DOWNLOAD PDF CAT Bucyrus Elektrohydraulic control unit 10 Function Operating Manual EM014981

EM014981-0 (EN-US)

Operating Manual Elektrohydraulic Control - 10 Functions Doc. no.: 8154 091 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 Telefax: +49 (0) 23 06 / 709 - 421

Email: infodbt@dbt.de Internet: www.dbt.de

EM014981-0 (EN-US)

Amendments and alterations to this publication are not subject to notification. DBT GmbH (DBT) reserves all rights to this publication.

Its content is protected by copyright laws, both domestic and international. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of the DBT. DBT declines all liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications obtained by technical development without previous notice!

DBT GmbH, Lünen 2004 E

EM014981-0 (EN-US)

Index

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

1.3

Who is this operating manual intended for? . . . . . . . . . . . .

What is the purpose of this operating manual? . . . . . . . . .

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

1.3 1.3 1.4

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

2.3

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

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.3

Conditions of operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

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

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

2.4 2.4

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

2.5

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

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Overview of the safety instructions . . . . . . . . . . . . . . . 2.10

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

3.3

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

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

3.3 3.4

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

3.5

Transport crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.5

4. Installation Requirements to the face hydraulic system . . . . . . . .

4.3

Removal of the elektrohydraulic control . . . . . . . . . . . . . . .

Installation of the elektrohydraulic control . . . . . . . . . . . . . .

4.3 4.4

5. Operation

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Operation and function of the pilot valves . . . . . . . . .

5.3

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

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3

Filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 5.5 5.7

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

6.3

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.4 6.4 6.4 6.5 6.5 6.5

Hydraulic flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Hydraulic fluids of group HFA . . . . . . . . . . . . . . . . . . . . . . . .

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

6.8 6.11

7.3

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

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

7.3 7.5

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

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

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7. For your information

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1

About this manual

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Before starting work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting work Take care to ensure that the operating manual available to you is applicable for the type of elektrohydraulic control used. Failure to do so can result in a safety hazard for yourself and others. Ensure that the data on the elektrohydraulic control comply with the data given in the operating manual.

This operating manual is designed for elektrohydraulic control (10 functions) with the order No.: 8154 091 00000 00 and is only permitted to be used for elektrohydraulic controls of this type.

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operating manual

An operating manual for the elektrohydraulic control must always be available. Ask for a new manual immediately if the existing manual is no longer complete or has become illegible.

DBT GmbH, Lünen 2004

Who is this operating manual intended for?

This operating manual is intended for all persons involved in the J installation, J maintenance, J repair, J operation and J dismantling

of the elektrohydraulic control.

In addition, the supervisory personnel who initiate and/or supervise the activities just indicated must also observe this operating manual.

What is the purpose of this operating manual? efficiency

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

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

safety

Read the chapter ”For your safety” with special attention. This chapter contains important information indicating possible hazards.

operating cost warranty

Observe the information given and follow the procedural instructions. This is the only way to minimize operating costs and to assert warranty claims.

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1.3

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

Try to memorize the symbols and their meanings.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

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.

1.4

J

Lists are marked with bullets.

–

Sub-lists are marked with a long dash at the start of the line.

.

The symbol of the hand asks you to do something. Several successive paragraphs marked with the symbol of the hand represent a string of actions which must be executed in the order specified. Follow the respective instructions step-by-step to perform the work safely and efficiently.

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

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

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

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2

Your safety

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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

supplementary regulations

The electrohydraulic control has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. However, a certain risk remains which might get you into hazardous situations when working with or on the electrohydraulic control. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

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 mining authority, and J of the miners’ accident insurance association.

DBT GmbH, Lünen 2004

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Personnel Persons employed in the operation, repair, and overhaul of hydraulic and/or electrohydraulic control components must have special qualifications. In addition to having received training in mining skills the following minimum requirements shall be met.

Operation and maintenance qualification

Operation and maintenance of the shield control is only allowed to be performed by trained personnel. The training shall be matched to the type of shield control actually used. The content of the operating manual, especially the chapter on safety, shall constitute a part of this training.

They shall possess and furnish proof of adequate familiarity with the J mechanical, J hydraulic, and J control systems.

Repair In general, repair work shall be performed only by persons who have the respective 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 control blocks, J working valves, J pilot control valves, J safety components, e.g. pressure relief valves, etc.

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

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Conditions of operation Conditions of operation Use in conformance with specifications The electrohydraulic control has been designed and manufactured exclusively as part of the control system for shields. It is only allowed to be used in connection with an electronic control unit, such as for example a PM4.

Use the electrohydraulic control only as intended.

