CAT Roof Support Shield support 12502780-2X3056-1500 Operation Manual

BI622821

Operating Manual Shield support 1250/2780-2X3056-1500 Doc. no.: 7420 165 000 BA 00

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

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

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

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

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

Bucyrus Europe GmbH, Lünen 2009E

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Contents

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

1.3

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

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

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

1.3 1.4 1.4

2. Your safety 2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3

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

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

3.3 3.4

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

3.5

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

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

3.5 3.5

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

4.3

Installation of the side flaps . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of lower protective wall . . . . . . . . . . . . . . . . . . . .

Installation upper protective wall . . . . . . . . . . . . . . . . . . . . . .

Installation relay bar assembly, exterior . . . . . . . . . . . . . . .

4.3 4.5 4.5 4.7

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

4.8

Pressure equalization of the electronic control system . . .

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

Establish a link between the connections . . . . . . . . . . . . . .

4.9 4.10 4.12

Requirements for the face hydraulic system . . . . . . . . 4.13 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

4.14 4.16

Corrosion protection of hydraulic components . . . . . 4.16

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

5.3

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

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

5.3 5.6

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

5.9

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

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

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

Plug with pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retracting or extending side seal . . . . . . . . . . . . . . . . . . . . .

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

Operation and functions of the electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15 5.16 5.22 5.31 5.33 5.34 5.36 5.40 5.41 5.42 5.42 5.42

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

Fault localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

5.43 5.43 5.46 5.46 5.47 5.47 5.47

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

6.3

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

Main dimensions not including additional equipment . . . . .

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

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

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

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

Side flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective wall on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective wall on side seal . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.4 6.6 6.7 6.13 6.15 6.18 6.20 6.20 6.21 6.22

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

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

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

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

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

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

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Contents Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 Shield control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R electronic control unit . . . . . . . . . . . . . . . . . . . . . . .

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

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

Technical data, hydraulic cylinder . . . . . . . . . . . . . . . . . . . .

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

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

6.23 6.24 6.25 6.27 6.30 6.32 6.34

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.35 6.37 6.39

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.41

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7. For your information

Doc. no.:7420 165 000 BA 00

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

7.3

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

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

America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

7.3 7.3 7.4 7.4 7.4 7.5

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

7.6

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

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

7.6 7.7

Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.8

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

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

7.8 7.8

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Contents

Shield support 1250/2780-2X3056-1500

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1

About this manual

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Before starting work

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

Before starting work applicable operating manual

shield type

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

This operating manual belongs to the: shield support 1250/2780-2X3056-1500 * ID No.:

7420 165 000 00 01

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

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

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

Send for a new operating manual immediately if the present operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the shields.

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

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

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

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

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Before starting work Purpose of this operating manual efficiency

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

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

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

service

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

safety

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

Observe this information and follow the procedural instructions.

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

Danger!

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

Warning!

These points contain information on hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

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

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

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

1.4

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Try to memorize the symbols and their meanings.

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2

Your safety

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Personnel

Your safety This chapter provides important information for your safety.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

J the hydraulic system,

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

2.4

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

Use the shield only as intended.

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

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

– advancing Bucyrus Europe GmbH, Lünen 2009

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– retracting J forming a thrust bearing for:

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

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

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

shield J setting of the canopy in roof falls.

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

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

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Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signaling systems and safety equipment in working condition.

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

EMERGENCY STOP

support lock-out switch

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

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

moving parts

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

automatic mode

2.6

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

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signaling systems and safety equipment

Maintain the lighting systems in a functional condition.

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lighting system

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

Never stand under unsecured or suspended loads.

Observe the specified storage periods and the storage instructions.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Fig. 1:

transport safety devices

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

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

travel way

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

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

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Safety instructions Operation shield control

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Safety instructions shield alignment

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

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

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

roof falls

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

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

exceeded,

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

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

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

retracting the conveyor

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

Secure all mining equipment against unauthorized starting.

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

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

raising the conveyor

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

Only use the points of attachment intended for that purpose.

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

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

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

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Bucyrus Europe GmbH, Lünen 2009

J the canopy will be loaded excessively in the longitudinal direc-

E

J the stabilizing cylinder locks,

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

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

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

J lifting tackle of adequate load-carrying capacity.

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

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

E

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

Bucyrus Europe GmbH, Lünen 2009

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

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

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

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

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

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

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

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

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

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

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

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

pressure or mechanical stress.

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

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

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

Hydraulic system handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

protective devices - hydraulic system

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

maintenance, repair

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

pressure relief valves

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

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

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

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

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

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

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

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Bucyrus Europe GmbH, Lünen 2009

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

Fig. 2:

Example hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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Safety instructions laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 4:

Laying a hydraulic hose, twisted WRONG

J are not bent directly behind the connectors (distance minimum

1.5 x nominal diameter), Fig. 5:

Laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe, Fig. 6:

2.14

Laying hydraulic hoses, crossing RIGHT

WRONG

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RIGHT

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

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

When installing the hydraulic hoses, make sure they cannot be: J torn out J kinked, J crushed, J driven over J twisted (Fig.: 7).

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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Safety instructions

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3

Storage and transport

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Storage

Storage and transport This chapter contains important information concerning the proper storage and transport of the shields.

Observance of the instructions and tips will increase the service life of the shields. In addition, you will be instructed to perform the tasks involved with transport safely and efficiently.

Reading this chapter carefully will help you to simplify your day-today work.

Storage Storage of new equipment anticorrosion protection

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Always store all electrical equipment, electronic components, spare parts made from rubber or plastic - such as seals and hoses - and hydraulic fluids in closed rooms at 15°C to 25°C.

moisture and dirt

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

E Bucyrus Europe GmbH, Lünen 2009

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

You need to protect the connecting faces of hydraulic components from corrosion and seal them with blind plates. Protect the hydraulic plug-type connections and the connectors of the electrical cables with the caps and plugs supplied. short-term storage

long-term storage

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

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

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

This inspection can be carried out by Bucyrus upon request.

natural aging

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

Important!

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

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

If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor (e.g. HYDROCOR® CV 50). If this is not done, the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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

*

3.4

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

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

Where technically possible, the load units have suitable lifting pointsfor transport and installation.

Warning!

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

Falling components can cause serious injury and death.

Use only suitable load handling devices.

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Before transport freezing temperature

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

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

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

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

electrical and electronic components

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

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

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Transport transport units

A support unit can be transported as a completely assembled unit or divided into subassemblies. If it is necessary to disassemble it into transport units, this is planned and agreed upon in close cooperation with the customer.

Tab. 1: Transport units Designation

Transport position

Remarks

Complete support unit

General purpose

Without side flap, protective wall and relay bar assembly, exterior

Side flap Protective wall 1 Protective wall 2 Relay bar assembly, exterior transport securing devices

For the purpose of safe transport, the movable parts of every transport unit are to be fastened in addition to the standard available transport securing devices, e.g. on side seals and flipper, so that their positions cannot shift inadvertently. Specifically, the following listed transport securing device are provided on the transport units.

Transport securing devices

Side seal, movable

Pin and securing element

4

Quantity

Relay bar Transport rod

1

Flipper

Faceside

Holding plate with screw

1

Hydraulic system

Hydraulic connections not used are protected by protective caps or plugs

-

Caution!

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

Caution!

If the attachment points on the caving shield are to be used to transport the assembled head drive, the canopy and base must first be mechanically connected to each other using an additional transport securing device so that they cannot move apart.

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Part

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Tab. 2: Transport securing devices on the shield

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Transport Fig. 8:

Transport of the shield support as a complete unit, without side flap, protective wall and relay bar assembly, exterior

S2 S0 Sy

H

SP

X1

Sx

S1

L S3 55

B

1200

810 1440

S2

S2

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S3

S1 Bore, 2x on the coal face end on the base, capacity: 8000 kg S2 Transport ring, 2x on the caving shield, capacity 8000 kg S3 Transport ring, 2x gobside on the bases, capacity: 8000 kg X1 Transport securing device for relay bar, faceside So Center of gravity

Important!

For transporting, use the four lifting eyes S1 and S2.

Tab. 3: Type specification for Shield 1250/2780-2X3056-1500 Device number Prop force Year of manufacturing Application 7420 165 000 00 01 2X3056 kN

2009

Segment shield

Tab. 4: Shield support 7420 165 000 00 01, dimensions and weights Device number 7420 165 000 00 01

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Length L in mm

Width B in mm

Height H in mm

Sx/Sy in mm

Weight in kg

6951

1580

1250

1267/731

18 863

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

Transport securing device, relay bar assembly (faceside)

b

b

a transport rod

b spring clips 2x

Transport securing device, flipper Fig. 10: Transport securing device, flipper

20

18

19

18 locking plate 19 hex. head screw M 16X55-A 2-70

3.8

20 hex. nut M 16-A 2-70

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a

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Transport Transport securing device, side seal For transport the movable side seals are retracted and locked mechanically with pins. The pins are secured using coupling clips see also chapter 6, “Side seal” section.

Fig. 11: Transport securing device, side seal

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b

a pin 22x128

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b coupling clip DN 12

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Transport Transport, side flap

215

Fig. 12: Side flap, R.H. design

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Weight: 615 kg

Transport, protective wall Fig. 13: Protective wall 1, L.H. design

180

2

Weight: 490 kg

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Transport

205

Fig. 14: Protective wall 2, L.H. design

Weight: 471 kg

Transport, relay bar assembly, exterior

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Fig. 15: Relay bar assembly - exterior

Weight: 244 kg

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Transport

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4

Installation

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Pre-assembly of the support units

Installation In this chapter, you will be given information about installing the support units. Please pay special attention to the warnings and tips.

Warning!

In addition to the safety instructions given in this manual, also make sure you observe the special safety instructions and operation instructions which apply to the operation of the mine.

Failure to do so can lead to extremely serious accidents which may be fatal.

Caution!

Before the hydraulic connections are joined with one another, the coupling sockets and nipples of the plug-O connections must be treated with the molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See Chapter 6, Section “Lubricating greases and pastes”.

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Caution!

All of the slide surfaces must be treated with the molybdenum disulfide-free B6 lubricating paste in accordance with EWN 7068 before the transport subassemblies of the steel structure are connected with one another. See Chapter 6, Section “Lubricating greases and pastes”.

Pre-assembly of the support units The support units are delivered completely pre-assembled. Accordingly, no further pre-assembly is required on the mechanics and hydraulics of the support units.

The installation parts that are mounted externally such as the side flap, protective wall and relay bar assembly are delivered individually.

