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Translationofthe originaloperating manual.
Amendmentsandalterationstothispublicationarenotsubject tonotification.Bucyrusreservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws.Nopartofthispublicationmay bereproducedortransferredinanywayorformwithoutthepriorwritten approvalofBucyrus.
Bucyrusdeclinesanyliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
BucyrusEuropeGmbH,Lünen2011E
Aboutthismanual
Aboutthismanual
Thischaptercontainsimportantinformationtomakeiteasierfor youtousethismanual.Italsoprovidesyouwithinformationonthe structureofthemanualandthesymbolsused.
Beforestartingwork
Usinganoperatingmanualthatwasnotspecificallywrittenforthe watervalveunitconcernedcanresultinasafetyhazardfor yourselfandothers.Ensurethatthespecificationsonthewater valveunitcomplywiththespecificationsintheoperatingmanual.
Thisoperatingmanualisdesignedfor: Watervalveunit-4functionsdevicenumber84010072400000
andisonlypermittedtobeusedforwatervalveunitsofthistype. Onlyusetheoperatingmanualwhichappliestotherespective watervalveunit.Failuretodosowillposeadangertoyourselfand others.
Itisabsolutelynecessarytoensurethatallpersonsworkingwithor onthewatervalveunitalwayshaveunrestrictedaccesstothe contentsofthecurrent,applicableoperatingmanuals.
Personsforwhomthisoperatingmanualisintended
Thisoperatingmanualisintendedforeveryoneconcernedwith J installing, J servicing, J repairing, J operatingand
J removing thewatervalveunit.
Thesupervisorswhoaskinitiatetheaboveworkorsuperviseit mustalsofollowthisoperatingmanual.
Purposeofthisoperatingmanual
Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtothewatervalveunit.
Readthisoperatingmanualcompletelyandatyourleisure.Pay specialattentiontothesafetyinstructions. Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.
Readchapter2“Yoursafety”closely.Thischaptercontains importantinformationindicatingpotentialhazards.
Observethisinformationandfollowtheinstructionsinthis operatingmanual.Thisistheonlywaythatyoucankeepthe operatingcostsdownandretainyourrightstomakeaclaimunder thewarranty.
Beforestartingwork
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafety instructionsandimportantinformationinthisoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymbolpointout immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
Warning!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare: minortomoderatelyseriousinjuriesanddamagetothe machine.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare:minordamage tothemachineordamageintheimmediatevicinity.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.
J Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Pointsinthetextthataremarkedinthiswaydescribe individualworksteps.Followthismanualstep-by-step.Thiswill helpyoucarryoutyourworkfasterand,moreimportantly,more safely.
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Yoursafety
Thischapterprovidesvitalinformationforyoursafety.
Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.
Thewatervalveunitwasmanufacturedinaccordancewithstateof theartandgenerallyrecognizedsafetystandardsandregulations. However,aresidualriskstillexistswhichmayinvolveyougetting intohazardoussituationswhenworkingwithoronthewatervalve unit.Thesemay,forexample,becausedbyunforeseeableexternal influences,machinedamageoroperatingerrors.
Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulations:
J oftheminingcompany,
J oftheminesinspectorate,and
J oftheminingsupervisoryauthorities.
Personnel
Personsemployedintheoperation,repairandoverhaulof hydraulicand/orelectrohydrauliccontrolcomponentsmustbe speciallyqualified.Inadditiontohavinghadtraininginmining technology,thefollowingminimumrequirementsmustbemet.
Operationandmaintenance
Operationandmaintenanceoftheshieldcontrol systemmayonly beperformedbytrainedpersonnel.
Thetrainingmustbespeciallytailoredtothetypeofwatervalve unitactuallybeingused.
Thecontentoftheoperatingmanual,especiallythechapteron safety,mustconstituteapartofthistraining.
Theymustpossessandfurnishproofofsufficientfamiliaritywith the
J mechanical,
J hydraulicand J controlsystems.
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Operatingconditions
Repairandmaintenance
Ingeneral,repairworkmayonlybeperformedbypersonswho havetheknowledgeandskillstomeetthespecialrequirements andhavebeenadequatelytrainedintherepairoftheequipment. Repairworkonandoverhaulof:
J watervalveunits,
J workingvalves,
J pilotvalves,
J safetycomponentssuchaspressurereliefvalvesetc.
shallbeperformedonlybyBucyrusservicetechniciansorby speciallytrainedpersonneloftheminingcompany.
Operatingconditions
Intendeduse
Thewatervalveunitservestocontrolthewatersprayingsystem. Itisonlyusedinconjunctionwithanelectroniccontrolsystem,for exampleaPMC®-Rcontrolsystem. Onlyusethewatervalveunitasintended.
watersprayingsystem
Thewatersprayingsystemservestoactivelycounteractdust. Usuallyseveralnozzlesareattachedtotheshieldsupport,through whichwatercanbesprayedasneeded.Thewaterspraying system isactivatedonlytemporarilydependingontheoperatingstateof thesystem,forexamplewhenpushingtheshieldandwhenthe miningequipmentpassesthesupport. Thewatersprayingvalvesarecontrolledbytheprogramofthe electronicshieldcontrolordirectlybymeansofthehydraulicshield controlsystem.
Unauthorizeduse
Alluse,whichisnotexpresslydeclaredasintended,isregardedas unauthorizeduse
Unauthorizedusecanendangeryourselfandothers.Youmightbe killedorseriouslyinjured. Youshouldthusonlyusetheelectrohydraulicwatervalveunitas intended.
