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Operating Manual DBT-Shield 2550/5500-2X4319-1750 DBT-Shield 2400/5000-2X4319-1750 Doc. No.: 7420 152 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 Email: infodbt@dbt.de Telefax: +49 (0) 23 06 / 709 - 1421 Internet: www.dbt.de

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 2005 E

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

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

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

2.3 2.4

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

2.5

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

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

2.5 2.5

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

2.6

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Overview of the safety instructions . . . . . . . . . . . . . . . 2.16

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

3.3

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

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

3.3 3.5

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

3.5

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

4.3

Installation of the shield units . . . . . . . . . . . . . . . . . . . .

4.3

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

Coupling between the connections . . . . . . . . . . . . . . . . . . .

4.5 4.6

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

4.6

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

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

Start-up of the shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 4.8

Corrosion protection of hydraulic components . . . . .

4.9

5. Operation

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Basic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Conditions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.3 5.6

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

5.9

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Safe working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Operation of the shield hydraulics . . . . . . . . . . . . . . . . 5.15 Location of hydraulic components on the shield . . . . . . . .

Operation of the dual backflush filter . . . . . . . . . . . . . . . . . .

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

Operation and functions of the control valve block . . . . . .

5.15 5.30 5.31 5.33

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36 Special measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

To be done every six months . . . . . . . . . . . . . . . . . . . . . . . .

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

5.36 5.37 5.37 5.37 5.38

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39 5.39 5.39 5.42 5.42 5.43 5.43 5.43

6. Technical data Shield description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

Base with lemniscatic links and central shifting unit . . . . .

Shield canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Technical data of the shield, steel structure . . . . . . . . . . . .

6.5 6.9 6.14 6.19 6.22 6.25

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double-telescopic prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.29 6.36

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Baselift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Flipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pusher cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data of hydraulic cylinders . . . . . . . . . . . . . . . . . .

6.38 6.39 6.39 6.40 6.41 6.41 6.42

Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45 Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.48 Electrohydraulic control units . . . . . . . . . . . . . . . . . . . . . . . .

Electronic shield control PANZERMATIC® PM4 . . . . . . . .

6.48 6.49

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.52 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.53 DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

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Fault finding on shield hydraulic system . . . . . . . . . . . . . . .

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

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

Pilot-operated check valves . . . . . . . . . . . . . . . . . . . . . . . . .

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

Faulty pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Anti-topple device “canopy - canopy” . . . . . . . . . . . . . . . . .

End anchorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End anchorage base - base . . . . . . . . . . . . . . . . . . . . . . . . .

Side flipper hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.53 6.54 6.55 6.57

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.58 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.58 6.61

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.63 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.63

7. For your information 7.3

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

7.3

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

7.5

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

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

7.5 7.5

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

Doc. No.: 7420 152 000 BA 00

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E DBT GmbH, Lünen 2005

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

1

About this manual

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 used.

Before starting work applicable operating manual

Take care to ensure that the operating manual available to you is applicable for the shield support used. Compare the data given below with the data on the type plate of the shield. Where to find the type plate on the shield is described in chapter 7 of this operating manual.

This operating manual is designed for: DBT-Shield 2550/5500-2x4319-1750 and DBT-Shield 2400/5000-2x4319-1750 and is only permitted to be used for shields of this type. Only use the operating manual applicable to the respective shield. If you don’t you will endanger yourself and others.

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Tab. 1: Type specification for DBT-Shield 2550/5500-2x4319-1750 and DBT-Shield 2400/5000-2x4319-1750 Year of Application Identification no.

Prop force construction

availability of operating manual

7420 152 000 00 01

2 x 4319 kN

2005

face shield

7420 152 000 00 02

2 x 4319 kN

2005

transition shield

7420 152 000 00 03

2 x 4319 kN

2005

face end shield, right with side flipper and sidewall

7420 152 000 00 04

2 x 4319 kN

2005

face end shield, right

7420 152 000 00 05

2 x 4319 kN

2005

face end shield, left

7420 152 000 00 06

2 x 4319 kN

2005

face end shield, left with side flipper and sidewall

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

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

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

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1.3

Before starting work J supervisory personnel who

– initiate and /or – supervise the activities just indicated.

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

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

Purpose of this operating manual operating manual

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

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

safety

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

Observe the information given and follow the procedural instructions.

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.

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

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

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

1.4

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

question?

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Therefore, 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.

Before starting work Items in lists are marked with black squares.

–

Points in 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.

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J

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1.5

DBT GmbH, Lünen 2005

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Before starting work

1.6

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

2

Your safety

Personnel

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

supplementary regulations

The shield 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 shields. 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.

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

Operation and maintenance Operation and maintenance of the shields is only allowed to be performed by trained personnel. qualification

The training shall be matched to the type of shield actually used.

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

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.

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2.3

Personnel 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 safety devices, as e.g. pressure relief valves J hydraulic props and cylinders J control blocks, valves, and filters

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

2.4

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Conditions of operation Conditions of operation Intended use The shield has been designed and manufactured exclusively for use as a support unit for longwall faces.

Use the shield only as intended!

Intended uses are: J propping the roof against the floor; J ensuring an adequate travelway; J the following shield operations:

– lowering, – pulling up, – alignment, and – setting; J the following conveyor operations:

– advancing, DBT GmbH, Lünen 2005

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– retracting; J forming an abutment for:

– the conveyor and the mining machine, – conveyor steering devices, – devices for raising the conveyor, – conveyor steering cylinders.