Intended uses are: J The electrohydraulic control is combined with an electronic con-

trol unit - as for example a single control unit of type PM4. Together they form a control unit designed to operate the functions of a shield support. The two devices are part of an adjacent control system for electrohydraulic shield supports for use in underground mining. The electrohydraulic control is an essential component of this electrohydraulic shield control. Operation of the functions is not allowed to be made direct by pressing the buttons of the electrohydraulic control, but via the respective single control unit which must be located in one of the adjacent shields.

By means of this control unit the pilot valves of the control block are actuated manually or program-controlled.

Unauthorized use Uses which are not expressly stated as intended are regarded as unauthorized uses and are not permissible.

Unauthorized use:: J Use of the electrohydraulic control as ”control unit” to operate

the functions of the shield in normal operation.

Actuating the shields exclusively by pushing a button on the pilot valve block is unauthorized use since operation of the shield functions must be performed from an adjacent shield.

By unauthorized uses you endanger yourself and others. You could be severely injured or even killed. Therefore only use the electrohydraulic control as intended!

DBT does not accept any liability for the consequences of unauthorized uses.

2.4

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

which the control block also serves as direct ”control unit”: - emergency operation and - repair operation.

In these cases the individual functions of the electrohydraulic shield support are executed direct at the pilot valve of the electrohydraulic control. Thus, the functions of the shield can be operated even if the single control unit is locked out or has failed but only in well-founded exceptions and under strict observance of the special safety regulations of the mine operator for these cases.

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J Additionally, there are two exceptional circumstances under

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Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Please also observe the operating manuals for the shield support and the control unit.

Always familiarize yourself with your working environment first before taking up work.

Never stay under a shield that is not secured.

Always wear your personal protective clothing and equipment.

Please observe the visual and audible pre-start warnings. Particularly observe the pre-start warning signals of the conveyor and the mining machine.

prerequisite

support lock-out switch

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EMERGENCY STOP

Employ only electrohydraulic controls which are in a technically flawless condition.

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

If the shield is equipped with an electrohydraulic control unit you have to operate the support lock-out switch (repair switch) in order to lock out the shield. After this has been done, the shield cannot be operated from the control unit.

Actuate the support lock-out switch before performing.

J maintenance work, J inspection work, J repair work, and before J 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 side seals, J base skids, J shifting units, J lemniscatic links, J hydraulic props and cylinders, J canopies and J flippers.

Storage and Transport Never store materials of any kind in the travelway or in your working area.

Immediately remove defective components from the face in order not to hinder the face crew and to prevent these parts being reinstalled elsewhere.

Pass them on for servicing without delay.

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2.5

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Safety instructions Observe the specified storage time limits and the storage instructions.

Installation Always secure all moving components mechanically before relieving the pressure in the hydraulic system.

Always depressurize the hydraulic systems before starting work on them.

Ensure that no dirt enters the hydraulic system.

Remove the protection caps on the ports only immediately before installing the control block.

Operation Operate the manual repair control only when it is absolutely necessary. Whenever possible, control a shield by the electronic control unit of an adjacent shield.

Check that all protective devices on the shield are in place and function properly.

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

Secure your working area over a wide range in order to avoid endangering yourself and others.

Close off your working area to prevent the mining machine going there. Stop and lockout the mining machine and the conveyor to prevent restarting.

Secure the shield mechanically to prevent it from lowering under its own weight before starting work, e.g. by: J supporting the canopies J positioning wooden wedges between the lemniscatic links.

Stop work on the shield immediately if conveying and mining work is being carried out in your working area.

Refit any protective devices removed immediately after completion of the work and check that they function properly.

Ensure that the prescribed maintenance and inspection intervals are observed. See also chapter 5 ”Operation”. original spare parts

Use only spare parts which satisfy the specified technical requirements. This is best ensured with original DBT spare parts.

Please refer to the spare parts catalog for the order numbers.

Do not carry out modifications or conversions. Modifications and conversions must be approved by DBT. Never use the control block without filter cartridge. Failure to fit a filter or using a filter with insufficient mesh size could cause malfunctions and damage of the control block.

2.6

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DBT GmbH, Lünen 2004

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

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

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Safety instructions Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

maintenance, repair

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

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: J the hoses are not pinched or trapped.

J the hoses have no bubbles or blisters.

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

J the outer sheath of the hoses is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

DBT GmbH, Lünen 2004

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

Replace hydraulic hoses only with 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. 1:

Example: 4SP hydraulic hose, designation

3

2 1

6 4 1 hose type 2 nominal diameter 3 date of manufacture

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5 4 manufacturer 5 flame-resistant and antistatic 6 standard

2.7

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Safety instructions Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses. Immediately replace damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. installation of hydraulic hoses

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

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

Fig. 2:

Laying of hydraulic hose lines, slack WRONG

RIGHT

J are not twisted.

