CAT Roof Support Shield Support operation and maintenance Manual - PDF DOWNLOAD

BI628668-00-EN

ID-Nr. BI628668 July 2001

Operation and Maintenance Manual Shield Support Typ 114.3 / 254 - 2 x 4113 kN Doc-No.: 7420 046 000 BA 00

SAFETY.CAT.COM SAFETY.CAT.COM

BI628668-00-EN

© 2003 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

BI628668-00-EN

Operating manual DBT - Shield Support Type 114.3 / 254 - 2 x 4113 kN Doc. no.: 7420.046.000.BA.00

BI628668-00-EN

The DBT reserves all rights to this publication. Its content is protected by copyright. No part of this publication may be reproduced in any way or form without the prior written approval of the DBT GmbH, Wuppertal.

The DBT declines all liability for direct or indirect consequences of printing errors. ã 1998 by DBT GmbH, Wuppertal

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

1.3

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

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

1.4 1.5

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

2.3

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

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

2.3 2.3

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

2.4

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

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

2.4 2.4

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Overview of the safety instructions . . . . . . . . . . . . . . . 2.13

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

3.3

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

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

3.3 3.4

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

3.4

Load Units; Dimensions and Weights . . . . . . . . . . . . . . . . .

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

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

3.4 3.4 3.6

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

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

4.3 4.3

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

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

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

4.4 4.5 4.6

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

4.7

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

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

Corrosion-Protected Props and Cylinders . . . . . . . . . . . . . .

4.7 4.7 4.8

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

5.3

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

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

5.3 5.5

Operating Shield Support . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Safety Precautions for Shield Supports with Electro-Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . 5.12

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Operation of the Shield Hydraulics . . . . . . . . . . . . . . . . 5.13 Location of hydraulic devices at the shield support . . . . . .

Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the backflushable double filter . . . . . . . . . . . . . .

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

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

5.13 5.16 5.22 5.26 5.28

Maintenance of the shield hydraulic . . . . . . . . . . . . . . . 5.33 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Maintenance to be executed periodically . . . . . . . . . . . . . .

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

5.33 5.33 5.33 5.34 5.34

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 Failure to operate the tip function . . . . . . . . . . . . . . . . . . . .

5.37

Fault Finding on Shield Support Hydraulic System . 5.38 By-passing or Sticking 3/2-Way Valve or Pilot Valve . . . . .

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

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

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

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

Faulty burst disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.38 5.39 5.39 5.39 5.39 5.40 5.40

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

6.3

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

Base with Lemniscatic Links and Central Shifting Unit . . .

Conveyor Pushing Device . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

6.4 6.5 6.6 6.7 6.8 6.9

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 Shield Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

6.11 6.15 6.16 6.17 6.18 6.19 6.21

Electro-Hydraulic Control System . . . . . . . . . . . . . . . . . 6.23 PANZERMATIC[ PM-4/A . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24

Angles of Inclination of the Canopy . . . . . . . . . . . . . . . 6.25 Hydraulic Fluids of Group HFA . . . . . . . . . . . . . . . . . . . 6.26 Recommended Lubricating Greases and Pastes . . . . 6.29 Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.29 6.30 6.30

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31 Screws with Metric Coarse Thread DIN 13 . . . . . . . . . . . . .

6.31

7. For Your Information

Doc. no.: 7420.046.000.BA.00

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

7.3

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

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

7.3 7.4

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DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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About this manual

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Before starting work

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

Before starting work Correct operating manual

Shield type

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

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

This operating manual applies to the following shield types: DBT Face shield 114.3 / 254 - 2 x 4113 kN Identification no.: 7420 046 000 00 00 Its use is permissible only for shields of these types!

New operating manual

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

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

This includes persons who: J

are in charge of transport, – erect the rise heading, – perform assembly / disassembly work, – operate the shields, – correct malfunctions, – perform daily routine work in the face, – monitor / care for the hydraulic system, – perform maintenance work, – perform repair work;

supervisory personnel who

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J

initiate or

J

supervise

J

the activities just indicated, or both.

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1.3

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Before starting work Purpose of this operating manual Economy

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

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

Service

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

Safety

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

Familiarize yourself with the specifications and observe the procedural instructions.

1.4

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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

Pay particular attention to these points.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

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

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

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

J

Items in lists are marked with bullets.

–

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

.

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

Follow these instructions step-by-step.

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

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1.5

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1.6

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Your Safety

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Personnel

Your Safety For your safety

This section provides vital information for your safety.

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

State of the art

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

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

Observe the safety and accident prevention regulations: J

of the mining company,

J

of the mining authority, and

J

of the miners’accident insurance association.

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

Training

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

They shall possess and furnish proof of adequate familiarity with the J

mechanical,

J

control systems.

J

hydraulic, and

Repairs In general, repair work shall be performed only by persons who have been adequately trained for these special requirements. Repair work on, and servicing of: J

the safety devices (pressure relief valves, etc.),

J

the long hydraulic devices (props and cylinders, etc.)

J

the hydraulic system, and

J

the control systems

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

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2.3

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Conditions for operation

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

Use the shield only in conformance with specifications!

Uses in conformance with specifications are: J

propping the roof against the floor;

J

ensuring a sufficient carriage road;

J

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

J

the following conveyor operations: – advancing, – raising, and – retracting;

J

forming an abutment for: – the conveyor and winning machine, – longwall, partial and block anchoring.

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

Uses contrary to specifications include, among others: J

resetting of the shield in a fractured area,

J

raising of the conveyor by means of the hydraulic force of the shield,

J

setting of the canopy bar in areas of roof fracture.

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

2.4

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Safety instructions

Safety instructions Basic principles General

Always concentrate on your work.

Become familiar with your working environment.

Always wear your personal protective clothing and equipment.

Inform your colleagues of:

Prerequisite

J

your exact location,

J

the work which you are performing,

J

the time which you will probably require.

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Protective devices

Maintain the signalling and lighting systems in a functional condition.

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

EMERGENCY STOP

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

Support blocking switch

Actuate the support blocking switch (repair switch) in the event of:

Moving parts

J

maintenance work,

J

inspection work,

J

repair work,

J

prolonged presence in the shield.

Never reach into or enter areas between machine components which can move. This applies especially to the: J

pressure pads,

J

canopy bars,

J

guide bars (lemniscatic links and shifting system),

J

gap covers,

J

front cantilevers,

J

hydraulic props and cylinders.

Storage and transport For this purpose, thoroughly read section 3, ”Concerning storage and transport”.

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

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2.5

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

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

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

Securing for transport

Fastening devices

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

the gap cover,

J

the front cantilever (coal seam bar),

J

the advancing beam (front and rear sides).

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

Observe the instructions on the transport sheets.

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

Damage of this kind necessitates elaborate and expensive repair work.

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

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

Fix the movable parts in place.

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

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

Mechanically secure the shield against lowering during: J

installation of the canopy bars,

J

installation of the longitudinal hydraulic system,

J

work on the open hydraulic system,

J

work in the shield.

