CAT Shield support 6001400-2x2283-1500 Operating Manual

Operating manual Shield support 600/1400-2x2283-1500 Doc. no.: 7420 195 000 BA 00

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

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 does not accept 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 DBT Europe GmbH, Lünen 2008 E

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

2.3

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

Repair and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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

3.3

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

Storage of used equipment . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.5

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

3.6

Transport lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport safety device, relay bar assembly . . . . . . . . . . .

Transport safety device, side seal . . . . . . . . . . . . . . . . . . . .

Shaft transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Face transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 3.10 3.11 3.12 3.15

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

4.3

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

4.3

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

Establishing a link between the connections . . . . . . . . . . .

4.5 4.8

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

4.9

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 To be observed prior to start-up . . . . . . . . . . . . . . . . . . . . . .

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

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

4.10 4.11 4.12

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 . . .

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

5.16 Shield components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5.27 Shield functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.28 Functions of the water valve unit . . . . . . . . . . . . . . . . . . . . .

5.30 5.31 5.32 5.33 5.33 5.33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34 Instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

5.34 5.34 5.37 5.37 5.38 5.38 5.38

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

6.3

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

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

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

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

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

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

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

6.4 6.5 6.6 6.11 6.14 6.16 6.18

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.19 6.25

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.27 6.28 6.28

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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

Carry out every six months . . . . . . . . . . . . . . . . . . . . . . . . . .

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

E

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31

Contents Seal cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.29 6.30

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32 Shield control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.34 6.35

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.37 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 Endshield steering device . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base/base steering device . . . . . . . . . . . . . . . . . . . . . . . . . .

6.38 6.40

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.42 6.45

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.47 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.47

Bucyrus DBT Europe GmbH, Lünen 2008

E

7. For your information

Doc. no.: 7420 195 000 BA 00

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

7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

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

7.6

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

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

7.6 7.6

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

7.7

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

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

7.7 7.7

VRVT / 01

Bucyrus DBT Europe GmbH, Lünen 2008

E

Contents

Shield support 600/1400-2x2283-1500

1

About this manual

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

Take care to ensure that the operating manual available to you applies to the shield support being used. Compare the data given below with the data given on the type plate of the shield support.

Where to find the type plate on the shield support is described in chapter 7 of this operating manual.

This operating manual is designed for: shield support 600/1400-2x2283-1500 *

availability of operating manual

Bucyrus DBT Europe GmbH, Lünen 2008

E

and is only permitted to be used for shields of this type. Only use the operating manual which applies to the respective support. Failure to do so will pose a danger to yourself and others.

It is absolutely necessary to ensure that all persons working with or on the support have access to the contents of the applicable support operating manuals at all times and without any restrictions.

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

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

– initiate and/or – supervise it.

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

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

*

Doc. no.: 7420 195 000 BA 00

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

VRVT / 01

1.3

Before starting work Purpose of this operating manual operating manual

This operating manual contains general information on the safe and efficient handling of shield supports and provides you with important instructions on the work performed directly on or with the shield support.

Therefore, 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.

questions?

Should you have any questions, please contact our service department. Contact details are given in chapter 7 of this operating manual.

safety

Read chapter 2 (“Your safety”) closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the procedural instructions.

Characters and symbols used

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 dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to moderately serious injuries and machine damage.

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

. The hand symbol prompts you to take action.

Several successive paragraphs marked with the hand symbol represent a sequence of actions which must be executed in the order specified.

Follow these instructions step-by-step in order to perform the work safely and efficiently.

1.4

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Try to memorize the symbols and their meanings.

E

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

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. residual risk

The shield support was manufactured in accordance with the state of the art and generally recognized safety standards and regulations. However, a residual risk still exists which may expose you to hazardous situations when working with or on the shields. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

supplementary regulations

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

Observe the safety and accident prevention regulations: J of the mining company J of the mines inspectorate

Bucyrus DBT Europe GmbH, Lünen 2008

E

J of the mining supervisory authorities.

Personnel Persons employed in the operation, repair and overhaul of hydraulic and/or electrohydraulic shield supports must be specially qualified. In addition to having had training in mining technology the following minimum requirements must be met.

Operation and maintenance Operation and maintenance of the shield supports may only be performed by trained personnel. qualification

The training must be specially tailored to the type of shield actually being used.

The electrohydraulic and hydraulic control systems may only be operated by personnel who have been adequately trained to operate the present control system.

The content 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 system.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.3

Personnel Repair and maintenance In general, repair work may only be performed by persons who have the knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment.

Repair work on and overhaul of: J safety devices, as e.g. pressure relief valves J hydraulic props and cylinders J control units, valves, and filters

Bucyrus DBT Europe GmbH, Lünen 2008

E

shall be performed only by Bucyrus service engineers or by specially trained personnel of the mining company.

2.4

Shield support 600/1400-2x2283-1500

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 include: J propping the roof against the floor J ensuring an adequate travel way J the following shield operations:

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

– advancing Bucyrus DBT Europe GmbH, Lünen 2008

– retracting J forming an abutment 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” section.

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

Inform your colleagues of: J your exact location J the work 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 applicable for shields provided with electrohydraulic shield control systems: Actuate the support lockout switch (repair switch) before performing: 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 support 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 support units may move on their own. Therefore, it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals sent by the control unit in the support unit currently operated.

Shield support 600/1400-2x2283-1500

E

signaling systems and safety equipment

Maintain the lighting systems in working condition.

Bucyrus DBT Europe GmbH, Lünen 2008

lighting system

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

J flippers J relay bars (face side and gob side). transporting

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

Non-standard transport assemblies are shown in special figures which are added 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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.7

Safety instructions Installation 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-locking hardwood wedges between the lemniscatic links fix the position of the caving shield.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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 fastening bolts either drop down or can be pulled out without the use of excessive force.

When removing the transport safety devices of the flipper, ensure that nobody is present in its swiveling area 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: 700 mm J Height: 500 mm.

Any devices added to the shield later, such as steering devices, may 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.

2.8

Shield support 600/1400-2x2283-1500

Safety instructions Operation shield control unit

In automatic mode, the support 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 support units may move on their own. 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 device in the shield unit currently operated.

Check to determine whether all safety equipment on the shield are present and functional. 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 system and know the contents of the respective operating manual for that control system.

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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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 recognizable This measure avoids faulty operation and any resulting accidents.

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 face

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

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.9

Safety instructions shield alignment

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

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

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

roof falls

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

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

exceeded J the stabilizing cylinder locks

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 respective operating instructions of the mine.

Secure all mining equipment against unauthorized starting.

Isolate 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 faceside.

Only use only 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. Under no circumstances should you disengage the canopy from the roof. It must always be in full contact over the entire length.

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

2.10

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

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

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

J lifting gear with adequate load-carrying capacity. attaching loads

Use only permitted attachment points. Reset all shields to which you wish to attach loads. Make sure that the entire length of the canopy always fits closely against the entire length of the roof.

Afterwards, check the setting pressure once again.

Maintenance Make sure that all safety and safety equipment of the support units are complete and functional. If the safety and protective devices are included in the Bucyrus scope of delivery, refer to chapter 6, “Technical Data”, for their 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 DBT Europe GmbH, Lünen 2008

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

Please refer to the spare parts catalog for the equipment to find the order numbers for the required spare parts.

Do not make modifications or carry out conversions which might impair the safety of the shield. All conversions and modifications must be reported by Bucyrus 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.

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 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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.11

Safety instructions 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.

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

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

Hydraulic system

When removing protective devices which include hydraulic components, keep in mind that these components may be pressurized.

You could be severely injured by hydraulic fluid jetting out wildly.

Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

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

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 defective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check 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 sheath of the hose is not damaged J the connectors are securely inserted into the sockets J the connections are leak-tight.

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

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

Before removing staples to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Make sure the line is depressurized.

Only secure the coupling sockets of the hydraulic elements with the proper coupling clips. Always fasten the staples completely with both sides.

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

2.12

Shield support 600/1400-2x2283-1500

E

protective devices - hydraulic system

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

Bucyrus DBT Europe GmbH, Lünen 2008

handling hydraulic fluids

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 2:

Example: 4SP hydraulic hose, identification 3 2 1

5

4

Bucyrus DBT Europe GmbH, Lünen 2008

E

6

1 manufacturer 2 hose type 3 date of manufacture, 1st quarter 2002

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a hydraulic hose that is thrashing about depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.13

Safety instructions laying hydraulic hoses

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

Lay hydraulic hoses so that they: J always have a little slack Fig. 3:

Laying hydraulic hose lines, slack RIGHT

WRONG

J are not twisted Fig. 4:

Laying hydraulic hoses, twisting WRONG

J are not bent directly behind the connections (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

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

RIGHT

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.

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

When installing the hydraulic hoses, ensure that they cannot be: J torn out J kinked J crushed J driven over J twisted by the movement of the equipment (Fig. 7).

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

Bucyrus DBT Europe GmbH, Lünen 2008

E

RIGHT

Doc. no.: 7420 195 000 BA 00

VRVT / 01

2.15

Bucyrus DBT Europe GmbH, Lünen 2008

E

Safety instructions

2.16

Shield support 600/1400-2x2283-1500

3

Storage and transport

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 how 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 corrosion protection

The surfaces of the equipment are coated with temporary corrosion protection. If stored properly, the equipment parts will be protected for a period of six months, starting from the date of delivery.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Prior to delivery, hydraulically operated equipment is filled with the anticorrosion and antifreeze fluid HYDROCOR® CV50* and tested.