Installation of the side flaps The side flaps are delivered as a complete unit. For installation the brackets (see Fig. 16, item 2) must be removed from the complete unit.

. Remove the locking clips (7) and the pins (5) which connect the hydraulic cylinders with the brackets.

. Remove the locking clips (6) and the pins (4). . Fasten the three brackets (2) on the side seal using hammer head bolts (9), washers (8) and hex. nuts (10).

. Install the side flap (1) on the brackets (2) using six pins (4) and secure the pins with locking clips (6).

. Re-install the hydraulic cylinder using pins (5) securing them with locking clips (7).

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Pre-assembly of the support units . Join the hydraulic connections to the shield.

Fig. 16: Installation, side flap

2

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1

3 4 6

8, 9, 10

5, 7 2

1 2 3 4 5

4.4

side flap bracket hydraulic cylinder ZE-75/60-150 pin, 40x120 pin 20x80

6 7 8 9 10

locking clip 4.5 locking clip 3.2 washer 24 hammer head bolt M 24X80-8.8 hex. nut M 24-8

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Pre-assembly of the support units Installation of lower protective wall

. Fasten the two brackets (2) on to the base using pins (4). Secure the pins with locking clips (7).

. Insert fasteners (3) into the side plate and turn them by 90 degrees.

. Position the side plate (1) onto the brackets (2) and guide the fasteners (3) into the mounting devices on the base.

. Fasten the side plate using pins (4) and secure them with lokking pins (7).

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Fig. 17: Installation protective wall 1

Bucyrus Europe GmbH, Lünen 2009

3 4

7 1 7 2

4

1 side plate 2 bracket 3 support

4 pin 50/35X147 7 locking clip 4

Installation upper protective wall

. Fasten the bracket (see Fig. 18 item 1) on the side seal using six hammer head bolts (8), washers (10) and hex. nuts (9).

. Hang the side plate (3) onto the mounting device on the brakket.

. Push the securing devices (2) through the square holes on the side plate.

. Fasten the securing device using pins (4) and secure them with locking pins (7).

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Pre-assembly of the support units Fig. 18: Installation protective wall 2 Fastening the bracket

1 8

4

4.6

bracket securing device side plate pin 50/35X147

3

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7

Fastening the wall

1 2 3 4

9 E

10

2 7 8 9 10

locking clip hammer head bolt M 24X80-8.8 hex. nut M 24-8 washer 24

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Pre-assembly of the support units Installation relay bar assembly, exterior Fig. 19: Installation relay bar assembly, exterior

10 11

1

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15

1 hydraulic cylinder ZE-150/90-700 10 mounting device

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11 pin, 65/58x145 15 locking element

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BI622821

Installation of the support units Installation of the support units Caution!

For transport underground, only the lifting points described in greater detail in Chapter 3 “Transport” may be used. Further information about this can be found in Chapter 3 “Transport”.

Failure to comply can lead to personal injury and damage to property. installation plan

The support units are installed in the face according to the installation plan of the mine.

Important!

When installing the shields in the face, be sure to pay attention to the shield numbers. Since some support units may be provided with different functions, their arrangement on the face is not arbitrary!

The shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the left-hand base on the shield.

Fig. 20: Shield number on the base, example

Tab. 5: Allocation of the shield numbers Shield number 1 and 2 162 and 163

4.8

Device number 7420 165 000 00 01

Use Segment shield on the head-end drive Segment shield on the tail-end drive

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shield number

In order to identify the support units or their transport units more easily for the purpose of assembling and installing in the face, they should be labeled with a sequential number. They should correspond to the order in which the support units are to be arranged in the face, for example. The numbers should be written in color so that they are clearly visible on the surface of the parts.

Bucyrus Europe GmbH, Lünen 2009

identification for installation in the face

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Installation of the support units Pressure equalization of the electronic control system The support units can be utilized in a number of different height positions at various prevailing air pressure levels.

These are equipped with a vented cap screw in order to enable pressure equalization between the internal and external pressure of the electronic control system housing.

. Release the pressure relief screw (hex socket 4 mm key width) on the control system with several rotations.

Pressure equalization is signalled by an audible hissing.

Caution!

Take care to ensure that the vented cap screw is released for the purpose of pressure equalization at the control system. The foil displays may become damaged if no pressure equalization is established.

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Fig. 21: Example of a vented cap screw on an electronic control system

a

b a vented cap screw

b electronic control system PMC®-R

. Afterwards, rotate the pressure relief screw until it is once again hand-tight.

Caution!

Take care to ensure that the vented cap screw is made handtight again after pressure equalization at the control system. If this is not done, then dirt and moisture could penetrate the control unit and firedamp protection is no longer ensured.

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Installation of the support units Supply connections During installation, pressure can be applied to the individual shield using the so-called auxiliary supply and operated. The auxiliary supply must be connected to connections a and b (Fig. 22).

Fig. 22: View of the supply block and the auxiliary connections (supply lines are bypassed for transport)

13

32 12

a

34 b E

P

c 1 16 W2

W1

1 electrohydraulic control unit (hidden behind the supply block) 12 PRV (80 bar) in the return line 13 supply block 16 plug DN 10 with pressure relief 32 HP ball valve DN 12, for auxiliary supply 34 HP ball valve DN 25, in the pressure supply line to the shield

a pressure line auxiliary supply b return line auxiliary supply c screw plug on chain for auxiliary supply P pressure line, DN 25 R return line, DN 32 W1 water line, DN 50 W2 water line, DN 20

Notice!

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

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Installation of the support units Fig. 23: Plug on the supply block

12

13

16 a 12 PRV (80 bar) in the return line 13 supply block

16 plug DN 10 with pressure relief a vented cap screw

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For operating the shield with the help of the auxiliary supply, the shield functions must be activated via an additional external PMC®-R control unit. This is connected to the internal PMC®-R control unit via a corresponding cable (see separate operating manual for the PMC®-R control unit).

The connections for the auxiliary supply are in front of the supply block (see Fig. 22 and the hydraulic circuit diagram, Fig. 35, in chapter 5).

For utilization of the auxiliary supply, the connections P, R, W1 and W2 (see Fig. 22) on the supply block with the hoses that will later be responsible for the connection to the neighboring shield must be blocked and bypassed - as a rule, this corresponds to status at the time of delivery. Should the blocking of the supply hoses not be possible in this way, then the connections must be sealed with corresponding plugs.

To connect the shields with one another, proceed as follows:

. Close the HP ball valves at Items 32 and 34 (see Fig. 22). . Remove the plugs c from connections a and b (see Fig. 22) of the auxiliary supply.

. Connect the auxiliary supply to the pressure and return line of the pump.

. Afterwards, reopen the HP ball valves at Items 32 and 34.

The shield is now movable via the external control units.

. Move the shield to the desired position.

To relieve pressure on the pressure hose,

. bypass the HP ball valve, item 32, and activate the function “Advance conveyor” briefly until the pressure hose is relieved (support is not yet connected to the conveyor).

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Installation of the support units Warning!

Pressure may build up in the return line due to incorrect operation (for example: closed return line). It must be reduced through the pressure relief valve (Item 16 see Fig. 23) by screwing in the vented cap screw. After relieving the pressure, this screw must be screwed all the way out again.

Make sure that all hose lines are free of pressure before you undo the connection lines at the supply block!

. Relieve the connections of the auxiliary supply. . Disconnect the connection lines of the auxiliary supply and seal the connections with the plugs.

. Loosen the four connection lines P, R,W1 and W2 on the supply block and connect them with the neighboring shield.

Establish a link between the connections

The supply block for supplying the shield hydraulics is located in the middle under the canopy in front of the props. The connection to the supply block of the neighboring structure is made using four hose lines: one pressure line DN 25, one return line DN 32, one water line DN 50 and one water line DN 20, see also Fig. 22 and the hydraulics schematics in Chapter 6 of these operating instructions.

lectrical shield control system

Each support unit is equipped with a model PMC®-R electronic control unit. The control unit and the electrohydraulic control unit are connected via a solenoid driver module. The connection cables required for this are included in the scope of delivery of the PMC®-R control system.

For more details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control system.

An overview of the design of the control system is also given in Chapter 6 of this operating manual in the Section “Shield control”.

additional equipment

The shield units are designed to accommodate the installation of additional equipment which is not included in the Bucyrus scope of delivery. For example: J lighting system, J two-way intercom system.

The information required for the installation of additional equipment can be found in the corresponding operating manual of the respective manufacturer.

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hydraulic system

E

The hydraulic connections on the support units are designed as plug connections in accordance with DIN 20043, which is standard for German mining.

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

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

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

pressure, permissible

Nominal pressure: . . . . . . . . . . . 320 bar Admissible tolerance: . . . . . . . . . ± 10% of nominal pressure If the face hydraulics are designed such that they are unstable or too weak, there could be a temporary pressure drop during operation.

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

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

Bucyrus Europe GmbH, Lünen 2009

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Caution!

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

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

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Commissioning Commissioning Warning!

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

Notice!

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

See Chapter 3, Section “Transport”.

To be observed prior to start-up Start-up may only be carried out by trained and qualified personnel.

If the support is being used for the first time, it is absolutely imperative that the start-up be carried out under the direction of the Bucyrus installation service.

Please observe the following items:

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

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

. Check all mechanical connections on the support units. . Check the plugs of the relay bar assembly.

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

J Hydraulic system:

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

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

Danger!

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

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

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

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

1) maximum possible plugging.

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J Mechanics:

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

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

J Signalling and lighting systems, information plates:

Important!

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

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

E

. Check whether the face area, especially the travel way, has Bucyrus Europe GmbH, Lünen 2009

sufficient signage. It is imperative that you observe the regulations of the responsible mines inspectorate.

J EMERGENCY STOP systems:

. Check that all EMERGENCY STOP systems function properly.

J Mining and conveying:

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

Warning!

Bent support canopies may not project into the mining area.

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Corrosion protection of hydraulic components How to put the support into operation Move the support units to their original positions, i.e.: J shields and conveyors are aligned in a straight line.

J the shields are aligned at right angles to the conveyor.

J the shield canopies are aligned parallel to the floor.

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

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

face.

. Check all functions of the shield control unit.

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

Corrosion protection of hydraulic components The Bucyrus hydraulic components are checked before delivery with an anticorrosion medium.

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

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

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Warning!

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

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

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5

Operation

BI622821

BI622821

Requirements

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

Danger!

You are only allowed to operate the shield control system if you have extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control system and have consolidated your knowledge during a corresponding training session on the object. Should this not be the case, you are not allowed to operate the control system! Inform your superior immediately and request the required training.