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

Unauthorized uses include, among others: J pushing the shield back into the caving area, J raising of the conveyor by means of the hydraulic force of the

shield, J setting of the canopy in areas of roof fracture.

Further information in this respect is given in the section ”Operation” of this chapter and in chapter 5 of this manual in the section ”Operation of the shield”.

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

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2.5

Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

Maintain the signalling systems and protective devices in a functional condition.

Observe the acoustic and visual start warnings. Pay special attention to the start warnings for the conveyor and for the mining machine.

EMERGENCY STOP

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.

support lock-out switch

- Only applicable for shields provided with electrohydraulic control systems Actuate the support lock-out switch (repair 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 base skids and shifting units J canopies, J links, J side seals, J front cantilevers, J hydraulic props and cylinders, J steering devices.

2.6

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signalling systems and protective devices

Maintain the lighting systems in a functional condition.

DBT GmbH, Lünen 2005

lighting

Safety instructions automatic mode

In automatic mode, the support units of a longwall face are controlled by an automatic programme without any human interference.

When travelling the face you should therefore always keep in mind that the support units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the support currently operated.

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

Never go under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

Defective components should be immediately transported away from the face, in order to avoid interference with the face crew.

Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

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Inform the persons concerned about the intended transport route and the probable duration of transport. securing for transport

Ensure that the transport securing devices have been correctly installed. In particular, ensure that the following are secured for transport: J the side seal, J the flipper, J the relay bar (face and gobsides).

transporting

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

Non-standard transport assemblies are shown on special drawings which are added in the annex to the manual, if required.

Do not damage the polished surfaces of the cylinders and props.

Damage of this kind necessitates elaborate and expensive repair work.

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

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

Firmly secure all components which might start moving.

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

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2.7

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

Prior to commencing any work on the shield make sure that the shield has been secured to prevent it retracting automatically.

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

For securing the shield, hardwood wedges, for instance, can be placed between the pairs of links.

Securing by means of hardwood wedges

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Fig. 1:

transport securing devices

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

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

travelway

Make sure that the minimum dimensions specified for the travelway within the shield are maintained under any circumstances. The minimum dimensions are: J width: 600 mm J height: 400 mm

Any devices added to the shield later such as for example steering devices are not allowed to reduce the minimum travelway. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travelway is maintained.

2.8

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Safety instructions Operation shield control

In automatic mode, the support units of a longwall face are controlled by an automatic programme without any human interference.

When travelling the face you should therefore always keep in mind that the support units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic warning signals sent by the control unit in the support currently operated.

Check to determine whether all protective devices on the shield are present and functional. See also chapter 6.

Operate the shield control system only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective control system and know the contents of the respective operating manual.

Do not stay in the shield whose functions you are to operate.

Always operate the shield only from the adjacent shield.

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

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When operating the shield manually the operator has to watch the shield movement area constantly before and while operating the shield in order to avoid potential hazards by cautious behavior.

DBT GmbH, Lünen 2005

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

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

Clean the control elements of the control units regularly. Ensure that the operating symbols are clearly recognizable. This measure avoids faulty operation and resulting accidents.

Keep the floor as clean as possible. Keep the floor free from debris.

This way you will be able to extend the shifting unit without hindrance and to advance the conveyor without problems.

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

On inclined faces it may be necessary to anchor the conveyor with respect to the support. This measure helps to prevent lateral displacement between the conveyor and the shield. And it reduces the risk of the shifting unit jamming between the skids.

Hydraulic anchorages must always be supplied with the specified working pressure since only thus a sufficient anchorage between shield and conveyor is ensured.

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

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2.9

Safety instructions On inclined faces, always advance the shields from the bottom to the top. Operate the shield to be advanced always from within the adjacent shield above. This reduces the risk for you to get hurt by falling rocks and also gives you a better view of the advancing operation. shield alignment

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

Align the shields as soon as possible. Alignment in due time prevents: J getting under the canopy of the adjacent shield, J canting of the shields, J slipping of the shields, J and ensures an early support of the newly mined roof.

roof falls

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

Never set the tip of the canopy into a roof fall-out such that J the max. admissible angle of inclination of the canopy is

J the canopy will be loaded excessively in longitudinal direction

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

During temporary support of a roof fall-out ensure that the drooping canopy does not get in the way of the passing mining machine. residual stroke

Ensure that sufficient residual stroke is still present in the props when the seam thickness decreases. This prevents the props from going solid between the roof and floor.

pulling back the conveyor

If possible, pull the conveyor back by operating the respective functions of the electronic shield control unit. If this is not possible, do as specified in the respective operating instructions of the mine.

Secure the entire mining machine against unauthorized starting.

Isolate your place of work such as to prevent any unauthorized persons entering this area.

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

raising of conveyor

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

Only use the points of attachment intended for that purpose. Never attach loads to hydraulic cylinders or their fastening points.

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

Check the setting pressure again. By no means, disengage the canopy from the roof. It must always be in contact over the entire length.

2.10

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

J the stabilizing cylinder locks

E

exceeded

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

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

Check that the fastening points are undamaged before attaching a load.

J lifting gear with sufficient permissible load-bearing capacity.

