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Translationofthe originaloperating manual.
Amendmentsandalterationstothispublicationarenotsubject tonotification.Bucyrusreservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofBucyrus.
Bucyrusdeclinesanyliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
BucyrusEuropeGmbH,Lünen2010E
Aboutthismanual
Aboutthismanual
Thischaptercontainsimportantinformationthatmakesiteasierfor youtousethismanual.Italsoprovidesyouwithinformationonthe structureofthemanualandthesymbolsused.
Beforestartingwork
Usinganoperatingmanualthatwasnotspecificallywrittenforthe controlunitconcernedcanresultinasafetyhazardforyourselfand others.Ensurethatthespecificationsonthecontrolunitcomply withthespecificationsintheoperatingmanual.
Thisoperatingmanualisdesignedfor:
Electrohydr.controlunit-16functions Devicenumber81540980000000
andisonlypermittedtobeusedforcontrolunitsofthistype.Only usetheoperatingmanualwhichappliestotherespectivecontrol unit.Failuretodosowillposeadangertoyourselfandothers.
Itisabsolutelynecessarytoensurethatallpersonsworkingwithor onthecontrolunitalwayshaveunrestrictedaccesstothecontents ofthecurrent,applicableoperatingmanuals.
Personsforwhomthisoperatingmanualisintended
Thisoperatingmanualisintendedforeveryoneconcernedwith J installing, J servicing, J repairing, J operatingand J removal.
Thesupervisorswhoinitiatetheaboveworkorsuperviseitmust alsofollowthisoperatingmanual.
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtothecontrolunit.
Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontothesafetyinstructions. Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.
Payspecialattentiontochapter2,“Yoursafety”.Thischaptercontainsimportantinformationindicatingpossiblehazards.
Observethisinformationandfollowtheinstructionsinthisoperatingmanual.Thisistheonlywaythatyoucankeeptheoperating costsdownandretainyourrightstomakeaclaimunderthewarranty.
Beforestartingwork
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationinthisoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare veryseriousinjuryorevendeath.
Warning!
Thesepointscontaininformationonhazardoussituations. Possibleconsequencesareveryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesareminortomoderatelyseriousinjuriesand damagetothemachine.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesareminordamage tothemachineordamageintheimmediatevicinity.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtomakeworkeasierforyou.Theydo notwarnaboutharmfulordangeroussituations.
J Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Pointsinthetextmarkedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step.Itwillhelpyou carryoutyourworkfasterand,moreimportantly,moresafely.
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.
Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.
Thecontrolunitwasmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations. However,aresidualriskstillexistswhichmayinvolveyougetting intohazardoussituationswhenworkingwithoronthecontrolunit. Thesemay,forexample,becausedbyunforeseeableexternal influences,machinedamageoroperatingerrors.
Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulations:
J oftheminingcompany,
J oftheminesinspectorateand
J oftheminingsupervisoryauthorities.
Personnel
Personsemployedintheoperation,repairandoverhaulofhydraulicand/orelectrohydrauliccontrolcomponentsmustbespecially qualified.Inadditiontohavinghadtraininginminingtechnologythe followingminimumrequirementsmustbemet.
Operationandmaintenance
Operationandmaintenanceoftheshieldcontrol systemmayonly beperformedbytrainedpersonnel. Thetrainingmustbespeciallytailoredtothetypeofcontrolunit actuallybeingused.
Thecontentoftheoperatingmanual,especiallythechapteron safety,mustconstituteapartofthistraining.
Theymustpossessandfurnishproofofadequatefamiliaritywith the
J mechanical system
J hydraulicsystemand
J controlsystem.
Repairandmaintenance
Ingeneral,repairworkmayonlybeperformedbypersonswho havetheknowledgeandskillstomeetthespecialrequirements andhavebeenadequatelytrainedintherepairoftheequipment. Repairworkonandoverhaulof: J controlunits, J workingvalves, J pilotvalves, J safetycomponentssuchaspressurereliefvalvesetc. shallbeperformedonlyBucyrusserviceengineersorbyspecially trainedpersonneloftheminingcompany.
Operatingconditions
Intendeduse
Theelectrohydrauliccontrolunitisexclusivelyconstructedand manufacturedasacomponentoftheshieldsupportcontrol system. Itmayonlyusedinconjunctionwithanelectroniccontrolsystem, forexampleaPMC®-Rcontrolsystem. Onlyusethecontrolunitasintended.