RIGHT

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Laying of hydraulic hose lines, twist WRONG

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter).

Fig. 4:

Laying of hydraulic hose lines, bend RIGHT

2.8

WRONG

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

Fig. 3:

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Safety instructions J cannot chafe.

Fig. 5:

Laying of hydraulic hose lines, crossing RIGHT

WRONG

J are not kinked.

J do not have to withstand tensile strains.

J are protected against thermal radiation.

J are accessible at all times.

Push hydraulic hoses into the sockets by hand only. 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: E

J torn out, DBT GmbH, Lünen 2004

J kinked, J crushed, J driven over or J twisted

by the movement of the machine (Fig. 6).

Fig. 6:

Laying of hydraulic hose lines, connections at movable parts RIGHT

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WRONG

2.9

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Overview of the safety instructions Overview of the safety instructions This is a summary of all safety instructions given in the individual chapters of this operating manual. As these safety instructions are cited out of their context the meaning is not always obvious.

Chapter 3: Storage and transport NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before installation and connection of the control block.

DANGER! Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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

NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals. The information required for start-up and operation of the electrohydraulic control is given in the manual for the respective control system used.

NOTICE! Do not secure the electrohydraulic control with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the electrohydraulic control and prevent slipping.

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Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

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Chapter 4: Installation

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Overview of the safety instructions Chapter 5: Operations and maintenance DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the control block if you have the required knowledge.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

DBT GmbH, Lünen 2004

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WARNING! Do not operate the electohydraulic control without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the electohydraulic control or the shield. This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

WARNING! If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

CAUTION! Use filter cartridges only once and do not try to clean them.

Soiling in the hydraulic system is a frequent cause of costly repairs.

Always use only new filter cartridges and seals.

CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

CAUTION! Impurities in the hydraulic medium can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

NOTICE! The recommended maintenance intervals must be understood as a guideline and must be adapted to the individual operating conditions . Depending on the actual operating conditions the maintenance intervals possibly must be shortened or can be prolonged.

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

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2.11

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Overview of the safety instructions IMPORTANT! The accumulator cartridge is not included in the scope of supply of the electohydraulic control. Please remember this information when ordering replacement parts.

IMPORTANT! A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

Chapter 6: Technical data WARNING! As soon as the current drops to a level below 30 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

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

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

IMPORTANT! Further information is contained in DIN 24320.

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 having the same saponification base but different origins.

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

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

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IMPORTANT! We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems. Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates.

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IMPORTANT! Please use the spare parts catalog supplied when ordering spare parts.

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3

Storage and transport

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Storage

Storage and transport This chapter contains important information on the correct storage and transport of the elektrohydraulic control.

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

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

Storage Storage of new equipment corrosion protection

Prior to delivery the hydraulically operated equipment will be tested and operated at the DBT site using the anti corrosive and anti freezing fluid HYDROCOR® CV50*). This fluid remains in the hydraulic system for transport and a following short-time storage period.

HYDROCOR ® CV50 is freeze-proof down to - 40 degrees Celsius and protects the metallic materials against corrosion.

HYDROCOR ® CV50 is equipped with a color indicator, which is responsive on the pH-value of the fluid. The color of the fluid will change from ”red” to ”yellow” in case the pH-value drops. A yellow colored fluid indicates insufficient corrosion protection.

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DBT GmbH, Lünen 2004

The surfaces of the equipment are provided with a temporary corrosion protection. If stored properly, the equipment parts will be protected for six months referred to the date of delivery.

For further particulars on the properties of HYDROCOR® CV50 please refer to the respective data sheet of the manufacturer. exposure to sunlight

Protect the equipment against direct exposure to sunlight.

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

natural ageing

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore recommended for these parts.

moisture and dirt

Protect all hydraulic elements during storage in a suitable manner against the ingress of dirt and moisture. The connecting surfaces of the hydraulic components must be protected against corrosion and closed with blind plates. Hydraulic plug-type connections and the connectors of the electric cables must be closed with suitable caps or plugs.

short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must, however, be particularly protected against environmental influences, including high temperatures, for example by suitable covers or sheathings for the controls and by additionally covering the equipment.

long-term storage

If the equipment is to be stored for more than 6 months, the cavities in the hydraulic components must be completely filled with a preserving fluid such as e.g. HYDROCOR® CV 50. This fluid must have corrosion-protection properties and should be frost-proof within the respective temperature range of the application. All ports must be *)

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HYDROCOR ® CV50 is a trade name of Theunissen, Chemische Fabriken GmbH, Wuppertal / Germany

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Storage sealed with durable and suitable plugs.