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

2.6

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Safety instructions Fig. 1 Securing by means of wooden wedges

Transport securing devices

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

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

Carriage road

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

J

Width: 600 mm

J

Height: 400 mm

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

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

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

Operate the shield only from the adjacent shield.

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

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

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

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

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

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2.7

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

Ensure that the water spray system responds during advancement.

Inclined deposits

Block and partial anchoring

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

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

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

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

Shield alignment

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

Align the shields as soon as possible. Use the aligning device or the gap cover. Alignment in due time prevents the following:

Roof caving

J

moving under the canopy bar of the adjacent shields,

J

tilting of the shields,

J

slipping of the shields,

J

support lag.

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

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

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

Residual stroke

Withdrawal of conveyor

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

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

Secure the entire winning machine against unauthorized starting.

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

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

Raising of conveyor

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

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

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

2.8

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

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

For raising the conveyor, employ only: J

undamaged, high-strength round link chains,

J

the fastening points provided for the purpose (Check the fastening points for cracks at the welds and damage to the load-supporting rings.),

J

hoisting gear with sufficient permissible load-bearing capacity.

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

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

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

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

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

Original spare parts

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

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

Working in the winning track is permissible only if J

the roof has been secured against rock fall,

J

the coal face has been secured against running out, and

J

the winning machine and conveyor have been shut down and secured against restarting.

Before disconnecting the shield from the conveyor, you must: J

stop production, and

J

relieve the load on the components which are under hydraulic pressure or mechanical stress.

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

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Safety instructions Secure the shield before all work: J

mechanically against inadvertent yield, for instance with the use of: – wooden wedges between the lemniscatic links, – and safety chains between the gob shield and roof.

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

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

Hydraulics Handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

Maintenance, repair

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

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: J

The hoses are not pinched or trapped.

J

The hoses have no bubbles or blisters.

J

The hoses or the outer sheathes of the hoses are not abnormally rigid or hard.

J

The outer sheath of the hoses is not damaged.

J

The connectors are securely inserted into the sockets.

J

The connections are leak-tight.

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

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

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

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

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

Permissible tubing

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

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

2.10

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Safety instructions Fig. 2 Example: 4SP hydraulic hose, designation

Hose type Manufacturer

Nominal diameter Flame-resistant and antistatic

Date of manufacture

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

Installation of hydraulic tubing

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

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

Fig. 3 Hydraulic hoses always must have a little slack

RIGHT

J

WRONG

are not twisted

Fig. 4 Hydraulic hoses must not be twisted

RIGHT

J

WRONG

are not bent directly behind the connections (distance min. 1.5 x nominal diameter).

Fig. 5 Hydraulic hoses must not be bent directly behind a connection

RIGHT

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Safety instructions J

Cannot chafe.

Fig. 6 Secure that crossing hydraulic lines cannot chafe

RIGHT

WRONG

J

Are not kinked.

J

Do not have to withstand tensile strains.

J

Are protected against thermal radiation.

J

Are accessible at all times.

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

When installing the hydraulic hoses, ensure that they cannot be: J

Torn out,

J

Kinked,

J

Crushed,

J

Driven over or

J

twisted by the movement of the shield (Fig.: 7).

Fig. 7

Hydraulic hoses must not be twisted caused by moving parts of the shield support

RIGHT

2.12

WRONG

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Overview of the safety instructions

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

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

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

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

Use only suitable load handling devices.

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

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

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

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

Take care that all transport safety devices are fitted properly.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Do not put the filter into operation, prior making sure that all connections have been made properly.

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

The control elements on the control block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for such opera-

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Overview of the safety instructions tions. They must not be used during normal operation, as otherwise dangerous situations may arise resulting in very serious injury or even death!

You may only operate the control elements on the control block when you have been thoroughly informed about the method of operation of the functions in relation to the shield-type support. You must therefore have undergone appropriate training. There is otherwise a danger of incorrect operation which may lead to very serious personal injury or even death!

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

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

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

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

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

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

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

Guide value: at least 20 mm!

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

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

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

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

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

Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

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

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

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

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

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

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

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

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

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

Observe the warning plate at the cylinder surface.

Never block the port to the annulus of a cylinder.

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

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

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

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

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

The pressure setting must not be changed.

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

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

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

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

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

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

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

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

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

Further information is contained in DIN 24320.

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

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

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

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

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

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

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3

Storage and Transport

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Storage

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

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

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

Storage Corrosion protection

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

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

Storage of new Equipment No direct exposure to sunlight

Protect the equipment against direct exposure to sunlight.

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

Moisture and dirt

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

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

Short-term storage

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

Long-term storage

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

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

Then seal the ports with plastic or steel plugs.

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

Plastic deformation

Random sample inspection

Natural ageing

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

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

On request, the inspection can be carried out by DBT. Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.

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Storage HFA fluids

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

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

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

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

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

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

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

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Transport

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

They contain information on: J

Dimensions

J

Weight

J

Lifting points

J

Center of gravity, etc.

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

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

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

Use only suitable load handling devices.

Before Transport temperatures below freezing

Electrical and electronic components

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

Transport of equipment at temperatures between -21°C and -40°C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and are only loaded statically or quasi-statically.

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

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

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

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

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

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

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

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

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

Fig. 8

Transport of the shield support units L

W

a1 S2

a2

S1

S0

Y

H

X1

X2

S3

S3 Sx

S1 S2 S3 X1, X2 Y So

Attaching eye, 2 pieces at caving shield, load-bearing capacity: 8000 kg Slot hole, 3 pieces at the coal face end of the canopy, load-bearing capacity: 8000 kg Attaching eye, 2 pieces at the coal face end and 2 pieces at the gob side end of the base, load-bearing capacity: 8000 kg Securing elements to fix the relay bar during transport Transport safety device: turnbuckles between canopy and base (not included in the extent of delivery) Center of gravity

Variant 00

3.6

Length

Width

Height

in mm

in mm

in mm

6610

1700

1143

Sx in mm

Weight in kg

1470 ca. 20410

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Installation

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Pre-assembly of the support shield units

Installation The individual shield support units will be transported as one complete unit. Only in case it is necessary to retract the support unit to it’s minimal height, the lifting cylinder must be disassembled before.

Disassembly into smaller subassemblies is not planned. However, if disassembly is necessary, the procedure is subject to agreement with the responsible agencies of DBT. CAUTION! Hoisting and haulage equipment with which the complete support shield unit is to be moved must be attached exclusively at the fastening points indicated in detail in the following figure!

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

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

Only in case the lifting cylinder has been disassembled as mentioned before, it must be reassembled again.

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

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

The sign plate with the shield number is placed at the base. The shield units are numbered from 32012 to 32179.

Fig. 9 Shield support unit ready for transport

a

a b

a b

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PTO connection at both sides under the canopy supply hoses, connected to the manifold pipe as needed for transport and power take off

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Installation of the support shield units Fig. 10 Shield numbering, example

a

a

Sign plate with shield number

Power take-off connections Fig. 11

PTO connections under the canopy at the right side of the support unit, ready for transport

T

P

11

11 P T

Shut-off tap at the PTO pressure supply, closed as shown PTO pressure supply, plugged as shown PTO return line, plugged as shown

The Power Take-Off (PTO) nipples are located under the shield canopy. See also chapter 6, section ”Hydraulic System: Lines”.

