” in chapter 6 of this operating manual.

pressure, permissible

Nominal pressure: . . . . . . . . . . . 320 bar Tolerance range: . . . . . . . . . . . . . ± 10% of nominal pressure

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Caution!

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

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

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If the face hydraulic system is designed such that it is unstable or too weak, there could be a temporary pressure drop during operation.

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

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

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Commissioning Commissioning Warning!

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

Notice!

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

See chapter 3, section “Transport”.

To be observed prior to start-up Commissioning may only be carried out by trained and qualified personnel. If the support is being used for the first time, it is absolutely imperative that the commissioning be carried out under the direction of the Bucyrus installation service.

Please observe the following items: E

J Mechanical: Bucyrus Europe GmbH, Lünen 2009

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

. Position the symbol bar on the brackets of the electrohydraulic control unit so that the symbols are clearly legible.

. Check all mechanical connections on the shield units. . Check the plug-in connections on the relay bar assembly.

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

J Hydraulic system:

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

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

Danger!

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

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

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

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

1) Maximum possible plugging.

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

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

J Signaling and lighting systems, information plates:

Important!

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

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

J EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems function properly.

J Mining and conveying:

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

Warning!

Bent support canopies may not project into the mining area.

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ciently marked with signs. It is imperative that you observe the regulations of the responsible mines inspectorate.

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. Check whether the face area, especially the travel way, is suffi-

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Anticorrosion protection of hydraulic components How to put the support into operation Move the shield units to their original positions, i.e.: J shields and conveyors are aligned in a straight line, J the shields are aligned at right angles to the conveyor, J the shield canopies are aligned parallel to the floor.

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

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

Warning!

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

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

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

Bucyrus Europe GmbH, Lünen 2009

face.

. Check all functions of the shield control unit.

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

Anticorrosion protection of hydraulic components The Bucyrus hydraulic components are tested before delivery with an anticorrosion medium.

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

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5

Operation

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Requirements

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

Danger!

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

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Warning!

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

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

Requirements Operating conditions face crew

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

The face crew must be instructed to stop the face conveyor immediately if dangerous situations could arise due to large layers of coal and rock having fallen onto the conveyor. This also applies in the case of accumulations of debris.

face equipment

The face must be sufficiently illuminated.

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

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

conveyor overload

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

In the event that this breaking up cannot be accomplished to the extent required, the layers of coal and rock may not be transported until it is has been ensured that nobody will endangered as a result.

Any work on the face must be stopped until the transport of the rock and coal layers has been completed.

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Requirements travel way

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

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travel way: Width:

600 mm

Height: 400 mm If the support is used in countries other than the Federal Republic of Germany, the respective regulations applicable in those countries must be observed.

Debris or objects lying in the travel way must be removed immediately. This applies particularly for low seam heights.

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

roof support work

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

work in the mining area

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

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

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 flippers.

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

If the shield units are not equipped with a flipper, some other kind of protection must be applied to shield the mining area from the rest of the face, e.g. extra-high spill plates, wire mesh, nets or the like.

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

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

5.4

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

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

E

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

BI622249

Requirements repair work

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

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

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

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

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

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

conveyor steering device

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

Bucyrus Europe GmbH, Lünen 2009

E

water spraying system

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

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.5

BI622249

Requirements Safety requirements automatic mode

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

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

Press the “Support lock-out” switch if you have to be in the shield for a longer period of time.

operating the shield unit

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

Never stand in a shield unit which hasn't been set.

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

You may not lower or advance a shield unit if there is any person in the vicinity of the shield unit or in the shield unit.

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

Advancing should be started in the lower section in the case of inclined faces. The neighboring control offers the operator in the above-lying shield unit protection and allows the shield unit being pulled up to be monitored.

The props of the shield units must always be set until the setting pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as thrust bearings for conveyor steering devices.

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

5.6

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

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

E

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

BI622249

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

Bucyrus Europe GmbH, Lünen 2009

E

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

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

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

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

Take care to avoid incorrect operation of the shield control system.

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

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

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.7

BI622249

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

Shutoff valves must not be installed in the return lines.

To make sure the return lines can't be clamped shut, safety valves must be installed in the return line (see hydraulic layout, if prepared

by Bucyrus). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line.

The valves should be set to 25 bar sprayed in the atmosphere. damage, replacement parts

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

Bucyrus Europe GmbH, Lünen 2009

E

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

5.8

Shield support 1143/2540-2x3973-1750

BI622249

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

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

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

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

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

Bucyrus Europe GmbH, Lünen 2009

E

shield canopy position

The shield units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible. Within the framework of the maximum inclination and swivel angles specified on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly, if required by geological or operational conditions.

Caution!

Never exceed the permissible angle of inclination of the canopy.

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

Fig. 20: Shield support in normal position

0 M

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.9

BI622249

Operation of the shield support Caution!

Never extend or retract the stabilizing cylinders of the shield support completely!

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm.

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

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

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

Fig. 21: Shield support with extremely inclined shield canopy.

1

s1

s2 2 M

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

Caution!

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

This is especially true if the shield control system is equipped with an automatic positive setting function. Then there is a danger that under unfavorable conditions, for example a soft floor and possibly an additional inclination toward roof falls, the automatic positive setting function could lead to the stabilizing cylinders not having enough residual stroke or that they even are completely extended.

Therefore, in such or similar cases, move the support without automatic positive setting.

5.10

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

M

BI622249

Operation of the shield support Caution!

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

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

Caution!

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

Since angle changes in the ends of the shield canopies or base ends involve major height changes, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the mine floor and roof, or fill roof falls.

Bucyrus Europe GmbH, Lünen 2009

E

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

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

WRONG

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.11

BI622249

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

RIGHT

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

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

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

The minimum residual stroke required for lowering the shield unit can be maintained by: J keeping the longwall opening sufficiently large using the mining

equipment, J avoiding the accumulation of debris and fine coal on the floor, J removing accumulated piles of rock on the shield canopies.

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

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

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

5.12

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

range of adjustment of the support/ changing face thickness

E

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

BI622249

Operation of the shield support operating on inclines

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

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

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

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

Bucyrus Europe GmbH, Lünen 2009

E

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

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

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

For shield units which are equipped with a special hydraulic lifting device, the base frame is lifted out by actuating a valve, or automatically during advancing.

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

draulically by actively retracting a prop J Shield units with undivided base frames must be lifted and sup-

ported using standard mining methods.

Important!

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.13

BI622249

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

Warning!

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

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

Caution!

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

Observe the following safety regulations:

Observe the following instructions if a support has failed to advance: 1. Determine the cause. Check the following possibilities: J malfunction of the electronic controls, J external obstructions:

– Shield is wedged in between the neighboring shields.

– Tip of the canopy is stuck in the roof.

– Floor step or debris is blocking the base.