Bucyrus Europe GmbH, Lünen 2009

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Warning!

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

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

Requirements Operating conditions face crew

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

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

face equipment

The face and the entry must be sufficiently lit.

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

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

conveyor overload

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

In the event that this breaking up cannot be accomplished to the extent required, then the layers of coal and rock may not be transported until it is has been ensured that nobody will endangered as a result. Any work on the face must be stopped until the transport of the rock and coal layers has been completed.

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Requirements travel way

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

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

600 mm,

Height: 400 mm.

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

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

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

roof support work

work in the mining area

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

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

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

With greater thicknesses, the coal face must also be protected against the coal collapsing in these places. On faces equipped with shield supports, this is best done by using flippers.

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

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

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

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

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

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

BI622821

Requirements repair work

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

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

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

If in exceptional cases, the pretension cannot be relieved completely, it must be reduced as far as possible and the respective part must be secured by suitable means, such as chains or locking elements, so that the tension can be safely absorbed as it is released.

All work in this area may only be carried out from a safe position.

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

The water spraying system serves to actively fight against the dust.

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

conveyor steering device

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

Bucyrus Europe GmbH, Lünen 2009

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water spraying system

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

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

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Requirements Safety requirements automatic mode

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

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

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

operating the support unit

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

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

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

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

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

Advancing should started in the lower section and move upwards in faces with an inclined angle. The neighboring control offers the operator in the above-lying support unit protection and allows the support unit being pulled up to be monitored.

The prop of the support units must always be set until the set pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for support units with special functions, such as abutments for conveyor steering device.

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

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

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

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Requirements Fig. 24: W r o n g , support advanced too late

Bucyrus Europe GmbH, Lünen 2009

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Fig. 25: R i g h t , support advanced in time

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

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

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

Do not operate the shield control system incorrectly.

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

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

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

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

Shut-off valves may not be installed in the return lines!

To make sure the return lines can't be closed, safety valves must be installed in the return line (see hydraulic layout, if prepared by Bucyrus). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line.

The valves should be set to 25 bar and to spray in the atmosphere. damage, spare parts

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

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

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

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

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

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

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

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shield canopy position

The support units should always be set so that the shield canopy and base frame are aligned as parallel to each other as possible.

Within the framework of the maximum inclination and swivel angles specified on the Technical Data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly if required by geological or operational conditions.

Caution!

Never exceed the permissible angle of inclination of the canopy!

Exceeding the permissible angle of inclination of the canopy specified in Chapter 6 of the section “Technical data” can lead to the support becoming damaged. This especially applies for stabilising cylinders for which the mounting elements and fulcrum points are on the shield canopy and the caving shield.

Fig. 26: Shield support in normal position

0 M

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

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5.9

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Operation of the shield Caution!

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

Stabilizing cylinders must always have sufficient residual stroke!

Guide value: at least 20 mm!

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

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

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

Fig. 27: Shield support with extremely inclined shield canopy

S1

M

S2 2 M

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

Caution!

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

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1

BI622821

Operation of the shield This is especially true if the shield control system is equipped with an automatic positive setting function. Then there is a danger that under unfavorable conditions, for example a soft floor and possibly an additional tendency toward roof falls, that the automatic positive setting function leads to the stabilizing cylinders not having enough residual stroke or even becoming “locked”. For this reason, move the support in such or similar cases without automative positive setting.

Caution!

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

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

Caution!

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

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

Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in roof falls (see Fig. 28), when the stabilizing cylinder is completely extended. There must always be enough residual stroke available so that dynamic loads from the roof can be absorbed by the hydraulically secured stabilizing cylinder.

Fig. 28: W r o n g, do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended!

WRONG

Roof falls can be overcome by filling them (see Fig. 29) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

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Operation of the shield Fig. 29: R i g h t, fill out roof falls

RIGHT

support range of adjustment/ changing face thickness

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

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

The minimum residual stroke required for lowering the support unit can be maintained by: J keeping the face opening sufficiently large with the aid of the

mining equipment, J avoiding the accumulation of debris and fine coal on the floor, J preventing accumulation buildup on the shield canopies.

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

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

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

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

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

BI622821

Operation of the shield operating in inclines

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

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

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

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

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

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

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

For support units which are equipped with a special hydraulic lifting device, it is lifted out by actuating a valve, or automatically during advancing.

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

draulically by actively lowering a prop.

J support units with an undivided base frame must be lifted and

supported using standard mining methods.

Important!

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

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

Warning!

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

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

Caution!

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

Observe the following safety regulations:

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

– shield is wedged in between the neighboring shields.

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the base.

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

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

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

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

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

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

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

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Tab. 6: Hydraulic components Item 01

Pcs. 1

03

2

Designation Electrohydraulic control unit, 14 functions Prop check valve, NG 13

04 05

1 1

Twin check valve Throttle check valve, DN 12

06

1

CV, NW 25

07

1

CV, twin DN 10

10

4

PRV, 450 bar

11

4

PRV, 380 bar

12 13 14

1 1 1

PRV, 80 bar Supply block Check valve, DN 12, piloted

16 21 23 27

1 1 1 2

Plug DN 10 with pressure relief Hose lines Brackets and accessories Distributor

29

1

32

1

34

1

37

1

39

2

S1 Z1 Z2 Z3 Z4 Z5 Z6 a b

1 2 1 1 4 2 3 1 1

HP ball valve DN 10 red handle HP ball valve DN 12 red handle HP ball valve DN 25 red handle Water filter DN 25 nipple socket 25 MIC. Glycerine pressure gauge NG 50 Pressure sensors Prop Shifting ram Stabilizing cylinder Seal cylinder Flipper cylinder Side flap cylinder CV, hydraulically piloted PRV, 380 bar

Arrangement Under the canopy, in the middle behind the props On prop respectively, coal face side Flanged on stabilizing cylinder (Z3) Under the canopy behind the electrohydraulic control unit On the supply block (item 16), above on the left Underneath the canopy on the right next the supply block a) 2x on the twin check valve (4) b) On prop respectively, coal face side a) On the seal cylinder annular space connection b) On piloted CV (14) c) 2x on the distributor for the flipper cylinder On the supply block (13) In the middle between the props Under the canopy behind the electrohydraulic control unit On the supply block

Under the canopy behind the right prop At the distributor in the annular space of the side seal In front of the supply block (13) On the right next to the supply block (13) At right next to supply block, behind HP ball valve (34) On each prop CV (3)

Remarks On a bracket

Throttles the speed of the relay bar In the return line For flipper cylinders a) In the piston and annular space on the stabilizing cylinder b) For the piston space a) For annular space side seal b) For shifting ram c) In the piston and annular space In the return line On a bracket For shifting rams Pressure relief valve Subassembly Subassembly In the circuit of the side seal For side seal For auxiliary supply Interrupts the main pressure line to the shield In the high pressure circuit

On the right-hand prop, faceside

Below the side flap In the pressure line to the side flap

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

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Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 29, 34

The following ball valves are closed during normal operation: J 32 Tab. 7: HP ball valves

29

red

HP ball valve DN 10

32

red

HP ball valve DN 12

34

red

HP ball valve DN 25

Designation

Function Used for shutting-off the ring chambers of the seal cylinder Pressure supply during start-up and for auxiliary devices Is used for shutting-off the pressure supply line to the shield

Use Close when transporting the shield, so that the side seal doesn't extend and the mechanical interlock can be installed For moving the shield during startup and for connecting hydraulically operated auxiliary devices For maintenance and repair work on the shield

Caution!

Achten Sie darauf, dass der Kugelhahn immer eingerastet ist.

Ein nicht eingerasteter Kugelhahn verhindert einen optimalen Durchfluss. Hierdurch kann der Kugelhahn beschädigt werden.

Fig. 30: HP ball valve, shown opened and closed

open

closed

Through-flow for medium enabled

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Color

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Item

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Operation of the shield hydraulics Shield hydraulics

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Fig. 31: Shield hydraulics, arrangement (1) Image caption: see Table 6

3

39 Fig. 32: Shield hydraulics, arrangement (2) Image caption: see Table 6 Z6

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Z6

10b

a

Z6

b

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Operation of the shield hydraulics Fig. 33: Shield hydraulics, arrangement (3) Image caption: see Table 6

32 12 7 13 16

34

23 21

37 1

6

11b 5

27

29 14 4

10a

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11c

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Operation of the shield hydraulics Fig. 34: Functions of the electrohydraulic control unit, instruction plate

12 14

13

12

10

11

9

8

6

7

4

5

3

2

T P

11

1

X1

X3

X5

X7

X9

X11

X13

T X11 X12 T

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X2

X4

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X6

10

T

X8

X10

X12

X14

P

14 13 12 11

10 9

8 7

6 5

4 3

2

T

1

14 Functions

P

extend.side flipper shield advance

1 2 leg raise

leg lower

conveyor push

waterspray

5

3

7

4

6

leg lower

canopy tip up

8 canopy tip down

extend. seal-cyl.

extend. flipper-cyl.

9

11

10 retracting seal-cyl.

13

14

12 retract.flipperl-cyl.

retract.side flipper

Tab. 8: Electrohydraulic control unit with 14 functions, allocation of functions Function, designation

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Function No.

Advance shield

1

Set props

2

Lowering props on the right

3

Lowering props on the left

4

Conveyor push

5

Extend stabilizing cylinder

6

No function

7

Retracting stabilizing cylinder

8

Extending seal cylinder

9

Retracting seal cylinder

10

Extending flipper cylinder

11

Retracting flipper cylinder

12

Side flap, extend

13

Side flap, retract

14

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Operation of the shield hydraulics Fig. 35: Shield hydraulics Image caption, see Table 6 1

34 37 6 12

16 13

32

4 Z4

E

a 10a

11a

14

Z4 Z3

29

Z6

27 39

39

10b 11b 5

10b

Z2

b

3

3

Z4 Z1

Z1

Z6

7 Z4

Z5

Z5 11c

5.20

21

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Bucyrus Europe GmbH, Lünen 2009

Z6

BI622821

Operation of the shield hydraulics Fig. 36: Hydraulic line diagram Image caption: see Table 6

Z2 10a

Z4

10a 11a 4

10x1400 10x1800

10x1400 10x1800

Bewegliche Spaltabdeckung, rechts

1*

14 5 Z4

A

10x500

10x500

Bewegliche Spaltabdeckung, links

9*

P

11b 29 10x600

10x450 12x450

10x600

10b 39

10x1400 10x1400

3

25x1400

W2 W1 R P

10x2000

34 16

Z4

12

10b 39

12*

6

13

7 10x2000

3

11* 37

10x600

12x1600 10x2000

1 25x1000

S1

Z1

P

10x600 12x1600 10x2000

T

27 Z1

10x3000 10x3000

E

2*

a

X

Bucyrus Europe GmbH, Lünen 2009

12x2200 12x2200

10*

Z4

Z3

11*

32 10x700 10x700

11c

11c

Z5

1* hose lines 2* plug-in parts 5* cable binder

Doc. no.: 7420 165 000 BA 00

8* protective hose DN 25-1100 9* protective hose DN 25-1600 10* protective hose DN 25-1600 bl.