The PTO connections are provided for connecting the shield to a hydraulic supply unit when the shield is set for the first time. The pressure line to the shield hydraulic can be shut off using the shutoff tap at the manifold pipe.

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

During normal operation the supply to the support shield unit proceeds exclusively by means of the manifold pipe. The PTO connections are then closed with plugs, and the shut-off valve in the P line of the PTO connection is closed.

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Installation of the support shield units Coupling between the connections Fig. 12

Connections at the manifold pipe

shield hydraulic P1

Water spray system

Control unit

Electrical system

W1

T P

T P

W

W

T P W 6 7 10 12 20 Hydraulic system

T1

Return line, DN 50 Pressure line, DN 40 Water line, DN 25 Non return valve Line Filter Shut-off tap for pressure supply to the shield hydraulic Shut-off tap for water supply to the shield water spray system Manifold pipe

A manifold pipe for the shield hydraulic system is located under the canopy of each support shield unit. This pipe provides the hydraulic supply to the individual support shield unit. The manifold pipes of adjacent support shield units are connected with the use of two hose lines: a pressure line (DN 40) and a return line (DN 50). See the hydraulic block diagram in chapter 6. The hose lines are equipped with plug-in O couplers.

The water supply connection for the spray nozzle system is likewise located under the canopy. This system is connected with the adjacent shield by means of a hose line (DN 25). The hoses are equipped with plug-in O couplers.

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

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

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

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Installation of the support shield units Requirements to the face hydraulic system nominal pressure admissible tolerance

320 bar ?10 % of nominal pressure

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

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

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

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

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Test-Run

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

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

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

J

Check the supporting power of the props at the pressure gauges.

J

Check whether the pressure required is available in the different hydraulic feed lines.

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

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

Check on the electro-hydraulic support control system J How to check the electro-hydraulic control system is described in the separate operating manual titled ”Electro- hydraulic control system”.

J

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

J

The safest area on the face is the travelway. In practice, it has proved useful to identify the travelway by a sign.

Start-Up

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J

First, the support units must be properly aligned following installation.

J

Then, tests for leaks and for isolation must follow, also functional checking of the auxiliary and monitoring switches, the power pack and the pressure control members. If hydraulic accumulators are being used, they must be tested by a qualified person.

J

The supports should only be put into operation by trained personnel. If it is the first time that the mine uses the shield support, the DBT service team should be present when the support is put into operation.

J

Shut-off valves should not be installed in the return lines. All hose connections have to be checked for leaks.

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Test-Run J

Any leakage should be eliminated.

J

Check the control functions.

J

Check the mechanical connections in the support units. Avoid damage to the connecting hoses.

J

Check quantity, temperature, pressure and condition of the emulsion and correct, if necessary.

J

Check the pump according to the respective operating instructions.

Corrosion-Protected Props and Cylinders Putting into Operation Before delivery props and cylinders are provided with a corrosion preventing oil for testing purposes.

If the hydraulic system is operated by means of emulsion, care must be taken that any oil left is removed before the equipment is put into operation for the first time.

To do this, we would recommend not to feed the oil displaced from the annuli into the pump tank but to drain it into a separate tank when the props/cylinders are raised/extended for the first time, which is already during installation.

The return line should only be connected to the pump tank after all cylinders have been fully extended once or twice.

Since remnants of the corrosion preventing oil can get into the pump tank, a check should be made after three days of operation and after longer standstills to ascertain whether oil has collected on the fluid in the pump tank. If so, the oil must be drawn off.

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Operation

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Safety Measures

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

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

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

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

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

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

General Guidelines The face crew must be informed about possible danger situations.

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

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

The face must be illuminated sufficiently.

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

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

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

In case large layers of rock and coal cannot be broken up sufficiently, they may only be transported after the face crew has been informed. In this case support operations and work on the face conveyor have to be stopped until the rock and coal have been transported off.

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

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

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

In the Federal Republic of Germany, the requirement is for a minimum travel way width of 600 mm.

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

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

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

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

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

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

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

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

This does not apply during support advance.

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

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

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

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

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

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

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

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

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

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

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

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

Special Guidelines for Operation A shield must always be operated from a safe position within its adjacent shield.

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

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

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

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

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

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

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

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

Fig. 13

Wrong, Supports have not been advanced in the right time

Fig. 14

Correct, Supports have been advanced in time

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

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

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

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

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

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

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

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

Special observations, in particular concerning defects or damage, have to be reported to the supervisor so that the defects can be eliminated as quickly as possible and necessary repair work can be carried out.

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

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Operating Shield Support

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

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

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

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

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

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

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

Fig. 15 Shield support in the normal position

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

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

Guide value: at least 20 mm!

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

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

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Operating Shield Support Fig. 16

Shield support with extremely inclined canopy

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

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

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

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

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

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

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

Fig. 17

W R O N G ! By no means the tip of the canopy must be set in a cavity, if the stabilizing cylinder is extended fully.

WRONG

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 18) or by leveling off the canopy.

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

Fig. 18

C O R R E C T ! Overcome a cavity by placing crib blocks onto the tip of the canopy

CORRECT

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

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

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

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

Countermeasures: J

Avoiding the accumulation of debris and fine coal on the floor

J

Removing accumulated dirt from the canopies

J

If necessary, producing a larger face opening by means of the mining machine.

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

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

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

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

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

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

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

Bad floor conditions

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

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

Supports without a hydraulic base lifting device can be raised out in different cases:

Doc. no.: 7420.046.000.BA.00

J

Individual skids of two-leg shields can, as a rule, be lifted hydraulically by retracting a prop.

J

Supports with solid bases must be lifted and underlaid by means usually applied in mines.

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Safety Precautions for Shield Supports with Electro-Hydraulic Controls IMPORTANT! Both cases require knowledge of the flow plan and instruction by trained personnel. The safety guidelines contained in this manual must strictly be observed.

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

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

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

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

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

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

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

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

Follow these steps if a shield has failed to advance : 1. Determine reason for failure to advance, there may be: J

Malfunctioning of electric controls

J

External obstructions: – Shield wedged in between adjacent shields – Canopy has tip lodged in roof – Floor step or excessive debris in front of base tip

2. In case of malfunctioning of electric controls advance the shield in repair control mode by using the hydraulic control modules in the shield to be advanced. For safety reasons this can only be done by operating two nipples in the correct sequence i.e. first press the nipple of the function pilot valve and then the nipple of the respective trigger valve.