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

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

5.14

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

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

E

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

BI622249

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

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

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

Bucyrus Europe GmbH, Lünen 2009

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Tab. 4: Hydraulic components Item 1

Qty. 1

3 4 5

1 1 1

6 7 8

1 1 1

9

Description electrohydraulic control unit 12 functions accumulator cartridge shifting ram check valve twin check valve

Location center of canopy between props

supply block under the canopy, R.H. under the canopy, L.H.

tank line water supply

2

check valve, NW 25 in-line-filter, NW 20 Dual filter, backflushed automatically high-pressure ball valve DN 20

on each prop check valve

red handle

10

1

high-pressure ball valve DN 25

under the canopy at supply block

12

3

high-pressure ball valve DN 10

a) prop check valve, R.H.

red handle in the pressure line a) red handle, compensating valve b) red handle, for lifting cylinder c) for nozzle rinsing, red handle connected to return line

electrohydraulic control unit under the canopy, L.H. mounted to stabilizing cylinder

b) under the canopy behind prop L.H. c) at supply block 13

1

pressure relief valve, 80 bar

14 15

2 2

pressure relief valve, 420 bar pressure relief valve, 380 bar

16

2

pressure relief valve, 450 bar

17 19 20 21 22 23

3 1 1 1 1 1

spraying valve supply block hose lines water spray system retainers and accessories bleeder fitting

24

1

25

1

28 29

2 5

Remark at holder

under the canopy close to supply block on each leg a) for baselift cylinder, under the canopy, L.H. b) at the shifting ram, under the canopy, L.H. a) at the stabilizing cylinder (ring space) b) at the stabilizing cylinder (piston space) under the canopy unter the canopy between legs

at holder subassembly subassembly subassembly in the return line

under the canopy close to the supply block prop check valve NG 20 prop, on the coal face side on the left prop check valve NG 20 prop, on the coal face side on the left pressure gauge connection on each prop check valve test and pressure relieve port high-pressure ball valve DN 10 a) canopy and lemniscate sprays water circuit, blue handle b) water curtain c) side plate spray d) isolate wash down hose e) isolate spray valve before flushing canopy nozzles.

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.15

BI622249

Operation of the shield hydraulics Qty. 1 2 2 2 1 1 1

Description high-pressure ball valve DN 20 pressure gauge pressure sensor prop shifting ram stabilizing cylinder lift cylinder

Location shut-off of entire spray system on each prop check valve at prop check valve

Remark blue handle

Bucyrus Europe GmbH, Lünen 2009

E

Item 30 35 S1 Z1 Z2 Z3 Z4

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

5.16

Shield support 1143/2540-2x3973-1750

BI622249

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 9, 10, 12a, 12b, 29a, 29b, 29c, 29e, 30

The following ball valves are closed during normal operation: J 12c, 29d

Bucyrus Europe GmbH, Lünen 2009

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Tab. 5: HP ball valves Item

Color

9

red

HP ball valve DN 20

10

red

HP ball valve DN 25

12a

red

HP ball valve DN 10

12b

red

HP ball valve 10

To isolate pressure to shield To isolate the stabilizing cylinder/compensating valve connection (Z3) To isolate pressure to the lifting cylinder (Z4)

12c

red

HP ball valve DN 10

To isolate canopy nozzle flushing function.

29a

blue

HP ball valve DN 10

29b

blue

HP ball valve DN 10

29c

blue

HP ball valve DN 10

29d

blue

HP ball valve DN 10

29e

blue

HP ball valve DN 10

30

blue

HP ball valve DN 20

Designation

Function To isolate pressure to both props (leg cylinders)

To isolate canopy & lemniscate sprays.

To isolate water curtain sprays.

To isolate side plate sprays.

To isolate washdown hose.

To isolate water spray valve during flushing of canopy nozzles with high pressure.

To isolate water spray system.

Use During maintenance work on the prop and any possible disassembly During maintenance and repair work on the shield In order to deactivate the compensating function of the stabilizing cylinder (Z3) Used for holding the lifting cylinder in a certain position and for deactivating the lift function With ball valve 29e closed, open ball valve 12c to flush canopy spray nozzles with high pressure

For cleaning soiled components Close ball valve 29e, prior to opening ball valve 12c when flushing canopy spray nozzles with high pressure.

In order to isolate main water supply to water spray system.

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

open

closed

Through-flow for medium enabled

Doc. no.: 7420 214 000 BA 00

SVVI / 01

Through-flow for medium stopped

5.17

BI622249

Operation of the shield hydraulics Shield hydraulics Fig. 25: Shield hydraulics, arrangement key, see table 4 12c 10

23

7 6

22

14

9 28

35

35

25

9

24

28

14

View B

13

5.18

30 29

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

12a

BI622249

Operation of the shield hydraulics Fig. 26: Shield hydraulics, arrangement key, see table 4

Bucyrus Europe GmbH, Lünen 2009

E

21

19 29e

20 15a

3

12b

B

B 1 29a 29b

4

29c

15b 8

17 16b 16a 5

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.19

BI622249

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

12 11 X12 12

10

X11

11

9

X10

10

X9

9

8

X8

8 7

7

X7 X6

6 5

6 X5 5

X4

4 3

X3

4

X2 3

X1 X2

E

2

2 P T

Bucyrus Europe GmbH, Lünen 2009

2 1

1

SP

12 functions

1 2

3

5

4

6

7 8

9 10

11 12

Tab. 6: Electrohydraulic control units with 12 functions, allocation of functions

Function

5.20

Function no.

advance shield

1

set both props

2

advance conveyor

3

extend lift cylinder

4

extend stabilizing cylinder

5

retract stabilizing cylinder

6

backflush filter

7

backflush filter

8

water curtain

9

side plate sprays

10

dust suppression system

11

lower both props actively

12

Shield support 1143/2540-2x3973-1750

BI622249

Operation of the shield hydraulics Fig. 28: Shield hydraulics key, see table 4 10

12c

P

R

10 9 8 7 6 5 4 3 2 1

12 11

23

W R

P

1

R W P

X1

19

X2

13

25 »m

X3 X2

X5

X6

X4

X9

X7

X8

X10

P DN25

SP

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

X12

coal

X11

6

3

29d

8 7

30 29b

29a 29e E

29c liftingcyl.