SSVI / 03

Z5

11* protective hose DN 32-2900 12* protective hose DN 50-2900l. a E-cabel

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Operation of the shield hydraulics Shield components Shield support Fig. 37: Shield, side view 11

a

g

51 31 21

c h b

d 61 1

e

1 11 21 31 41 51 61

5.22

f

base canopy side seal caving shield prop stabilizing cylinder hydraulics

a b c d e f g h

PMC®-R control unit electrohydraulic control unit supply block shifting ram relay bar assembly relay bar assembly, exterior side flap protective wall

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

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41

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Operation of the shield hydraulics Fig. 38: View from the front below the canopy 32

12

34 P R W1 16 13 6 27

Bucyrus Europe GmbH, Lünen 2009

E

37

1 29

11b 14

1 electrohydraulic control unit, 14 functions 5 throttle CV, DN12, for relay bar 6 CV, NW 25 in the return line 11b PRV, 380 bar 12 PRV (80 bar) in the return line 13 supply block 14 CV, DN 12, for shifting ram 16 plug DN 10 with pressure relief 27 distributor for side seal

Doc. no.: 7420 165 000 BA 00

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5

29 HP ball valve DN 10, for seal cylinder 32 HP ball valve DN 12, for auxiliary supply 34 HP ball valve DN 25, interrupts the main line to the shield 37 water filter DN 25 P pressure line, DN 25 R return line, DN 32 W1 water line, DN 50

5.23

BI622821

Operation of the shield hydraulics Supply block Fig. 39: View of the supply block

13

32 12

a

34 b R

P

c

W2

W1

1 electrohydraulic control unit (hidden behind the supply block) 12 PRV (80 bar) in the return line 13 eupply block 16 plug DN 10 with pressure relief 32 HP ball valve DN 12, for auxiliary supply 34 HP ball valve DN 25, in the pressure supply line to the shield

5.24

a pressure line auxiliary supply b return line auxiliary supply c screw plug on chain for auxiliary supply d PMC®-R control unit P pressure line, DN 25 R return line, DN 32 W1 water line, DN 50 W2 water line DN 20

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

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1 16

BI622821

Operation of the shield hydraulics Water filter Fig. 40: View of the water filter

12

34 6

Bucyrus Europe GmbH, Lünen 2009

E

37

6 CV, NW 25 in the return line

34 HP ball valve DN 25, interrupts the main line to the shield 37 water filter

12 PRV (80 bar) in the return line

Check valve, piloted, for shifting ram Fig. 41: View of the piloted CV

11b

14

5 throttle CV DN 12 for shifting ram 11b PRV, 380 bar

Doc. no.: 7420 165 000 BA 00

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5

14 CV, piloted, for shifting ram

5.25

BI622821

Operation of the shield hydraulics Distributor for side seal The distributor for the side seal cylinder is located, depending on the shield variant, behind the right or left hand props below the canopy.

Fig. 42: View of the distributor for the side seal cylinder

29

27 distributor for side seal

29 HP ball valve

Pressure relief valve for side seal Fig. 43: View into the side seal

11a

Z4

11a PRV, 380 bar Z4 side seal cylinder

5.26

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Bucyrus Europe GmbH, Lünen 2009

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27

BI622821

Operation of the shield hydraulics Twin check valve for flipper cylinder The check valve for the flipper cylinder is located in front of the right hand prop below the canopy.

Fig. 44: View of the twin check valve from below the canopy

Bucyrus Europe GmbH, Lünen 2009

E

7

7 twin check valve for flipper cylinder

Pressure relief valves for flipper cylinder Fig. 45: View of the flipper cylinder from below the canopy

11c

11c

Z5

11c PRV, 380 bar

Doc. no.: 7420 165 000 BA 00

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Z5 flipper cylinder

5.27

BI622821

Operation of the shield hydraulics Check valve, piloted, for side flap The check valve for the side flap cylinder is located on the inner side of the side flap.

Fig. 46: View of the distributor for the side flap cylinder

a

Pressure relief valve for side flap cylinder Fig. 47: View underneath the side flap

b

Z6

b PRV, 380 bar Z6 side flap cylinder

5.28

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Bucyrus Europe GmbH, Lünen 2009

E

a CV, hydraulically piloted, for side flap

BI622821

Operation of the shield hydraulics Control units Fig. 48: PMC®-R control units

b

c

a

Bucyrus Europe GmbH, Lünen 2009

E

1

1 bracket for PMC®-R a PMC®-R control unit

b emergency stop switch c support lock-out switch

Fig. 49: View of the electrohydraulic control unit

d

c

b a 1

1 electrohydraulic control unit a pilot valve b button

Doc. no.: 7420 165 000 BA 00

SSVI / 03

c symbol plate d connecting cable

5.29

BI622821

Operation of the shield hydraulics Prop Fig. 50: Right-hand and left-hand prop, view from the face side

S1

39

39

10b

10b

3

3 prop control valve 10b PRV, 450 bar

Bucyrus Europe GmbH, Lünen 2009

E

3

39 pressure gauge S1 pressure sensor

Dual check valve on the stabilizing cylinder Fig. 51: View of stabilizing cylinder

Z3

10a

4

Z3 stabilizing cylinder 4 dual check valve

5.30

10a PRV 450 bar

Shield support 1250/2780-2X3056-1500

BI622821

Operation of the shield hydraulics Plug with pressure relief Via a pressure relief valve, the enclosed pressure can be relieved by screwing in the vented cap screw.

After relieving the pressure, this screw must be screwed all the way out again.

Fig. 52: Plug DN 10 with pressure relief Open pressure relief: screw in screw

Bucyrus Europe GmbH, Lünen 2009

E

Close pressure relief: screw out screw

18

13

13 O-ring 18 hex. head screw M 6x16-A 2-70

Important!

Check the porosity of the sealing ring (13) regularly. Just to make sure, you can cover the ring with a rag to prevent hydraulic fluid from spraying out.

Doc. no.: 7420 165 000 BA 00

SSVI / 03

5.31

BI622821

Operation of the shield hydraulics The shield is equipped with a plug DN 10 with pressure relief: J on the supply block.

The plug (16) with pressure relief located on the supply block is for reducing any pressure that may arise in the return line. This can be necessary, e.g. when the supply line connections have been closed off for transport and increased pressure has built up in the return line during installation.

Fig. 53: Plug on the supply block

12

13

a 12 PRV (80 bar) in the return line 13 supply block

5.32

16 plug DN 10 with pressure relief a vented cap screw

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

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16

BI622821

Operation of the shield hydraulics Retracting or extending side seal The side seals seal the gaps between neighboring shield units.

They are also used to align a shield unit to the adjacent shield units.

The HP ball valve (see Fig.54, item 21a) is located on the righthand side of the shield in the rear area under the canopy. This shut-off valve is always open during normal operation. The moving side seals are then extended because of the permanently acting suspension forces.

Fig. 54: View of the distributor for the side seal cylinder

E

29

Bucyrus Europe GmbH, Lünen 2009

27

27 distributor for seal cylinder

29 HP ball valve DN 10, for seal cylinder

With the aid of the HP ball valve, the annular space sides of all of the seal cylinders of a shield are blocked off simultaneously. The moving side seals can thus be temporarily held in a retracted intermediate position against the permanently active force of the springs. As soon as the shut-off valve is opened, the side seals will be pressed abruptly outwards by the permanently active forces of the springs.

Fig. 55: View into the side seal 11a

Z4

11a PRV 380 bar, for side seal Z4 seal cylinder

Doc. no.: 7420 165 000 BA 00

SSVI / 03

5.33

BI622821

Operation of the shield hydraulics Danger!

There is an increased danger of injury caused by sudden and unexpected movements of the side seals, in view of the fact that the side seals are permanently pressed outward by the suspension force.

Actuation of the function “Extend side seal” extends the side seal abruptly outwards, despite closed HP ball valve (21a) because the pressure relief valve is triggered and sprays.

Danger!

For that reason, never stand in the movement range of the side seals. Otherwise, you could be severely injured or even killed by sudden movements of the side seals.

If the side seals - e.g. for transport purposes - are to be kept in retracted configuration, then they must always be mechanically engaged with the aid of the transport securing devices.

Repair and emergency operation

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

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

Warning!

The actuators on the electrohydraulic control unit should only be used in an emergency and for repair work and only in accordance with the special work instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury or death.

Caution!

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

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Bucyrus Europe GmbH, Lünen 2009

In the following, it is assumed that the shield has already been correctly installed. It is also assumed that all shut-off valves are open as during normal operation.

E

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

BI622821

Operation of the shield hydraulics Fig. 56 shows the layout of the PMC®-R control unit, Fig. 57 shows the layout of the electrohydraulic control unit on the support.

Operation of the PMC®-R control unit is not described in this operating manual. For information on this, please refer to the separate operating manual for the PMC®-R control unit.

Fig. 56: PMC®-R control unit

b

c

a

Bucyrus Europe GmbH, Lünen 2009

E

1

1 bracket for PMC®-R a PMC®-R control unit

b emergency stop switch c support lock-out switch

Fig. 57: View of the electrohydraulic control unit

d

c

b a 1

1 electrohydraulic control unit a pilot valve b button

Doc. no.: 7420 165 000 BA 00

SSVI / 03

c symbol plate d connecting cable

5.35

BI622821

Operation of the shield hydraulics Symbol plate The symbol plate is located above the pilot valves on the electrohydraulic control unit. The symbols correspond to the various functions which are initiated by actuating the respective button.

The meaning of the symbols and functions are described below.

Fig. 58: Symbol plate for electrohydraulic control unit with 14 functions extend.side flipper shield advance

1 2 leg raise

leg lower

3 4 leg lower

conveyor push

waterspray

5

7 6

canopy tip up

8 canopy tip down

extend. seal-cyl.

extend. flipper-cyl.

9

11

10 retracting seal-cyl.