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

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

Location of hydraulic devices at the shield support Fig. 19

1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 20 21 22 23

Hydraulic components at the shield support

Control valve block Prop check valve Check valve Twin check valve Check valve Line filter Double Filter, backflushable Block ball valve Ball valve Ball valve Block ball valve Pressure gauge Yield valve F, 420 bar Yield valve, 440 bar Valve for water spray system Manifold pipe Compensation valve Yield valve, 70 bar Shield control components please refer also to the spare parts book

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Operation of the Shield Hydraulics Fig. 20

Hydraulic Flow Plan, overview

1 Control valve block 2 Prop check valve 4 Check valve 5 Twin check valve 6 Check valve 7 Line filter 8 Double Filter, backflushable 9 Block ball valve 10 Ball valve 11 Ball valve

12b

12 Block ball valve 13 Pressure gauge 14 Yield valve F, 420 bar

Manifold pipe Compensation valve Yield valve, 70 bar Shield control components

Z1 Z2 Z3 Z4

Prop D.A ram Stabilizing cylinder Lift cylinder

12a

20 21 22 23

12d

15 Yield valve, 440 bar 16 Valve for water spray system

Z4

please refer also to the spare parts book

Z1

Z1

12c

Z2

Z3

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DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Operation of the Shield Hydraulics Tab. 1: Hydraulic components

Item

Qty.

1 2 4

1 2 1

Description control valve block prop check valve check valve

Location under canopy, between props at both props under canopy, left side

5 6 7 8 9

1 1 1 1 2

twin check valve check valve line filter double filter, backflushable block ball valve

at stabilizing cylinder at manifold pipe, return line in water line at manifold pipe under canopy, right side at both props

10

1

ball valve

at manifold pipe, pressure line

11

2

ball valve

under the canopy at both sides

12

4

block ball valve a) in hose line between control valve block port 4 and lift cylinder piston side b) at the manifold pipe in water supply line c) at the compensation valve at the prop on left side

d) at the water spray valve

13

2

pressure gauge

at both props

14

4

yield valve F, 420 bar

15

2

yield valve, 440 bar

2 at twin check valve (5), one at the D.A. ram ring side and one at the ball valve at the control valve block port 4 at props, piston side

16 20

1 1

water spray valve manifold pipe

21

1

compensation valve

22

1

yield valve, 70 bar

23

1

shield control components, electronic control unit

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Remark

serves to shut off the supply line to the piston chamber serves to shut off the pressure supply for the hold support unit serves to shut off the pressure supply at the PTO connection serves to shut off a) the supply line to the lifting cylinder piston chamber b) the supply line to the water spray system c) the line between stabilizing cylinder piston side and compensation valve; disables function of compensation valve d) serves to shut off the water supply for the nozzles at the gob side

under canopy, left side under canopy between the props at prop, right side under the canopy, in return line near the manifold pipe see parts book

5.15

BI628668-00-EN

Operation of the Shield Hydraulics Lines Fig. 21

Hydraulic lines of the shield support, overview

1 Control valve block 2 Prop check valve 4 Check valve 5 Twin check valve 6 Check valve 7 Line filter 8 Double Filter, backflushable 9 Block ball valve 10 Ball valve 11 Ball valve 12 Block ball valve 13 Pressure gauge 14 Yield valve F, 420 bar 15 Yield valve, 440 bar 16 Valve for water spray system 20 Manifold pipe 21 Compensation valve 22 Yield valve, 70 bar 23 Shield control components Z1 Z2 Z3 Z4

Z1

Z1 Z4

Prop D.A ram Stabilizing cylinder Lift cylinder

Z2

Z3

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Operation of the Shield Hydraulics Fig. 22

Single shield support unit, view from face-side, supply hoses connected as ready for power take off

Fig. 23

View into the shield support from face side

PTO

PTO

20 1 a

PTO 1 20 a

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Power take off supply lines (P and T) Electronic control unit, PM4 Manifold pipe Protective cover

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BI628668-00-EN

Operation of the Shield Hydraulics Fig. 24

Extendable holder for electronic control unit PM4, retracted as shown

b canopy

a

1 5 6 a b

Holder Bolt Formed spring Electronic control unit, PM4 Guide

Fix extendable holder of the PM4 electronic control unit in working position at both sides using the formed springs as shown above.

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DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Operation of the Shield Hydraulics Fig. 25

View to the under side of the rear canopy

20 10 a 1 b c

8

1 4 8 10 16 20 a b c

Doc. no.: 7420.046.000.BA.00

4

16

Control valve block Check valve Double filter, backflushable Ball valve to isolate the shield hydraulic P-line from pressure supply Water spray valve Manifold pipe Electric line to the solenoid driver Pilot control valve Symbol plate

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BI628668-00-EN

Operation of the Shield Hydraulics Fig. 26

Right-hand prop, view from face side, protective cover removed

12d

13

a 2 12c 9 15

2 9 12c

12d

13 15 21 a

5.20

21

Prop check valve Block ball valve, to isolate the props piston chamber from pressure supply. Open as shown.

Block ball valve, shuts off pressure supply to the stabilizing cylinder, piston side. Closed as shown.

Enables / disables function of compensation valve.

Block ball valve, serves to shut off the water supply to the gob side nozzles of the water spray system.

Closed as shown.

Pressure gauge Yield valve, 440 bar Compensation valve Pressure sensor

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Operation of the Shield Hydraulics Fig. 27

Left-hand prop, view from face side, protective cover removed

13

2

9

a

15

2 9 13 15 a

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Prop check valve Block ball valve, to isolate the props piston chamber from pressure supply. Open as shown.

Pressure gauge Yield valve, 440 bar Pressure sensor

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Operation of the Shield Hydraulics Fig. 28

View to the back-flush filter at the right side of the rear canopy, levers in position for normal operation as shown.

b

8

a

8 a b

b

a

Double filter, backflushable Lever position for normal operation Lever in back-flush position

Operating the backflushable double filter WARNING! Do not put the filter into operation, prior making sure that all connections have been made properly.

Operation

Backflushing

The filter is works, if both backflush levers are in parallel position.

The filter needs to be backflushed after contamination accumulates to the point of increased pressure drop and restricted flow.

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

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

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

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

Fig. 29

Double filter, backflushable (part no. 7338 129 000 00 00)

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Operation of the Shield Hydraulics Fig. 30

Shut-off valve for the water spray system at the manifold pipe

12b 20

12 b 20 Fig. 31

Block ball valve to shut off the water supply to the water spray system, closed as shown Manifold pipe

Shut-off valve for the gob side nozzles of the water spray system placed at the left side of the rear canopy

14

16

4

12d

4 12d 14 16

5.24

Check valve Block ball valve to shut off the water supply to the gob side nozzles of the water spray system Yield valve F, 420 bar Water spray valve

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Operation of the Shield Hydraulics Fig. 32

Block ball valve in hydraulic line to the lift cylinder piston side, closed as shown

a

12a

14 b

12a 14 a b

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Block ball valve, serves to shut off the hydraulic line between control block (port 4) and piston side of the lift cylinder Yield valve F, 420 bar To control valve block, port 4 To lifting cylinder, piston side

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

Operation of the control unit for the electronic controller is not described here. For information, please refer to the separate operating manual for the control unit. If the control unit forms part of the DBT scope of supply, you will find the corresponding operating manual in the DBT documentation on the system.

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

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

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

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

Fig. 33

Symbol plate at control block

8

3

1

4

7

5

2

6

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

The meaning of the symbols is explained in the following text.