Maintenance Make sure that all safety and protective devices of the shield supports are complete and functional. If the safety and protective devices are included in the DBT scope of supply, refer to chapter 6 for their location.

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

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

DBT GmbH, Lünen 2005

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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 other persons.

Replace damaged components affecting safety immediately. Stop and lockout the respective shield immediately if the component damage entails a hazard and an immediate repair is not possible.

Secure this area and notify the entire coal face crew and the responsible foremen without delay, if there is a safety hazard.

Use only spare parts which conform with the specified technical requirements. This is best ensured by the use of original spare parts from DBT. As to the order numbers for the required spare parts please refer to the spare parts catalog provided for the equipment.

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

Any modifications carried out without authorization result in the certificate of conformity of DBT becoming invalid and require a new conformity test.

During work on the shifting unit, isolate the working area for the mining machine.

Working in the mining track is permissible only if J the roof has been secured against rock fall, J the coal face has been secured against sloping down, and J the mining machine and conveyor have been shut down and

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

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2.11

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

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

pressure or mechanical stress.

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

When performing any work which might entail the risk of the support retracting automatically secure the shield mechanically to prevent it lowering by itself.

On inclined faces secure the components to be replaced against slipping by using e.g. chains or lifting gear.

Immediately after completion of the work, reinstall protective devices which have been removed, and check them for correct functioning.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective equipment -hydraulic

When removing protective equipment which includes hydraulic components keep in mind that these components may be pressurized. You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

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

maintenance, repair

pressure relief valves

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

Make sure that pressure relief valves are always provided with protection caps. Replace defective caps without delay.

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

J the hoses have no bubbles or blisters.

J the hoses or the outer sheathes of the hoses are not abnor-

mally rigid or hard.

J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

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

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

2.12

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

handling of hydraulic fluids

E

Hydraulics

Safety instructions Before removing staple locks to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is still pressurised. If the hose is difficult to turn or does not turn at all the line is still pressurised. Be sure to depressurise the line.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely.

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. 2:

Example: 4SP hydraulic hose, designation 3 2

DBT GmbH, Lünen 2005

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1

6

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

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a pulsing hydraulic hose. Depressurise the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying 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. 3:

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Laying hydraulic hoses, slack RIGHT

WRONG

2.13

Safety instructions J are not twisted, Fig. 4:

Laying hydraulic hoses, twisting RIGHT

WRONG

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter), Fig. 5:

Laying hydraulic hoses, bending WRONG

DBT GmbH, Lünen 2005

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RIGHT

J cannot chafe, Fig. 6:

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

When installing the hydraulic hoses, ensure that they cannot be: J torn out, J kinked, J crushed,

2.14

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Safety instructions J driven over or J twisted (Fig.: 7) by the movement of the equipment.

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

DBT GmbH, Lünen 2005

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RIGHT

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2.15

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 WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices.

Chapter 4: Installation DANGER! Damaged hoses might burst and hydraulic fluid could escape under high pressure. This could severely injure or even kill you or others.

Make sure that the movements of the shield do not cause any damage to the hose lines.

Lay the hose lines correctly behind the retainers provided for that purpose.

WARNING! When performing any work, observe the safety instructions given in this manual and also the special safety instructions and operating manuals provided by the mine management. Failure to comply can lead to most serious accidents which might even result in death.

The first start-up and the test run should only be performed by a well-trained and experienced crew who are familiar with the special conditions prevailing in underground mines, particularly with the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

2.16

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

If the points of attachment on the caving shield are to be used for transporting the assembled support unit, canopy and base skid must be connected mechanically by means of an additional transport safety device to prevent them moving apart.

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CAUTION! Transport safety devices may get damaged during transport to the mine, for example when loading and unloading the transport units.

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

Overview of the safety instructions Canopies must not be sloping downwards and reach into the track for the mining machine.

Do not install shut-off valves into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could e.g. cause hose lines to burst. This may result in serious injuries to persons or even death.

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”.

Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

For transport underground only the attachment points detailed in chapter 3 ”Transport” are allowed to be used. Further information is given in chapter 3 ”Transport”. Failure to comply may lead to injury to persons and damage to property.

DBT GmbH, Lünen 2005

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Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

NOTICE! Take care to ensure that all transport safety devices required for transport have been removed. See chapter 3, section ”Transport”.

IMPORTANT! When installing the shields in the face, be sure to observe the shield numbers. Since the individual shields might be provided with different functions they must be arranged in the specified order.

For details, please refer to the respective separate operating manual of the manufacturer.

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2.17

Overview of the safety instructions Chapter 5: Operation DANGER! You are only allowed to operate the shield control if you have a profound knowledge of the control elements and of the way the control system works. You must have been task-trained on the present control system and should have practiced to deepen your knowledge. Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or death to the operator.

Therefore, never fix the push buttons and take care to ensure that damaged pilot valves are always replaced without delay.

During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. Pay attention to the separate manual of the electronic control system.

Do not put the filter into operation, prior making sure that all connections have been made properly.

Never put both levers into backflush position simultaneously, because the emulsion flow will be completely shut off and backflushing will be impossible.

The control elements on the control valve block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose. They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries.

During normal operating mode, the shield is operated exclusively by means of the electronic control. In this respect it is imperative that you observe the separate operating manual of the control unit.

If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

2.18

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

Always stay clear of a shield which is being moved. Circumstances which are not always obvious may lead to unexpected movements of the shield unit which could result in severe injuries or even death.