Bucyruswillacceptnoresponsibilityfortheconsequencesof unauthorizeduse.
Safetyinstructions
Thefollowingalwaysapplies:
Alwaysconcentrateonyourwork.
Itisalsoimperativethatyoufollowtheoperatingmanualforthe supportandthewatervalveunit.
Alwaysfamiliarizeyourselfwiththeworkingenvironmentbefore startingwork.
Alwayskeepoutofanyshieldwhichisnotset.
Alwayswearyourpersonalprotectiveclothingandequipment.
Observetheacousticandvisualstart-upwarnings.Payspecial attentiontothestart-upwarningsfortheconveyorandforthe miningequipment.
Onlyusewatervalveunitswhichareinatechnicallyflawless condition.
PresstheEMERGENCYSTOPswitchimmediately,intheeventof faultsorirregularitiesinoperation.Notifyyoursupervisorofany peculiarity,inorderthatnecessaryactioncanbetaken immediately.
Iftheshieldisequippedwithanelectrohydraulicwatervalveunit, youmustlock-outtheshieldbypressingthesupportlock-out switch (repairswitch).Thismeanstheshieldcannotbecontrolledviathe watervalveunit.
Pressthesupportlock-outswitchwhenperforming:
J maintenancework, J inspectionwork, J repairwork, J andduringprolongedpresenceintheshield. Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe:
J sideseals, J skids, J relaybarassemblies, J lemniscaticlinks, J hydraulicpropsandcylinders, J canopiesand J flippers.
Safetyinstructions
Storageandtransport
Neverstorematerialsofanykindinthetravelwayorinyour workingarea.
Toavoidhinderingorendangeringthefacecrew,immediately removeanyfaultycomponentsfromtheface.
Neverstorefaultypartswithgoodparts.Thiswayyoucanavoid inadvertentreinstallationofthesefaultycomponentssomewhere else.Havethesefaultycomponentsrepaired.
Observethespecifiedstorageperiodsandthestorageinstructions.
Installation
Mechanicallysecureallmovingpartsbeforeyoudepressurizethe hydraulicsystem.
Asamatterofprinciple,onlyworkondepressurizedhydraulic systems.
Makesurethatnodirtorimpuritiescangetintothehydraulic system.
Onlyremovetheprotectivecapsfromtheconnectionsimmediately beforeinstallingthewatervalveunit.
Operation
Onlyworkinrepairmodeifitisabsolutelynecessary.Ifpossible controltheshieldsfromthewatervalveunitoftheneighboring shield.
Checktodeterminewhetherallprotectivedevicesontheshieldare presentandfunctional.
Makesurethatnooneisintheareaoftheshieldbeingactuated.
Watchtheshield'srangeofmotionsothatpotentialhazardscanbe recognizedintimeandpreventativeactioncanbetaken.
Maintenance
Informthesupervisorypersonnelandthefacecrewabout maintenanceandrepairwork.Providethemwithinformationonthe intendedworkanditsprobableduration.
Keepyourworkingareacleartoavoiddangertoyourselfandother persons.
Blockofftheworkingareafortheminingequipmentorstopthe equipmentandtheconveyorandlockthe system,topreventitfrom beingturnedonagain.
Beforeperformingwork,mechanicallysecuretheshieldtoprevent itfromaccidentallysinkingintothefloor,e.g.by:
J proppinguporsupportingthecanopy, J placingwoodenwedgesbetweenthelemniscaticlinks.
Immediatelydiscontinueanyworkontheshield,ifconveyingand miningoperationsareinprogressinyourworkingarea.
Immediatelyaftercompletingwork,refitanyremovedprotective devicesandcheckthattheyworkproperly.
Makesurethattheprescribedmaintenanceandinspectionintervals areobserved.
Useonlysparepartswhichconformtothespecifiedtechnical requirements.ThisisbestensuredbyusingoriginalBucyrusspare parts.
Pleaserefertothesparepartsfolderfortheordernumbers.
Donotmakeanymodificationsorchanges.Allmodificationsand changesmustbeapprovedbyBucyrus.
Neverusethewatervalveunitwithoutafiltercartridge.Ifthefilter ismissingorifitisnotfineenough,thiscanleadtomalfunctions anddamagetothewatervalveunit.
Hydraulicsystem
Avoiddirectcontactbetweenyourskinandhydraulicfluids. Hydraulicfluidwhichpenetratestheskincancauseserious infections.
Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids representaveryseriousdangertohealth.
Notethatwhendismantlingprotectiveequipmentthatincludes hydrauliccomponents,thattheycanbepressurized.Youcouldbe severelyinjuredbyhydraulicfluidjettingoutwildly.Therefore,itis imperativethatyoudepressurizethehydrauliccomponentsbefore removingtheprotectiveequipment.
Onlypersonswhohaveandcandemonstratespecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Takecaretoensurethatpressurereliefvalvesarealways equippedwithprotectivecaps.Replacedefectivecapswithout delay.
Carryoutavisualinspectionofallthehydrauliccomponentsat regularintervals.Inparticularcheckthat:
J thehosesarenotpinchedortrapped,
J thehoseshavenobubblesorblisters,
J thehosesortheoutersheathsofthehosesarenotabnormally rigidorhard,
J theoutersheathofthehoseisnotdamaged,
J theconnectorsaresecurelyinsertedintothecouplingsockets,
J theconnectionsareleak-tight.