Bucyrus Europe GmbH, Lünen 2009

17

Z4

17

15a

20

12b

9

28

17

28

35

9

dust suppression system

pi

35

14 14

12a 25

water curtain

x x

24

21

Z1

D.A.ram

si

4

15b

Z1

Z2

16b

Z3

side plate sprays

linkcyl.

side plate sprays

5 16a

Doc. no.: 7420 214 000 BA 00

SVVI / 01

5.21

BI622249

Operation of the shield hydraulics Fig. 29: Hydraulic lines, overview key, see table 4

12x2400 20x2500 12x2000

8*

6* 10x600 NIRO

10x1100 Niro

17

10x900

DB

5

10x800

15b

1*

A

29b

B

16b

4

12x1000

1, 3

29d

10x700 NIRO

10x600 NIRO 10x1700 NIRO

a

P

R

W

10*10* 10*

10

20

6x1800 Niro

23 21

a

a

a

a 1* 2* 6* 7*

5.22

12b

40 SS-0x2400 rot

25x1200

6

35 28

50x2400 blau 50x2400 gruen

R

10x1000 NIRO

12c

9

P

R

19

P

W

R

P

W

20x900 Niro DN 20

P

10x900 NIRO

10x2100 NIRO

13

a

9*

10x700 NIRO 10x600 NIRO 10x1700 NIRO

30

24

25x1200

10x800 NIRO

7*

15a

hose lines fittings protective hose DN 25-1100 lg protective hose DN 25-2000 lg

8* 9* 10* a

protective hose DN 32-1500 lg protective hose DN 32-2050 lg protective hose DN 50-2100 lg Nozzle

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

10x200 10x2600

9*

E

10x200 NIRO PBA PB PA A AA

28 35

10x2100 NIRO

9

25

8241 224

12a

14

D-S

14 7 29e

10x1600

10x1600

20x2500 10x1800 NIRO

20x600 10x2600

10x800 10x1000 10x700 12x500

10x1200 10x1200

25x1600 12x900

25x1400

20x600

10x2800

10x2000

20x600

10x800 10x3500 NIRO 10x1600 NIRO 20x2500

10x1400 NIRO 10x2200 10x300

10x600

10x600 NIRO

10x500 NIRO 10x400 NIRO

10x1200

Z PBA PB PA A AA

20x700 Niro

10x900 Niro

10x200 NIRO

10x200 NIRO

10x300 NIRO 10x500 NIRO

29a

DA

VKV 11-70 VKV 11-70 VKV 11-70

29c

8

16a 2*

12x700

17

17

BI622249

Operation of the shield hydraulics Shield components Shield support Fig. 30: Shield a

19

8

Bucyrus Europe GmbH, Lünen 2009

E

1

1 electrohydraulic control 8 Dual filter, can be backflushed automatically

Doc. no.: 7420 214 000 BA 00

SVVI / 01

19 supply block a PM4 control unit

5.23

BI622249

Operation of the shield hydraulics Supply block Fig. 31: View on the supply block of the face shield

12c

b

10 a

P

R

19

29d

30

10 high pressure ball valve DN 25, (shut-off pressure supply to shield) 12c high pressure ball valve DN 10 (for nozzle flushing) 19 supply block

29d high pressure ball valve DN 10 (isolate washdown hose) 30 high pressure ball valve DN 20 (shut-off of the entire spray system)

a pressure line (auxiliary supply) b return line (auxiliary supply) P pressure line DN 40 R return line DN 50 W water line DN 50

Fig. 32: View under the supply block

13

29d

30

13 pressure relief valve 80 bar 29d high pressure ball valve DN 10 (to isolate washdown hose)

5.24

30 high pressure ball valve DN 20 (to isolate water spray system)

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

W

BI622249

Operation of the shield hydraulics Dual filter, backflushed automatically Fig. 33: View on the dual filter of the face shield

4 a

b 8

E

c

Bucyrus Europe GmbH, Lünen 2009

4 shifting ram check valve

a side plate spray b side plate spray c lemniscate spray

8 Dual filter, backflushed automatically

Control units Fig. 34: PM4 control unit, under the canopy L.H. a b

c

d

a PM4 control unit b holder for PM4 control unit

Doc. no.: 7420 214 000 BA 00

SVVI / 01

c Emergency-Stop button d Local-Lockout button

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Operation of the shield hydraulics Fig. 35: View of the electrohydraulic control unit

d

b c

a

c symbol plate d connecting cable

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1 electrohydraulic control unit a pilot valve

Bucyrus Europe GmbH, Lünen 2009

1

b button

Twin check valve for stabilizing cylinder Fig. 36: View of the twin check valve for stabilizing cylinder

16a 16b

Z3

5

Z3 stabilizing cylinder 5 twin check valve

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16 PRV, 450 bar

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Operation of the shield hydraulics Prop Fig. 37: View on the props with protective cover for prop check valve

1

9

12a

1 protective cover 9 high pressure ball valve DN 20 (isolate piston side of prop)

E Bucyrus Europe GmbH, Lünen 2009

9

12a high pressure ball valve DN 10 (isolate compensating valve)

Fig. 38: Prop R-H. and Prop L-H., face side, shown without protective cover

9 b 12a

9

28 14

b

28

14 35 35

24 25 a

a compensating valve b pressure sensor 9 high-pressure ball valve, DN 20 serves to isolate the prop piston chamber from pressure supply,

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open as shown 12a high-pressure ball valve DN 10, shown closed enables auto aligning function of the canopy, if open 14 pressure relief valve 420 bar

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24 prop check valve 25 prop check valve 28 pressure gauge connection (test and pressure relief port) 35 pressure gauge

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Operation of the shield hydraulics Spray system Fig. 39: View under the canopy R.H.

17

29a 17

29b

17 spraying valve

29c

29b high pressure ball valve DN 10 (water curtain) 29c high pressure ball valve DN 10 (side plate sprays)

Bucyrus Europe GmbH, Lünen 2009

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29a high pressure ball valve DN 10 (canopy and lenmiscate sprays)

17

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Operation of the shield hydraulics Retracting or extending the lift cylinder The lift cylinder serves to raise the base frame to overcome soft floor conditions or variations in the floor..

In normal operation, the HP ball valve is opened (pos. 12b Fig. 40).

The front base frame is raised either automatically by the program or by actuating the ”Extend lift cylinder” function. When the HP ball valve is closed (12b), this function is switched off. The base frame cannot be raised and the lift cylinder can no longer be retracted.

Fig. 40: View under the canopy, rear L.H.

Bucyrus Europe GmbH, Lünen 2009

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12b

15a 4

15b

8

4 shifting ram check valve (for shifting 15a pressure relief valve 380 bar unit) (for lift cylinder) 8 dual filter, backflushed 15b pressure relief valve 380 bar automatically (shifting ram) 12b high pressure ball valve DN 10 (to isolate lift cylinder)

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Operation of the shield hydraulics Bleeder fitting The bleeder fitting can be used to relieve presssure by screwing in the vented cap screw.

After relieving the pressure, this screw must be screwed all the way out again to close the bleeder fitting.

Fig. 41: Bleeder fitting Open bleeder fitting: turn vented cap screw clockwise (inwards) to open and bleed pressure

a

b

a hex. head screw M 6x16-A 2-70

b O-ring

Important!

Prior to operating the bleeder fitting, make sure the sealing ring (b) is covering the vent hole and that the sealing ring is not damaged. As added protection, cover the sealing ring with a rag prior to opening the bleeder fitting.