13

14

12 retract.flipperl-cyl.

retract.side flipper

Operation and functions of the electrohydraulic control unit

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

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

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

The function stops as soon as you release the button.

Danger!

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

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

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Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

Warning!

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

E

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

BI622821

Operation of the shield hydraulics Warning!

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

1

Advance shield

Bucyrus Europe GmbH, Lünen 2009

E

Before this function can be performed, Function 3 “Prop, retract on the right” and Function 4 “Prop, retract on the left” must be carried out.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

As long as the function is activated, the pilot-operated check valve (14), which hydraulically shuts-off the annular space of the shifting ram, is opened automatically.

2

Set props Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

3

Prop, retract on the right Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

4

Prop, retract on the left Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function is executed as long as the button is pressed or until the end position is reached.

5

Advance conveyor Before initiating this function, ensure that the support unit is completely set.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Doc. no.: 7420 165 000 BA 00

SSVI / 03

5.37

BI622821

Operation of the shield hydraulics 6

Extend stabilizing cylinder The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

No function

8

Retracting stabilizing cylinder Before initiating this function, it must be made sure that the neighboring shields are completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke!

9

Extending seal cylinder The function serves to align the support unit to the adjacent support. The seal cylinders continue to extend out as long as the button is held down, until there is a balance of forces or until the end position is reached. In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

10

Retracting seal cylinder The function serves to align the support unit to the adjacent support. The seal cylinders continue to retract as long as the button is held down or until the end position is reached. In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

Extending flipper cylinder 11

5.38

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

7

E

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke!

BI622821

Operation of the shield hydraulics Flipper cylinder, retract 12

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Side flap cylinder, extend 13

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Side flap, retract The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Bucyrus Europe GmbH, Lünen 2009

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14

Doc. no.: 7420 165 000 BA 00

SSVI / 03

5.39

BI622821

Maintenance Maintenance Warning!

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

Refer to the separate original operating manual for the PMC®-R control unit.

hydraulic control system

Special measures

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

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

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

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

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

replacing filters

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

We recommend:

water filters double filter, can be backflushed

5.40

J Replace the water filters directly.

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

Shield support 1250/2780-2X3056-1500

E

At the latest one week after start-up, the filter cartridges on the electrohydraulic control units of the shield control system in the entire face must be spot-checked for contamination. If inspection indicates that the probability of malfunctions caused by contaminated filter elements is high, all filter cartridges along the face must be replaced.

Bucyrus Europe GmbH, Lünen 2009

one week after start-up

BI622821

Maintenance piston rods

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

pressure relief valves

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

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

Bucyrus Europe GmbH, Lünen 2009

E

high pressure hydraulic hoses

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

Daily maintenance hydraulic system

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

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

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

Doc. no.: 7420 165 000 BA 00

SSVI / 03

5.41

BI622821

Maintenance Weekly maintenance control system

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

. Clean the control systems, especially the operating panel.

Notice!

It is important that the control system symbols be easily legible. This prevents the risk of operational errors and any resulting accidents.

Every six months

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

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Bucyrus Europe GmbH, Lünen 2009

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

E

Regular, scheduled damage assessment

BI622821

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

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

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

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

Bucyrus Europe GmbH, Lünen 2009

E

Warning!

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

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

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

Fault localisation support cannot be lowered

Doc. no.: 7420 165 000 BA 00

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve!

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

The shield canopy is stuck between the neighboring supports.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

SSVI / 03

5.43

BI622821

Troubleshooting Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve!

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

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

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

The prop control valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

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

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve!

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

The support is stuck between the neighboring supports.

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

Steps on roof or floor prevent advance of the support.

Lower canopy sufficiently to clear the step or lift the base to pass over a rise on the floor.

The pressure of the hydraulic supply is too low.

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

The control piston on the piloted check valve does not work.

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

The prop control valve may be defective.

Damaged or trapped hose lines.

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

Shifting ram is defective.

Check whether the - shifting ram is damaged - the piloted check valve is working properly

support cannot be advanced

Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressure fluid escapes, replace the shifting ram.

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Bucyrus Europe GmbH, Lünen 2009

E

support cannot be set

BI622821

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

Bucyrus Europe GmbH, Lünen 2009

E

canopy cannot be positioned

canopy cannot be lowered

Doc. no.: 7420 165 000 BA 00

Possible cause

Remedy

Prop control valve is defective.

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

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop lower connection and check whether pressure fluid is escaping even though the prop is no longer being extended.

If applicable: piston packing defective, replace prop.

Pressure relief valve defective

Monitor pressure drop on the pressure gauge.

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

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve!

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve isn't working.

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

The check valve may be defective.

Damaged or trapped hose lines.

Check for damaged or kinked prop hose lines.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

Possible cause

Remedy

The shut-off valve for the pressure feed line on the supply block is closed.

Open the shut-off valve!

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

The shield canopy is stuck between the neighboring supports.

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

The pressure of the hydraulic supply is too low.

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

Piloted check valve isn't working.

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

The check valve may be defective.

Damaged or trapped hose lines.

Check hose lines for controlling the prop/stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and replace, if necessary.

SSVI / 03

5.45

BI622821

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

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

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

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

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

internal leakage

. Locate the faulty valve by initiating the functions individually

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

. Then operate the functions manually to depressurize the system.

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

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

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

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

. Check the valve and replace if defective.

Checking the check valves on the props To check the prop check valves please proceed as follows:

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

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

5.46

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

valve replacement

E

one by one.

If the noise stops while a function is initiated, this valve is faulty.

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

BI622821

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

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

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

If there is an internal by-pass in the prop, for example due to damaged piston packing, fluid will flow out of the prop lower connection.

If this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

Pressure relief valve defective

Bucyrus Europe GmbH, Lünen 2009

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

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

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

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

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

. Check the filters in the hydraulic system.

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

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5.47

BI622821

Bucyrus Europe GmbH, Lünen 2009

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Troubleshooting

5.48

Shield support 1250/2780-2X3056-1500

BI622821

6

Technical data

BI622821

BI622821

Description

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

Description Type 1250/2780-2x3056-1500 The two-prop shield mainly consists of the following listed main subassemblies: J Base frame with lemniscatic links and relay bar assembly, J Canopy with flipper, J Side seal, moveable on the right or left side, J Caving shield, J Hydraulic props, J Side flap, J Protective wall, Bucyrus Europe GmbH, Lünen 2009

E

J Relay bar assembly, exterior, J Hydraulic equipment with hose lines and control.

Tab. 9:

Shield support (1)

Application

Device number

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

Segment shield

7420 165 000 00 01

6466 x 24231) x 2780 6869 x 18602) x 1750

Approximate weight in kg 18863

Tab. 10: Shield support (2) Application

Device number

Shield No.

Special equipment Canopy 4985 mm long

Segment shield

7420 165 000 00 01

Protective wall can be mounted 1 and 2 162 and 163 Side flap can be mounted Relay bar assembly, externally mountable

The two-prop shield is equipped with a two-part base frame. It consists of two single bases that are connected on the gobside through the yoke of the relay bar assembly. The relay bar assembly is centrally located between the bases. The shifting ram functions directly.

The caving shield is a one-piece steel construction connected by means of the lemniscatic links to the base frame.

The shield canopy transmits the support load of the props into the roof. The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

Programmed methods of calculation ensure the best possible support. This ensures that the support resistance and range of vertical adjustment is optimally coordinated. The multistage hydraulic props have the same load capacity at any stage and act on both sides.

1) 2)

Doc. no.: 7420 165 000 BA 00

Side seal completely extended, side flap extended Side seal completely retracted, side flap retracted

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6.3

BI622821

Description The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

The support units are equipped with all components required for realising an electrohydraulic neighboring control with the electronic PMC®-R control system.

Depending on the application the shield is equipped with a side flap, a protective wall and an external relay bar assembly. This additional equipment can be mounted on the right or left hand side.

Main subassemblies Fig. 59: Shield, side view 11

a

g

51 31 Bucyrus Europe GmbH, Lünen 2009

E

21 c h1 b 41

h2 d

61 1

e 1 11 21 31 41 51 61 a

6.4

f base canopy side seal caving shield prop stabilizing cylinder hydraulics PMC®-R control unit

b c d e f g h1 h2

electrohydraulic control unit supply block baselift cylinder relay bar assembly relay bar assembly, exterior side flap protective wall on side seal protective wall on base

Shield support 1250/2780-2X3056-1500

BI622821

Description Tab. 11: Shield 7420 165 000 00 01, main assemblies and additional equipment

1

7420 165 000 00 01 Base frame/ base

7420 165 300 00 01

Approximate weight in kg 5545

11 21 31 41 51

7420 165 000 00 01 7420 165 000 00 01 7420 165 000 00 01 7420 165 000 00 01 7420 165 000 00 01

7420 165 400 00 01 7420 165 700 00 01 7420 165 800 00 01 8250 147 000 00 00 8241 355 000 00 00

4895 2148 2460 910 140

8112 259 000 00 00

383

7420 165 360 00 01

867

7420 165 460 00 00 7420 165 750 00 00

615 471

7420 165 370 00 00

490

Item

61

f g h1

Designation

Canopy Side seal Caving shield Hydraulic prop Stabilizing cylinder 7420 165 000 00 01 Shield control system - 14 functions Relay bar assembly, exterior Side flap Protective wall Protective wall

ID No.

Remarks Shifting ram. Ø 150 Relay bar assembly, max.3855 long Flipper

8241 354 000 00 00 7420 165 330 00 01 7420 003 420 00 00

Electrohydr. control unit 8154 138 000 00 00 Lines 8112 259 010 00 00 Holders 8112 259 030 00 00 Can be used on the right and left hand side Can be used on the right and left hand side On the side seal, can be used on the right and left hand side On the base, can be used on the right and left hand side

Bucyrus Europe GmbH, Lünen 2009

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h2

for device number

Doc. no.: 7420 165 000 BA 00

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6.5

BI622821

Description Main dimensions not including additional equipment Fig. 60: Segment shield, dimensions L1 L2

L3

152

HE

H

MG

800

L B

Bucyrus Europe GmbH, Lünen 2009

1000

E

B3

MG height, extended HE height, retracted

L transport length B width

840 1500

Tab. 12: Shield variant, dimensions not including additional equipment Device number

L

L1

L2

L3

H

MG

HE

B

B3

7420 165 000 00 01

6951

4985

3550

1300

2400

2780

1250

1440

150

Important!

The retracted height is limited to 1 750 mm when a protective wall is fitted.