The fluid remains in the hydraulic system for the purpose of transport and (if required) subsequent storage.

HYDROCOR® CV50 is frost-free down to -40 °C and protects the metallic materials used from corrosion. It contains a color indicator which reacts when the pH value drops. The color of the medium changes from “red” to “yellow” here. The yellow coloration indicates that the anticorrosion protection is no longer adequate.

Additional information concerning the characteristics of the HYDROCOR® CV50 can be obtained as needed from the respective manufacturer’s data sheet.

Water-bearing parts, such as the parts for the water spraying system of a shield, must be completely emptied or might have to be filled with an antifreeze medium. short-term storage

During short term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. They do however still need to be protected, particularly against environmental influences, also against high temperatures, e.g. by suitable protective covers and/or sheathings for the control systems and by supplementary covering of the equipment. If the storage period exceeds four weeks, additional special precautions must be taken, depending on the ambient conditions. For example, it may be necessary to remove the electronic control unit for the purpose of proper storage.

long-term storage

If storage is expected to last longer than six months, then all of the cavities in the hydraulic components must be filled completely with a corrosion inhibitor, such as HYDROCOR® CV 50. The fluid must possess corrosion protection properties and be frost-proof within the temperature range intended for the application. All connections must be sealed with durable and suitable plugs.

It is highly recommended that the equipment not be stored outdoors. It should be stored in a dry, well-ventilated room. If this is not possible for the entire support unit, for example, then the hydraulic and electronic components might have to be dismantled and stored separately. *

Doc. no.: 7420 195 000 BA 00

HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

VRVT / 01

3.3

Equipment which is stored outdoors must be protected against direct sunlight, precipitation and contamination, for example by using tarpaulins. It must also be stored in such a way that liquids will not be able to accumulate in hollow spaces. Liquids which get into hollow spaces during transport or handling must be able to drain freely.

electrical equipment, rubber and plastic parts

Electrical equipment, electronic components, replacement parts made of rubber or plastic - such as seals and hoses - and pressure fluids must be generally stored in closed spaces at 15 °C to 25 °C, and protected against direct sunlight. Exceptions: see “short-term storage”.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. A storage period of approximately two years is therefore specified for these parts as an indicative value.

dirt and moisture

All hydraulic elements must be appropriately protected against the penetration of dirt and moisture during storage. The connection surfaces of the hydraulics components that remain in the device must be protected against corrosion and sealed with blind plates. Hydraulic plug connections and electrical cables must be sealed with suitable caps or plugs.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be carried out. This will make it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

This can be checked by Bucyrus upon the request of the mine. The mining company will bear the cost for this.

HFA fluids

The regulations stipulated by the manufacturer or of the supplier take precedence in every instance involving the storage of HFA fluids and/or concentrates for the production of HFA fluids. You will also find supplementary instructions in the “Permissible Media” Section of these operating instructions.

When removing stock from storage or when placing it there, take care to ensure that any new supplies are stored separately from existing stock in such a way that old stock is always taken first when supplies are required for use. Label the containers accordingly.

3.4

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

storage outdoors

E

Storage

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

corrosion protection

Doc. no.: 7420 195 000 BA 00

VRVT / 01

3.5

Transport Transport Warning!

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

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

Use only suitable load handling devices.

points of attachment

Where technically possible, the load units have suitable, fixed lifting points for transport and installation. Otherwise, corresponding tapped holes or other fastening options are to be provided for temporarily attaching the lifting points. More detailed information about the arrangement and capacity of the points of attachment can be found in the figures of the replacement part catalog or the special figures for transport subassemblies which, if applicable, can be found in the Appendix of this manual.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic parts which were previously operated with a frost-sensitive medium, such as an oil-in-water emulsion (HFAE), must be completely emptied and then filled with a frost-proof corrosion inhibitor, for example HYDROCOR® CV 50. If the fluids could not be completely exchanged due to technical reasons, a corrosion inhibitor is to be selected which can be mixed with the originally used medium, and it is to be made sure that the media are sufficiently mixed.

Transport of equipment at temperatures in the range of -21 °C to -40 °C is only permissible when certain measures have been taken to meet these conditions at the design and manufacturing stages.

Nevertheless, the components 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. Here, external forces are only to be applied to the lifting points and mounting device surfaces as specified in special figures, if available.

The equipment may not be transported at temperatures below -40 °C. 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 a maximum of 25 km/h for truck transport.

electrical and electronic components

3.6

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors or outdoor storage of the equipment during winter, unless these components or all 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 contamination.

Shield support 600/1400-2x2283-1500

E

In agreement with the customer, the transport units were defined taking the special local conditions into account as follows: - The support units are transported as a complete unit.

Bucyrus DBT Europe GmbH, Lünen 2008

transport units

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

transport safety devices

Designation

Transport position

Complete shield unit

As for normal use

Remarks

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

Tab. 2: Transport safety devices Part

Transport safety device

Quantity

Transport safety device

1

Side seal, movable

Pin and securing device

4

Hydraulic system

Hydraulic connections not used are protected by protective caps or plugs

-

Relay bar

Bucyrus DBT Europe GmbH, Lünen 2008

E

Coal face side

Caution!

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

Caution!

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

3.7

Transport Fig. 8:

Transporting the shield support as a complete unit

H SY

SO

X1

S2 S1

Sx l

X2

B

Bucyrus DBT Europe GmbH, Lünen 2008

E

S1 load ring, 2 x on the coal face side in the base, capacity: 8000 kg S2 load ring, 2 x gobside on the caving shield, capacity: 8000 kg X1 transport safety device for relay bar, face side X2 transport safety device for movable side seal So center of gravity

Important!

For transporting, use the two lifting points S1 and S2.

Tab. 3: Shield support 7420 195 000 00 01 and 7420 195 000 00 02, dimensions and weights Variant

3.8

Order No.

Length in mm

Width in mm

Height in mm

Sx/Sy in mm

Weight in kg

01 7420 195 000 00 01

4696

1450

600 2580/344

8840

02 7420 195 000 00 02

4696

1450

600 2580/344

8840

Shield support 600/1400-2x2283-1500

Transport Transport lock The transport lock prevents collisions with other parts during transport.The entry height with the transport lock is 615 mm.

Caution!

During transport ensure that the transport lock is fitted on both sides of the support. Parts of the support can be seriously damaged if a transport lock has not been fitted.

Transport lock

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 9:

1

2

3 1 transport lock 2 pin 40/34x90

3 locking clip 4.5

Notice!

The transport locks on each side must be exchanged with additional devices before commissioning.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

3.9

Transport Transport safety device, relay bar assembly A transport safety device is to be attached to the relay bar assembly during face-side transportation. The transport safety device fixes the relay bar assembly to the canopy.

The transport safety device is screwed onto the canopy and relay bar assembly with screw connections.

Fig. 10: Transport safety device, relay bar assembly

1

7

1 transport safety devices 6 hex. head screw M 30x170-8.8

3.10

6

7 hex. nut M 30-8 10 hex. head screw M 30x85-8.8

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

10

Transport Transport safety device, side seal For transport, the movable side seals are retracted and locked mechanically with pins. The pins are secured using staples or locking clips (see also chapter 6, “Side seal” section).

Transport safety device, side seal

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 11:

14

30

15 28

14 pin 27x144 15 pin 40x205

Doc. no.: 7420 195 000 BA 00

VRVT / 01

28 staple 30 locking clip

3.11

Transport Shaft transport This section contains important information for transporting the shields vertically in the shaft.

Warning!

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

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

Use only suitable load handling devices.

transport equipment

The shield may only be transported in the shaft with this transport equipment (Fig. 12). This, in turn, may only be mounted to the shield described here. The maximum load capacity is 10 000 kg.

Fig. 12: Transport equipment for the vertical shaft transport b

a

2

11 1

1 transport equipment 2 threaded pins 78/58x235 10 hex. nut M 42-8 11 washer

3.12

10

12

12 locking clip 4,5 a lifting eye 15 000 t b load ring 30 000 t

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Warning!

In addition to the safety information given in this manual, also make sure you observe the safety regulations and operation instructions which apply to the operation of the mine. Failure to do so can lead to extremely serious accidents which could also be fatal.

E

Caution!

Transport safety devices can be damaged during transport to the mine. Check all shields, transport safety devices and the transport equipment for damage. Replace the damaged parts before you release the transport units for shaft transport. Damaged transport safety devices and transport equipment can cause further serious material damage.

Transport Mounting of the transport equipment The transport equipment must be mounted to the tip of the canopy before the vertical shaft transport.

To mount the transport equipment, proceed as follows:

. Guide the transport equipment as far as it will go on the tip of the canopy (Figure 1). Use suitable lifting gear to lift the transport equipment.

. Place the threaded pins in the bores and screw them with the washers and hex nuts (Figure 2).

. Secure the screw connections with the locking clips (Figure 3).