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

E

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

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

Overview of the safety instructions You are only allowed to operate the controls of the control valve block when you know exactly which effects the functions have with respect to the shield. Therefore you should have received adequate training. If not, there is a risk of operating errors involved which might cause severe injuries to persons, possibly resulting in death.

The manual operation of a push button on one of the pilot valves causes the direct execution of the respective function. In this case, dependencies between the individual functions will not be considered. This could lead to dangerous situations if, for example, functional sequences are initiated in the wrong order. For example, the function ”advance shield” can be activated without the functions ”retract side seal” and ”actively lower shield” having been actuated before. This could cause hazardous situations resulting in very severe injuries.

When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior.

DBT GmbH, Lünen 2005

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Trouble shooting on hydraulic systems entails an increased accident hazard. Particularly by malfunctions of the hydraulic system and hydraulic medium escaping at high pressure severe injuries could be caused.

Therefore you are required to be very cautious and wear the specified protective equipment. Failure to comply with these instructions could cause severe injuries.

CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of a tendency to roof fall-outs and/or extremely soft floor.

Avoid an excessive inclination of the canopy by filling roof fall-outs or by supporting minor fall-outs with the shield in horizontal position.

At this point, we explicitly emphasize again that any damage caused by the non-compliance with these instructions is possibly not covered by the guarantee.

Do not exceed the angles of inclination of the canopy (angle between shield canopy and caving shield) specified in chapter 6 ”Technical data”. If the angles are exceeded, this will cause damage to props and hydraulic cylinders, their arresting elements as well as the articulations of the components.

Take care not to damage the push-buttons of the pilot valves.

Jammed push-buttons will cause malfunctions of the valves which may result in accidents.

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2.19

Overview of the safety instructions Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

NOTICE! It is important that the control symbols are legible to avoid the risk of operating errors and resultant accidents.

IMPORTANT! Both cases require knowledge of the flow plan and skilled personnel. The safety guidelines contained in this manual must strictly be observed.

Chapter 6: Technical data WARNING! Risk of getting squeezed between moving parts of the shifting unit and the shield.

Keep away from advancing shield units or such which are going to be advanced.

Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic hose lines caused by dangerous overpressure.

Never close the lowering ports of double-acting props pressuretight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

Be sure that the misalignment between shield 1 and shield 2 does not exceed the max. permissible value.

If this dimension is exceeded the steering cylinders or their holders could be heavily damaged. You may be severely injured or even killed by falling parts. The misalignment is never allowed to exceed 300 mm.

CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy - caving shield) will not be exceeded.

2.20

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

E

During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

Overview of the safety instructions Do not change the pressure setting of pressure relief valves! Only use pressure relief valves which have been factory-set to the required value and are provided with the relevant color code.

Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

Always replace pressure relief valves with valves which are as new and have the same properties. Refer to the hydraulic flow plan in this respect. Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

If the max. angles stated are exceeded, damage will be caused to the props and cylinders as well as to their arresting elements and to the articulations.

An incorrect sequence of steps when pulling up the shields could cause severe damage to the shields.

Advance the shields only in the sequence of steps 2-1-3 or 2-3-1.

E

NOTICE! Remove transport securing devices, items 24, 38 and 45, 37 at moveable side before putting the shield into operation.

All sliding surfaces and joints coated with lubricating paste B6 to EWN 7068 DBT GmbH, Lünen 2005

The technical data of the cylinders are given in the section “Technical data” of the shield used.

Always fit new seals when replacing a pressure relief valve. Failure to comply may result in leakages at the plug-type connection and impair the operational safety of the hydraulic system.

How to operate the electronic shield control unit type is not subject of this manual. See separate operating instructions.

Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

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.

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

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

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2.21

DBT GmbH, Lünen 2005

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Overview of the safety instructions

2.22

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

3

Storage and transport

Storage

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

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

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

Storage Storage of new equipment corrosion protection

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

DBT GmbH, Lünen 2005

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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 inside metallic materials against corrosion.

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

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

Water-bearing parts of the equipment such as for example the components belonging to the water spraying system of a shield should be completely emptied or, if required, be filled with an anti freezing fluid. 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. If the equipment is to be stored for more than four weeks additional special measures may have to be taken, depending on the environmental conditions. It may, for example, be necessary to remove the electronic control unit in order to store it adequately.

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

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3.3

3.4

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 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.

storage outdoors

Equipment parts stored outdoors must be protected against direct sunlight, precipitation and dirt - for example by using tarpaulins.

These parts have to be stored such that fluid will not be allowed to collect in cavities. Fluids entering any cavities during transport or loading/unloading must be able to flow off freely.

electrical equipment, rubber and plastic parts

As a general rule, electrical equipment, electronic components, spare parts made of rubber or plastic - such as seals and hoses as well as pressure fluids have to be stored in closed rooms at 15 °C. to 25 °C. protected against direct sunlight. Exceptions: see ”Short-term storage”.

natural ageing

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value 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.

plastic deformation

When storing assemblies - such as props and cylinders - containing contacting joints, sealing elements may suffer plastic deformation as they are constantly subjected to static unilateral loads due to the weight of the components. This may render the seals useless or reduce the life of the sealing element. This effect is greatly influenced by the size and duration of the load and the prevailing temperature.

Therefore, props, cylinders and similar components should only be stored in an upright position. This especially applies if the components are to be stored for a longer period of time.