6.6

Shield support 1250/2780-2X3056-1500

BI622821

Description Base with lemniscatic links and relay bar assembly The bearing strength of the hydraulic props is transmitted to the floor through both bases. The props are simply supported in the ball sockets in the bases and are held on both sides by prop retainers.

Both pairs of lemniscatic links are hinged to the base frame with a pin connection.

The relay bar assembly is located between the two bases in the center. The yoke connects the two bases to each other on the gob side and to the relay bar assembly. The bases are not connected to each other on the face side. The shifting ram functions directly.

That means that the force generated by the piston surfaces is used to advance the conveyor. The lesser force of the annular surface is used to advance or pull up the shield. The shifting ram can be equipped with a reed rod for measuring forward movement.

The relay bar assembly is fastened to the conveyor using the clevis assembly on the crawl pan. The hemispherical shell in the front area of the crawl pan is the thrust bearing for the hydraulic cylinder of the outrigger steering system that stabilizes the hinge between the crawl pan and the conveyor.

715

Bucyrus Europe GmbH, Lünen 2009

E

Fig. 61: Base (base frame), dimensions

300

1074 1502

368 3400

780

810

840 1400 1500

Doc. no.: 7420 165 000 BA 00

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6.7

BI622821

Description Fig. 62: Base (base frame), positions 8 17

9 23, 50 34, 40, 45 10

31, 32, 33, 4

30, 32, 33, 41 1 5

16

1 5 8 9 10 15 16 17 23

shifting ram, ZE-150/90-700 relay bar assembly lemniscatic link, rear prop retainer, right prop retainer, left base, right base, left lemniscatic link, front pin 35/24x75

30 31 32 33 34 40 41 45 50

lemniscatic link pin Ø128,5x457 lemniscatic link pin Ø118,5x457 securing device washer pin 75/60x130 hex. head screw M 16x145-A 4-80 hex. head screw M 30x45-8.8 hex. nut M 16-1.4301 spring cotter 5

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.8

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Bucyrus Europe GmbH, Lünen 2009

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15

BI622821

Description Relay bar assembly The relay bar assembly unit is used to push the conveyor and advance the shield. To do this, it is telescopically extended or retracted using the shifting ram. The shifting ram functions directly. This means that the greater force that is generated by the piston surface is used to advance the conveyor.

920 80

255

328

105

Fig. 63: Relay bar assembly, dimensions and positions

Bucyrus Europe GmbH, Lünen 2009

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150

240

380

1235

600

975 7, 8 9

2

6

10 3 14, 15

22

4

16, 17

1

5 12, 13 11

19, 29, 21

1 2 3 4 5 6 7 8 9 10 11

yoke cylinder bearing cylinder seat beam guiding rod pin 75/60x93 hex. head screw M16x145-A 4-80 hex. nut M 16-1.4301 clamp spring clip 8x42 ring

12 13 14 15 16 17 19 20 21 22

locking plate locking clip 4.5 fastening bolts Ø28x138 coupling clip DN 20 pin Ø38.5x171 coupling clip DN 25 pin 85/58x265 washer 48 hex. nut M 48-10 fastening eye

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

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6.9

BI622821

Description Description

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

It primarily consists of the gobside cylinder bearing (2), the yoke (1), the cylinder seat (3) with the guiding rods (5) and the beam (4), the shifting ram (a) and the required connecting elements.

The gobside part of the relay bar assembly, the cylinder bearing (2), is attached to the base of the base frame by the yoke (1). The piston rod of the shifting ram affects the cylinder seat (3).

The guiding rods (5) can be replaced. They are attached to the cylinder seat (3) with bolts and are guided into the gobside cylinder bearing (2) in the longitudinal direction.

The absolute length of the relay bar assembly is variable within limits since the beam (4) can be fastened to the cylinder seat (3) in a variety of positions. With respect to the lengths represented in Fig. 63, the relay bar assembly can be lengthened and shortened by approx. 150 mm.

Fig. 64: Relay bar assembly with crawl pan 2

Bucyrus Europe GmbH, Lünen 2009

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9

a

5

3

2 cylinder bearing 3 cylinder seat 5 guiding rod

6.10

9 clamp a shifting ram

Shield support 1250/2780-2X3056-1500

BI622821

Description Functions of the relay bar assembly Warning!

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

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

The conveyor is used as the thrust bearing, meaning that the shield must be lowered. The faceside part of the relay bar assembly supports itself on the conveyor. The gobside part of the relay bar assembly moves in the direction of the face when the pusher ram is retracted. The conveyor is pulled up. The power required for pulling up the shield is generated by the annular surface of the pusher ram.

Bucyrus Europe GmbH, Lünen 2009

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pull shield

The shield is used as the thrust bearing, meaning that the shield must be set. The gobside part of the relay bar assembly, the cylinder bearing (2), supports itself with the yoke (1) on the set shield.

The face side part of the relay bar assembly moves in the direction of the face when the shifting ram is extended. The conveyor is advanced. The power required for advancing the conveyor is generated by the piston surface of the pusher ram.

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6.11

BI622821

Description Relay bar assembly, exterior The exterior relay bar assembly of the segment shield is to support the conveyor's (drives) advancing operation.

Before the cylinder is installed, the cylinder seat (10) is inserted into the base mounting device and turned by 90 degrees.

155

105

Fig. 65: Relay bar assembly - exterior, dimensions and positions

E Bucyrus Europe GmbH, Lünen 2009

300

490

580

840*)

1374

X

5 1

1 5 10 11 15

hydraulic cylinder ZE-150/90-700 fastening eye mounting device pin 65/58x145 locking element

11 *)

15

10

prop clearance

X left hand base 7420 165 302 as illustrated right hand base 7420 165 301 symmetrical

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.12

Shield support 1250/2780-2X3056-1500

BI622821

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

It is articulated and connected to the caving shield with pins. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the props are fastened to the canopy and can be rotated.

Caution!

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

The canopies are equipped with moveable side seals on the right and left hand side and a flipper.

Fig. 66: Canopy for the segment shield, dimensions and positions

790 1390

A

Bucyrus Europe GmbH, Lünen 2009

E

A

4980 905

130

335

1300

12 15 1

6

14 13 17 16 5

18, 19, 20 1 canopy 5 flipper fastening assembly (hidden) 6 flipper 12 pin Ø54x220 13 pawl R 80 14 pin Ø24,3x136

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15 16 17 18 19 20

locking clip 5.6 spring cotter 5 locking clip 3.2 locking plate hex. head screw M 16x55-A 2-70 hex. nut M 16-A 2-70

6.13

BI622821

Description Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Flipper

1000

Fig. 67: Flipper, dimensions and positions

Bucyrus Europe GmbH, Lünen 2009

E

1550 1488

22, 34, 50 25, 34, 50 21, 34, 50

20, 33, 34, 50

29

27, 33, 34, 50 23, 32, 34, 50 10

27, 34, 50

31 1

5

1 5 10 20 21 22 23 24 25

6.14

hydraulic cylinder ZE-90/63-485 fork control arm flipper pin Ø38.5x140 pin Ø28.5x112 pin Ø28.5x105 pin Ø28.5x125 lemniscatic link pin Ø28.5x143

26 27 29 31 32 33 34 50

pin Ø28.5x190 pin Ø38.5x156 clevis assembly cylinder bearing washer 31 washer 41 locking clip 4 lubricant

Shield support 1250/2780-2X3056-1500

BI622821

Description Prop head Fig. 68: Prop head

17

14

13

Bucyrus Europe GmbH, Lünen 2009

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13 pawl R80 14 retaining bolt Ø24.3x136

17 locking clip 3.2

Side seal The side seals seal the gaps between adjacent support units. They are also used to align a support unit to the adjacent support units.

The fixed side of the side seal is fastened to the shield canopy or the caving shield with pins. The free side is arranged so that it is movable. It is guided through using guiding pins and pressed permanently against the neighboring shield using compression springs. The side seals can be extended and retracted using hydraulic cylinders.

Warning!

Risk of injury due to unexpected movements of the side seal!

The movable side seal is under spring pressure! Never remove connecting elements of the side seal before the side seal is pulled together and secured using clamp clips.

Caution!

Before putting the shield unit into operation, the transport securing devices (see Fig. 69 marked with a *) of the side seal must be removed.

For transport the movable side seals are retracted and locked mechanically with pins. The pins are secured with coupling clips.

Doc. no.: 7420 165 000 BA 00

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6.15

BI622821

Description Notice!

When putting the side seals into operation, remove transport securing devices Fig. 69 Item 18* on the movable side.

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

Notice!

If the side seal on the other side is movable, the seal cylinders and their respective guiding pins are to be installed symmetrically.

Warning!

Risk of injury! The moveable side seal is under spring pressure! Secure the side seal using clamps before dismantling the side seal cylinders and their guiding pins.

Fig. 69: Side seal shown, left hand side movable, dimensions LEFT

RIGHT Fixed

450

3300

2065

800

6.16

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

E

1440

Movable

BI622821

Description Fig. 70: Side seal shown, left hand side movable, positions 18* 3 14, 32, 33 18*

17, 32, 33

5 18*

18*, 30

LINKS beweglich

8

20

19, 34

10

21

2 23, 25, 35

RECHTS

6, 36

fest

4

7, 36

Bucyrus Europe GmbH, Lünen 2009

E

26, 35

9

1

11 15, 28

22, 31

16

18*, 30

18*, 30 13, 27

18*, 30 12, 31 18*, 30 24, 29

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

hydraulic cylinder ZE-63/50-215 side seal, canopy, right side seal, canopy, left side seal, caving shield, right side seal, caving shield, left cover plate for canopy cover plate for caving shield guiding pin Ø103x783 guiding pin Ø103x580 guiding pin Ø82x795 guiding pin Ø82x535 pin 40/34x64

Doc. no.: 7420 165 000 BA 00

13 14 15 16 17 18 19 20 21 22 23 24

SSVI / 03

pin 40/34x145 pin Ø22x206 pin Ø28x74 cylinder liner Ø103x105 pin Ø22x169 transport securing devices pin Ø28x93 compression spring, 12x79x560 compression spring, 12x64x621 pin 40/34x174 torque support pin Ø25x155

25 26 27 28 29 30 31 32 33 34 35 36

retaining washer securing device screw pin M 10x12-45 H sprung pin 5x50 coupling clip DN 12 NIRO coupling clip DN 12 NIRO coupling clip DN 25 NIRO washer 23 spring clip splint pin, 6.3x40 hex. head screw M 16x30-A 2-70 hex. head screw M 12x20-A 4-80

6.17

BI622821

Description Caving shield The caving shield protects the face area toward the caving area.