Fig. 13: Mounting the transport equipment

Figure 3

Bucyrus DBT Europe GmbH, Lünen 2008

E

Figure 1

Figure 2

Doc. no.: 7420 195 000 BA 00

VRVT / 01

3.13

Transport Lifting and lowering the shield lifting operation

Before lifting, it must be guaranteed that the shield on the floor of the shaft is received correctly positioned and is further transported.

Maintain constant contact with the responsible persons involved with the transport during the transport preparation and transport.

Danger!

You could be injured or killed by unforeseen shield movements. Go to a safe place sufficiently far away from the suspended shield.

Secure yourself against falling into the shaft using your personal protective clothing and equipment (safety harness).

Important!

You can use the two lifting eyes (item a) on the caving shield for fastening ropes in order to control the shield movement at the transport hook.

. Lift the shield up slowly in order to avoid dangerous swinging movements as far as possible (Figure 1).

E

. Swivel the suspended shield carefully over the shaft (Figure 2).

Figure 1

Bucyrus DBT Europe GmbH, Lünen 2008

Fig. 14: Lifting the shield

Figure 2

a a

a lifting eye on the caving shield

. Lower the shield slowly to the shaft floor.

Important!

When lowering the shield, make sure it’s positioned correctly so that it rests on the bases.

3.14

Shield support 600/1400-2x2283-1500

Transport Face transport This section contains important information for transporting the shields on the face.

If required, an additional transport console can be mounted on the face side on each shield base.

The transport console is only allowed for the bases of the shield described here and may not be mounted to other bases.

Fig. 15: Transport console 6 a

5

1

Bucyrus DBT Europe GmbH, Lünen 2008

E

1 transport console 5 hex. head screw M 24x85

6 hex. nut M 24 a load ring 8000 t

To mount the transport console, proceed as follows:

. Insert four hex. head screws in the bores of the base. . Place the transport console on the base and secure it with the screw connections.

Fig. 16: Mounting the transport console

Doc. no.: 7420 195 000 BA 00

VRVT / 01

3.15

Bucyrus DBT Europe GmbH, Lünen 2008

E

Transport

3.16

Shield support 600/1400-2x2283-1500

4

Installation

Pre-assembly of the support units

Installation In this chapter, you will get information about installing the shield 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”.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Installation of the support units Caution!

For transport underground only the attachment detailed 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 property damage. installation plan

The shield 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!

identification for installation in the face

Doc. no.: 7420 195 000 BA 00

In order to identify the shield 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.

VRVT / 01

4.3

Installation of the support units shield number

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.

Tab. 4: Allocation of the shield numbers

4.4

Shield number

Device number

Application

1 to 135

7420 195 000 00 01/02

Face shield

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 17: Shield number on the base, example

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.18).

Fig. 18: View of the supply block and the auxiliary connections

c

a

23

c

b R

P 19

Bucyrus DBT Europe GmbH, Lünen 2008

E

W

10 17

10 supply block 17 HP ball valve, for water spraying 19 HP ball valve, for auxiliary supply 23 HP ball valve, in the pressure supply line 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 W water line, DN 32

Notice!

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

4.5

Installation of the support units Fig. 19: Plug on the supply block x

b

a 9 13b R P

10 W

P connection for pressure line, DN 25 R connection for return line, DN 32 W connection for water line, DN 32

E

x vented cap screw

For operating the shield with the help of the auxiliary supply, the shield functions must be activated via an additional external PMC®-R control device. 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 on the supply block (see Fig. 18 and the hydraulic circuit diagram, Fig. 31, in chapter 5).

For utilization of the auxiliary supply, the connections P, R and W (see Fig. 18) on the supply block must with blocked with the hoses that will later be responsible for the connection with the neighboring shield (this corresponds as a rule to the 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.

Proceed as follows to join the shields to one another:

. Close the HP ball valves - items 19 and 23 (see Fig. 18). . Remove the plugs c from connections a and b (see Fig. 18) of the auxiliary supply.

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

. Afterwards, reopen the HP ball valves - items 19 and 23.

The shield is now movable via the external control units.

. Move the shield to the desired position. . To relieve the pressure hose, short-circuit the HP ball valve, item 19, and activate the function “Advance conveyor” briefly until the pressure hose is relieved (support is not yet connected to the conveyor).

4.6

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

9 PRV (80 bar) in the return line 10 supply block 13b plug DN 10 with pressure relief a connection for pressure line, auxiliary supply b connection for return line, auxiliary supply

Installation of the support units Warning!

Pressure may build up in the return line due to incorrect operation. This must be relieved via the pressure release valve (see Fig. 19, item 13b) by screwing in vented cap screw (x). 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.

. Release the three connection lines P, R and W on the supply

Bucyrus DBT Europe GmbH, Lünen 2008

E

block and connect them to the neighboring shield.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

4.7

Installation of the support units Establishing a link between the connections

The supply block for supplying the shield hydraulics is located to the right underneath the canopy in front of the right-hand prop. The connection to the supply block of the neighboring support is made using three hose lines: one pressure line (DN 25), one return line (DN 32), one water line (DN 32). See also Fig. 18 and the hydraulics schematics in chapter 6 of these operating instructions.

control unit

Every third 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 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 support 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.

4.8

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

hydraulic system

E

The hydraulic connections to the support units are designed as plug-type connections in accordance with DIN 20043.

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.

permissible pressure

Nominal pressure: 320 bar Tolerance range: ± 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 DBT Europe GmbH, Lünen 2008

E

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 hydraulics.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

4.9

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 safety 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 safety devices have been removed.

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

. Check all mechanical connections on the 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 in the “lowering position” 1) .

. Make sure that the additional device is mounted and secured on the bases.

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, particularly on the articulations.

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 plug-ins

4.10

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

J Mechanics:

Commissioning . Check the hydraulic supply pressure. . Check the load-carrying function of the prop. The current pres-

sure 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 Signaling and lighting systems, information plates:

Important!

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

E

. Check all signaling systems. . Make sure that the face lighting is sufficient. . Check whether the face area, especially the travel way, is suffiBucyrus DBT Europe GmbH, Lünen 2008

ciently marked with signs. 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. . Check 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.

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.

Warning!

Shut-off valves may not be installed into the return lines for the shield hydraulics. 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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

4.11

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

. Check all functions of the shield control unit.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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.

4.12

Shield support 600/1400-2x2283-1500

5

Operation

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 in addition to hands-on training. It is recommended that you read this chapter as a supplement to the training, but this 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 DBT Europe GmbH, Lünen 2008

E

Warning!

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

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

Requirements Operating conditions face crew

face equipment

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 must be sufficiently illuminated.

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

travel way

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

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

700 mm,

Height: 500 mm.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.3

work in the mining area

repair work

5.4

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

roof support work

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

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

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

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.

Roof support work must be carried out so that the filling section of the face conveyor remains unobstructed. This means that the shield canopies of the 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 of the inclined face, additional barricades, such as air cushions, must be set up above the work area in the conveyor to protect against the following material. The design and amount of required safety equipment depends on the local conditions.

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 pretension 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.

E

Requirements

Requirements 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. water spraying system

The water spraying system serves to actively counteract dust. Usually several nozzles are attached to the shield support, through which water can be sprayed as needed. The water spraying system is activated only temporarily, depending on the operating state of the system, for example, when pushing the shield and when the mining equipment passes the support. The 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 opposite the support, if necessary. This way, you can prevent the conveyor from shifting to the side with respect to the support. This allows you to reduce the risk that the relay bar assembly will get stuck in the base frame.

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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.5

Requirements Safety requirements automatic mode

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

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

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

operating the 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 may 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 be started in the lower section in faces with an inclined face. 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 shield 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 shield units with special functions, such as abutments for the conveyor steering device.

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

5.6

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

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

Requirements Fig. 20: W r o n g, support advanced too late

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 21: 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. hydraulic system, controls

Take care to avoid operating errors on the shield control system.

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

Hoses must always be freely moveable. They may not be squeezed or overstretched. Make sure the hose lines are bundled properly.

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.7

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 sprayed in the atmosphere. damage, replacement parts

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

5.8

Shield support 600/1400-2x2283-1500

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 face system.

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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 damage. This especially applies for stabilizing cylinders, whose mounting elements and fulcrum points are on the shield canopy and the caving shield.

Fig. 22: Shield support in normal position

α=0 M

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.9

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. 23: Shield support with extremely inclined shield canopy

α1

M

s2 α2 M

M = height of the set shield support α = 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.

5.10

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

s1

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

For this reason, in such or similar cases, move the support without the automatic positive set.

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.

E

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.

Bucyrus DBT Europe GmbH, Lünen 2008

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 break outs (see Fig. 24), 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. 24: 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. 25) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.11

Operation of the shield Fig. 25: 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 using the mining

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

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

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

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

5.12

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

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.

Operation of the shield operation on inclines

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

Since, in operations where there are inclines, the support unit advance usually begins in the lower-lying part of the face, it is important that the face end shields are well-aligned. Usuallyhydraulic 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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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, in the “Accessories” section, or in the operating manual for the conveyor steering device. 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 retracting a prop.

J Shield units with undivided bases 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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.13

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

Warning!

Never be on a support which is currently being moved. Circumstances which are not always apparent may lead to unexpected movements in the 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.

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

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

– Shield is wedged in between the neighboring shields.