If you intend to store a machine containing any of the above-mentioned components you may have to dismantle such components in order to store them adequately.

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.

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

long-term storage

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Storage

Transport HFA fluids

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.

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

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.

Transport DBT GmbH, Lünen 2005

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WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices. transport units

In consultation with the customer and taking into consideration the local conditions prevailing at the site transport units were specified as follows: The shields are delivered as completely pre-assembled units.

points of attachment

As far as technically possible, the load units are provided with suitable and fixed points of attachment for transport and assembly. If not, adequate threaded holes or other provisions are available for the temporary attachment of parts. Details on the arrangement and load-carrying capacity of the attachment points are given in the spare parts catalog or on the special drawings for transport assemblies which are added in the annex to this manual, if required.

temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with a medium sensitive to frost, for example, an oil-in-water emulsion (HFAE) have to be completely drained and then filled with a frost-proof preserving fluid, e.g.

HYDROCOR® CV 50. If, for technical reasons, the fluid cannot be drained completely choose a preserving fluid which can be mixed with the medium originally used and ensure that the media are adequately mixed.

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3.5

Transport Transport of equipment at temperatures between -21°C and -40°C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and are only loaded statically or quasi-statically. External forces are only allowed to be introduced via the points of attachment and absorption surfaces indicated on separate drawings, if any.

The equipment is not allowed to be transported at temperatures below -40 °C.

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

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

transport units

A shield can be transported as a completely assembled unit or divided into transport units. If dismantling into transport units is necessary, this is planned and laid down in close cooperation with the customer.

Tab. 2: Transport units

transport safety devices

Designation

Transport position

support unit complete 1)

as for normal use

side flipper

hydraulic cylinders on top

Remarks

For the purpose of ensuring safety during transport, the movable parts of each transport unit must be fastened such as to prevent their changing their position inadvertently, if required in addition to the standard securing devices, e.g. on side seals and flipper. The following transport safety devices are provided on the transport units: Tab. 3: Transport safety devices Part

Transport safety device

flipper

chain

1

side seal, moveable side

pin and retaining clip

4

relay bar, faceside

transport rod

1

relay bar, gobside

chain

1

hydraulics

hydraulic ports not used are closed with protection plugs

-

1)

3.6

Quant.

end shield variants 03 and 05: side flipper detached

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

electrical and electronic components

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

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

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

CAUTION! If the points of attachment on the caving shield are to be used for transporting the assembled support unit, canopy and base skid must be connected mechanically by means of an additional transport safety device to prevent them moving apart.

Fig. 8:

Transport of shields as complete unit

B X5 X4

X3 H

Y

S0

DBT GmbH, Lünen 2005

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X4

SY X1

X2

S3 S4

Sx L

S3 slot hole, 2 x on the coal face end of the base, load-bearing capacity: 15000 kg S4 slot hole, 2 x on the gob side end of the base, load-bearing capacity: 15000 kg X1, X2 securing elements to fix the relay bar during transport, faceside and gobside X3 securing elements to fix the flipper X4 securing elements to fix the moveable side seals X5 transport safety devices at the side flipper Y transport safety device between canopy and base not included in the scope of delivery So center of gravity

Tab. 4: Shield support 7420 152 000 00 .. , dimensions and weights of variants Variant

Order no.

Length in mm

Width in mm

Height in mm

Sx/Sy in mm

Weight approx. in kg

01 7420 152 000 00 01

7520

1650

2550 1579 / 1507

27200

02 7420 152 000 00 02

8020

1650

2550 1442 / 1537

28400

8225

16501)

2400 1340 / 1428

03 7420 152 000 00 03

30400 1) 29700

04 7420 152 000 00 04

8225

1650

2400 1340 / 1428

28800

05 7420 152 000 00 05

8225

1650

2400 1340 / 1428

28800

8225

16501)

2400 1340 / 1428

06 7420 152 000 00 06

30400 1) 29700

1)Side flipper and protective wall detached.

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3.7

Transport Fig. 9:

Securing elements to fix the relay bar (faceside)

131

130

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130 transport rod 131 spring clip 2x

Fig. 10: Securing elements to fix the relay bar (gobside)

132 131

133 134

132 chain 6x42 133 hex. head screw M 12x45-8.8 134 hex. nut M 12-8

3.8

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Transport Fig. 11:

Securing elements to fix the flipper

133 132

134

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132 chain 6x42 133 hex. head screw M 12x45-8.8 134 hex. nut M 12-8

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3.9

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Transport

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4

Installation

Pre-assembly of the shield units

Installation This chapter contains information on the installation of the shield units. Please pay particular attention to the warnings and tips.

WARNING! When performing any work, observe the safety instructions given in this manual and also the special safety instructions and operating manuals provided by the mine management.

Failure to comply can lead to most serious accidents which might even result in death.

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”.

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CAUTION! Prior to assembly, the sliding surfaces of the transport units of the steel structure must be coated with lubricating paste B6 to EWN 7068 which does not contain molybdenum disulfide. See chapter 6, section ”Recommended lubricating greases and pastes”.

Pre-assembly of the shield units The shields are delivered as completely pre-assembled units.

Hence, no further pre-assembly is required for the mechanical and hydraulic systems of the shields.