It is highly recommended not to store the equipment outdoors but in a well ventilated room. If it is not possible to store the complete equipment indoors, remove the hydraulic and electronic components and store them separately. plastic deformation

During long-term storage, the sealing elements may suffer plastic deformation due to the weight of the components. This may render the seals useless or reduce the life of the seals. Therefore, props and cylinders, for example, should only be stored in an upright position. If this is not possible with the components installed, they have to be dismantled.

random sample inspection

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

On request, the inspection can be carried out by DBT. The cost will be borne by the mine.

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the ”first in, first out” principle. Mark the containers accordingly.

Used equipment If there is any need to store hydraulic equipment that has been in use before the items specified above apply analogously, with the exception of the item corrosion protection. corrosion protection

3.4

In case the hydraulic system is to be put out of operation temporarily the complete system has to be flushed thoroughly and filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50). If this is not done, considerable damage to the hydraulic components may be caused within a short time since the properties of the medium used may change very fast and negatively, e.g. due to microbial attack.

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With respect to the storage of HFA fluids or concentrates for the production of HFA fluids in any case the regulations of the manufacturer or supplier of those media have to be observed first. Supplementary information is given in the section ”Pressure fluids of group HFA” in this manual.

DBT GmbH, Lünen 2004

HFA fluids

EM014981-0 (EN-US)

Transport Transport Transport crates Several elektrohydraulic controls are packed together in transport crates. They should remain in these crates until they reach their final place of installation in order to protect them from damage.

Ensure that the crates are not damaged during transport. Pay attention in particular that they do not: J fall or J burst open

during transport.

Protect the transport crates from moisture. temperatures below freezing

Before transporting the elektrohydraulic control at temperatures below freezing, the block must be completely emptied and then filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50).

E

If the electrohydraulic control is subjected to temperatures below -20 °C during transport special measures are required. In this case, please contact the DBT service department prior to the commencement of transport to clarify the requirements.

DBT GmbH, Lünen 2004

Dimensions and weight J depth:

276 mm

J width:

340 mm

J height:

154 mm

J weight:

ca. 51.3 kg

Plugs The connections of the individual electrohydraulic controls are sealed with plastic plugs to protect these from damp, dirt and damage.

NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before connection of the electrohydraulic control.

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4

Installation

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Requirements to the face hydraulic system

Installation This chapter contains information on the installation and removal of the elektrohydraulic control. Please pay particular attention to the warnings and tips.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

Requirements to the face hydraulic system NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals.

The information required for start-up and operation of the electrohydraulic control is given in the manual for the respective control system used.

For all hydraulic components included in the scope of supply of DBT, the hydraulic medium must meet the following requirements:

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– Pressure fluid according to list of approved products, see section ”Operating media” in chapter 6 of this manual.

– Purity class 18 / 14 to ISO 4406

Installation of the elektrohydraulic control Removal of the elektrohydraulic control Before starting the installation or replacement of elektrohydraulic controls, you must take safety precautions: safety

. Close off your working area to prevent other persons getting there.

. Arrange for the mining work to be stopped in this area. . Inform your colleagues about the type and duration of the repair work and about your exact location.

. Actuate the support lock-out switch . Secure the shield to prevent it from lowering under its own

weight; e.g. by placing hardwood wedges between the pairs of lemniscatic links or by supporting the canopy otherwise.

shut off hydraulic pressure

move elektrohydraulic control

. Depressurize the hydraulic system of the shield in question. . Check that the hydraulic lines are really depressurized.

When everything is OK, you can proceed with the next steps.

. Mark the connecting cables and hydraulic hoses to prevent confusions.

. Pull the connecting cables from the covers of the pilot control valves.

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Installation of the elektrohydraulic control DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

. Loosen all hydraulic connections on the rear of the elektrohydraulic control and ensure that the connections are not damaged or soiled.

. Secure the elektrohydraulic control with hoists and transport belts.

NOTICE! Do not secure the elektrohydraulic control with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the elektrohydraulic control and prevent slipping.

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. Loosen the bolts of the elektrohydraulic control mounting. . Pull the elektrohydraulic control out of the mounting.

Installation of the elektrohydraulic control Fig. 7:

Mounting arrangement, example

5 6

1

2 15 3

12

8 1, 2 holder 3 pin 5 staple NW 8/10 6 pin 7 symbol plate, control valve block

7

11

8 retainer, symbol plate 11 hex. head bolt M6x8 12 hex. nut M10x20 15 retaining clip

. Place the elektrohydraulic control into the mounting and tighten the bolts (M10) properly.