– Tip of the canopy is stuck in the roof.

– Floor step or debris is blocking the base.

2. If the automatic function of the electronic control system is not working properly, the support can be manually controlled 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.

5.14

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

Observe the following safety regulations:

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

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

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

Tab. 5: Hydraulic components

01

Quantity 1

02 03 04

2 1 1

Electrohydraulic control unit, 10-way Prop CV, NG 13 Twin CV Throttle check valve, DN 12

05 06 07

1 1 4

CV, NW 25 CV, hydraulically piloted PRV, 430 bar

Designation

Arrangement

Remarks

In the middle beneath the canopy

On a bracket

On the supply block In the middle beneath the canopy a) To the right under the canopy

On prop respectively, face side On the right beneath the canopy On the right beneath the canopy

Bucyrus DBT Europe GmbH, Lünen 2008

E

Item

b) Each on the prop 08

5

PRV, 380 bar

09 10 11

1 1 1

PRV, 80 bar Supply block CV, DN 12, piloted

12 13

1 3

Shuttle valve DN 12 Plug DN 10 with pressure relief

14 16 17

1 1 1

Water valve unit Connection plate HP ball valve, blue handle

18

1

HP ball valve, red handle

19 20 21

1 1 1

22 23

1 1

HP ball valve, red handle Hose lines Water spraying system accessories Brackets and accessories HP ball valve, red handle

24 25

1 1

Water filter Water filter DN 20-25

26

2

27

2

Glycerine pressure gauge NG 50 Plug

Z1 Z2 Z3 Z4

2 1 2 3

Prop Shifting ram Stabilizing cylinder Seal cylinder

a) Each on the prop b) In the middle beneath the canopy c) To the right under the canopy In the supply block On the right beneath the canopy On the shuttle valve, to the right under the canopy On the right beneath the canopy a) Each on the prop b) On the supply block On the left beneath the canopy On the right beneath the canopy In the inlet line of the water sprayingunit In the middle beneath the canopy On the right in the supply block

To the left in the supply block To the right next to the electrohydraulic control unit Each on prop CV Each on prop, on connection for rapid yield valves

For stabilizing cylinders Throttles the speed of the shifting unit In the return line For seal cylinder a) For each piston/annular space of the stabilizing cylinder b) In the piston space of the prop a) In the ring space of the prop b) For seal cylinder c) For shifting ram In the return line On a bracket For shifting rams For shifting rams Pressure relief valve For spraying Retainer for twin CV Used for shutting off the water sprayingsystem Used for shutting off the seal cylinder For auxiliary supply Subassembly Subassembly Subassembly Interrupts the main pressure line to the shield In the water circuit In the high pressure circuit

Rapid yield valves not included in scope of delivery

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.15

Operation of the shield hydraulics Functions of the HP ball valves The following ball valves are open during normal operation: J 17, 18, 23

The following ball valves are closed during normal operation: J 19 Tab. 6: HP ball valves Color

Designation

17

Blue

HP ball valve

18

Red

HP ball valve

19

Red

HP ball valve

Pressure supply during start-up and for auxiliary devices

23

Red

HP ball valve

Is used for shutting off the pressure supply line to the shield

Use In order to deactivate the function of the water spraying system Close when transporting the shield, so that the side seal doesn’t extend and the mechanical shield support unit can be installed For moving the shield during start-up and for connecting hydraulically operated auxiliary devices During maintenance and repair work on the shield Bucyrus DBT Europe GmbH, Lünen 2008

Function Used for shutting-off the water supply Used for shutting off the ring chambers of the seal cylinder

E

Item

Fig. 26: HP ball valve, shown opened and closed

open

closed

Medium flow enabled

5.16

Medium flow stopped

Shield support 600/1400-2x2283-1500

Operation of the shield hydraulics Shield hydraulics Fig. 27: Shield hydraulics, configuration Image caption, see Table 5

11

21

12 8c 7b 4 22 16 3

22

Bucyrus DBT Europe GmbH, Lünen 2008

E

23 25 1

10

19

13 14 9 2 17 18 2 6

5

Doc. no.: 7420 195 000 BA 00

8b

VRVT / 01

5.17

Operation of the shield hydraulics Fig. 28: Shield hydraulics, configuration Image caption, see Table 5

Bucyrus DBT Europe GmbH, Lünen 2008

E

13

26

8a 7b 8a

7b 13

5.18

26

Shield support 600/1400-2x2283-1500

Operation of the shield hydraulics

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 29: Functions of the electrohydraulic control unit, instruction plate

10 Functions

Tab. 7: Electrohydraulic control unit with 10 functions, allocation of functions Function, designation

Function No.

Advance shield

1

Set props

2

Lowering propson the right

3

Lowering propson the left

4

Advance conveyor

5

No function

6

Extend stabilizing cylinder

7

Retract stabilizing cylinder

8

Extend seal cylinder

9

Retract seal cylinder

10

Fig. 30: Functions of the water valve unit, instruction plate

W1

W2

Tab. 8: Water valve unit with 2 functions, allocation of functions Function, designation

Doc. no.: 7420 195 000 BA 00

Function No.

Water curtain

W1

Canopy roof and gob water spraying system

W2

VRVT / 01

5.19

Operation of the shield hydraulics Fig. 31: Shield hydraulics, Image caption, see Table 5

Z3

Z3 7a

20

16

Z1 8a

Z1

3 8a 13a

26 4

7b 21

7b

26

8c

8b

Z2 Z4

11

Z4

12 Z4 8b

14 6

17 10

23

25

19

18 24

9 1 13b

5.20

5

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

2

2

E

13a

Operation of the shield hydraulics Fig. 32: Hose diagram Image caption: see Table 5

11 21

7a

A

8c 16

4 12

3

Z4 10

23

25x1800 32x1800 32x1800 NIRO

19 13b

2

14 7b 26

1

13a

25

18 10

8

6

4

2

2

6

5 7b

17

9 2

26

8a

13a

Z1

Bucyrus DBT Europe GmbH, Lünen 2008

E

8a 27

Z1

8b

27

R

20

Z4

Z3 R

Z3 Z4

Z2

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.21

Operation of the shield hydraulics Shield components Main components Fig. 33: Shield, side view

21

11

c

61

51

1 b

1 base 11 canopy 31 caving shield 41 prop

5.22

a d

41

51 stabilizing cylinder 61 hydraulics a PMC®-R control unit b electrohydraulic control unit

c supply block d shifting ram e relay bar assembly

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

e

E

31

Operation of the shield hydraulics Supply block Fig. 34: View of the supply block and the auxiliary connections

c

a

23

c

b R

P 19

W

10

Bucyrus DBT Europe GmbH, Lünen 2008

E

17 10 supply block 17 HP ball valve, for water spraying 19 HP ball valve, for auxiliary supply 23 HP ball valve, in the pressure supply line

a pressure line, auxiliary supply b return line, auxiliary supply c plug on chain for auxiliary supply P pressure line, DN 25 R return line, DN 32 W water line, DN 32

Fig. 35: Plug on the supply block X

b

a 9 13b R P

10 W

9 PRV (80 bar) in the return line 10 supply block 13b plug DN 10 with pressure relief a connection for pressure line, auxiliary supply b connection for return line, auxiliary supply

Doc. no.: 7420 195 000 BA 00

VRVT / 01

P connection for pressure line, DN 25 R connection for return line, DN 32 W connection for water line, DN 32 x vented cap screw

5.23

Operation of the shield hydraulics Control units For every 3 face shields, one PMC®-R control device and 2 support lock-out switches are provided. The PMC®-R is placed on the middle shield here. The two neighboring shields of this group have a support lock-out switch.

Important!

Every third shield is equipped with a PMC®-R control device.

The other two shields are given a support lock-out switch.

Fig. 36: Overview of a shield group

b

a

b PMC®-R control unit

a support lock-out switch

Fig. 37: Support lock-out switches, each on the outermost shield of a group c b

a

a emergency stop switch b support lock-out switch

c electrohydraulic control unit

Fig. 38: PMC®-R control unit on the middle shield of a group c

a

b

a emergency stop switch b support lock-out switch

5.24

c electrohydraulic control unit

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

a

Operation of the shield hydraulics Prop Fig. 39: Left and right prop, view from the coal face side

8a

27 8a

26

7b

13a 26

13a 2

E

2

2 prop control valve 7b PRV, 430 bar 8a PRV, 380 bar

Bucyrus DBT Europe GmbH, Lünen 2008

7b

13a plug DN 10 with relief 26 pressure gauge 27 plug

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

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

The fundamental design of the support unit and the shield control system is shown in the chapter 6, “Technical Data”, Section “Description”, of this manual.

In addition, it is assumed that the reader is familiar with the fundamental principles of the hydraulic shield support and the operation of the control device.

Warning!

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

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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.25

Operation of the shield hydraulics Fig. 40 shows the layout of the PMC®-R control unit and 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. 40: Control device PMC®-R in the middle shield of a group

b

c

d

1

1 electrohydraulic control unit a PMC®-R control unit

c support lock-out switch d protective cover

b emergency stop switch

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.

Important!

Note that - depending on the marking on the connecting cable the end with the shorter distance is to be connected to the pilot valve. See also the separate operating instructions for the control unit.