Installation of the shield units CAUTION! For transport underground only the attachment points detailed in chapter 3 ”Transport” are allowed to be used. Further information is given in chapter 3 ”Transport”. Failure to comply may lead to injury to persons and damage to property. installation plan

The shields are installed in the longwall face in correspondence with the installation plan of the mine.

IMPORTANT! When installing the shields in the face, be sure to observe the shield numbers. Since the individual shields might be provided with different functions they must be arranged in the specified order.

identification for installation in the face

shield number

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To facilitate identification for assembly and installation in the face the shields or the transport units should be provided with consecutive numbers. This numbering should, for example, correspond to the order in which the shields are to be arranged in the face. The numbers should be written on the surface of the components with a clearly visible color.

The shield number is an identification feature. All shields are numbered consecutively. Firmly attached plaques showing the respective shield number are provided at the base skid.

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4.3

Installation of the shield units

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Fig. 12: Shield number at the base, example

Tab. 5: Allocation of shield numbers

4.4

shield no.

order no

application

5 to 137

7420 152 000 00 01

face shield

4 and 176

7420 152 000 00 02

transition shield

1

7420 152 000 00 03

face end shield, right with sideflipper and sidewall

2 and 3

7420 152 000 00 04

face end shield, right

177 and 178

7420 152 000 00 05

face end shield, left

179

7420 152 000 00 06

face end shield, left with side flipper and sidewall

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Installation of the shield units Supply connections During the first start-up as well as during normal operation the shield is supplied via the ports at the manifold pipe.

Fig. 13: View on the manifold pipe

16

b

21c

P 21d R W

a

E

16 manifold pipe DBT GmbH, Lünen 2005

21d high-pressure ball valve, auxiliary water line, closed as shown 21c high-pressure ball valve, supply line to water spray system, open as shown

a protective cover for electrohydraulic control unit b protective cover for dual filter, R return line, DN 50 P pressure line, DN 40SS W water line, DN 25

Fig. 14: View on the rear manifold pipe and the dual filter, protective cover open

21b

20

23 16

16 manifold pipe 20 dual filter, back flush type 21b high pressure ball valve, serves to isolate the water supply to the “water curtain”, open as shown

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23 high-pressure ball valve, serves to isolate the shield hydraulics from pressure supply, open as shown

4.5

Requirements for the face hydraulic system Coupling between the connections The hydraulic connectors are plug-type connectors according to DIN 20043. hydraulic system

A manifold pipe for the shield hydraulic system is located between the front lemniscatic links of each shield unit. This pipe provides the hydraulic supply to the individual shield unit. The manifold pipes of adjacent shield units are connected with the use of three hose lines: a pressure line (DN 40), a return line (DN 50) and a water line (DN 25). See the hydraulic block diagram in chapter 6.

control unit

The shield units are equipped with an electronic control unit of type PM4. The connection between the control unit and the electrohydraulic control block is provided by a solenoid driver module. The connecting cables required for this purpose are included in the scope of supply of the PM4 control system. How to connect the control unit is described in the separate operating manual for the PM4 control system. An overview of the design of the control is also given in chapter 6 of this operating manual in the section titled ”Shield control”.

additional equipment

Provision is made on the shield units to allow the attachment of additional equipment which is not included in DBT’s scope of supply, as for example:

For information on the installation of the additional equipment, please refer to the pertinent operating manual of the respective manufacturer.

Requirements for the face hydraulic system hydraulic medium

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

permissible pressure

nominal pressure

320 bar

admissible tolerance

10 % of nominal pressure

CAUTION! Face hydraulic systems which are unstable or not amply dimensioned could cause temporary pressure drops during operation.

A pressure drop down to 180 bar or less entails the danger of malfunctions of the electrohydraulic control system. Possibly, valve functions will not be executed. It may even result in valves starting to vibrate which could lead to valve damage.

Under unfortunate conditions this could result in hazardous situations with accidents entailing injury to persons and damage to property.

Therefore, take all measures required to ensure that the system pressure cannot drop to less than 180 bar anywhere in the face hydraulic system.

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J two-way intercom system

E

J lighting system

Start-up Start-up WARNING! The first start-up and the test run should only be performed by a well-trained and experienced crew who are familiar with the special conditions prevailing in underground mines, particularly with the safety regulations. The crew must also be skilled in handling the equipment properly and know the content of the respective operating manuals.

NOTICE! Take care to ensure that all transport safety devices required for transport have been removed. See chapter 3, section ”Transport”.

To be observed prior to start-up Start-up must be performed by trained and qualified personnel. If the mine uses the shield support for the first time, it is imperative that the DBT field service is present during start-up.

Please observe the following items: J Mechanics E

. Check to make sure that all transport safety devices have been

DBT GmbH, Lünen 2005

removed

. Check all mechanical connections on the shields . Check attachment of the shifting unit On shifting units with adjustable crawl pan make sure that the crawl pan has been attached properly. Never use the last slot for connection.

J Hydraulic system

. Test the entire hydraulic system for leaks. Seal any connections that are leaking.

. Check whether shield movements, particularly in the links, could cause damage to hoses.

DANGER! Damaged hoses might burst and hydraulic fluid could escape under high pressure. This could severely injure or even kill you or others.

Make sure that the movements of the shield do not cause any damage to the hose lines.

Lay the hose lines correctly behind the retainers provided for that purpose.

. Check the hydraulic supply pressure.