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Close bleeder fitting: turn vented cap screw counterclockwise (outwards) to close bleeder fitting

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Operation of the shield hydraulics The shield is equipped with a bleeder fitting with vented cap screw.

The bleeder fitting located on the supply block is for reducing any pressure that may arise in the return line. This can be necessary, e.g. when the supply line connections have been closed off for transport and increased pressure has built up in the return line during installation.

Fig. 42: View of the supply block

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a

19 supply block

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a bleeder fitting

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Operation of the shield hydraulics Flushing canopy spray nozzles HP ball valve (pos. 29e Fig. 43) is always in the open position during normal operation of the water spray system. The valve is only closed when preparing to flush the spray nozzles on the top of the canopy. In order to flush the spray nozzles on the top of the canopy with high pressure emulsion, the HP ball valve (pos. 29e Fig. 43) is closed and then HP ball valve (pos. 12c Fig. 31) is opened to direct high pressure emulsion through the canopy spray nozzles.

Bucyrus Europe GmbH, Lünen 2009

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Fig. 43: View under the canopy, back R.H.

29e

29e high pressure ball valve (to isolate the flushing canopy spray nozzles)

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

Do not put the filter into operation, before making sure that all connections have been made properly. Observe the separate operating manual for the filter. flushing

The filter needs flushing when the contamination of the filter elements causes reduced flow or pressure losses.

When to flush the filter elements depends on the degree of contamination of the emulsion used (HFA fluid) and therefore has to be determined on a case-by-case basis. We recommend to flush the dual filter regularly once every shift.

The filter elements are flushed alternatingly by operating function keys 7 and 8 of the electrohydraulic control unit.

Please keep in mind that a minimum volume flow of 70 l/min is required for flushing.

Bucyrus Europe GmbH, Lünen 2009

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Fig. 44: View on the dual filter

8

8 Dual filter, backflushed automatically

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

In the following, it is assumed that the shield has already been correctly installed. It is also assumed that all of the ball valves are aligned for normal operation as shown in Table 5.

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

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

Figure 45 shows the arrangement of the PM4 control unit and the control valve block.

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

See separate manual for the PM4 control unit.

Fig. 45: Arrangement control unit PM4

a

b

a control unit PM4 b pressure line (connection line for the auxiliary supply)

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c

c return line (connection line for the auxiliary supply)

Shield support 1143/2540-2x3973-1750

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Caution!

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

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Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special operating instructions of the mining company. During normal operation they should not be used.

Otherwise, dangerous situations could arise which could result in very serious injury.

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Operation of the shield hydraulics Fig. 46: Electrohydraulic control (12 functions), centered under the canopy

d

b c

a

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1 electrohydraulic control unit a pilot valve

c symbol plate d connecting cable

b button

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

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

Fig. 47: Symbol plate for 12 function control valve block

1 2

3

5

4

6

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7 8

9 10

11 12

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

Warning!

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

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

The function stops as soon as you release the button.

Danger!

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

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

Warning!

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

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There are two pushbuttons on the cover of each individual pilot solenoid valve. When you press a button, the corresponding work valve is operated immediately.

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

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Operation of the shield hydraulics 1

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

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

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

2

Set both props Before this function is initiated the canopy should be aligned properly.

While this function is performed the lift cylinder will be retracted actively.

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

During setting of the props, the canopy of the shield which is set at too steep an angle will adjust itself automatically to the roof as long as the function of the compensating valve is not isolated. The canopy may then have to be aligned again.

Bucyrus Europe GmbH, Lünen 2009

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Compensating valve The compensating valve and the related HP valve are located at the R.H. prop as seen looking towards the coal face. See figure 48.

When the ball valve (12a), see figure 48, is open (handle aligned to the direction of flow), the compensating valve is active. If the HP ball valve is closed (handle perpendicular to the direction of flow), the compensating valve will be disabled.

While the props are being set, the pressure limit of the stabilizing cylinder will be reduced by the compensating valve to 200 bar as long as the pressure under the piston of the prop does not exceed 100 bar. This means that the stabilizing cylinder retracts if the canopy is inclined at too steep an angle. The canopy then presses only with the tip against the roof and automatically adjusts itself to the roof.

Fig. 48: R.H. prop, faceside view

12a

12a ball valve, shown in closed position to isolate the compensating valve

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Operation of the shield hydraulics 3

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

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

4

Extend base lift cylinder Before this function is executed the props must have been lowered.

The piston chamber of the baselift cylinder is connected to return when this function is not activated.

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

The baselift cylinder retracts automatically due to the weight of the shield or when the props are being set.

The ball valve (12b), see figure 40, serves to enable / disable this function.

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

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

Caution!

Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

6

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

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

Caution!

Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Backflush filter

7

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

Backflush filter 8

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

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Extend stabilizing cylinder

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Operation of the shield hydraulics 9

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

10

Side seal water sprays The function is performed as long as the button is held depressed.

11

Lemniscate and canopy water sprays The function is performed as long as the button is held depressed.

12

Actively lower both props

Bucyrus Europe GmbH, Lünen 2009

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

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

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Maintenance Maintenance Warning!

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

Refer to the separate original operating manual for the PM4 control unit.

hydraulic control system

Special measures

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

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

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

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

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

replacing filters

The time intervals between mandatory filter replacements depends on the degree of contamination in the water and/or of the emulsion (HFA fluid) used and must therefore be determined on a case-bycase basis. Clogged filters may be the reason that functions start to slow down or even reach a point where they can no longer be carried out.

We recommend:

water filters double filter, can be backflushed

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J Replace the water filters directly.

J Backflush double filters (both filters) regularly once per shift.

Shield support 1143/2540-2x3973-1750

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No later than one week after start-up, the filter cartridges on the electrohydraulic control units of the shield control system in the entire face must be spot checked for contamination. If inspection indicates that the probability of malfunctions caused by contaminated filter elements is high, all filter cartridges along the face must be replaced.

Bucyrus Europe GmbH, Lünen 2009

one week after start-up

BI622249

Maintenance piston rods

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

pressure relief valves

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

Pressure relief valves which are charged with gas pressure must be additionally spot checked at regular intervals to ensure their correct function. We recommend such random sample inspections at quarterly intervals.

Bucyrus Europe GmbH, Lünen 2009

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high pressure hydraulic hoses

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

Daily maintenance hydraulic system

. Check all shields by visually inspecting them for escaping hydraulic fluid at the following points: – hose lines, – electrohydraulic control unit, – valves, – props, – shifting ram and baselift cylinders (lifting), – stabilizing, alignment and flipper cylinders.

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

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

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Maintenance Weekly maintenance control system

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

. Clean the control systems, especially the symbol plates.

Notice!