Fig. 41: Symbol plate for the electrohydraulic control unit

Fig. 42: Functions of the water valve unit, instruction plate

1

5.26

2

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

a

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

Warning!

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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. This could seriously injure or kill you.

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

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 “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”. This can cause dangerous situations which can result in very serious injuries.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.27

Operation of the shield hydraulics Shield functions (10 functions) 1

Advance shield 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

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.

Important!

For more detailed instructions concerning the functions “Withdraw props” and “Set props”, consult the “Conveyor steering device” operating instructions.

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.

6

5.28

No function

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

3

E

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.

Operation of the shield hydraulics 7

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.

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

8

Retract 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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Caution!

Do not exceed the permissible inclination!

Observe the value for minimum residual stroke.

9

Extending seal cylinder Before executing this function, the function “Retract prop” must have been carried out for both props with the side seal in place.

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

Retract seal cylinder Before executing this function, the function “Retract prop” must have been carried out for both props with the side seal in place.

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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.29

Operation of the shield hydraulics Functions of the water valve unit W1

Water curtain The function is executed as long as the button is pushed.

Canopy roof and gob water spraying system The function is executed as long as the button is pushed.

Bucyrus DBT Europe GmbH, Lünen 2008

E

W2

5.30

Shield support 600/1400-2x2283-1500

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 operating manual for the PMC®-R control unit.

hydraulic controlsystem

Special measures

one week after start-up

At the latest one week after start-up, the filter cartridges on the electrohydraulic control units of the 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 DBT Europe GmbH, Lünen 2008

E

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

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

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

If problems occur in the preparation of the hydraulic 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 filter

Doc. no.: 7420 195 000 BA 00

J Replace the water filters directly.

VRVT / 01

5.31

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.

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 of the section planned to be minded will only be reached shortly after this deadline, the hose lines, can as an exception, be replaced after the respective section has been completed.

Daily maintenance hydraulic system

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

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

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

5.32

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

high-pressure hydraulic hoses

E

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 spot checks at quarterly intervals.

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.

Carry out every six months

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

Assessment of damage according to schedule Bucyrus DBT Europe GmbH, Lünen 2008

E

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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.33

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 schematics and hose diagrams for the shield hydraulics. Also refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

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

Fault localization support cannot be lowered

5.34

Possible cause

Measure required

The shut-off valve for the shield supply 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.

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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.

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

E

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

Troubleshooting support cannot be set

Possible cause

Measure required

The shutoff valve for the shield supply 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 Find the cause. If required, lower neighboring between the neighboring supports. supports and align them in order to free the canopy.

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

Measure required

The shutoff valve for the shield supply 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.

Step on roof or floor preventing advance.

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

The pressure of the hydraulic supply is too low.

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

The pressure of the hydraulic supply is too low.

support cannot be advanced

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.35

canopy cannot be positioned

canopy cannot be lowered

5.36

Possible cause

Measure required

Prop control valve is defective.

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

Props are damaged.

Check props for damage and replace, if necessary.

Remove hose from prop 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

Measure required

The shut-off valve for the shield supply 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

Measure required

The shut-off valve for the shield supply 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.

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

Troubleshooting

Troubleshooting 3/2-way or pilot solenoid 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 solenoid 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 electrohydraulic control unit or the control valve block.

internal leakage

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.

E Bucyrus DBT Europe GmbH, Lünen 2008

. Locate the faulty valve by initiating the functions individually

valve replacement

. 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 electrohydraulic control unit or the control valve block.

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.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

5.37

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.

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 catalog.

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

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

. Check the filters in the hydraulic system.

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

5.38

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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.

E

Pressure relief valve defective

6

Technical data

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 600/1400-2x2283-1500 The two-prop shield mainly consists of the following listed main subassemblies: J base frame with lemniscatic links and relay bar assembly J canopy J caving shield J hydraulic prop J hydraulic equipment with hose lines and control.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 9:

Shield support variants, dimensions and weight

Application

Order no.

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

Approximate weight in kg

Face shield

7420 195 000 00 01

4696 x 1 600 x 1 400 4440 x 1 400 x 600

8840

Face shield for conveyor steering device

7420 195 000 00 02

4696 x 1 600 x 1 400 4440 x 1 400 x 600

8840

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 capacity at all stages and act on both sides.

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 realizing an electrohydraulic neighboring control with the electronic PMC®-R control system.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.3

Description Main subassemblies Fig. 43: Shield, side view

21

11

c

61 31

1 a

b

41

d

1 base 11 canopy 31 caving shield 41 prop

E

51

51 stabilizing cylinder 61 hydraulics a PMC®-R control unit b electrohydraulic control unit

c supply block d shifting ram e relay bar assembly

Tab. 10: Shield 7420 195 000 00 01/02, main assemblies

Item

Variant

For device number

1

01

7420 195 000 00 01

2

02

Base frame/ 7420 195 000 00 02 skid

01

7420 195 000 00 01

02

7420 195 000 00 02

01

7420 195 000 00 01

02

7420 195 000 00 02

01

7420 195 000 00 01

02

7420 195 000 00 02

01 02

7420 195 000 00 01 Stabilizing 7420 195 000 00 02 cylinder

01

7420 195 000 00 01

02

Shield control 7420 195 000 00 02 10 functions

11 31 41 51

61

6.4

Designation

ID no.

Approximate weight in kg

7420 195 300 00 01 7420 195 300 00 02

2985

Canopy

7420 195 400 00 01

2545

Caving shield

7420 195 800 00 01

1315

Hydraulic prop

8250 153 000 00 00

324

8241 376 000 00 00

41

8112 281 000 00 00

-

Remarks Shifting ram For relay bar assembly variants,

8241 375 000 00 00 see Fig. 48

Electrohydr. control unit Lines

8154 133 000 00 00 8112 281 010 00 00

Water spraying system Brackets

8112 281 020 00 00 8112 281 030 00 00

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

e

Description Main dimensions Fig. 44: Face shield, dimensions L1 M L3

B

L2

B3 MG 700

H

500

HE

L5

B2

L4

B1

L

B width M support centre distance

Bucyrus DBT Europe GmbH, Lünen 2008

E

MG height, extended HE height, retracted L transport length

Tab. 11: Shield variants, dimensions Var.

l

L1

L2

L3

L4

L5

H

MG

HE

B

B1

B2

B3

M

01

4696

3400

950

2450

2630

1040

860

1400

600

1450

1250

330

150

1500

02

4696

3400

950

2450

2630

1040

860

1400

600

1450

1250

330

150

1500

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.5

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 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.

80

640 350

60

3455 150 150

483

780

110

1040

215

590

230

122 74

5

477

330 790 1250 1312 1410

75

6.6

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 45: Base (base frame), dimensions

Description Fig. 46: Base (base frame), items 13

1 19

26, 51

11 52 33 31 Bucyrus DBT Europe GmbH, Lünen 2008

E

20

12 8

34 52 35 15

56 32

27 25 1 shifting ram ZE-135/80-800 8 relay bar assembly 11 base, right 12 base, left 13 lemniscatic link, front 15 lemniscatic link, rear 19 prop retainer 20 prop retainer

57

52

33

25 bolt 75/60x125 26 pin 40/29.5x67 27 washer 31 lemniscatic link pin 78.5x303 32 lemniscatic link pin 58.5x303 33 securing device 34 pin 40x432

35 pin 40/34x90 51 locking clip 4 52 locking clip 4.5 56 hex. head screw M 12x140-A 4-80 57 hex. nut M 12

Notice!

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.7

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 generated by the piston surface is used to advance the conveyor.

For the shield variant 7420 195 000 00 02, the crawl pan is for accommodating the conveyor steering device.

Fig. 47: Relay bar assembly, dimensions for shield variant 7420 195 000 00 01 and 7420 195 000 00 02

112 74

110

5

72 28

70

Variant 01

50

30

2.5

720

65

75 135 150 150

495

667

1275

3157

112 74

110

5

72 28

70

Variant 02

50

30

2.5

220 690 710 880

85

315

3455

2.5

720

495

65

75 135 150 150

667

1275

3157

Notice!

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

6.8

Shield support 600/1400-2x2283-1500

E Bucyrus DBT Europe GmbH, Lünen 2008

2.5

220 690 710 880

85

315

3455

Description Fig. 48: Relay bar assembly, items for shield variant 7420 195 000 00 01 and 7420 195 000 00 02 6 25, 26 5 23, 24

21 22, 27 18, 19 16, 17 Variant 01 10 1 15

4 12, 13, 14 2

Variant 02

Bucyrus DBT Europe GmbH, Lünen 2008

E

28, 29, 30

X 1 guiding rod 2 crawl pan 4 cylinder seat 5 cylinder bearing 6 yoke 10 hemispherical shell 12 fastening bolts 28x126 13 staple DN 20 14 protective plug 15 bolt 30x87

Doc. no.: 7420 195 000 BA 00

16 hex. head screw M 6x85-A 2-70 17 cap nut M 6-A 2-70 18 washer 19 hex. nut M 20-40-A 2-70 21 securing device 22 pin 30/23X95 23 pin 60/50x85 24 protective plug

VRVT / 01

25 hex. head screw M 10x140-A 2-70 26 cap nut M 10-A 2-70 27 staple DN 12 28 half-round screw M 20x85 29 hex. nut M 20-40-A 2-70 30 washer x crawl pan for conveyor steering device (see separate operating manual for the conveyor steering device)

6.9

Description Functions of the relay bar assembly

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 (5), supports itself with the yoke (6) 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 shifting ram (Figure 1).

pull shield

The conveyor is used as the thrust bearing, meaning that the shield must be lowered. The face side part of the ram system, the crawl pan (2), supports itself at 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 advancing the shield is generated by the annular surface of the shifting ram (Figure 2).