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4.7

Start-up . Check supporting power of the props. The actual pressure under the piston of a prop can be read off the PM4 control unit.

You can either read off the pressure of an adjacent support or of the support where you are currently located. The pressure gauge at the prop check valve indicates the pressure direct.

. Check all operating elements to make sure that the correct function is executed when actuating the respective operating element.

J Signalling and lighting systems

IMPORTANT! For details, please refer to the respective separate operating manual of the manufacturer.

. Check all signalling systems, signs. . Check that the face is illuminated sufficiently. . Check that the face area, especially the travelway, is provided with all signs required. It is imperative that you observe the regulations of the responsible mining authority.

J Mining and conveying

. Check all functions of the longwall system before start-up. . Check correct interaction of the complete longwall system (mining machine, conveyor system, shields).

WARNING! Canopies must not be sloping downwards and reach into the track for the mining machine.

Start-up of the shields Bring the shields into initial position, which means: J shields and conveyor are aligned in a straight line, J the shields are aligned at right angles with respect to the con-

veyor, J the shield canopies are parallel to the floor.

Check the shields for any installation errors or any other sources of errors.

. Check all line connections made during the installation of the shields, particularly the supply lines for the hydraulic system of the shields, to make sure they are complete and correct.

WARNING! Do not install shut-off valves into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could e.g. cause hose lines to burst. This may result in serious injuries to persons or even death.

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DBT GmbH, Lünen 2005

. Check that all emergency stop systems function properly.

E

J Emergency stop systems

Corrosion protection of hydraulic components . Check the function of the hydraulic and water supply systems for the face.

. Check all functions of the shield control system.

Do not allow the shield to be operated until all defects have been eliminated and the shield is fully functional.

Corrosion protection of hydraulic components Before delivery, DBT hydraulic components are provided with a corrosion preventing medium for testing purposes.

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There are no special measures required to remove remnants of the testing fluid before putting the hydraulic components into operation.

The testing fluid is fully compatible with the permissible media listed in the “Approval list”, see section “Hydraulic Fluids of Group HFA” in chapter 6.

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4.9

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Corrosion protection of hydraulic components

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Operation

Basic requirements

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

DANGER! You are only allowed to operate the shield control if you have a profound knowledge of the control elements and of the way the control system works. You must have been task-trained on the present control system and should have practiced to deepen your knowledge. Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

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

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

Basic requirements Conditions for operation face crew

The face crew must be informed about possible danger situations.

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

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

face equipment

The face must be illuminated sufficiently.

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

The face conveyor must be equipped with a pre-start warning system and a shut-down and lock-out device.

conveyor overload

Large layers of coal and rock must be broken up to prevent spillage and jamming under shield canopies. Compressed-air picks have to be kept on hand for this purpose. The face conveyor and the mining machine must be at a standstill during the process of breaking up the layers of rock and coal.

In case large layers of rock and coal cannot be broken up as required they may only be transported when it is ensured that nobody will be put in danger. Any work on the face must be stopped until the transport of the rock and coal layers has been finished.

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5.3

Basic requirements travel way

The minimum dimensions for the travelway specified must be maintained.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travelway: Width: 600 mm Height: 400 mm If the support is used in countries other than the Federal Republic of Germany the respective regulations applicable in those countries must be observed.

Debris or objects lying in the travelway must be removed immediately. This does especially apply for low seam heights.

If crawl pans are used whose length is adjustable, care has to be taken that a safe travelway of adequate width remains.

roof supporting work

Care must be taken that the filling section of the face conveyor remains unobstructed. This means that the canopies of the shields must be set against the roof immediately after the shields have been lowered and advanced.

work in the mining track

Work in the mining track may only be carried out from a safe position. The conveyor and the mining machine must be at a standstill and locked-out to prevent restarting.

The conveyor and the space above the conveyor may only be entered if there is a protection against fall of rock from the roof.

In thick seams the coal face must also be protected against slabbing in these places. On faces equipped with shields this is best done by using flippers.

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

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

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

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DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

If the area behind the front props is to be used as travelway, e.g. in case of thick seams, steeply inclined faces, or if the shield can be moved up to the conveyor, the travelway must be marked at the face ends by a sign.

E

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

Basic requirements On inclined faces the conveyor must additionally be provided with barriers, for example air cushions, which have to be fitted above the place where the work has to be carried out. Their number and type depends on the gradient and other local conditions. repair work

Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been depressurized. In addition, you should take adequate measures to prevent any unauthorized persons from restoring pressure.

If support units are to be detached from the conveyor, stop the mining operation completely or ensure by other means that the mining work continues only outside the safety zone required to safely perform the repair work.

Components which are subject to mechanical stress or hydraulic tension are only allowed to be loosened or removed after they have been relieved of their tension or stress, for example by aligning, lifting or lowering.

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If, in exceptional cases, the tension or stress cannot be relieved completely, it should be reduced as far as possible and the respective component be secured by suitable means such as for example chains or locking elements to permit the tensions to be absorbed safely when they occur. Any work in this area is only allowed to be performed from a safe position.

Protection equipment increases safety; it is only allowed to be removed if this is required for performing the work. After completion of the work, the protection equipment should immediately be installed again properly. water spraying system

The water spraying system is designed for the active suppression of dust. The shield support is equipped with several nozzles which spray water as and if required. Depending on the operating mode of the installation, the spraying system will be activated from time to time, for example when advancing the support and when the mining machine passes the support. Operation of the spraying valves is program-controlled via the electronic shield control or direct by the hydraulic shield control system.

conveyor steering devices

On inclined faces, the conveyor has to be secured by anchorages, if required. This measure is required to prevent the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid.