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

. Connect the hydraulic hoses, ensuring that the connections are not confused.

Observe the hose connection plan and the markings on the hoses.

DANGER! Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely. safety

. Check the hose connections again. The hose nipples must fit

tightly in the sockets and be secured with staples. Make sure to insert both ends of the staples and push them in completely.

Ensure that the connections are leak-tight.

. After connecting the hoses and checking the connections, plug DBT GmbH, Lünen 2004

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the connecting cable of the electrohydraulic control unit into the respective sockets of the pilot valves. Observe the circuit diagram and the markings on the cables.

. Check all the connections once more against the hose connection diagram.

. Test all functions of the shield and remove the securing devices installed at the beginning of the work.

WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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5

Operation

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Operation and function of the pilot valves

Operation This chapter contains information on the operation of the electrohydraulic control and on its functions. Be sure to also observe the operating manuals for the support and the control unit.

DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the electrohydraulic control if you have the required knowledge.

Operation and function of the pilot valves Control of the shields is particularly dangerous in repair mode, as you then directly control the shield under which you are working. It is therefore extremely important that you know and understand the different functions and sequences of movement of the shield control.

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If you are operating the shield in repair control mode, no one else is allowed to remain in the movement area of the shield.

Operation Two push buttons are provided on the cover of each pilot valve. By pressing a button you directly actuate the respective directional valves.

The function is terminated as soon as you release the button.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

Fig. 8:

Push buttons

Function variable functions

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The function of the individual pilot valves is variable and depends on the external connections. The assignment Function/Push-button is shown on a symbol plate. This symbol plate should be attached to the electrohydraulic control underneath the pilot valves.

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Filter cartridge Filter cartridge A filter cartridge is provided in the manifold section of the electrohydraulic control. It protects the valves of the control unit against damage from impurities in the hydraulic medium.

Maintenance intervals IMPORTANT! The maintenance intervals recommended are standard values.

Special operating conditions may require different maintenance intervals. It is absolutely necessary that you adapt the maintenance intervals to the individual operating conditions. after one week

The filter cartridge in the manifold section should be checked for soiling one week after start-up of an electrohydraulic control system, at the latest. Replace the filter cartridge, if soiled.

according to schedule

5.4

If problems occur in the preparation of the medium there will be an increased risk of failures due to clogged filters. To maintain the operational reliability of the installation, certain measures may then have to be taken regularly. For example, you should take the precaution to maintain regular random inspections of the filter cartridges of all electrohydraulic control units on the face. It may be necessary to replace the filter cartridges at regular intervals as a precaution.

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

When extensive work has been performed on the hydraulic system or after start-up of a new face there is an increased risk of dirt having entered the hydraulic system. Depending on the degree of contamination this may lead to the filter cartridges on the whole face being soiled. This, in turn, results in the functions being operated slower or not at all. We therefore recommend that you take the measure described above in order to prevent failures occurring during operation of the shield hydraulics.

E

If a large number of electrohydraulic control units have been placed in service on a face at the same time, it is sufficient to examine the filter cartridges randomly. If the inspection reveals that there is a high probability of failures due to soiled filter cartridges all filter cartridges on the face must be replaced.

EM014981-0 (EN-US)

Filter cartridge Replacing the filter cartridge Preparation

. Secure the shield mechanically to prevent it from lowering under its own weight

WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

. Close the shut-off valve in the pressure feed line P. . Check the system for any residual pressure. This pressure can build up in the hydraulic system as a result of the loads on the props and cylinders.

. Depressurize the system. Make sure to observe the hose con-

nection diagram and hydraulic circuit diagram.

When the hydraulic circuit has been depressurized, you can continue with the next working steps.

Unscrew the filter cartridge E

. Remove any dust and dirt from the electrohydraulic control.

DBT GmbH, Lünen 2004

CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Unscrew the filter cartridge using a screwdriver.

Fig. 9:

Unscrew the filter cartridge

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

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Filter cartridge Screw in the new filter cartridge

. Screw in the new filter cartridge.

. Tighten the cartridge finger-tight (15 Nm). . Check that the cartridge is fitted leak-tight.

When you have completed the check without finding any faults, the electrohydraulic control can be pressurized again. Remove the securing elements only when you are sure that the hydraulic components function properly.

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Fig. 10: Fitting the new filter cartridge

EM014981-0 (EN-US)

Filter cartridge Accumulator cartridge WARNING! Do not operate the electohydraulic control without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the electohydraulic control or the shield.