Fig. 49: Extension and retraction of the relay bar assembly, principle diagram 6

5 Figure 1

Figure 2 2

2 crawl pan 5 cylinder bearing

6.10

6 yoke

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

advance conveyor

E

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.

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

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

Caution!

To avoid overloading the stabilizing cylinders, 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 an area of fracture.

Fig. 50: Canopy, dimensions A

E Bucyrus DBT Europe GmbH, Lünen 2008

1410

93.5

B

790

B

325

150

A

135 950 3400

Notice!

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.11

Description Fig. 51: Canopy, items

4 37, 38 14

13 12 31

11 16 32 15 36

1 canopy 4 clevis assembly 11 pawl R70-S 12 securing device 13 joint pin Ø93.5x428 14 pin 24.5x136

6.12

15 pin 10x90 16 pin 30/24.52x121 21 pin 33.5x135 30 locking clip 2.5 31 spring clip 5x32 32 spring cotter 6.3

30 21 36 washer 37 hex. head screw M 16x60-A 2-70 38 hex. nut M 16

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

1

Description Prop head Fig. 52: Fastening the prop head

14

31

16

Bucyrus DBT Europe GmbH, Lünen 2008

E

11

a 11 pawl R70-S 14 pin 24.5x136

31 spring clip 5x32 a telescopic prop SD-2280-260-500/1110

16 pin 30/24.52x121

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.13

Description 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 right side (viewed in the shifting direction) of the side seal is tightly fastened to the shield canopy or the caving shield. The left side is attached 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 props.

Caution!

Before putting the shield unit into operation, the transport safety devices (see Fig. 54 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.

Notice!

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

Fig. 53: Side seal, dimensions

1450 + 150 stroke

Left

82

82

82

250 20

82

Right

6.14

153

78

95

565

15

2030

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Notice!

When putting the side seals into operation, remove the transport safety devices items 14*, 28* and 15*, 30* on the movable side.

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

E

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.

Description Fig. 54: Side seal, items Right side, rotated

2

4

29 16 12 15

30

8, 35

13

1

27

9, 26

14

Right 17

Bucyrus DBT Europe GmbH, Lünen 2008

E

10, 25 Left

Left side, rotated 5 7 15*

6

30* 3

29 28*

14*

34, 36

1 hydraulic cylinder ZE-63/50-215 2 side seal, canopy, right 3 side seal, canopy, left 4 side seal, caving shield, right 5 side seal, caving shield, left 6 guiding pin, 82x560 7 guiding pin 82x815 8 cover plate 9 pin 30/25x152

Doc. no.: 7420 195 000 BA 00

11

10 pin 28x74 11 pin 22x160 12 pin 40/34x134 13 pin 40/34x142 14 pin 27x144 15 pin 40x205 16 pin 22x177 17 compression spring 12x64x621 25 spring dowel pin 5x50

VRVT / 01

26 staple DN 12

16

27 staple DN 25 28 staple DN 12 29 spring clip 30 locking clip 4 34 hex. head screw M 10x75-A 2-70 35 hex head screw M 12x20-A 4-80 36 hex. nut M 10-8

6.15

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 hinge.

The caving shield has retainers for the cylinders and guiding pins of the side seal.

Fig. 55: Caving shield, dimensions 1378 423

600 260

600 260

Bucyrus DBT Europe GmbH, Lünen 2008

E

1394

530

230

230 660 1410

Notice!

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

6.16

Shield support 600/1400-2x2283-1500

Description Fig. 56: Caving shield, items 1

21

S1

22

11

Bucyrus DBT Europe GmbH, Lünen 2008

E

26

13

12

1 caving shield 11 pin 33.5x135 12 pin 15/12x85 13 locking plate 16 lemniscatic link pin 78.5x303

Doc. no.: 7420 195 000 BA 00

16

23

17 lemniscatic link pin 58.5x303 21 spring cotter 5 22 spring cotter 6.3 23 locking clip 2.5 26 washer

VRVT / 01

S2

17

S1 load ring, load capacity: 3000 kg S2 load ring, load capacity: 5000 kg

6.17

Description Technical data, steel structure

15

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

600

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

1400

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

800

Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

750

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

800

Prop clearance on inclines . . . . . . . . . . . mm

790

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

2450

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

950

Width of canopy with side seals . . . . . . . mm

1450

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

3510

Caving shield inclination: Support retracted . . . . . . . . . . . . . . . . . . . degrees

3.75

Support extended . . . . . . . . . . . . . . . . . . . degrees

42.2

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

1450

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

1250

Total surface area of the bases . . . . . . . cm2

18792

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

1500

Support force with medium seam thickness of . . . . . . . . . . . . . . . . . . . . . . . . mm

1000

a) with 320 bar setting pressure . . . . . . . kN

2750

b) with 430 bar nominal pressure . . . . . . kN

3695

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

1000

Face shield

6.18

a) for 320 bar setting pressure . . . . . . . . kN/m2

495

b) for 430 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

553/665

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Securing from tipping permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . degrees

E

Shield support, device number 7420 195 000 00 01/02

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 catalog of the shield support.

The pilot 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.

Warning!

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

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

Shield hydraulics Bucyrus DBT Europe GmbH, Lünen 2008

E

The following table shows the hydraulic components for the support.

Tab. 12: Hydraulic components Item

Designation

Arrangement

Remarks

In the middle beneath the canopy

On a bracket

01

Quantity 1

02

2

Electrohydraulic control unit, 10-way Prop CV, NG 13

03 04

1 1

Twin CV Throttle check valve, DN 12

On prop respectively, coal faceside On the right beneath the canopy On the right beneath the canopy

05 06 07

1 1 4

CV, NW 25 CV, hydraulically piloted PRV, 430 bar

On the supply block In the middle beneath the canopy a) To the right under the canopy

08

5

PRV, 380 bar

09 10 11

1 1 1

PRV, 80 bar Supply block CV, DN 12, piloted

12 13

1 3

14 16 17

1 1 1

Shuttle valve DN 12 Plug cap DN 10 with pressure relief Water valve unit Connection plate HP ball valve, blue handle

18

1

HP ball valve, red handle

19 20 21

1 1 1

HP ball valve, red handle Hose lines Water spraying system accessories

b) Each on the prop a) Each on the prop b) In the middle beneath the canopy c) To the right under the canopy In the supply block On the right beneath the canopy On the shuttle valve, to the right under the canopy On the right beneath the canopy a) Each on the prop b) On the supply block On the left beneath the canopy On the right beneath the canopy In the inlet line of the water sprayingsystem In the middle beneath the canopy On the right in the supply block

For stabilizing cylinders Throttles the speed of the shifting unit In the return line For seal cylinder a) Respectively for the piston annular space of the stabilizing cylinders b) For the prop piston space a) In the annular space of the prop b) For seal cylinder c) For shifting ram In the return line On a bracket For shifting rams For shifting rams Pressure relief valve For spraying Retainer for twin CV Used for blocking the water spraying Used for shutting off the seal cylinder For auxiliary supply Subassembly Subassembly

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.19

Hydraulic system Designation

Arrangement

22 23

Quantity 1 1

Brackets and accessories HP ball valve, red handle

To the left in the supply block

24 25

1 1

Water filter Water filter DN 20-25

26

2

27

2

Glycerine pressure gauge NG 50 Plug

Z1 Z2 Z3 Z4

2 1 2 3

Prop Shifting ram Stabilizing cylinder Seal cylinder

To the right next to the electrohydraulic control unit Each on prop CV Each on prop, on connection for rapid yield valves

Remarks Subassembly Interrupts the main pressure line to the shield In the water circuit In the high pressure circuit

Rapid yield valves not included in scope of delivery

Bucyrus DBT Europe GmbH, Lünen 2008

E

Item

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

6.20

Shield support 600/1400-2x2283-1500

Hydraulic system Shield hydraulics Fig. 57: Shield hydraulics, configuration Image caption, see Table 5

11

21

12 8c 7b 4 22 16 3

22

Bucyrus DBT Europe GmbH, Lünen 2008

E

23 25 1

10

19

13 14 9 2 17 18 2 6

5

Doc. no.: 7420 195 000 BA 00

8b

VRVT / 01

6.21

Hydraulic system Fig. 58: Shield hydraulics, configuration Image caption, see Table 5

Bucyrus DBT Europe GmbH, Lünen 2008

E

13

26

8a 7b 8a

7b 13

6.22

26

Shield support 600/1400-2x2283-1500

Hydraulic system

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 59: Functions of the electrohydraulic control unit, instruction plate

10 Functions

Tab. 13: Electrohydraulic control unit with 10 functions, allocation of functions Function, designation

Function no.