It is important that the control system symbol plates be easily legible. This prevents the risk of operational errors and any resulting accidents. hydraulic support prop

. Apply grease to the dirt strippers of both telescopic stages using the grease nipples. Use grease A2 according to EWN 7068, see chapter 6 section ”Lubricating greases and pastes”.

b

a

a grease nipple at the sleeve holder

b escaping grease at the dirt stripper

Every six months

. Apply a preservative to the piston rods of the hydraulic cylinders. Further details are contained in this chapter in the section “Special measures”.

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

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Fig. 49: Grease nipples at the prop

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Troubleshooting Troubleshooting Instructions for troubleshooting The shield hydraulics of a shield unit consists of a multitude of individual components. The linking of the components with each other is shown in the circuit and hose diagrams for the shield hydraulics.

Also refer to the section “Operating the shield hydraulics” in this chapter or the replacement parts catalog.

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

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

Bucyrus Europe GmbH, Lünen 2009

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Warning!

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

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

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

Fault localization support cannot be lowered

Doc. no.: 7420 214 000 BA 00

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shutoff valve!

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

The shield canopy is stuck between the neighboring supports.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

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Troubleshooting support cannot be set

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shutoff valve!

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

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shutoff valve!

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

The support is stuck between the neighboring supports.

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

Step on roof or floor blocking the support.

Lower canopy sufficiently to clear the step or lift the base.

The pressure of the hydraulic supply is too low.

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

The control piston on the pilot-operated check valve does not work.

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

The prop control valve may be defective.

Damaged or trapped hose lines.

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

Shifting ram is defective.

Check whether the - shifting ram is damaged - the piloted check valve is working properly Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressure fluid escapes, replace the shifting ram.

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

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

support cannot be advanced

The pressure of the hydraulic supply is too low.

BI622249

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

Bucyrus Europe GmbH, Lünen 2009

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canopy cannot be positioned

canopy cannot be lowered

Doc. no.: 7420 214 000 BA 00

Possible cause

Measure required

Prop control valve is defective.

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

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lowering connection and check whether pressure fluid is escaping even though the prop is no longer being extended. If applicable: piston packing defective, replace prop.

Pressure relief valve defective.

Monitor pressure drop on the pressure gauge.

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

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shutoff valve!

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve isn't working.

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

The check valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and exchange, if necessary.

Possible cause

Measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shutoff valve!

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve isn't working.

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

The check valve may be defective.

Damaged or trapped hose lines.

Check hose lines for controlling the prop/ stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and exchange, if necessary.

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Troubleshooting 3/2-way or pilot valve The valve is jammed or a bypass has formed due to internal leakage. The latter can normally be detected on the work valves of the electrohydraulic control unit by an easily audible hissing noise.

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

Defective pilot valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, such as discharged fluid, for example.

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

. Try to solve the problem by activating the function several times on the electrohydraulic control unit or electronic control unit. sequence.

If the noise stops while a function is actuated, that valve is faulty.

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

replace valve

. Close the main shut-off valve (item 10, fig. 31) in the pressure feed line at the supply block.

. Then operate the functions manually to depressurize the system.

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

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

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

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

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

. Set the prop until the setting pressure has been reached. . Remove the “Set prop” hose line on the piloted check valve.

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

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. Locate the faulty valve by actuating the functions individually in

Bucyrus Europe GmbH, Lünen 2009

internal leakage

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

. Set the prop until the setting pressure has been reached. . Make sure that the annular space of the prop is depressurized. . Release the hose of the prop annular space connection at the prop.

. Actuate the “Set prop” function from the neighboring support.

If there is an internal bypass in the prop, for example, due to damaged piston packing, fluid will flow out of the prop lowering connection. If this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

Pressure relief valve defective

Bucyrus Europe GmbH, Lünen 2009

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

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

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

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

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

. Check the filters in the hydraulic system.

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

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Troubleshooting

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6

Technical data

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Shield description

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

Shield description Type 1143/2540-2x3973-1750 The two-prop shield mainly consists of the following listed main subassemblies: J base frame with lemniscatic links and relay bar assembly, J canopy, J caving shield, J hydraulic props, J hydraulic equipment with hose lines and control.

Tab. 7: Shield support, dimensions and weight Order-no.

Dimensions max. / min., L x W x H in mm

Weight approx. in kg

Face shield

7420 214 000 00 01 6 609 x 1 700 x 1 143 6 407 x 1 700 x 2 540

20 860

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Application

The shield is provided with a solid base which has the two interconnected skids separated by a tunnel.

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

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

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

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

The 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.

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.3

BI622249

Shield description Main subassemblies Fig. 50: Main components of the shield a

61

11

31

51

b

c 1

1 11 31 41 51

base of shield canopy caving shield prop stabilizing cylinder

61 a b c

electrohydraulic shield control, control unit PM4 protection cover baselift cylinder

Tab. 8: Shield 7420 214 000 00 01, applicable components item description

6.4

order no.

weight remarks approx. in kg

01

base

7420 207 300 00 01

8 538 shifting ram, dia. 135 lift cylinder relay bar assembly 3938 long

11

canopy 4730 long

7420 214 400 00 01

5 918

31

caving shield

7420 214 800 00 01

3 520

41

prop

8250 099 000 00 00

995

51

stabilizing cylinder

8241 222 000 00 00

140

61

shield control system - 12 functions -

8112 310 000 00 00

120 el.-hydr. control unit hose lines water spray system retainer & accessories

8241 230 000 00 00 8241 224 000 00 00 7420 207 330 00 00

8154 080 000 00 00 8112 310 010 00 00 8112 222 020 00 00 8112 310 030 00 00

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

41

BI622249

Shield description Main dimensions Fig. 51: Shield dimensions L1 L2

130

HE

H

HA

L3

L4

E

L Bucyrus Europe GmbH, Lünen 2009

B

B1

a

HA height, extended HI height, retracted L transport length

B width M support center distance a Shield number

Tab. 9: Shield dimensions

Doc. no.: 7420 214 000 BA 00

L

L1

L2

L3

L4

HA

HE

H

B

B1

M

6 609

4 720

3 470

1 120

2 561

2 540

1 143

1 778

1 700

890

1 750

SVVI / 01

6.5

BI622249

Shield description Base frame with lemniscatic links and relay bar assembly The solid base transmits the shield 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 shield and the smaller force of the ring surface area to advance the pan line.

The connection to the conveyor is provided via a universal joint.

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

Fig. 52: Base, positions

4 2

Bucyrus Europe GmbH, Lünen 2009

E

5

10

6

11

1 9

1 2 4 5

6.6

base front lemniscatic link, L.H. rear lemniscatic link, R.H. rear lemniscatic link, L.H.