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Operation of the Shield Hydraulics Fig. 34

Hydraulic control valve block

d c a b

a b c d

Pilot control valve Symbol plate Push button to operate the pilot control valve manually Electric line to the solenoid driver

Fig. 35

Control valve block

1

2 3 4

5 1 Control valve block 2 Pilot control valve for electromagnetic operation 3 Push-button for manual operation 4 Plug contact, electrical connection to the control unit 5 Filter cartridge

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

WARNING! You may only operate the control elements on the control block when you have been thoroughly informed about the method of operation of the functions in relation to the shield-type support. You must therefore have undergone appropriate training. There is otherwise a danger of incorrect operation which may lead to very serious personal injury or even death!

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

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

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

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

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

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

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

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

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Operation of the Shield Hydraulics Extend canopy cylinder (1)

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

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

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

Retract canopy cylinder (2)

CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual travel.

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

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

Set both props (3) The function is performed as long as the button is held depressed or until the end position is reached.

During setting of the props, a canopy bar 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 barred.

The canopy bar may then have to be aligned again.

Compensating valve The compensating valve and the related shut-off valve are located at the right-hand prop as seen looking towards the coal face. See figure 36. When the shut-off valve is open (lever aligned to the direction of flow), the compensating valve is active. If the shut-off valve is closed (lever across to the direction of flow), the compensating valve has no function.

While the props are being set, the pressure limit of the stabilizing cylinder will be reduced by the compensating valve to 40 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 bar is inclined at too steep an angle. The canopy bar then presses only with the tip against the roof and automatically adjusts itself to the roof.

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Operation of the Shield Hydraulics Fig. 36

Shut-off valve for compensating valve at the right-hand prop front side, protective cover removed

9 21

9

21

Block ball valve, shuts off pressure supply to the stabilizing cylinder, piston side.

Enables / disables function of compensation valve.

Compensation valve

Extend lift cylinders (4) The function will be performed only as long as the button is held depressed or until the end position is reached.

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

Fig. 37

Block ball valve in hydraulic line to the lift cylinder piston side, closed as shown

12a

12a

5.30

Block ball valve, serves to shut off the hydraulic line between control block (port 4) and piston side of the lift cylinder

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Operation of the Shield Hydraulics Actively lower both props (5) Before this function is initiated, ensure that the neighboring shields have been completely set.

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

Activate water spray system (6) The function is performed as long as the button is held depressed.

There are two block ball valves in the water circuit, see hydraulic flow plan fig. 20. The block ball valve 12b at the manifold pipe serves to isolate the water spray system of the shield unit from water supply completely. The gob side nozzles can be isolated from water supply by the block ball valve 12d.

Fig. 38

Shut-off valve for the water spray system at the manifold pipe

12b 20

12 b 20 Fig. 39

Block ball valve to shut off the water supply to the water spray system, closed as shown Manifold pipe Shut-off valve for the gob side nozzles of the water spray system placed at the left side of the rear canopy

16 12d

12d 16

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Block ball valve to shut off the water supply to the gob side nozzles of the water spray system Water spray valve

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Operation of the Shield Hydraulics Advance support (7) Before this function is initiated, the function ”Actively retract support”must have been executed.

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

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

Advance conveyor (8) Before initiating this function, ensure that the support unit has been set.

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

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Maintenance of the shield hydraulic

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

Special measures J

After the first 100 hours of operation, the filter cartridge located in the control block must be replaced on every support shield unit.

J

All pressure relief valves must be tested for correct function at least once annually, and in any case after every relocation in the coal face.

J

For reasons of safety and for ensuring correct function of the unit, all high pressure hydraulic hoses must be replaced every 2 years, regardless of recognizable damage.

Daily inspection Hydraulics

. Check all shield support units by visual inspection for escaping hydraulic fluid on the: J

hose lines,

J

control units,

J

props,

J

pusher

J

canopy cylinder, adjusting and aligning cylinders.

. Check pressure gauges at the props. . Clean backflush filter.

For correct operation see operating instructions.

Steel structure

. Check all shield support units by visual inspection for damage to the steel structure, for instance: J

on the walking travel gear,

J

on the gap cover,

J

on holders, etc.

Weekly inspection Control unit

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

. Clean the control units, especially the control panel.

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

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Maintenance of the shield hydraulic Maintenance to be executed periodically WARNING! Never conduct any maintenance work while the system pressure is on.

. Replace filter elements at the backflush filter.

The filter elements should be replaced after a certain operating time, depending on the system contamination and frequency of backflush cycles. This is accomplished by removing the staple and pulling out the filter element. The installation of the new filter element is done in reverse order.

. Check pressure relief valves regularly. We recommend to remove a sample pressure relief valves (e.g. every three months) on random basis and to return them to MTA for testing.

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

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Trouble shooting

Trouble shooting Failure to lower the support

Possible Cause Check Required The isolating valve on the support is Feed line must be open to allow closed pressure to the support Check leg isolation valve (if fitted) is Lines to leg and return must be open to closed allow lowering of support

Failure to advance the support

Support canopy is trapped by adjacent supports

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

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Legs are damaged

Check cylinder for damage (if damaged, replace cylinder)

Lack of fluid from control valves

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

Possible Cause The isolating valve on the support is closed

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

Support is trapped by adjacent supports

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

Step on roof or floor preventing advance

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

System pressure is too low for operation

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

Pilot piston in the POCV valve is not operating

Check if there is enough pressure to operate the piston (minimum 80 bar) POCV faulty and leg has not lowered Check for damaged or kinked hoses in supply line to face

Damaged or trapped hoses

Advancing cylinder is faulty

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

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Trouble shooting Failure to set the support

Possible Cause The isolating valve on the support is closed

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

Check leg isolation valve (if fitted) is closed

Lines to leg and return must be open to allow raising of support

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

Failure to maintain the leg pressure after setting the support

5.36

System pressure is too low for operation

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

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Legs are damaged

Check cylinder for damage (if damaged, replace cylinder)

Possible Cause Faulty POCV

Check Required Check the POCV by replacing unit

Legs are damaged

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

Faulty Yield valve

Check pressure gauge for reading Is yield valve weeping?

Replace yield valve and check functions

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Trouble shooting Failure to operate the tip function Failure to operate the tip up function

Failure to operate the tip down function

Doc. no.: 7420.046.000.BA.00

Possible Cause The isolating valve on the support is closed

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

Support canopy is trapped by adjacent supports

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

Support canopy is trapped by adjacent side seals

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

System pressure is too low for operation

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

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Stabilising cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

Possible Cause The isolating valve on the support is closed

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

Support canopy is trapped by adjacent supports

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

Support canopy is trapped by adjacent side seals

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

System pressure is too low for operation

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

Pilot piston in the POCV valve is not operating

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Stabilising cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

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

Possible Cause The isolating valve on the support is closed

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

The isolating valve for baselift is closed

Feed line must be open to allow pressure to the cylinder

System pressure is too low for operation

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

Damaged or trapped hoses

Check for damaged or kinked hoses in leg circuit

Baselift cylinder is damaged

Check cylinder for damage (if damaged, replace cylinder)

Shield is not lowered from roof

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

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

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

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

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

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

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

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

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Fault Finding on Shield Support Hydraulic System J

this indicates it is the 3/2-way valve or pilot valve

J

shut off the main isolation valve to the support and operate the manual functions to depressurize the system

J

change the 3/2-way valve or pilot valve

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

If the problem still exists: J

this indicates it is a bypass

J

check/change the POCV

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

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

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

Internal by-pass in leg If an internal bypass in the leg is suspected, this procedure should be followed: J

pump legs up to roof to set pressure

J

isolate the support at the main isolation handle

J

depressurize the control unit

J

remove the leg lower hose from the top of the leg and cap the hose

J

turn on the isolation valve

J

operate the leg raise function from adjacent support

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

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

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

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

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Fault Finding on Shield Support Hydraulic System The permissible pressure for the yield valves in use here is 450 bar and is indicated by a red and white color code.