Advance shield

1

Set props

2

Lowering propson the right

3

Lowering propson the left

4

Advance conveyor

5

No function

6

Extend stabilizing cylinder

7

Retract stabilizing cylinder

8

Extending seal cylinder

9

Retract seal cylinder

10

Fig. 60: Functions of the water valve unit, instruction plate

W1

W2

Tab. 14: Water valve unit with 2 functions, allocation of functions Function, designation

Doc. no.: 7420 195 000 BA 00

Function no.

Water curtain

W1

Canopy roof and gob water spraying system

W2

VRVT / 01

6.23

Hydraulic system Fig. 61: Shield hydraulics, Image caption, see Table 5

Z3

Z3 7a

20

16

Z1 8a

Z1

3 8a 13a

26 4

7b 21

7b

26

8c

8b

Z2 Z4

11

Z4

12 Z4 8b

14 6

17 10

23

25

19

18 24

9 1 13b

6.24

5

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

2

2

E

13a

Hydraulic system Two-stage telescopic prop The two-stage telescopic prop is double acting and is designed for equal load-bearing capacity on both stages. Equal load-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 prop head is fastened by means of two clampable pawls on the canopy, which engage in the recesses on the prop head. The cams of the prop base are clamped with the so-called prop retainers on the base of the support.

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

Fig. 62: Two-stage telescopic prop, type SD-2280-260-500/1110

Bucyrus DBT Europe GmbH, Lünen 2008

E

3

2

b

e

b

d a 32

1 c

1 prop base 2 piston pipe 3 piston rod 32 spring cotter a piston space connection b annular space connection

c cam d load ring 3000 kg e connection for rapid yield valves

Tab. 15: Telescopic prop Length in mm

Doc. no.: 7420 195 000 BA 00

Stroke in mm

ID No. Telescopic prop

Retracted

Extended

Upper stage

Lower stage

8250 153 000 00 00

500

1110

302

308

VRVT / 01

6.25

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

6.26

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

setting props

E

Function

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

Fig. 63: Hydraulic cylinder, typical example Model a)

2 1

3

5

4

1

4

6

Bucyrus DBT Europe GmbH, Lünen 2008

E

Model b)

2 1 outer cylinder 2 cylinder bottom 3 piston rod

3

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 seal the lowering connections of double-acting hydraulic cylinders so that they are pressure-tight!

Otherwise, when extending the cylinder, 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 195 000 BA 00

VRVT / 01

6.27

Hydraulic cylinder Shifting ram Fig. 64: Hydraulic cylinder, type ZE-135/80-800

75 L 7

c

1 21 2

a

33 b d 1 cylinder tube 2 reed rod 7 relay bar adaptor 21 piston rod 33 screw fitting a annular space connection

Bucyrus DBT Europe GmbH, Lünen 2008

E

b piston space connection c load ring 1000 kg d cylinder disk L retracted: 667 extended: 1467 stroke: 700

Stabilizing cylinder Fig. 65: Hydraulic cylinder ZE-105/60-220

35

35 L a

b

2

1 1 cylinder tube 2 piston rod a annular space connection b piston space connection

6.28

L retracted 530 extended 750 stroke: 220

Shield support 600/1400-2x2283-1500

Hydraulic cylinder Seal cylinder Fig. 66: Hydraulic cylinder ZE-63/50-215

30 L b 2

a

E

1

Bucyrus DBT Europe GmbH, Lünen 2008

1 cylinder tube 2 piston rod a piston space connection

Doc. no.: 7420 195 000 BA 00

VRVT / 01

b annular space connection L retracted 440 extended 655 stroke: 215

6.29

Hydraulic cylinder Technical data, hydraulic cylinder

stabilizing cylinder, double-acting

6.30

Length a) Retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

500

b) Extended . . . . . . . . . . . . . . . . . . . . . . . . mm

1110

Stroke, hydraulic . . . . . . . . . . . . . . . . . . . . mm

610

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

260/185

Piston rod diameter. . . . . . . . . . . . . . . . . . mm

240/170

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

530.9/268,8

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

78.5/41.8

Prop force with setting pressure, 320 bar . . . . . . . . . . . . . kN

1699

Setting pressure, 430 bar . . . . . . . . . . . . kN

2283

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

252

Type ZE-135/80-800, Device no. 8241 375 000 00 00, version with reed rod

E

shifting ram double-acting, driven directly

Type SD-2280-260-500/1110 Device no. 8250 153 000 00 00

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

800

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

135

Piston rod diameter . . . . . . . . . . . . . . . . . mm

80

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

50.3

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

92.9

Thrust force at 320/380 bar . . . . . . . . . . . kN

160.8/191.1

Pulling force at 320 bar . . . . . . . . . . . . . . kN

297.2

Type ZE-105/60-220, Device no. 8241 376 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

220

Piston diameter . . . . . . . . . . . . . . . . . . . . . mm

105

Piston rod diameter . . . . . . . . . . . . . . . . . mm

60

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

86.6

Annular surface . . . . . . . . . . . . . . . . . . . . . cm2

58.3

Thrust force at 320/430 bar . . . . . . . . . . . kN

277.1/372.4

Pulling force at 320/430 bar . . . . . . . . . . kN

186.6/250.7

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

telescopic prop, double-acting, 2-stage

Hydraulic cylinder 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 320/380 bar . . . . . . . . . . . kN

100/118.6

Pulling force at 320/380 bar . . . . . . . . . . kN

37/43.7

Bucyrus DBT Europe GmbH, Lünen 2008

E

seal cylinder, double-acting

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.31

Pressure relief valves 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 catalog.

Model

Setting pressure in bar

Device no.

For return line

Spring-loaded

80

8220 042 080 00 00

For prop and side seal

Spring-loaded

380

7337 486 380 00 00

For stabilizing cylinders and props

Spring-loaded

430

7337 486 430 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. marking

Pressure relief valves are color-coded and letter-coded pursuant to DIN 21557.

The letter code includes the following information: J setting pressure, setpoint J the week the setting was made J the year the setting was made J person who made last changes

6.32

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Application

E

Tab. 16: Pressure relief valves, use of the various models

Pressure relief valves Tab. 17: 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. 67 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. 67: Pressure relief valve, example

b Bucyrus DBT Europe GmbH, Lünen 2008

E

a

a color code b protective cap

The following table shows the relationship between the color code and the pressure range.

Tab. 18: Color codes for pressure relief valves, overview

1)

Doc. no.: 7420 195 000 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

VRVT / 01

6.33

Shield control system Shield control system Electrohydraulic control unit The electrohydraulic control unit has 10 functions and is the same with face and transitions shields.

Fig. 68: Electrohydraulic control unit, 10-way a

g

b

a distributor block, 10-way b dual 3/2 way magnetic pilot solenoid valve c screw fitting d filter cartridge

c

e e push-button

f connecting sockets for control unit g connection sockets on the rear side

Warning!

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

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

6.34

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

d

E

f

Shield control system PMC®-R control device Notice!

Please observe the instructions in the PMC®-R control unit’s separate operating manual.

Control device PMC®-R, input allocation; Face shield device number 7420 195 000 00 01/02 Fig. 69: PMC®-R control unit, input allocation Front view

Bucyrus DBT Europe GmbH, Lünen 2008

E

Rear view A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

PMC®-R inputs A1 = neighboring shield, left (PMC®-R left) A2 = not assigned B1 = not assigned B2 = not allocated C1 = sensor shifting ram C2 = pressure sensor D1 = emergency stop, right shield D2 = emergency stop, left shield

Doc. no.: 7420 195 000 BA 00

VRVT / 01

E1 = emergency stop, sensors, valve block, right shield E2 = emergency stop, sensors, valve block, left shield F1 = neighboring shield, on the right (PMC®-R right) F2 = own valve block

6.35

Shield control system Fig. 70: PMC®-R control unit, diagram Left-hand neighboring shield

Right-hand neighboring shield

*

4

** Mining direction 4

4 Front view X4

21

X2 X3

X4

X3 X2

X1 X1

21

A1 B1 C1 D1 E1 F1

1 Mining direction

5 5 a

a

Left-hand neighboring shield

a

Right-hand neighboring shield

1 shield control device (SCU) 4 solenoid drivermodule 5 pressure sensor 21 support lock-out switch

6.36

5

a reed rod, shifting ram * = Coding plug, anchoring device ** = Coding plug, block anchorage Other components: see spare parts catalog

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

Rear view A2 B2 C2 D2 E2 F2

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15 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. 71: Angle α 1 / α 2

α1 α2

Bucyrus DBT Europe GmbH, Lünen 2008

E

M

Tab. 19: Angle α 1 / α 2 change at height M Inclination α at height M

Shield ID no.

α1 in °

α2 in°

M in mm

7420 195 000 00 01 7420 195 000 00 02

5

5

600 to 900

10

10

>900 to 1400

Caution!

Exceeding the permissible angles specified can lead to damage to the props and cylinders and their fastening elements as well as to the part hinges.

Important!

When the support is extended or retracted as far as possible, the canopy/caving shield crosspoint moves correspondingly when the canopy is lowered or positioned.

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.37

Accessories Accessories Endshield steering device The endshield steering device is for aligning the shield (no. 1 on the head gate or no. 135 on the tail gate).