6 9 10 11

baselift cylinder bracket relay bar assembly hydraulic cylinder ZE-135/90-1130 baselift cylinder ZE-135/90-240

Shield support 1143/2540-2x3973-1750

BI622249

Shield description Fig. 53: Base, dimensions and positions 890

8 7

30 31 23

A

49 3826

1650

15 24 34 17 31 35 20 21

22

16

33

19 A

Bucyrus Europe GmbH, Lünen 2009

E

31 36

7 8 15 16 17 19 20 21 22

pin Ø16x117 staple DN 10 pin 155x533 pin 130x533 retainer protective cap prop securing device, right prop securing device, left locking plate

23 24 30 31 33 34 35 36

pin 60/50x116 pin Ø34x90 hex. screw M 16x120-A 4-80 hex. nut M 16-A 2-70 locking clip spring cotter hex. screw M 16x80-A 2-70 hex. screw M 16x110-A 2-70

Notice!

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

*) EWN = works standard

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.7

BI622249

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

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

The force of the reverse-mounted shifting ram is applied directly to the relay bar. Here, the force on the piston surface side is used to advance the shield, while the smaller force of the ring surface is used to advance the conveyor.

With the help of the lifting equipment, the base frame can be lifted from the floor when advancing.

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

Fig. 54: Relay bar assembly, dimensions 350

W

W

215

Bucyrus Europe GmbH, Lünen 2009

E

110

300

3495

280

200

3974

Fig. 55: Relay bar assembly, positions

2

a 1

5 3

6

a

9

7

10, 11

4 1 2 3 4 5 6

relay bar clevis assembly for conveyor shear pin 70/53x144 hex. head screw M 16x140-A 4-80 hex. nut M 16-A 2-70 pin 80/48x290

7 8 9 10 11 a

washer 48 hex. head screw M 16x70-A 2-70 pin 65/58x180 hex. head screw M 12x110-A 4-80 hex. nut M 12-A 4-80 load ring, 3 000 kg

Notice!

Apply lubricant B6 EWN 7068*) to all connecting points and slide surfaces. *) EWN = works standard

6.8

Shield support 1143/2540-2x3973-1750

BI622249

Shield description Function description: 1. Original position of the shield The shifting ram is retracted.

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

Warning!

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

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

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

Bucyrus Europe GmbH, Lünen 2009

E

4. Advancing the conveyor The shifting ram is retracted.

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.9

BI622249

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

It is hinged to the caving shield by means of pin connections. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the props are fastened to the canopy and can be rotated.

Caution!

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

Bucyrus Europe GmbH, Lünen 2009

E

890

1700

Fig. 56: Canopy, dimensions

4720 1120

130

994

195 480

240

4730

Notice!

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

*) EWN = works standard

6.10

Shield support 1143/2540-2x3973-1750

BI622249

Shield description Fig. 57: Canopy, positions 9

6, 7

10, 11

5

c

8

1

a

Bucyrus Europe GmbH, Lünen 2009

E

b d

1 5 6 7 8

10 hex. head screw M 10x90-A 2-70 11 hex. nut M 10-A 2-70 a load ring 1 000 kg

canopy prop retainer R90 pin Ø24,3x156 linchpin 6x42 pin Ø53x200

b clamp 8 000 kg c bolt holder d nozzle holder

9 retaining ring Fig. 58: Prop head with retainer

7

5

6

5 prop head retainer 6 pin Ø24,3x156

Doc. no.: 7420 214 000 BA 00

SVVI / 01

7 retaining clip

6.11

BI622249

Shield description Caving shield The caving shield protects the face area toward the caving area.

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

2152

1001

2110

Notice!

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

*) EWN = works standard

6.12

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

520

975

1654

1698

153

370

Fig. 59: Caving shield, dimensions

BI622249

Shield description Fig. 60: Caving shield, positions 14, 15, 20 5

6

1

7 8, 9, 10

21

S1

Bucyrus Europe GmbH, Lünen 2009

E

S1

11 12

S2

S2 1 5 6 7 8 9 10 11 12

Doc. no.: 7420 214 000 BA 00

13, 20

caving shield lemniscatic link pin Ø155x533 lemniscatic link pin Ø130x533 pin Ø53x200 retaining ring hex. head screw M 10x90-A 2-70 hex. nut M 10-A 2-70 pin Ø133,5x328 securing device

SVVI / 01

13 pin Ø15/12x120 14 securing device 15 pin Ø12x120 20 locking clip 2,5 21 spring cotter 5 S1 load ring, load capacity: 3 000 kg S2 load ring, load capacity: 8 000 kg

6.13

BI622249

Shield description Technical data of the shield, steel structure face shield, device no. 7420 214 000 00 01

15

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

1 143

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

2 540

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

1 397

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

1 067

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

1 130

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

890

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

3 470

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

1 250

Width of canopy . . . . . . . . . . . . . . . . . . . . mm

1 670

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

4 720

Caving shield inclination:

6.14

Support retracted . . . . . . . . . . . . . . . . . . . deg.

3.92

Support extended . . . . . . . . . . . . . . . . . . . deg.

45.07

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

1 665

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

1 650

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

39 064

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

1 750

Supporting force of support for average seam of . . . . . . . . . . . . . . . . . . . . mm

1 800

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

5 135

b) at 425 bar nominal pressure . . . . . . . . kN

7 040

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

1 800

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

566

b) at 425 bar bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

644 / 776

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

Securing from tipping, permissible inclination, omnidirectional . . . . . . . . . . . . . . . . . . . . . deg

BI622249

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. Supplemental information can be found in the replacement parts catalog for the shield support or the hydraulic components listed in chapter 5.

normal and exceptional operation

During normal operation, the shield functions may only be operated via the PM4 control unit.

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

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

Fig. 61: Electrohydraulic control unit, 12 functions

Bucyrus Europe GmbH, Lünen 2009

E

a

1

2 a connection (DN 20) for accumulator cartridge 1 distributor block 2 pilot valve actuated electromagnetically

3

4 3 button for manual operation 4 contact for electrical connection to the solenoid driver module

Warning!

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

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

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.15

BI622249

Hydraulic system Electronic shield control PM4

Fig. 62: Control unit type PM4, input configuration front view

PM4 inputs A1 = L.H. adjacent unit

rear view A2

B2

C2

D2

E2

F2

C1 = pressure sensor C2 = pressure sensor D2 = ram sensor F1 = R.H adjacent support

A1

B1

C1

D1

E1

F1

F2 = solenoid driver module of unit

Fig. 63: Electronic shield control unit PM4, schematic diagram rear view

front view

A1 B1 C1 D1 E1 F1

F1 L.H adjacent support

R.H adjacent support

5

3

5

a

POWER SUPPLY F1

A1

PA PM4 A1

1 single control unit (SCU) 3 solenoid driver 5 pressure sensor

a reed rod, shifting ram * Marking for connection to the valve block other: see spare parts catalog

Notice!

Please observe the instructions in the PM4 control unit's separate operating manual.