Theintendedusesareasfollows:
J Theelectrohydrauliccontrolunit,togetherwithanelectronic controlunit-forinstanceaPMC®-Rcontrolunit-,formsan electrohydraulicshieldcontrolsystem.Thisisusedtocontrol shieldsupportfunctions.Togethertheyarepartofaneighboringcontrolsystemforelectrohydraulicshields upportsandare intendedforuseinundergroundmining.
Theelectrohydrauliccontrolunitisanessentialpartoftheelectrohydraulicshieldcontrolsystem.Thefunctionsmaynotbe operateddirectlyattheelectrohydrauliccontrolunit,butrather onthecorrespondingelectroniccontrolunitlocatedinoneof theneighboringsupports.Thepilotvalvesontheelectrohydrauliccontrolunitareactivatedmanuallyorviaaprogramusing thecontrolunit.
J Theelectrohydrauliccontrolunitisalsousedasa“controlunit” intwotypesofexceptionalcases: -emergencyoperationand -repairoperation.
Theindividualfunctionsoftheshieldsupportareactuated directlyonthepilotvalveoftheelectrohydrauliccontrolunit.In justifiedexceptionalcasesandinstrictcompliancewiththecorrespondingsafetyregulationsofthemineoperator,thefunctionsofasupportcanalsobeactuatedwhentheelectronic controlunitisblockedorithasfailed.
Unauthorizeduse
Alluse,whichisnotexpresslydeclaredasintended,isregardedas unauthorizeduse.
Unauthorizeduseincludes:
J theuseoftheelectrohydrauliccontrolunitsas“controlunits”for theoperationofsupportfunctionsduringnormalshieldunit operation.
Actuatingtheshields exclusively viathepilotvalves bypressingabutton,isregardedasunintendeduseasitisnotpossible, whichisnotauthorized,tocontroltheshieldfroma neighboringshield.
Unauthorizedusecanendangeryourselfandothers.Youmightbe killedorseriouslyinjured.
Youshouldthusonlyusetheelectrohydrauliccontrolunitas intended.
Bucyruswillacceptnoresponsibilityfortheconsequencesof unauthorizeduse.
Safetyinstructions
Safetyinstructions
Thefollowingalwaysapplies:
Alwaysconcentrateonyourwork.
Itisalsoimperativethatyoufollowtheoperatingmanualforthe supportandthecontrolunit.
Alwaysfamiliarizeyourselfwiththeworkingenvironment,before startingwork.
Alwayskeepoutofanyshieldwhichisnotset.
Alwayswearpersonalprotectiveequipment.
Observetheacousticandvisualstart-upwarnings.Payspecial attentiontothestart-upwarningsfortheconveyorandforthe miningequipment.
Onlyusecontrolunitswhichareinatechnicallyflawlesscondition. PresstheEMERGENCYSTOPswitchimmediately,intheeventof faultsorirregularitiesinoperation.Notifyyoursupervisorofany peculiarity,sothatnecessaryactioncanbetakenimmediately.
Iftheshieldisequippedwithanelectrohydrauliccontrolunit,you mustlock-outtheshieldbypressingthesupportlock-outswitch (repairswitch).Thismeanstheshieldcannotbecontrolledviathe controlunit.
Pressthesupportlock-outswitchwhenperforming:
J maintenancework,
J inspectionwork,
J repairwork
J andduringprolongedpresenceintheshield.
Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe:
J sideseals,
J bases,
J relaybarassemblies,
J lemniscaticlinks,
J hydraulicpropsandcylinders,
J canopiesand
J flippers.
Storageandtransport
Neverstorematerialsofanykindinthetravelwayorinyourworkingarea.
Toavoidhinderingorendangeringthefacecrew,immediately removeanyfaultycomponentsfromtheface.
Neverstorefaultypartswithgoodparts.Thiswayyoucanavoid inadvertentreinstallationofthesefaultycomponentssomewhere else.Havethesefaultycomponentsrepaired.
Observethespecifiedstorageperiodsandthestorageinstructions.
Installation
Mechanicallysecureallmovingpartsbeforeyoudepressurizethe hydraulicsystem.