Before aligning, shield 1 must be lowered. Shield 03, on which the chain of the endshield steering device is attached, must be set.

Caution!

Serious damage can be caused to the shields by not following the correct sequence of steps when pulling up the shields.

Only pull up the shields in the sequence 2-1-3 or 2-3-1.

. Open the HP ball valve for supplying pressure to the endshield steering device.

. Pull shield 2 forward and set shield 2 afterwards. . Lower shield 3 and pull shield 3 forward afterwards (the cylinder for the endshield steering device extends).

der for the endshield steering device retracts).

Fig. 72: Endshield steering device Tail gate Endshield steering device in the right shifting direction 12 14 39

Head gate 9

Endshield steering device in the left shifting direction 20, 21 5 31, 35 Shield 3 30

31, 35

Shield 2

Shield 1

41 42 39 13

11 34, 35

1 hydraulic cylinder ZE-139-110/80-850 5 chain attachment 6 cylinder protection 9 chain guide 10 chain guide 11 cylinder clevis 12 cylinder clevis 13 cover plate

6.38

14 cover plate 16 protective plate 20 pin 21 staple 30 chain connection 31 pin 40/29x105 32 chain joint for plow chain 33 chain

16, 40

6

1

32

36

33

10

34 pin 55/40x125 35 locking clip 4 36 flat connecting chain link 39 hex. head screw M 20x50 40 hex. head screw M 12x25 41 hex. head screw M 24x85 42 hex. nut M 24-1

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

. Set shield 3. . Lower shield 1 and pull shield 1 forward afterwards (the cylin-

Accessories Fig. 73: Hydraulic system for endshield steering device Shield 1 Head gate

ndshield steering device in the left shifting direction

12

16

3 12

10

12

1 2

Prop

10

Shifting ram

11

Tensioner cylinder

Bucyrus DBT Europe GmbH, Lünen 2008

E

40, 41, 42

10

10 13

4 12 15

14

Doc. no.: 7420 195 000 BA 00

1 valve for anchoring device 2 hydr. piloted check valve 3 hP ball valve 4 pressure relief valve, 380 bar 10 plug-in elbow socket DN10 11 plug-in elbow socket DN10/135° 12 plug-in L-socket DN10 13 plug-in T-socket DN10 14 reducing socket DN12/10 15 plug-in elbow socket DN12 16 reducing L socket DN12/10

VRVT / 01

20 hose line 10x1000 21 hose line 10x1800 22 hose line 10x2000 23 hose line 10x4500 29 staple DN10 30 staple DN12 31 protective hose DN25 1000 long 32 protective hose DN25 3000 long 40 hex. head screw M 10x70 41 hex. nut.

6.39

Accessories Base/base steering device The base/base steering device is for aligning the shields on the face. The arrangement of steering devices on the face depends on the local conditions.

Before aligning, shield 2 must be set.

Caution!

Serious damage can be caused to the shields by not following the correct sequence of steps when pulling up the shields.

Only pull up the shields in the sequence 2-1-3 or 2-3-1.

. Open the HP ball valve for supplying pressure to the steering device.

. Pull shield 2 forward and set shield 2 afterwards. . Lower shield 1 (cylinder for steering device retracts). . Pull shield 1 forward (shield is aligned).

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 74: Base/base steering device

Shield 3

Shield 2 2 58 53 1 Shield 1

57 55

54

2

1 hydraulic cylinder ZE 54-80/50-600 2 bracket 44 hex. head screw M 24x85 45 hex. nut M 24 48 pin 80x238 49 hex. head screw M 16x160-8.8 50 hex. nut V M 16-8

6.40

44

45

52

56

48

49

51

50

51 washer 52 hex. head screw. M 24x50-8.8 53 chain joint for plow chain 54 pin 55/40x125 55 universal joint 56 universal joint 57 locking clip 58 flat connecting chain link

Shield support 600/1400-2x2283-1500

Accessories

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 75: Hydraulic system for base/base steering device

11

1

12 3

10 12

10

2

12

12 10 10 1 3/2-way valve DN 10 2 pressure relief valve, 380 bar 3 HP ball valve 10 plug-in elbow socket DN10 11 plug-in elbow socket DN10/135° 12 plug-in L-socket DN10

Doc. no.: 7420 195 000 BA 00

VRVT / 01

13 plug-in T-socket DN10 28 staple DN10 30 hose line 10x1000 31 hose line 10x1500 32 hose line 10x1800

6.41

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, for operating hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

Suitability test Before the certificate of Bucyrus is issued 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: J stability J sealing materials J corrosion.

In addition, 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 required.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive the respective Bucyrus certificate.

6.42

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

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, for example, to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by Bucyrus on request.

E

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

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 respectively 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 DBT Europe GmbH, Lünen 2008

E

Fig. 76: Typical certificate

Doc. no.: 7420 195 000 BA 00

VRVT / 01

6.43

Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

These properties include: temperature, foaming, pH-value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– Target value: 7.5 to 9.5 – Target value: see certificate J microbial load

– target value: ≤ 105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used for the preparation of 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.

The following table, Table 20, lists limit values for the essential properties and components of the water.

If the limits shown are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will also lead to the loss of the certificate, even if they are within the limit values mentioned.

6.44

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

J Concentrate ratio

Permissible media

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 20: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g. turbidity, bad smell, etc.

Electrical conductivity

< 1800 µS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

< 750 mg/l CaCO3 equivalent (≤ 42° dH)

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

Ratio of solid foreign matter at 1.2 µm -filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

-/18/14

Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e. g.: Installation, Maintenance.

Lubricating greases properties

lubricating grease A1

Base:

Lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presenceof water:

practically non-soluble in water

Temperature range of application:

-20 to +120 °C

Flash point :

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *) 7068).

Tab. 21: 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. 22: Lubricating greases with additives Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*)

Doc. no.: 7420 195 000 BA 00

Flash point in °C

Supplier

EWN = Bucyrus works standard

VRVT / 01

6.45

Permissible media 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. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

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. 23: Lubricating pastes free of molybdenum disulphide Type

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flash point in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 is used in accordance with the Bucyrus standard EWN 7068: 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 at the shield support.

Behavior in the presence of water: non-soluble in water Temperature of application:

-34 to +120 °C

When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B 6 in accordance with the Bucyrus works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flash point 132 °C) Important!

The instructions for mixing lubricating greases also naturally apply to the lubricating pastes.

*)

6.46

The products listed in table 21 are suitable lubricating greases for filling of adjacent cavities.

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

E

Supplier

Tightening torques Tightening torques Screws with ISO metric thread Tab. 24: Tightening torques at µtotal = 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

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Bucyrus DBT Europe GmbH, Lünen 2008

Tightening torque 4)

Pitch P

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

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

42 m

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 for installation and maintenance work!

1) 2) 3) 4)

Doc. no.: 7420 195 000 BA 00

The dimensions listed in brackets are used in exceptional cases only.

According to works standard (EWN 6110, February 1985 edition).

Only for expansion screws having a reduced shaft cross-section of 24.2 mm.

The tightening torques comply with the works standard (EWN 6003).

VRVT / 01

6.47

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tightening torques

6.48

Shield support 600/1400-2x2283-1500

7

For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestrasse 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

E

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 DBT Europe GmbH Office Moscow Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com OOO Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

Doc. no.: 7420 195 000 BA 00

VRVT / 01

7.3

Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd.

+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

7.4

Shield support 600/1400-2x2283-1500

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

E

Customer Service 20 Killara Close, Beresfield, New South Wales 2322

Service addresses Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Doc. no.: 7420 195 000 BA 00

VRVT / 01

7.5

Identification of the shields Identification of the shields Type plate The main subassemblies of the shields are identified by a type plate.

Fig. 77: Type plate, example

3

12345 06/08

678

7420 195 000 00 0x 6

7

2

4 5

2283 kN

1 manufacturer 2 SAP/Order no.

3 date of manufacture

5 device number 6 number of props 7 prop force

4 serial no.

Shield number The shields are numbered consecutively. Plates showing the shield number are on the basic frame, faceside at the left.

Fig. 78: Shield number on the base, example

Tab. 25: Allocation of the shield numbers

7.6

Shield number

Order no.

Application

1 to 135

7420 195 000 00 01/02

Face shield

Shield support 600/1400-2x2283-1500

E

2

Bucyrus DBT Europe GmbH

Bucyrus DBT Europe GmbH, Lünen 2008

1

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 26: National standards and directives, extract

Designation

Title

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 hydraulic system 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 bolts T-head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

Bucyrus DBT Europe GmbH, Lünen 2008

E

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. 27: 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

Directive of the European Parliament and the 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 equipment for potentially explosive 2002-04 atmospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres 2004-12 - Part 0: General requirements Basic and safety principles for man-machine interfaces 2000-08 Preparation of instructions 2001-11 - Structuring, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water - Distillation method Equipment and components intended for use in potentially 2006-01 explosive atmospheres in underground mines Mobile extracting machines at the face - safety 2003-09 requirements for shear loaders and plough systems 1)

Doc. no.: 7420 195 000 BA 00

EWN = Bucyrus works standard

VRVT / 01

7.7

Bucyrus DBT Europe GmbH, Lünen 2008

E

Standards and guidelines

7.8

Shield support 600/1400-2x2283-1500