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

The caving shield has mounting devices for the cylinders and guiding pins of the side seal.

1390

810

Bucyrus Europe GmbH, Lünen 2009

E

310

153

500

747

1354

Fig. 71: Caving shield for endshield, dimensions

165 190

1865

420

980 1865

Fig. 72: Caving shield, from above

S2

S2

S2 S2 load ring, load capacity: 8000 kg

6.18

Shield support 1250/2780-2X3056-1500

BI622821

Description Fig. 73: Caving shield for endshield, positions 21

18, 19

23

24

28 12

S1

S2

S1

Bucyrus Europe GmbH, Lünen 2009

E

17

1

10 S2 25 16 15 1 10 12 15 16 17 18 19

caving shield pin Ø54x220 securing device lemniscatic link pin Ø118.5x422 lemniscatic link pin Ø128.5x445 joint pin Ø113.5x290 retaining washer 155 sleeve

21 23 24 25 28 S1

hex. head screw M 30x50-8.8 pin Ø9x300 locking clip 2.5 locking clip 5.6 protective plug load ring, load capacity: 3000 kg S2 load ring, load capacity: 8000 kg

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

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6.19

BI622821

Description Side flap

Fig. 74: Side flap, R.H. design 1

6 4 5, 7 3

E

8, 9, 10 side flap bracket hydraulic cylinder ZE-75/60-150 pin Ø40x120 pin Ø20x80

6 7 8 9 10

locking clip 4.5 locking clip 3.2 washer 24 hammer head bolt M 24x80-8.8 hex. nut M 24-8

Protective wall on base

Fig. 75: Protective wall 1, L.H. design 7

4

1 3

1 side plate 2 bracket 3 support

6.20

2

4 pin 50/35x147 7 locking clip 4

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

1 1 2 3 4 5

BI622821

Description Protective wall on side seal

Fig. 76: Protective wall 2, L.H. design 8, 9, 10

1

2

Bucyrus Europe GmbH, Lünen 2009

E

3 4, 7 1 bracket 2 securing device 3 side plate 4 pin 50/35x147

7 8 9 10

locking clip 4 hammer head bolt M 24x80-8.8 hex. nut M 24-8 washer 24

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Doc. no.: 7420 165 000 BA 00

SSVI / 03

6.21

BI622821

Description Technical data, steel structure Segment shield, device number 7420 165 000 00 01

Height, retracted . . . . . . . . . . . . . . . . . . . mm (not including additional equipment)

1 250

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

2 780

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

1 530

Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

650

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

700

Length change of the support / conveyor connection . . . . . . . . mm

2 x 150

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

790 / 840

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

3 550

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

1 430

Width of canopy with side seal . . . . . . . . mm

1 440

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

4 980

Caving shield inclination:

6.22

Support retracted . . . . . . . . . . . . . . . . . . . degrees

10

Support extended . . . . . . . . . . . . . . . . . . . degrees

46

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

1 440

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

1 400

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

27 560

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

1 500

Support force for medium seam thickness of . . . . . . . . . . . mm

2 400

a) for 315 bar setting pressure . . . . . . . . kN

4 684

b) for 380 bar nominal pressure . . . . . . kN

5 651

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

2 400

a) for 315 bar setting pressure . . . . . . . . kN/m2

628

b) for 380 bar nominal pressure (KAKO large / small) . . . . . . . . . . . . . . . . kN/m2

670 / 757

Shield support 1250/2780-2X3056-1500

E

15

Bucyrus Europe GmbH, Lünen 2009

Securing from tipping permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

BI622821

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. You can find additional information in the spare parts catalogue of the shield support.

Normal and exceptional operation

During normal operation, the shield functions may only be operated via the PMC®-R control unit.

Shield control unit Electrohydraulic control unit The electrohydraulic control unit has 14 functions.

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

Fig. 77: Electrohydraulic control unit, 14 functions c

Bucyrus Europe GmbH, Lünen 2009

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1

a 2 6

1 distributor block, 14 functions 2 double 3/2 way magnetic pilot solenoid valve 4 control valve cartridge NG 13 5 screw fitting

4, 5

b

6 filter cartridge a pushbutton b connecting socket for control unit c connection socket on the rear side

Warning!

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

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

Doc. no.: 7420 165 000 BA 00

SSVI / 03

6.23

BI622821

Hydraulic system PMC®-R electronic control unit Notice!

Please observe the instructions in the PMC®-R control unit's separate operating manual.

PMC®-R control unit, input allocation; Face shield device number 7420 165 000 00 01 Fig. 78: PMC®-R control unit, input allocation PMC®-R inputs A1 = Left hand, adjacent unit

Front view

A2 = Not assigned B1 = Not assigned B2 = Coding plug C1 = Sensor shifting ram C2 = Pressure sensor, prop

Rear view

A1

B1

C2 D2 E2

C1 D1 E1

F2

E1 = Not assigned E2 = Not assigned F1 = Right hand, adjacent unit

F1

F2 = Solenoid driver module

Fig. 79: PMC®-R control unit, diagram A2 B2 C2 D2 E2 F2 1 A1 B1 C1 D1 E1 F1

5

4

a 1 PMC®-R control unit, complete 4 solenoid driver module 5 pressure sensor, prop

6.24

a shifting ram other components: see spare parts catalog

Shield support 1250/2780-2X3056-1500

E

B2

Bucyrus Europe GmbH, Lünen 2009

A2

D1 = Not assigned D2 = Not assigned

BI622821

Hydraulic system Two-stage telescopic prop The prop described is a double-telescopic prop with equal loadbearing capacity at all stages. Equal load-bearing capacity is ensured by a piloted check valve which is installed in the piston pipe.

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

The head is fastened using two pegs each that are inserted into the bore holes in the mounting device before the prop head is installed.

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

The technical data can be found in the section “Technical data, Hydraulic Cylinders”.

Fig. 80: Double-telescopic prop, type SD-3050-320-1095/2475-CR 21

Bucyrus Europe GmbH, Lünen 2009

E

2

b

a

d

1

c

1 Prop base 2 Piston pipe 21 Piston rod

a b c d

Piston space connection Annular space connection Safety cam Load ring 3000 kg

Tab. 13: Telescopic prop Length in mm ID No. Telescopic prop 8250 147 000 00 00

Doc. no.: 7420 165 000 BA 00

SSVI / 03

Stroke in mm

Retracted

Extended

Upper stage

Lower stage

1095

2475

680

700

6.25

BI622821

Hydraulic system Warning!

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

Never close the lowering connections on double-acting props so that they're pressure-tight! Otherwise, pressure might build up in the annular space when extending the prop, which is several times more than the set pressure.

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

loading props

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

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

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

The further course of the force flow up to the setting of the piston pipe is as described under a).

lowering props

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

Both stages of the prop can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston rod can then retract.

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

6.26

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Bucyrus Europe GmbH, Lünen 2009

set props

E

Function

BI622821

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

Fig. 81: Hydraulic cylinder, typical example Model a)

2 3

1

5

4

Bucyrus Europe GmbH, Lünen 2009

E

Model b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

1

4

6

4 guide bushing 5 connection 6 connection

Notice!

The technical data for the cylinders can be found in the “Technical Data, Hydraulic Cylinders” section for the support unit used.

Warning!

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

Never close the prop-lowering connections of double-acting props pressure-tight!

Otherwise, when extending the prop, pressure can build up in the annular space which is several times more than the set pressure!

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

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

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

Doc. no.: 7420 165 000 BA 00

SSVI / 03

6.27

BI622821

Hydraulic system Shifting ram Fig. 82: Hydraulic cylinder Model ZE-150/90-700

83 L c

1

4

a

21

b d

Cylinder tube Reed rod Relay bar adaptor Piston rod Screw fitting Annular space connection

b c d L

Piston space connection Load ring 1000 kg Cylinder disk Retracted 600 Extended 1300 Stroke 700

E

1 3 4 21 30 a

3

Bucyrus Europe GmbH, Lünen 2009

30

Stabilizing cylinder Fig. 83: Hydraulic cylinder ZE-165/100-420

55

55 L a

b

21 1 1 Cylinder 21 Piston rod a Valve connection plate

6.28

b Load ring 1000 kg L Retracted 860 Extended 1280 Stroke 420

Shield support 1250/2780-2X3056-1500

BI622821

Hydraulic system Alignment cylinder (seal cylinder) Fig. 84: Hydraulic cylinder ZE-63/50-215

30 L

a 2

b

1

Bucyrus Europe GmbH, Lünen 2009

E

1 cylinder tube 2 piston rod a piston space connection

b annular space connection L retracted 440 - extended 655 stroke: 215

Flipper cylinder Fig. 85: Hydraulic cylinder ZE-90/63-485 for segment shield

Ø30

Ø30 L a

2 b 1

1 cylinder tube 2 piston rod a piston space connection

Doc. no.: 7420 165 000 BA 00

SSVI / 03

b annular space connection L retracted 860 extended 1345 stroke: 485

6.29

BI622821

Hydraulic system Technical data, hydraulic cylinder

stabilizing cylinder, double-acting

6.30

Length a) Retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1095

b) Extended . . . . . . . . . . . . . . . . . . . . . . . . mm

2475

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

1380

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

320 / 230

Piston rod diameter. . . . . . . . . . . . . . . . . . mm

295 / 210

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

804.2 / 415.5

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

120.8 / 69.1

Prop force with setting pressure, 315 bar . . . . . . . . . . . . . kN

2 533

Setting pressure, 380 bar . . . . . . . . . . . . kN

3 056

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

380

Type ZE-150/90-700, device no. 8241 354 000 00 00, version with reed rod

E

shifting ram double-acting, driven directly without counterpressure

Type SD-3050-320-1095/2475-CR device no. 8250 147 000 00 00

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

700

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

150

Piston rod diameter . . . . . . . . . . . . . . . . . mm

90

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

176.7

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

113.1

Thrust force at 315 / 380 bar . . . . . . . . . kN

557 / 672

Pulling force at 315 bar . . . . . . . . . . . . . . kN

356

Type ZE-165/100-420,

device no. 8241 355 000 00 00

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

420

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

165

Piston rod diameter . . . . . . . . . . . . . . . . . mm

100

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

213.8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust force at 315 / 380 bar . . . . . . . . . kN

673 / 812

Pulling force at 315 / 380 bar . . . . . . . . . kN

426 / 514

Shield support 1250/2780-2X3056-1500

Bucyrus Europe GmbH, Lünen 2009

telescopic prop, double-acting, 2-stage

BI622821

Hydraulic system alignment (seal) cylinder, double-acting

Bucyrus Europe GmbH, Lünen 2009

E

flipper cylinder, double-acting

Doc. no.: 7420 165 000 BA 00

Type ZE-63/50-215,

device no. 8241 352 000 00 00

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

215

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

63

Piston rod diameter . . . . . . . . . . . . . . . . . mm

50

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

31.2

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

11.5

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

98 / ---

Pulling force at 315 / 380 bar . . . . . . . . . kN

36 / 44

Type ZE-90/63-485,

device no. 8241 007 000 00 00

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

485

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

90

Piston rod diameter . . . . . . . . . . . . . . . . . mm

63

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

63.6

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

32.4

Thrust force at 315 / 380 bar . . . . . . . . . kN

200 / 241

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

102 /---

SSVI / 03

6.31

BI622821

Hydraulic system Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the setting pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalogue.