This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

IMPORTANT! The accumulator cartridge is not included in the scope of supply of the electohydraulic control. Please remember this information when ordering replacement parts.

IMPORTANT! A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

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Accumulator cartridges must be checked for correct operation at regular intervals. We recommend to perform this test on a random sample basis. For this purpose, select a few samples and replace them by new cartridges. Test the samples to make sure they function properly. If they do, they can be installed again.

The accumulator cartridge is located at the front of the manifold block, to the left of the solenoid pilot valves. See Fig. 11.

Fig. 11: Accumulator cartridge, arrangement

a

a accumulator cartridge

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Filter cartridge Replacing the accumulator cartridge Preparations

. Secure the shield mechanically to prevent it from lowering under its own weight.

WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

. Close the shut-off valve in the pressure feed line. . Operate the opposite acting pairs of hydraulic functions several times alternating, to depressurize the hydraulic system of the shield support.

. Check the electohydraulic control for any residual pressure.

Observe also the hose connection diagram and hydraulic circuit diagram.

CAUTION! Impurities in the hydraulic medium can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Remove any dust and other impurities from the accumulator

cartridge and the surroundings in order to prevent dirt entering the hydraulic system during assembly / disassembly of the accumulator cartridge.

Fig. 12: Replacing the accumulator cartridge

a

b a staple

5.8

b accumulator cartridge

Electrohydraulic Control 10-Functions

DBT GmbH, Lünen 2004

Removing the accumulator cartridge

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Only when you are sure the system has been depressurized, you can continue with the next working steps.

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Filter cartridge WARNING! If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

. Pull the staple out sideways. . Pull the accumulator cartridge out to the front.

Installing the accumulator cartridge

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The new accumulator cartridge is installed in the reverse order of removal. Prior to installation, apply a separating agent/lubricant (B6 acc. to EWN 7068) to the surfaces to be joined. See also chapter 6, section ”lubricating greases and lubricating pastes”.

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6

Technical data

EM014981-0 (EN-US)

EM014981-0 (EN-US)

Description

Technical data This chapter contains important and useful information on the design and materials used, etc. A list of media approved by DBT (hydraulic fluids and process water) can be found at the end of the chapter.

IMPORTANT! Please use the spare parts catalog supplied when ordering spare parts.

Description Functions The electrohydraulic control permits to control 10 independent functions. The directional valves of the control block are actuated via solenoid-operated pilot valves. Operation of the pilot valves requires an electronic control unit such as for example a shield control unit of type PM4.

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Fig. 13: Front view of the electrohydraulic control

a

b

a port (DN20) for accumulator cartridge b manifold block

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c c pilot control valve

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Description Design The main components of the electrohydraulic control are: J manifold block with

– directional valves, – check valve, – filter cartridge – accumulator port and – connecting sockets J channel plate J pilot control valves Fig. 14: Control valve block

DBT GmbH, Lünen 2004

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a

b

c

d

a connecting sockets, rear side b manifold block c pilot control valves

e d push button e connectors for the control unit

Materials employed The electrohydraulic control is made of corrosion-resistant materials such as stainless steel, brass, bronze, etc.

The connection between manifold block and channel plate is sealed with O-rings. The seal materials are designed for operation with HFA hydraulic fluids (oil-in-water emulsions).

Dimensions and weight depth/ width/ height

276 mm / 340 mm / 154 mm

weight

ca. 51.3 kg

Pressure

6.4

permissible working pressure

320 bar

test pressure

350 bar

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Description Filter The filter cartridge protects the pilot control circuit against impurities. Use only new filter cartridges, never ”cleaned” cartridges.

Only new filter cartridges have the necessary filtration properties (mesh size = 25 µm).

See also chapter Operation, “Replacing filter cartridge”.

Mountings There are 4 threaded bores (M 10) on the top of the electrohydraulic control and 2 bores (M 10) on each side.

Fig. 15: Threaded bores

a

a

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a

a threaded bore M10, 14 deep

Valves Directional valves: J 3 x 3/2-way directional control valves (NG 20) J 8 x 3/2-way directional control valves (NG 13)

They are controlled by pilot control valves.

Pilot control valves: J 5 x double 3/2-way directional control valves (NG 0.5)

The pilot control valves are operated by a control unit (e.g. PM4).

They can also be operated direct in an emergency or for repair purposes. To this end, the valve covers are provided with 2 push buttons each.

Power is supplied from the single control unit. A four-pin connector is provided on the housing cover of each pilot valve for connection of the required cables.

Specification of the double 3/2-way directional control valves Tab. 1: Certified Dust-Ex unit

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area of application

certification body

approval no.