6.16

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

A2 B2 C2 D2 E2 F2

BI622249

Hydraulic system Two-stage telescopic prop The two-stage telescopic prop is double acting and is designed for equal load-bearing capacity on both stages. Equal load-carrying capacity is ensured by a piloted check valve which is installed in the piston pipe.

The bottom and top of the prop are designed as a globe joint. This allows the prop to be joined to the support via a rotatable fastening.

The head is fastened using two pegs each that are inserted into the bore holes in the retainer before the prop head is installed. The pegs are secured in the second groove by a pin and spring clip.

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

The technical data can be found in the section “Technical data, hydraulic cylinders”.

Fig. 64: Two-stage telescopic prop, type SD-4100-345-1010/2225-BN

X

Bucyrus Europe GmbH, Lünen 2009

E

21

2 b

section X 41 b

d

d

a

c

1

c

1 2 21 41

prop bottom end piston pipe piston rod grease nipple

a b c d

valve connection plate annular space connection safety am load ring 3000 kg

Tab. 10: Telescopic props Length in mm ID No. Telescopic prop 8250 099 000 00 00

Doc. no.: 7420 214 000 BA 00

SVVI / 01

Stroke in mm

Retracted

Extended

Upper stage

Lower stage

1010

2225

605

610

6.17

BI622249

Hydraulic system Warning!

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

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

Function

a) Piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. Further transmission of the force is hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the base frame (base).

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated control valve. If the pressure set on the pressure relief valve is exceeded, the pressure fluid flows out of the prop and the prop is pushed in under the nominal prop force. b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure fluid, which is blocked by the check valve in the bottom of the piston pipe.

Further transmission of force up to the setting of the piston pipe is as described under a).

lowering props

The pressure fluid is connected to the return under the piston pipe via the control valve for the prop.

Both stages of the prop can be actively lowered. Once the piston rod has completely retracted, the check valve in the bottom of the piston pipe is opened by the tappet, allowing the piston pipe to then retract.

A few millimeters before the piston pipe is “fully retracted”, the check valve is opened by a tappet, whereby the pressure fluid underneath the piston pipe acts like a spring lifting the piston pipe to close the valve again. When lowering along the entire stroke, the procedure repeats itself.

6.18

Shield support 1143/2540-2x3973-1750

E

loading props

Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the annular space is conducted away into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends. The pressure fluid is supplied at the same time via the check valve in the bottom of the piston pipe.

Bucyrus Europe GmbH, Lünen 2009

set props

BI622249

Hydraulic system Hydraulic cylinder Design The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod.

Fig. 65: Hydraulic cylinder, typical example Type a)

2 3

1

5

4

Bucyrus Europe GmbH, Lünen 2009

E

Type b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

4

1

6

4 guide bush 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical data, hydraulic cylinders” section for the shield unit used.

Warning!

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

Never seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, pressure that is several times higher than the setting pressure can build up in the annular space when extending the cylinder.

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against working loose using clamping screws or a clamping sleeve connection.

The pressure fluid is fed through the connections either on the outer cylinder (Type a) or on the piston rod (Type b).

If a double acting cylinder is only to be operated as a single-acting cylinder, the annular space connection must be protected against the penetration of dirt with a filter screw. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.19

BI622249

Hydraulic system Stabilizing cylinder Fig. 66: Hydraulic cylinder, type ZE-165/100-420 21 a d 55

55 L

1

1 cylinder tube 21 reed rod a valve connection plate

d load ring 1 000 kg L retracted 860 - extended 1280 stroke: 420

Shifting ram

62

70 L

21 d c

a

b

25

3 e 4

3 4 21 25 a b

6.20

cylinder tube reed contact rod piston rod screw fitting piston space connection annular space connection

c reed rod adapter d load ring 1000 kg e journal L retracted 1469 - extended 2599 stroke: 1130

Shield support 1143/2540-2x3973-1750

Bucyrus Europe GmbH, Lünen 2009

E

Fig. 67: Hydraulic cylinder type ZE-135/90-1130

BI622249

Hydraulic system Baselift cylinder Fig. 68: Hydraulic cylinder, type ZE-135/90-240

355

c

a

2

b

1 L

Bucyrus Europe GmbH, Lünen 2009

E

3 1 2 3 a

cylinder tube piston rod wearing bottom piston space connection

b annular space connection L retracted 525 - extended 765 stroke: 240

Technical data, hydraulic cylinders telescopic prop, double-acting - 2 stages

Doc. no.: 7420 214 000 BA 00

Type SD-4100-345-1010/2225-BN,

device no. 8250 099 000 00 00

Length a) Retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1 010

b) Extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2 225

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

1 215

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

345 / 250

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

320 / 230

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

934.8 / 490.9

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

130.6 / 75.4

Prop force with setting pressure, 310 bar . . . . . . . . . . . . . kN

2 898

Setting pressure, 425 bar . . . . . . . . . . . . kN

3 973

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

405

SVVI / 01

6.21

BI622249

Hydraulic system

baselift cylinder, double-acting

6.22

device no. 8241 222 000 00 00

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

420

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

165

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

100

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

213.8

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

135.3

Thrust force at 310 / 470 bar . . . . . . . . . kN

663 / 1005

Pulling force at 310 / 470 bar . . . . . . . . . kN

419 / 636

Type ZE-135/90-1130-SC-W-CR,

device no. 8241 230 000 00 00,

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

1130

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

135

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

90

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

143.1

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

79.5

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

458 / ---

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

254.5 / ---

Type ZE-135/90-240-LI-CR,

device no. 8241 224 000 00 00

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

240

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

135

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

90

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

143.1

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

79.5

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

443.7 / ---

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

236.8 / ---

Shield support 1143/2540-2x3973-1750

E

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

Type 165/100-420-EC-DN,

Bucyrus Europe GmbH, Lünen 2009

stabilizing cylinder, double-acting

BI622249

Hydraulic system Pressure relief valves Pressure relief valves protect the hydraulic equipment, such as props and cylinders, connected with them from overload. When the set pressure is reached, the valve opens and the pressure fluid is discharged to atmosphere.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and replacement parts catalog.

Tab. 11: Pressure relief valves, use of different types set pressure in bar

order no.

general application, spring-loaded not for props and stabilizing cylinders

380

7337 486 380 00 00

only for stabilizing cylinder

spring-loaded

450

7337 486 450 00 00

only for props

spring-loaded

420

8220 027 420 00 00

for return line

spring-loaded

80

8220 042 080 00 00

application

type

Bucyrus Europe GmbH, Lünen 2009

E

Caution!

The set pressure of pressure relief valves should not be changed. Only use pressure relief valves which have been factoryset to the required value and which have a corresponding color code.

Noncompliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system's circuit diagram. Noncompliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

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

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The text code includes the following information: J setting pressure, setpoint, J the week the setting was made, J the year the setting was made, J person who made last changes.