Faulty burst disk The burst disk can usually be seen to be weeping and a check on the pressure gauge or if the unit is still weeping at setting pressure may indicate a problem.

If the fluid flow is small, the seal may be damaged and must be replaced.

If the flow is high, the disk has ruptured and the disk must be replaced. These are throw away items.

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

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Technical Data

BI628668-00-EN

BI628668-00-EN

Shield Support

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

Shield Support Type 114.3 / 254 - 2 x 4113 kN, Face shield The two-leg shield support units basically comprises the following main components: J

a base with lemniscatic links, a shifting unit, and a base lift cylinder

J

a main canopy

J

a caving shield

J

side seal, welded on at both sides

J

two hydraulic props

J

hydraulic equipment with hose lines and controls

The shield is provided with a solid base which has the two interconnected skids separated by a tunnel. The bases are equipped with different shifting cylinders depending on their use as face shield or as transition shield.

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

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

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

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

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

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

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Shield Support Main Subassemblies Fig. 40

Components of the face shield support type 114.3 / 254 - 2 x 4113 kN according to drawing no. 7420 046 000 00 00

Tab. 2: Components of the face shield support type 114.3/ 254 - 2 x 4113 kN according to drawing no. 7420 046 000 00 00

6.4

Item 1

Qty. 1

Description Base

Order no 7420 046 300 00 00

Weight (kg) 7 880

2 3 10

1 1 2

7420 046 400 00 00 7420 046 800 00 00 8250 032 000 00 00

5 882 3 615 1 011

11

1

Canopy Caving shield Hydraulic prop VHED 4100/2 Stabilizing cylinder

8241 106 000 00 00

149

15

1 1

Hydraulic control Face shield support

8112 056 000 00 00 7420 046 000 00 00

---19 740

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

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Shield Support Base with Lemniscatic Links and Central Shifting Unit Fig. 41

Base

1 Base 2 Lemniscatic link, front 4, 5 Lemniscatic link, rear right / left 8 Ram system 10 Shifting ram 11 Lift cylinder 40 securing elements for transport only, face side 41,42,43 securing elements for transport only, gob side For the components not mentioned here, please refer to the spare parts list provided.

The solid base transmits the support load of the hydraulic props into the floor. The prop holders 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 connection to the conveyor is provided via a universal joint.

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

A base lift cylinder serves for raising the base out of a soft floor during support advance.

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Shield Support Conveyor Pushing Device The conveyor pushing device is arranged in the middle of the base frame. It consists mainly of the relay bar, the conveyor pushing cylinder, the base lifting cylinder and the necessary fastening elements. It serves to advance conveyor and shield support.

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

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

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

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

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

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

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

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

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

The lifting cylinder remains without pressure.

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

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

The support units are provided with an adjustable side seal at the left side.

Fig. 42

Canopy

L1 L2

L2

L3

L4

L4

1 canopy 5,6,7,10 fastening elements for the prop head 8,9,10 fastening elements for the stabilizing cylinder L1, L2 L3 L4

load bearing capacity: 8000 kg load bearing capacity: 3000 kg load bearing capacity: 1000 kg

For the components not mentioned here, please refer to the spare parts list provided.

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

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

Fig. 43

Caving shield

L2

L1

1 5,6 10 7,21 15,31

Caving shield lemniscatic pin Hinge pin fastening elements for stabilizing cylinder securing elements for item 10

L1 L2

load bearing capacity: 8000 kg load bearing capacity: 3000 kg

For the components not mentioned please refer to the spare parts list provided.

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Shield Support Technical Data of Shield Support applicable to face shield and transition shield.

Closed height

. . . . . . . . . . . . . . . . . . . . . mm

1 143

(only for transport, lift cylinder removed)

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

2 540

Hydraulic height adjustment of shield . . mm

1 397

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

1 067 1 130

Distance of prop centers (inclination) . . mm

890

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

3 470

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

1 250

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

1 700

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

4 720

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

3.93 45.05

Width of caving shield, incl. side seals . mm

1 700

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

1 680

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

39 865

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

1 750

Support resistance at average seam height of . . . . . . . . . . . . . mm a) at 320 bar setting pressure . . . . . . . . . kN b) at 440 bar yield pressure . . . . . . . . . . kN

2 032 5 423 7 456

Specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 2 032 a) at 320 bar setting pressure . . . . . . . . kN/m2 598 b) at 440 bar yield pressure (distance canopy tip to face low / high) . kN/m2 682 / 822

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Hydraulic System

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

Normal and exceptional operation

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

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

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

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

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Hydraulic System Shield Hydraulics Fig. 44

1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 20 21 22 23

Hydraulic components at the shield support

Control valve block Prop check valve Check valve Twin check valve Check valve Line filter Double Filter, backflushable Block ball valve Ball valve Ball valve Block ball valve Pressure gauge Yield valve F, 420 bar Yield valve, 440 bar Valve for water spray system Manifold pipe Compensation valve Yield valve, 70 bar Shield control components please refer also to the spare parts book

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Hydraulic System Fig. 45

Hydraulic Flow Plan, overview

1 Control valve block 2 Prop check valve 4 Check valve 5 Twin check valve 6 Check valve 7 Line filter 8 Double Filter, backflushable 9 Block ball valve 10 Ball valve 11 Ball valve

12b

12 Block ball valve 13 Pressure gauge 14 Yield valve F, 420 bar

Manifold pipe Compensation valve Yield valve, 70 bar Shield control components

Z1 Z2 Z3 Z4

Prop D.A ram Stabilizing cylinder Lift cylinder

12a

20 21 22 23

12d

15 Yield valve, 440 bar 16 Valve for water spray system

Z4

please refer also to the spare parts book

Z1

Z1

12c

Z2

Z3

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Hydraulic System Fig. 46

Hydraulic lines of the shield support, overview

1 Control valve block 2 Prop check valve 4 Check valve 5 Twin check valve 6 Check valve 7 Line filter 8 Double Filter, backflushable 9 Block ball valve 10 Ball valve 11 Ball valve 12 Block ball valve 13 Pressure gauge 14 Yield valve F, 420 bar 15 Yield valve, 440 bar 16 Valve for water spray system 20 Manifold pipe 21 Compensation valve 22 Yield valve, 70 bar 23 Shield control components Z1 Z2 Z3 Z4

Z1

Z1 Z4

Prop D.A ram Stabilizing cylinder Lift cylinder

Z2

Z3

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Hydraulic System Fig. 47

Water spray system of the shield support, flow plan

16

12d

1, 2 3,4 5,6 12d 16

6.14

Nozzle holder Nozzle holder Nozzle Block ball valve Water spray valve

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

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

Bottom and top end of the prop are designed as a globe joint. This allows to join the prop to the base and the canopy with angular articulation.