Model

Setting pressure in bar

Device No.

For return line

Spring-loaded

80

8220 042 080 00 00

For flipper cylinder and seal cylinder

Spring-loaded

380

7337 486 380 00 00

For stabilizing cylinder and for props

Spring-loaded

450

7337 486 450 00 00

Caution!

The setting pressure of pressure relief valves should not be changed! Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system's circuit diagram. Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Failure to comply with these instructions can lead to leaky plug connections and impair the operational safety of the hydraulics. identification

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The letter code includes the following information: J setting pressure, target value, J the week the setting was made, J the year the setting was made, J last changes made by.

6.32

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Bucyrus Europe GmbH, Lünen 2009

Application

E

Tab. 14: Pressure relief valves, use of the various models

BI622821

Hydraulic system Tab. 15: Letter code, example 420 or 42 1)

09

03

xy

Setting pressure

Week

Year

Last changes made by:

Color coding is with either one or two colors. It indicates the range within which the setting pressure is located. The following Fig. 86 shows a pressure relief valve provided with a blue/white color code.

This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 86: Pressure relief valve, example

b Bucyrus Europe GmbH, Lünen 2009

E

a

a color code b protective cap

The following table shows the relationship between the color code and the pressure range.

Tab. 16: Color codes for pressure relief valves, overview

1)

Doc. no.: 7420 165 000 BA 00

Color

Pressure range (bar)

Black

0 - 49

Black/white

50 - 99

Brown

100 - 149

Brown/white

150 - 199

Green

200 - 249

Green/white

250 - 299

Blue

300 - 349

Blue/white

350 - 399

Red

400 - 449

Red/white

450 - 499

Yellow

500 - 549

Yellow/white

550 - 599

Orange

600 - 649

Orange/white

650 - 699

Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” equals 420 bar, “08” equals 80 bar

SSVI / 03

6.33

BI622821

Hydraulic system Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between shield canopy and caving shield.

Fig. 87: Angles 1/2

1 2

Tab. 17: Angle  1 / 2 change at height M Inclination  at height M

Shield ID No. 7420 165 000 00 01

1 in °

 in °

M in mm

10

10

1250 to 1600

15

15

1600 to 2780

Caution!

Exceeding the specified permissible angles can lead to damage to the props and cylinders and their fastening elements, as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the “Canopy - Caving shield” crosspoint moves correspondingly when the canopy is raised or engaged.

6.34

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Bucyrus Europe GmbH, Lünen 2009

E

M

BI622821

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, for operating hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

Bucyrus Europe GmbH, Lünen 2009

E

If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies, e.g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc.

The respective exemption permit will be issued by Bucyrus on request.

Suitability test Before Bucyrus will issue a certificate for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by Bucyrus. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to the following: J Stability J Sealing materials J Corrosion.

In addition if required a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive a corresponding certificate from Bucyrus.

Doc. no.: 7420 165 000 BA 00

SSVI / 03

6.35

BI622821

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

Bucyrus Europe GmbH, Lünen 2009

E

Fig. 88: Typical certificate

6.36

Shield support 1250/2780-2X3056-1500

BI622821

Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected, but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH, concentrate ratio, and microbial load.

The operator of the equipment must prepare a hydraulic fluid maintenance plan for the specific application. The maintenance plan should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH

– Setpoint: 7.5 to 9.5 J Concentrate ratio E

– Setpoint: see certificate Bucyrus Europe GmbH, Lünen 2009

J Microbial load

– Setpoint:  105 col/ml.

In addition, the electrical conductivity, foaming, and operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water use for hydraulic fluids

The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

If the limits shown in Table 18 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with, this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

However, the customer shall in any case provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

use as spraying water

Doc. no.: 7420 165 000 BA 00

Water used for this purpose may not contain aggressive components and dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100 m. In order to protect the components, the limit values listed in the table must not be exceeded.

SSVI / 03

6.37

BI622821

Permissible media limit values

The following table lists limit values for the essential properties of the process water.

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulics system. Use only water that conforms to the specified limit values.

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad smell, etc.

Electrical conductivity

< 1800 S/cm

pH

6.5 to 8.5

Na+ content

Not specified

Mg+

Not specified

content

Water hardness

< 750 mg/l CaCO3 equivalent ( 42° dH)

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 m filtering in conformity with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1 mg/l

1) The values listed must be observed during the production of hydraulic fluids.

They do not apply when the water is used exclusively as spraying water.

6.38

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Bucyrus Europe GmbH, Lünen 2009

Test criterion

E

Tab. 18: Properties of the process water, limit values

BI622821

Permissible media Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

Base: . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium soap NLGI class: . . . . . . . . . . . . . . . . . . . . . 2 Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . practically insoluble in water Temperature of application: . . . . . . . . -20 to +120 C Flashpoint: . . . . . . . . . . . . . . . . . . . . . . ≧ 200 C

lubricating grease A1

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths, and for installation (according to EWN *) 7068).

Bucyrus Europe GmbH, Lünen 2009

E

Tab. 19: Lubricating greases for general application

lubricating grease A2

Flashpoint in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

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

Tab. 20: Lubricating greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. If in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

*) EWN = works standard

Doc. no.: 7420 165 000 BA 00

SSVI / 03

6.39

BI622821

Permissible media Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 21: Lubricating pastes free of molybdenum disulfide Supplier

Type

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI Class

Flashpoint in °C

2

220

When the equipment is lubricated at our factory for the first time, the lubricant type used as lubricating paste B 3 in accordance with the works standard EWN 7068 is: gleitmolybdän “gleitmo 805” lubricating paste B6

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements on the shield support.

When the equipment is treated at our factory for the first time, the lubricant type used as lubricating paste B 6 in accordance with the works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flashpoint 132 C) Important!

The instructions for mixing lubricating greases also apply to the lubricating pastes.

*) The products listed in table 19 are suitable lubricating greases for filling of adjacent cavities.

6.40

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Bucyrus Europe GmbH, Lünen 2009

Temperature of application: . . . . . . . . -34 to +120 C

E

Behavior in the presence of water: . . non-soluble in water

BI622821

Tightening torques Tightening torques Screws with ISO metric thread Tab. 22: Tightening torques for total = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

3

535

-

-

3

965

1360

1630

-

1600

-

M 24 DM 24

Bucyrus Europe GmbH, Lünen 2009

Torque 4)

Pitch P

2 2)

(M 27) (M 27) (DM 27

Fine thread

2))

M 30

2 3

580

-

-

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed during installation and maintenance work.

1) 2) 3) 4)

Doc. no.: 7420 165 000 BA 00

The dimensions listed in brackets are used in exceptional cases only.

According to in-house works standard (EWN 6110, edition February 1985).

Only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

The tightening torques comply with the works standard (EWN 6003).

SSVI / 03

6.41

BI622821

Bucyrus Europe GmbH, Lünen 2009

E

Tightening torques

6.42

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BI622821

7

For your information

BI622821

BI622821

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus Europe GmbH Industriestraße 1 D-44534 Lünen Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd.

Bucyrus Europe GmbH, Lünen 2009

E

Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: info@gb.bucyrus.com Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus Europe GmbH Office Moscow 125009 Moscow ul. Tverskaja, dom 9/17, str. 7, office 315 Russian Federation Tel.: +7 (495) 9409209 Fax: +7 (495) 9407145 E-mail: viktor.sobolev@ru.bucyrus.com

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Our service OOO Bucyrus Service ul. Kirzavodskaja 4/8 654004 Novokuzneck Russian Federation Tel: +7 (3843) 991381 Fax: +7 (3843) 991384 E-mail: Andrey.Ravnyushkin@ru.bucyrus.com

America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 E

+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Australia Australia

Bucyrus Australia Underground Pty. Ltd. Customer Service 20 Killara Close, Beresfield, New South Wales 2322 Tel: Fax:

+61 / 24 91 4 - 7144 +61 / 24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

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Tel: Fax:

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Our service Asia China

Bucyrus Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

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Identification of the shields Identification of the shields Type plate The main subassemblies of the shields are identified by a type plate.

Fig. 89: Type plate, example

1

3

12345 08/09

678

7420 165 000 00 01 2

1 manufacturer 2 SAP/Order No. 3 date of manufacture

7

5

3 056 kN

5 device number 6 number of props 7 prop force

4 serial No.

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6

4

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2

Bucyrus Europe GmbH

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Identification of the shields Shield number The shields are numbered consecutively. Plates with the shield number are fitted at the faceside on the base at the left.

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Fig. 90: Shield number on the base, example

Tab. 23: Allocation of the shield numbers Shield number 1 and 2 162 and 163

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Device number 7420 165 000 00 01

Use Segment shield on the head-end drive Segment shield on the tail-end drive

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Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 24: National standards and directives, extract

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation system Plug connectors for hydraulics Fire-resistant hydraulic fluids Maintenance and inspection for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for pins T-head bolts Greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 25: European standards and directives, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 DIN EN 1710 DIN EN 1552

Date of issue

Title

EC directive of the European Parliament and Council on 1998-06-22 the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and 1994-03-23 protective systems intended for use in potentially explosive atmospheres Safety of Machinery 2004-04 Safety of Machinery 2004-04 Non-electrical devices for use in potentially explosive at2002-04 mospheres - Part 1: Basic methods and requirements Electrical apparatus for explosive gas atmospheres 2004-12 - Part 0: General requirements Basic and safety principles for man-machine interfaces 2000-08 Creating manuals 2001-11 - Structure, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water - Distillation method Equipment and components for use in areas susceptible to 2006-01 firedamp in underground mines Mobile extracting machines at the face - safety require2003-09 ments for shearer loaders and plough systems 1) EWN = works standard

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Title

Bucyrus Europe GmbH, Lünen 2009

Designation