Europe

INERIS

03 ATEX 0127

USA

MSHA

IA 663-0

Australia

AUS

Ex 3561X

MDA

Ex ia 11649

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Hydraulic flow diagram Classification according to directive 94/9/EG (ATEX)

group I, category M2

protection type:

EExib l

connectors:

Fa. Lumberg, type 068 B 04/5

solenoid design:

Fa. Thomas Magnete, Typ: 81-9133-040/001

rated voltage:

12 V, DC

perm. deviation:

-2 V

Schaltstrom:

138 mA

current reduction:

max. down to 25 mA

WARNING! As soon as the current drops to a level below 25 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

Hydraulic flow diagram DBT GmbH, Lünen 2004

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Fig. 16: Electrohydraulic control, 10 functions,circuit diagram

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Connections Connections The connection ports for the hydraulic lines are located on the rear of the control valve block.

Fig. 17: Rear view of the electrohydraulic control

1

4

6

8

10

12

2

2 P

11

9

7

5

3

T

Hydraulic connections

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large-volume consumers

mean-volume consumers

connections:

3 x DN 20 socket, plug-type

marking:

1, 2, 2

flow rate:

max 340 l/min

application:

large-volume consumers

connections:

2 x DN 12 and 8 x DN 10 socket, plug-type

marking: DN12 3, 12 DN10 4, 5, 6, 7, 8 9, 10 plugged, no function

pressure supply, tank line and accumulator cartridge

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flow rate:

max 180 l/min

application:

mean-volume consumers

connections:

2 x DN 25 socket, plug-type 1 x DN 20 socket, plug-type (front side)

marking:

P T SP

application:

pressure supply to the system, return line to the tank socket for accumulator cartridge

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- pressure supply, DN 25 - tank line, DN 25 - accumulator cartridge socket, DN20

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

Hydraulic fluid concentrates List of approved water-miscible hydraulic fluid concentrates for the production of fire-resistant hydraulic fluids of Group HFA. Tab. 2: Approval list (Part 1)

type X test water

type Y test water

type Z test water

P 87 AF

not tested

1.5 %

3%

Carl Bechem

Fimitol P 87 AF

not tested

1.5 %

3%

Castrol

Anvol C 18

not tested

5%

not tested

Anvol C 19

not tested

5%

not tested

Anvol SF 2000

not tested

2.5 %

not tested

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

5%

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1.5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1.5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

not tested

Quintolubric 814-01

not tested

5%

not tested

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

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

ARAL Lubricants

Fuchs/Century

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Product designation

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Manufacturer

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Operating media Tab. 3: Approval list (Part 2) Manufacturer

Product designation

Recommended concentration for use with process water according to the chemical composition type X test water

type Y test water

type Z test water

GS 460 N

not tested

1.5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1.5 %

Hydrocor TS 100 N

not tested

2%

not tested

Isosynth VX 110 BF 1) 2)

not tested

1.5 %

1.5 %

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTh Theunissen i

1) Will be distributed as “Anvol JD 2000” by Castrol.

2) Only permissible is the variant manufactured in Germany.

The variant of Isosynth VX 110 BF, manufactured and distributed in USA, is not permissible because of different ingredients.

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

The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

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

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

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

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

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

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

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

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Operating media Quality of the process water The quality of the process water is a critical factor for the functional reliability of the emulsion. The water must not contain any solid or liquid impurities and must satisfy the bacteriological requirements for drinking water (DIN 2000).

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

The chemical composition of the test water samples used are shown in the table below for your orientation. type Y test water (DIN 24320 resp.

Luxembourg Report)

type Z test water (NCB 19 to Luxembourg Report)

pH value

6.5 - 8.5

6.5 - 8.5

6.5 - 8.5

hardness mmol/l

2.5 (=14°d)**

3.58 (= 20°d)**

7.5 (= 42°d)**

chloride

200 mg/l

200 mg/l

200 mg/l

sulfate

240 mg/l

150 mg/l

720 mg/l

nitrate

0 mg/l

20 mg/l

0 mg/l

magnesium

30 mg/l

50 mg/l

90 mg/l

sodium

130 mg/l

115 mg/l

130 mg/l

calcium

50 mg/l

61 mg/l

150 mg/l

iron, max.

0.3 mg/l*

0.3 mg/l*

0.3 mg/l*

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

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

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

Checking of the emulsion values At least once per week, check: J the pH value J the concentration

test method: by agreement with the concentrate manufacturer

J the microbial load

test method: dip slides

IMPORTANT! Further information is contained in DIN 24320.