The cams at the bottom end of the prop will be fixed at the base using bolted arresting devices.

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

Figure 48 shows the telescopic prop used at the face shield. The telescopic prop used at the gate-end shields is of same construction but longer because of the greater extended height of the gate end shield. See spare parts book.

Fig. 48 Double-telescopic prop type VHED 4100/2, in use at the face shield and transition shield ball R 90

retracted 1025 stroke lower stage 585 extended 2245 stroke upper stage 635

2 3 4 20

ball R 200

outer prop center prop bottom valve piston rod

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

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

Observe the warning plate at the cylinder surface.

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Hydraulic System Operating props Setting

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

Load acceptance (resistance)

Load is transmitted mechanically from the canopy to the inner prop via the prop head and, then, to the valve housing installed in the center prop. The hydraulic pressure under the center prop cannot exceed the pre-determined value, as a pressure relief valve is installed in the respective control valve. When the preset pressure is exceeded, the pressure relief valve will open and permit fluid to escape; it is important to note, however, that this yield of the prop will occur without a decrease in the rated prop resistance. b) Center Prop and Inner Prop Extended Load is transmitted mechanically from the canopy to the inner prop via the prop head. The inner prop bears on the pressure fluid under its piston. This fluid is trapped by the check valve. If load in excess of the rated load is applied, the center prop will gradually lower, as fluid escapes through the pressure relief valve. Just before the piston of the center prop reaches its lowest position, the tappet of the check valve strikes against the bottom of the outer prop and the check valve opens. As fluid escapes now from the piston surface area of the inner prop through the check valve, the fluid will raise the piston of the center prop and the check valve closes again. This process is repeated several times until the entire stroke has been used up.

Lowering

6.16

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

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

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Hydraulic System Hydraulic Cylinder, double and single acting Design

The following figure shows the main components of a hydraulic cylinder

Fig. 49 Hydraulic cylinder, example main components Type a)

2

1

3

5

4

Type b)

2

3

1

4

6

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

The end of the piston rod can either be attached directly or it is designed in such a way that the means of attachment - e.g. rod head or fork head - can be screwed on and secured against working loose by clamping screws or a spring dowel sleeve.

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

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

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

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

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

If a double-acting cylinder is to be used as single-acting cylinder only, the annulus connection must be provided with a screw with filter element to avoid contamination by dirt.

If the cylinder is used without the seals which seal off the annulus, the grooves for the seals have to be filled with lubricating grease.

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Hydraulic System Shifting cylinder Fig. 50

Shifting cylinder type SC135/90-1130

stroke 1130 retracted 1469 extended 2599

3 4 21 22 28

cylinder pipe reed rod piston rod piston toric magnet

please refer also to the spare parts book

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BI628668-00-EN

Hydraulic System Technical Data of Hydraulic Cylinders Double-Telescopic Prop, double-acting - 2 stages

Shifting Ram double-acting, el. connection, reverse-mounted

Stabilizing Cylinder, double-acting

Doc. no.: 7420.046.000.BA.00

Type VHED 4110/2, drawing no. 8250 032 000 00 00 Prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1 025

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

2 245

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

1 220

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

345 / 260

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

325 / 230

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

934.8 / 530.9

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

115.5 / 105.2

Prop force at 320 bar setting pressure . . . . . . . . . . . . . . . . . . . . kN

2991

Prop force at 440 bar yield pressure . . . . . . . . . . . . . . . . . . . . . . kN

4113

Retracting force at 320 bar . . . . . . . . . . . kN

369

Drawing No. 8241 085 000 00 00 (equipped with reed contact rod and distance bush at the piston side) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1 130

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

135

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

90

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

143.1

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

79.5

Thrust at 320 bar . . . . . . . . . . . . . . . . . . . kN

458

Pulling force at 320 / ---- bar . . . . . . . . . . . . . . . . . . . . . . . kN

254 / ---

Drawing No. 8241 106 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

420

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

165

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

100

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

213.8

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

135.3

Thrust at 320 / 440 bar . . . . . . . . . . . . . . kN

684 / 940.5

Pulling force at 320 / 440 bar . . . . . . . . . kN

433 / 595.4

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Hydraulic System Base Lifting Cylinder, double-acting

6.20

Drawing No. 8241 105 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

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

125

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

90

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

122.7

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

59.1

Thrust at 320 / --- bar . . . . . . . . . . . . . . . . kN

393 / ---

Pulling force at 320 / --- bar . . . . . . . . . . kN

189 /---

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

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

For the type of valve used please see the hydraulic flow plan or the parts list.

CAUTION! The pressure setting must not be changed.

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

NOTICE! New seals must be fitted whenever a pressure relief valve is repaired. Failure to do so may cause malfunction resulting in serious bodily injury or death.

Fig. 51 Pressure Relief Valve drawing no. 7337 486 010 00 51, example

1 Switch pin 2 Nipple NW 8/10 3 Piston guiding sleeve 4 Housing 5 Spring washer 90 ... 110 l/ min 6 Screw fitting 440 bar 7 Compression spring 8, 9 Support ring Color identification: red 10 Screw pin 11, 13 Oil valve body 12 O-Ring seal 15 Dust cap NW 8/10, (Assembly for transport chain tension device)

Doc. no.: 7420.046.000.BA.00

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

Color Identification of Pressure Relief Valves

6.22

Color

Pressure range (bar)

black

0 - 49

black-and-white

50 - 99

brown

100 - 149

brown-and-white

150 - 199

green

200 - 249

green-and-white

250 - 299

blue

300 - 349

blue-and-white

350 - 399

red

400 - 449

red-and-white

450 - 499

yellow

500 - 549

yellow-and-white

550 - 599

orange

600 - 649

orange-and-white

650 - 699

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Electro-Hydraulic Control System

Electro-Hydraulic Control System Fig. 52 Control valve block, drawing. no. 8154 037 000 00 00

1

2 3 4

5 1 Control valve block 2 Pilot control valve for electromagnetic operation 3 Push-button for manual operation 4 Plug contact, electrical connection to the control unit 5 Filter cartridge

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

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

Doc. no.: 7420.046.000.BA.00

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Electro-Hydraulic Control System PANZERMATICÒ PM-4/A Fig. 53

PanzermaticÒ PM-4/A with electric lines

x

1 control unit 4 solenoid driver 5 pressure sensor

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

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BI628668-00-EN

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.

Angle a1 measured with extended stabilizing cylinder: a1 µ ..... ° at M = ..... mm

Angle a2 measured with retracted stabilizing cylinder: a2 µ .....° at M = ...... mm .