Doc. no.: 7420 214 000 BA 00

SVVI / 01

6.23

BI622249

Hydraulic system Tab. 12: Letter code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last person who made changes

Color coding is with either one or two colors. It indicates the range within which the setting pressure is located.

The following Fig. 69 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 69: Pressure relief valve, example

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

Tab. 13: Color codes for pressure relief valves, overview

1)

6.24

color

pressure range (bar)

black

0 - 49

black / white

50 - 99

brown

100 - 149

brown / white

150 - 199

green

200 - 249

green / white

250 - 299

blue

300 - 349

blue / white

350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow /white

550 - 599

orange

600 - 649

orange / white

650 - 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” equals 420 bar, “08” equals 80 bar

Shield support 1143/2540-2x3973-1750

E

a

Bucyrus Europe GmbH, Lünen 2009

b

a color code b protective cap

BI622249

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.

Fig. 70: Angles  1 /  2

1 2

Bucyrus Europe GmbH, Lünen 2009

E

M

Tab. 14: Angles  1 /  2 at height M Inclination  at height M

Shield Order-no.

1 in °

 in °

M in mm

3

10

1143 to 1550

7420 214 000 00 01

15

15

1550 to 2240

15

15

2240 to 2540

Caution!

Exceeding the permissible angles specified can lead to damage to the props and cylinders and their fastening elements as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the canopy/caving shield crosspoint moves correspondingly when the canopy is lowered or aligned/positioned.

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, for operating hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

Suitability test Before Bucyrus will issue a certificate for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by Bucyrus. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to the following: J stability, J sealing materials, J corrosion.

In addition if required a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive a corresponding certificate from Bucyrus.

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If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies, e.g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc.

The respective exemption permit will be issued by Bucyrus on request.

E

In addition, national – and sometimes also regional – regulations on health and safety at work and any environmental regulations must be observed for operation.

BI622249

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

Bucyrus Europe GmbH, Lünen 2009

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Fig. 71: Typical certificate

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Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected, but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– Target value: 7.5 to 9.5 J Concentrate ratio

J Microbial load

– Setpoint:  105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water using hydraulic fluids

The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limits shown in the Table 15 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

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– Target value: see certificate

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Permissible media using as spraying water

limit values

Water used for this purpose may not contain aggressive components and dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100 m. In order to protect the components, the limit values listed in the table must not be exceeded.

The following table lists limit values for the essential properties of the process water.

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Use only water that conforms to the specified limit values.

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Tab. 15: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad odor, etc.

Electrical conductivity

< 1800 S/cm

pH value

6.5 to 8.5

Na+ content

Not specified

Mg+

Not specified

content

Water hardness

< 750 mg/l CaCO3 equivalent ( 42° dH)

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 mfiltering in conformity with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1 mg/l

1) The values listed must be observed during the production of hydraulic liquids.

They do not apply when the water is used exclusively as spraying water.

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Permissible media Lubricating greases and pastes Important!

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

Lubricating greases properties

Grease base: . . . . . . . . . . . . . . . . . . . . Lithium soap NLGI class: . . . . . . . . . . . . . . . . . . . . . 2 Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presenceof water: . . practically insoluble in water Temperature of application: . . . . . . . -20 oC to +120 oC Flashpoint: . . . . . . . . . . . . . . . . . . . . . . ≧ 200 oC

lubricating grease A1

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths, and for installation (according to EWN *) 7068).

Tab. 16: Lubricating greases for general application

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

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

Tab. 17: Lubricating greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

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

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. If in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

*) EWN = works standard

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Type

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lubricating grease A2

Flashpoint in °C

Supplier

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Permissible media Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 18: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

Gleitmolybdän

gleitmo 805 *)

Li

NLGI Class

Flashpoint in °C

2

220

When the equipment is lubricated at our factory for the first time, the lubricant type used as lubricating paste B 3 in accordance with the works standard EWN 7068 is: Gleitmolybdän “gleitmo 805” lubricating paste B6

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic props, of pin connections and similar connecting elements at the support.

Behavior in the presence of water: . . non-soluble in water

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Application temperature range: . . . . . -34 oC to +120 oC Bucyrus Europe GmbH, Lünen 2009

When the equipment is treated at our factory for the first time, the lubricant type used as lubricating paste B 6 in accordance with the works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flashpoint 132 ºC) Important!

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

*) The products listed in table 16 are suitable lubricating greases for filling of adjacent cavities.

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Tightening torques Tightening torques Screws with ISO metric thread Tab. 19: Tightening torques for total = 0.14 Torque 4)

Pitch P (mm)

d

Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

3

535

-

-

3

965

1360

1630

-

1600

-

24 m DM 24

2 2)

(M 27) (M 27) (DM 27

Fine thread

2))

M 30

2 3

580

-

-

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the replacement parts lists must be observed during installation and maintenance work.

1) 2) 3) 4)

6.32

The dimensions listed in brackets are used in exceptional cases only.

According to in-house works standard (EWN 6110, edition February 1985).

Only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

The tightening torques comply with the works standard (EWN 6003).

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For your information

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Service addresses

For your information If you require spare parts or technical problems occur, contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus Europe GmbH Industriestrasse 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: info@gb.bucyrus.com Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44/16 98 83 5 - 000 +44/16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus Europe GmbH Office Moscow 125009 Moskau ul. Tverskaja, dom 9/17, str. 7 office 315 Russian Federation Tel.: +7 (495) 9409209 Fax: +7 (495) 9407145 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Kirzavodskaja 4/8 654004 Novokuzneck Russia Tel.: +7 (3843) 991381 Fax: +7 (3843) 991384 E-mail: Andrey.Ravnyushkin@ru.bucyrus.com

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Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd. Customer Service 20 Killara Close, Beresfield, New South Wales 2322 E

+61/24 91 4 - 7144 +61/24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

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Tel: Fax:

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Service addresses Asia China

Bucyrus Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus Europe GmbH, Lünen 2009

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

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Standards and directives Standards and directives Referenced national standards and guidelines Tab. 20: National standards and directives, extract

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

Quality of drinking water Documentation System Plug connectors for hydraulics Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic Systems - Design Principles Determination of the acid number Determination of the sulfated ash Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 21: European standards and directives, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on the approximation of the laws of the Member States relating to machinery EC Directive on the approximation of the laws of the MemDirective 94/9/EC ber States concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery DIN EN ISO 12100-2 Safety of machinery Non-electrical devices for use in potentially explosive atDIN EN 13463-1 mospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces Preparation of instructions DIN EN 62079 - Structuring, content and presentation Petroleum products and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Equipment and components intended for use in potentially DIN EN 1710 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 ments for shear loaders and plough systems Directive 2006/42/EC

1)

7.6

2006-05

1994-03-23 2004-04 2004-04 2002-04 2004-12 2000-08 2001-11 2003-02 2006-01 2003-09

EWN = works standard

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Title

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Designation