Asamatterofprinciple,onlyworkondepressurizedhydraulic systems.
Makesurethatnodirtorimpuritiescangetintothehydraulicsystem.
Onlyremovetheprotectivecapsfromtheconnectorsimmediately beforeinstallingthecontrolunit.
Operation
Onlyworkinrepairmodeifitisabsolutelynecessary.Ifpossible controltheshieldsfromthecontrolunitoftheneighboringshield.
Checktodeterminewhetherallprotectivedevicesontheshieldare presentandfunctional.
Makesurethatnooneisintheareaoftheshieldbeingactuated.
Watchtheshield'srangeofmotionsothatpotentialhazardscanbe recognizedintimeandpreventativeactioncanbetaken.
Maintenance
Informthesupervisorypersonnelandthefacecrewaboutmaintenanceandrepairwork.Providethemwithinformationonthe intendedworkanditsprobableduration.
Keepyourworkingareacleartoavoiddangertoyourselfandother persons.
Blockofftheworkingareafortheminingequipmentorstopthe miningequipmentandtheconveyorandlockthe system,topreventitfrombeingturnedonagain.
Beforeperformingwork,mechanicallysecuretheshieldtoprevent itfromaccidentallysinkingintothefloor,e.g.by:
J proppinguporsupportingthecanopy,
J placingwoodenwedgesbetweenthelemniscaticlinks.
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originalparts
Immediatelydiscontinueanyworkontheshield,ifconveyingand miningoperationsareinprogressinyourworkingarea.
Immediatelyaftercompletingwork,refitanyremovedprotective devicesandcheckthattheyworkproperly.
Makesurethattheprescribedmaintenanceandinspectionintervals areobserved.Alsoseechapter5,“Operation”.
Useonlysparepartswhichconformtothespecifiedtechnical requirements.ThisisbestensuredbyusingoriginalBucyrusspare parts.
Pleaserefertothesparepartsfolderfortheordernumbers.
Donotmakeanymodificationsorchanges.Modificationsand changesmustbeapprovedbyBucyrus.
Neverusethecontrolunitwithoutafiltercartridge.Ifthefilteris missingorifitisnotfineenough,thiscanleadtomalfunctionsand damagetothecontrolunit.
Hydraulicsystem
handlinghydraulic fluids maintenance,repair
Avoiddirectcontactbetweenyourskinandhydraulicfluids. Hydraulicfluidwhichpenetratestheskincancauseseriousinfections.
Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids poseaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstratespecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Carryoutavisualinspectionofallthehydrauliccomponentsat regularintervals.Inparticularcheckthat:
J Thehosesarenotpinched.
J Thehoseshavenobubblesorblisters.
J Thehosesortheoutersheathsofthehosesarenotabnormallyrigidorhard.
J Theoutersheathofthehoseisnotdamaged.
J Theconnectorsarefirmlyinsertedinthecouplingsockets.
J Theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicssystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamagetothewhole system.Flushoutthehydrauliclinesthoroughlybeforeconnecting. Beforeremovingstaplestodisconnecthydraulichosesturnthe hoseattheconnectortocheckwhetherthelineispressurized. Ifthehoseisdifficulttoturnordoesnotturnatallthelineisstill pressurized.Makesurethelineisdepressurized.
Ifstaplescannotbepulledoutorcanonlybepulledoutwithdifficulty,thehydrauliclinemightstillbeunderpressure.Makesurethe lineisdepressurized.
Securetheconnectorsofthehydraulicelementswiththeproper staplesonly.Alwaysfastenthestaplescompletelywithbothsides. Neverusenails,wireorsimilarmaterials.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystem again.
Useonlyhydraulichosesapprovedfortheprevailingpressures. Donotuseanyhydraulichoseswithdamaged connectorsorwornO-rings.
Replacehydraulichosesonlywithhosesofthesameorahigher quality.
Observethedateofmanufacturestampedonthehosefittingof thehydraulichose.Neverusehydraulichoseswhicharemorethan 2yearsold,eveniftheyshownovisiblesignsofdamage.
Nevertrytoholdahydraulichosethatisthrashingabout. Depressurizetheaffectedlinesectionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesevenifyouonlysuspecttheyhavebeen damaged.