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

Doc. no.: 7420.046.000.BA.00

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Hydraulic Fluids of Group HFA

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

Hydraulic fluid concentrates List of approved water-miscible hydraulic fluid concentrates for the production of barely inflammable hydraulic fluids of Group HFA. Tab. 3: Approval list (Part 1)

Manufacturer

Recommended concentration for use with process water according to the chemical composition.

Test water Type: X

Test water Type: Y

Test water Type: Z

ARAL Lubricants

P 87 AF

not tested

1,5 %

3%

Carl Bechem

Fimitol P 87 AF

not tested

1,5 %

3%

Castrol

Anvol C 18

not tested

5%

not tested

Anvol C 19

not tested

5%

not tested

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 3 A

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

not tested

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1,5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1,5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

Quintolubric 814-01

not tested

5%

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

Fuchs/Century

6.26

Product designation

not tested not tested

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN

BI628668-00-EN

Hydraulic Fluids of Group HFA Tab. 4: Approval list (Part 2)

Manufacturer

Product designation

Recommended concentration for use with process water according to the chemical composition.

Test water Type: X

Test water Type: Y

Test water Type: Z

GS 460 N

not tested

1,5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1,5 %

Hydrocor TS 100 N

not tested

2%

not tested

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTheunissen

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

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

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

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

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

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

For use in international mining, the relevant national regulations must be observed. Approval by the responsible authorities may be necessary. Responsibility for the approvals procedure lies with the equipment operator.

Suitability of the Hydraulic Fluid The suitability of the hydraulic fluid for use in mining equipment must be demonstrated by positive experience in practice. Should a product exhibit any negative characteristics during operation, we reserve the right to delete the product from our approval list.

Working Concentration of the Hydraulic Fluid The recommended working concentration of the products essentially corresponds to the concentration at which the product passed the crevice corrosion test in accordance with the DBT Works Standard or RAG Standard.

Doc. no.: 7420.046.000.BA.00

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Hydraulic Fluids of Group HFA Quality of the Process Water The quality of the process water is a critical factor for the functional reliability of the emulsion.

The water must contain no solid or liquid impurities and must satisfy the bacteriological requirements for drinking water (DIN 2000).

The figures quoted for the concentration of the hydraulic fluids were obtained from trials with test water samples.

The chemical composition of the test water samples used are shown in the table below for your orientation.

Tab. 5: Chemical Composition of the Test Water Samples Used

Test water Type: X (NCB 18 accord. to Luxemburger report)

Test water Type: Y (DIN 24320 resp.

Luxemburger report)

Test water Type: Z (NCB 19 accord. to Luxemburger report)

pH value:

6,5 - 8,5

6,5 - 8,5

6,5 - 8,5

Hardness mmol/l:

2,5 (=14°d)**

3,57 (= 20°d)**

7,5 (= 42°d)**

Chloride:

200 mg/l

201 mg/l

200 mg/l

Sulfate:

240 mg/l

150 mg/l

720 mg/l

Nitrate:

0 mg/l

20 mg/l

0 mg/l

Iron:

0,3 mg/l*

0,3 mg/l*

0,3 mg/l*

Magnesium:

30 mg/l

50 mg/l

90 mg/l

* These values deviate from the quoted standard or from the Luxemburger Report. ** °d = degree German hardness (is no longer permissible in accordance with the applicable legal regulations. The information given is intended only for orientation.

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

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

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

the pH value.

J

the concentration.

– Test method: by agreement with the concentrate manufacturer J

the microbial load.

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

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Recommended Lubricating Greases and Pastes

Recommended Lubricating Greases and Pastes Lubricating Greases General Properties

Base:

Lithium soap

NLGI class:

2

Penetration:

265 to 295 (0.1 mm)

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

-20 to +120 oC

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

Tab. 6: Lubricating greases for general application

Supplier ARAL BP ESSO MOBIL SHELL TEXACO CALYPSOL

Type Aralub HL 2 BP Energrease LS 2 BEACON 2 MOBILUX 2 Shell Alvania Grease R 2 MULTIFAK 20 Multipurpose grease 20

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

Lubricating greases for application under high pressure

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

Tab. 7: Lubricating greases containing additives

Supplier ARAL BP ESSO MOBIL SHELL TEXACO

Type Aralub HLP 2 BP Energrease LS-EP 2 BEACON EP 2 MOBILUX EP 2 Shell Alvania E.P. Grease 2 MULTIFAK EP 2

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

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

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

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

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

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

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

Tab. 8: Lubricating pastes free from molybdenum disulfide Supplier

Type

gleitmolybdän

gleitmo

805 1)

Klüber Lubrication

Altemp Q NB 50

Liqui Moly

LM 841 1)

2)

Base

NLGI class

Li

2

Ba-complex

2/3

Li

2

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

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

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

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

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

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Tightening Torques

Tightening Torques Screws with Metric Coarse Thread DIN 13 Tab. 9: Recommended Tightening Torques at mtotal = 0.14 Thread 1)

Pitch

Tightening torque 4)

(mm)

(mm)

MA (Nm)

d

P

8.8

10.9

12.9

M8

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

3

535

-

-

3

965

1360

1630

DM 24

2)

(M 27) DM 27

2)

3

580

-

-

M 30

3,5

1310

1845

2215

M 32 3)

2

-

1450

-

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

M 64 5)

4

-

13500 6)

-

-

6)

-

M 72

5)

4

16000

1) Dimensions in brackets in exceptional cases only 2) According to works standard (EWN 6110), February 1985 edition 3) Only for necked down bolts having a shaft diameter (reduced shaft diameter) of 24.2 mm.

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

5) It is only allowed to use a approved special tool to tighten this kind of screws.

6) DBT-speciifications

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

Doc. no.: 7420.046.000.BA.00

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For Your Information

BI628668-00-EN

BI628668-00-EN

Our Service

For Your Information Our Service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly.

Service address USA

MTA -MINE TECHNIK AMERICA Inc. Service 2045 West Pike Street Houston, PA 15342-1010

Germany

Phone:

412 / 743 - 1200

Fax:

412 / 743 - 1201

DEUTSCHE BERGBAU-TECHNIK GmbH Service Bornberg 97 or 42109 Wuppertal

Doc. no.: 7420.046.000.BA.00

Postfach 10 02 69 42002 Wuppertal

Phone:

0049 / 2 02 / 75 90 0

Fax:

0049 / 2 02 / 75 90 421

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

Designation DIN EN 292/1 DIN EN 292/2 DIN EN 60445 DIN 2000 DIN 6789 DIN 8418 DIN 20043 DIN 21555 DIN 24320 DIN 24343 DIN 24346 EWN 6003 EWN 7068 EWN 7069

7.4

Title Safety of Machinery Safety of Machinery Identification of Connections Quality of drinking water Documentation System Information for Users Plug Connectors for Hydraulics Graphic Symbols for Self-Advancing Supports Fire Resistant Hydraulic Fluids Maintenance and inspection list for hydraulic installations Hydraulic Systems; Design Principles Tensioning force, tightening torque and surface pressure for steel bolts Lubricating grease and solid lubricants Nonmetallic surface protection

DBT - Shield Support 114.3 / 254 - 2 x 4113 kN