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type X test water (NCB 18 to Luxembourg Report)

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Tab. 4: Chemical composition of the test water samples used

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Operating media Lubricating greases and pastes IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

Lubricating greases general properties

lubricating greases A1

base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble in water

temperature 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 assembly according to EWN 1) 7068 Tab. 5: Lubricating greases for general application Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

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Flash point in °C

lubricating greases A2

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 6: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Flash point in °C

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 having the same saponification base but different origins.

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

1)

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Operating media Lubricating pastes lubricating pastes B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Tab. 7: Lubricating pastes free from molybdenum disulfide

Supplier

Type

Base

NLGI class

flash point °C

gleitmolybdän

gleitmo 805 *)

Li

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is: gleitmolybdän ”gleitmo 805” Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Temperature of application:

non-soluble in water -34 to +120° C

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent and lubricant 785 (flash point 132 °C) IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

*)

6.12

The products listed in table 5 are suitable lubricating greases for filling of adjacent cavities.

Electrohydraulic Control 10-Functions

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Behavior in the presence of water:

DBT GmbH, Lünen 2004

lubricating pastes B6

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For your information

EM014981-0 (EN-US)

EM014981-0 (EN-US)

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service addresses Germany

DBT GmbH Industriestraße 1 D-44534 Lünen Tel:

+49 / 23 06 70 9 - 0

Fax:

+49 / 23 06 70 9 - 4 21

E-mail: infodbt@dbt.de Internet: http://www.dbt.de Great Britain

DBT GB Ltd. Hallam Fields Road

DBT GmbH, Lünen 2004

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Ilkeston, Derbyshire DE7 4BS Tel:

+44 / 11 59 51 - 2500

Fax:

+44 / 11 59 32 - 9683

E-mail: info@dbtgb.com Internet: http://www.dbt.de USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel:

+ 001 / 72 47 43 12 - 00

Fax:

+ 001 / 72 47 43 12 - 01

E-mail: infodbt@dbt.de Internet: http://www.dbt.de Australia

DBT Australia Pty. Ltd. 10-14 Kellogg Road P.O. Box 41 Rooty Hill, NSW 2766 Tel:

+ 61 / 2 98 30 - 9500

Fax:

+ 61 / 2 98 30 - 9555

E-mail: infodbt@dbt.de Internet: http://www.dbt.de

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Our service China

DBT China Beijing Representative Office Room 502, Prime Tower No. 22 Chaowai Street Beijing 100020 Tel:

+86 / 10 65 88 - 2998

Fax:

+86 / 10 65 88 - 6570

E-mail: Info.beijing@dbtchina.com Internet: http://www.dbt.de DBT Langfang Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone 065001 Hebei Province P.R. Tel:

+ 86 / 3 16 60 86 - 840 (& 841, 842, 843)

Fax:

+ 86 / 3 16 60 86 - 845 E

E-mail: Info.langfang@dbtchina.com

South Africa

DBT GmbH, Lünen 2004

Internet: http://www.dbt.de DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston, 1401 Tel:

+ 27 / 11 82 58 21 2

Fax:

+ 27 / 11 82 57 38 9

E-mail: infodbt@dbt.de Internet: http://www.dbt.de France

DBT France S.A.R.L. 1, rue d‘Annecy, BP 144 57150 Creutzwald Tel:

+ 33 / 38 72 92 08 0

Fax:

+ 33 / 38 79 02 30 9

E-mail: info@dbtfrance.com Internet: http://www.dbt.de

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Electrohydraulic Control 10-Functions

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Our service Referenced Standards and Guidelines The following table shows only a selection of the standards and guidelines employed by us during the development and manufacture of the control block.

DBT GmbH, Lünen 2004

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Tab. 8: Referenced standards and guidelines

Designation

Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery

DIN EN 982

Safety of machinerySafety requirements for fluid power systems and their components

DIN EN 60445

Identification of Connections

DIN EN 62079

preparation of instructions

DIN 2000

Central drinking water supply - Guidelines regarding requirements for drinking water, planing, construction operation and maintenance of plants

DIN 6789

Documentation System

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self-Advancing Supports

DIN 24320

Fire Resistant Hydraulic Fluids

DIN 24343

Hydraulic fluid power systems and components; list for attendance inspection of hydraulic equipments

DIN 24346

Hydraulic Systems; Design Principles

EWN1) 6003

Pretensioning forces and tightening torques

EWN1) 7068

Lubricants

EWN1) 7069

Nonmetallic surface protection

ISO 4406

Hydraulic fluid power - fluids - method for coding the level of contamination by solid particles

1) EWN = DBT standard

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7.6

Electrohydraulic Control 10-Functions