Fig.1:Examplehydraulichose,identification
Safetyinstructions
layinghydraulic hoses
Laythehydraulichosescorrectlybehindthebracketsandclipsprovidedforthem.
Alwayslayhydraulichosessothatthey: J alwayshavealittleslack,
Fig.2:Layinghydraulichoses,slack RIGHT WRONG
J arenottwisted,
Fig.3:Layinghydraulichoses,twisting WRONG RIGHT
J arenotbentdirectlybehindtheconnectors(distanceminimum 1.5xnominaldiameter),
Fig.4:Layinghydraulichoses,bending RIGHT WRONG
J cannotchafe,
Fig.5:Layinghydraulichoses,crossing RIGHT WRONG
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J arenotkinked, J donothavetowithstandtensileloads, J areprotectedagainstthermalradiation, J areaccessibleatalltimes.
Onlypushhydraulichosesintothesocketsbyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagethe connections.
Whenlayingthehydraulichoses,ensurethattheycannotbe:
J tornout, J kinked, J crushed, J drivenover
J twistedasaresultofmovingequipment.(Fig.6).
Fig.6:Layinghydraulichoses,connectionsonmovingparts RIGHT WRONG
Storageandtransport
Storageandtransport
Thischaptercontainsimportantinformationaboutthecorrectstorageandtransportoftheelectrohydrauliccontrolunit.
Followingtheinstructionsandtipswillincreasethelifecycleand servicelifeoftheelectrohydrauliccontrolunit.Youwillbeableto carryouttransportworkmoresafelyandquickly.
Payingcarefulattentiontothepointsinthischapterwillalsohelp youtosimplifyyourday-to-daywork.
Storage
Storingtheequipment
Componentswithatemporaryanticorrosioncoatingareprotected foraboutsixmonths.
Protecttheequipmentfromdirectexposuretosunlight.
Onlystoretheelectricalequipment,electroniccomponents, replacementpartsmadeoutofrubberorplasticsuchassealsand hosesaswellashydraulicfluidsinclosedroomsat15
Cto25
C.
Protectallpartsoftheequipmentstoredoutdoorsagainstmoisture anddirt,e.g.,usingtarpaulins.
Themountingsurfacesofhydrauliccomponentsmustbeprotected againstcorrosionandsealedwithblindplates.Protectthehydraulic plug-typeconnectionsandtheconnectorsoftheelectricalcables withthecapsandplugssupplied.
Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors,butattemperatures above freezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularly protectedagainstexcessivetemperatures,dirtandmoisture.
Duringlong-termstorage(morethan4weeks),theequipmentmust notbestoredoutdoors.Itneedstobestoredinadry,well-ventilatedroom.
Afterastorageperiodofapproximatelytwoyears,arandomsampleinspectionmustbeperformedtodeterminewhetherthemeasurestakenandthemethodofstoragehavepreventeddamage. ThisinspectioncanbecarriedoutbyBucyrusuponrequest.
Evenwithproperstorage,sealsandhoselinesaresubjecttonaturalaging.Donotusethesecomponentsiftheyhavebeenstored formorethantwoyears.
Important!
Ensureduringstoragethatanynewsuppliesarestoredseparatelyfromexistingstocksinsuchawaythatonremoval,old stocksarealwaystakenfirst.
Storage
Storingusedequipment
Thepointslistedabove,withtheexceptionoftheoneconcerning anticorrosionprotection,canbeappliedanalogouslyforthestorage ofhydrauliccomponentsthathavealreadybeeninuse.
Ifthehydraulicssystemistobeputoutof operationtemporarily, theentirehydraulicssystemmustbethoroughlyflushedoutin advanceandthenfilledwithasuitableanticorrosiveandantifreeze liquid(e.g.HYDROCOR® CV50*).Ifthisisnotdone,thenthe hydraulicscomponentsmaysufferconsiderabledamagewithin ashorttime,becausethepropertiesofthemediumusedcan undergoveryrapid,verynegativechanges,e.g.duetomicrobial infestation. *HYDROCOR® CV50isacommercialtrademarkusedby TheunissenChemischeFabrikenGmbH,Wuppertal,Germany
Transport Transportboxes
Thecontrolunitsarepackedinseveraltransportboxes.They shouldstayintheseboxesuntiltheyreachtheirfinaloperating location.Thisprotectsthemfromexternaldamage.
Makesurethattheboxesarenotdamagedduringtransport.During transport,makesurethattheyarenot:
J droppedor
J brokenopen.
Protectthetransportboxesfrommoisture.
Beforetransportingtheequipmentattemperaturesbelowfreezing,allofthehydrauliccomponentsmustbecompletelyemptiedandthencompletelyfilledwithacorrosioninhibitor (e.g.HYDROCOR® CV50).
If,duringtransport,thecontrolunitisexposedtotemperatures below-20 C,thenspecialmeasuresmayhavetobetaken.Inthis case,beforestartingtransport,contactBucyrus'sservicedepartmenttoclarifythenecessarymeasures.
Dimensionsandweight
Plugs
Theconnectorsfortheindividualcontrolunitsareclosedoffwith plasticplugs.Thisprotectsthemfrommoisture,dirtanddamage.
Notice!
Impuritiesinthehydraulicsystemcanleadtothefailureofthe entiresystem,makingexpensiverepairsnecessary. Forthisreason,youshouldonlyremovetheplugsjustbefore thecontrolunitisconnected.
Bracketwithcontrolunit
Important!
Whentransportingtheshieldensurethatthebracketisfixedto thecontrolunitsuchthatitcannotcollidewithother componentswhenshieldisbeingretracted.
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4 Installation
Installation
Thischaptercontainsinformationontheinstallationand deinstallationofelectrohydrauliccontrolunits.Pleasepayspecial attentiontothewarningsandtips.
Warning! Improperorfaultyinstallationcanendangeryourselfand others.
Youmayonlycarryouttheinstallationifyoucandemonstrate thatyouhavetherequisite,specialknowledge.
Requirementsforthefacehydraulicsystem
Notice!
Thehydraulicandelectronicpartsoftheshieldcontrolsystem aredealtwithinseparateoperatingmanuals. Youwillfinddetailsonthecommissioninganduseofthe shieldcontrolsystemintheoperatingmanualontheelectronic controls.
Thehydraulicmediummustmeetthefollowingconditionsforall hydraulicsystemcomponentsincludedintheBucyrusscopeof delivery:
J IfthetestspecifiedinEWN8350,part1,issuccessful,the hydraulicfluidwillbeclassifiedassuitable.Seethesection “Operatingmedia”inchapter6ofthisoperatingmanual J ContaminationClass18/14pursuanttoISO4406.
Installationofthecontrolunit
Removingthecontrolunit
Beforeyoucanstartwiththeinstallationorexchangeofthecontrol unit,youmusttakesafetyprecautions:
. Sealoffyourworkingareatokeepallotherpersonnelout.
. Haveminingstoppedinthisarea.
. Informyourcolleaguesaboutthenatureanddurationofthe repairworkandaboutyourexactlocation.
. Pressthesupportlock-outswitch.
. Securetheshieldtostopitsinkingbyitself;e.g.byusingwedgesinthelemniscaticlinksorbyproppinguporsupportingthe canopy.
. Depressurizethehydraulicsystemoftheshieldconcerned.
. Checkthatthehydrauliclinesarereallydepressurized. IfeverythingisOKsofar,thenyoucancontinuewiththenextstep.
. Labeltheconnectingcablesandhydraulichosestoavoidmixupslateron.
. Pullofftheconnectingcablefromthecoverofthepilotvalve.
Danger!
Neverworkonahydraulicline,ifyouarenotsurethattheline iscompletelydepressurized.
Ifloosehydraulichosesarethrashingaboutandhydraulicfluid isescaping underpressure,youcouldbeseriouslyinjuredor evenkilled.
Itisthusvitalthatyoudepressurizehydrauliccomponents beforeyoustarttodismantlethem.
Ifastaplecan'tbepulledout,orisverystiff,thenyoushould beverycareful.Itispossiblethatthehydrauliclineisstill underpressure.
. Undoallofthehydraulicconnectionsontherearsideofthe controlunitandmakesurethattheconnectionsarenot damagedorsoiledwhendoingthis.
. Securethecontrolunitwithliftinggearandtransportstraps.
Notice!
Donotsecurethecontrolunitwithchainsorsteelcables.It couldbedamagedbythat. Onlyusetransportstrapswhichsitcloselyonthecontrolunit andwhichpreventitfromslippingthrough.
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