Hydraulic anchorages must always be supplied with the specified working pressure. Only thus is a sufficient anchorage between support and conveyor ensured.

When pulling up the shields, always observe the specified sequence of steps. If not, the anchorage device might be damaged and become unfit for use.

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5.5

Basic requirements Safety requirements automatic mode

Exercise special care and caution when travelling a face that is operated automatically. Be sure to observe the warnings at the face entry and the respective safety regulations of the mine.

You must always be prepared for the shield which you are in being addressed by the automatic system. Therefore it is vital that you observe the acoustic and optical warning signals sent by the control unit of a shield which is just being operated.

Operate the ”support lock-out switch” when you have to stay in a shield for a longer period of time.

shield operation

A shield must always be operated from a safe position and from within an adjacent shield.

Never ever stay under a shield which has not been set.

Take care that no part of your body ever gets between the canopy and the roof, the base and the floor, skid and shifting unit or between the side seals of adjacent shields.

You are not allowed to lower or advance a shield as long as a person is in the immediate vicinity of the support unit or in the support unit.

You are not allowed to lower or advance a shield manually when the mining machine is before or in the range of action of the support unit.

On inclined faces, shield advance should be started in the lower section. Since the shields are to be operated by adjacent control, the operator can operate and observe the unit to be advanced from a safe position within the adjacent shield.

The props of the shields must always be set until the setting pressure has been reached to ensure good roof support and in case of shields with special functions, e.g. shields serving as abutments for conveyor alignment systems, sufficient anchoring between roof and floor.

The shields must be advanced as soon as possible to prevent the potential danger of roof fall-outs.

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DBT GmbH, Lünen 2005

Nobody is allowed to stay in a shield which is being advanced.

E

When operating the shield manually the operator has to always watch the area of movement of the shield before and while operating the shield in order to prevent potential hazards by cautious behavior.

Basic requirements Fig. 15: W r o n g , shields have not been advanced in the right time

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Fig. 16: C o r r e c t, shields have been advanced in time

A canopy which is sloping downwards at a step in the roof must not obstruct the passing of the mining machine.

The flipper must be folded back completely prior to advancing the shield unit. Never advance a shield against the coal face with a folded-out flipper. Otherwise the flipper cylinders and the link joints of the flipper will be damaged seriously.

While advancing a shield unit special care must be taken that the shield canopy does not get under the side seal of an adjacent shield. Otherwise the side seal of the adjacent shield will be damaged seriously. hydraulics, controls

Take care to avoid misoperation of the shield control.

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

Hoses must remain free to move. They must not be squeezed or overstretched. Care must be taken that they are properly bundled.

Damaged hydraulic hoses and hose connections must be replaced at once. This work must only be carried out by trained persons.

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5.7

Basic requirements Hose lines between pilot-operated check valves and props or cylinders, which have a load-accepting function, e.g. stabilizing cylinders or swivel canopy cylinders, may only be replaced after the canopy and the caving shield have been secured in position mechanically. This also applies to the work on the articulations.

Shut-off valves must not be installed in the return line.

To prevent damage in case the return line is closed safety valves must be installed in the return lines (see hydraulic layout, if provided by DBT). If the hydraulic layout is provided by the operator we recommend to install safety valves into the return line, spaced 50 m apart. The valves should be set to 25 bar and relieve to atmosphere. damages, spare parts

Special observations, in particular concerning defects or damage, have to be reported immediately.

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Machine parts and hydraulic elements may only be replaced by genuine spare parts.

5.8

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield Operation of the shield A good training of the operating personnel, knowledge and observance of the safety regulations and of the operating instructions listed afterwards largely help to prevent the occurrence of hazardous situations. Moreover, they are good prerequisites for a reliable interaction of shield and mining machine within the longwall system.

If the shield is equipped with an electrohydraulic control system, a profound knowledge of the separate operating manual for this control system is absolutely necessary for shield operation.

The shields must be set until the setting pressure has been reached to ensure good roof support and, in case of shields with special functions, e.g. shields serving as abutments for anchorages, sufficient anchoring between roof and floor.

It is a general rule that the shields should be advanced as soon as possible to achieve an early support of the newly mined roof.

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

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canopy adjustment

The shields must always be set in such a way that the canopies and the bases are as parallel as possible. Within the maximum angles given in the technical data sheet it is possible, however, to adapt the canopy to steps in the roof and to overcome steps in the floor, if required by geological or operational conditions.

CAUTION! Never exceed the max. permissible angles of inclination of the canopy. Exceeding the permissible angles of inclination of the canopy stated in chapter 6, section ”Technical data” can result in damage to the shield. This does particularly apply to the stabilizing cylinders, their fastening elements and points of attachment to shield canopy and caving shield.

Fig. 17: Shield in the normal position

α=0 M

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

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5.9

Operation of the shield CAUTION! Never extend or retract the stabilizing cylinders of the shield completely. They must always have sufficient residual stroke.

Standard value: min. 20 mm!

The same applies analogously for the swivel canopy cylinders.

This is the only way of cushioning high peak loads, which may occur suddenly, by the hydraulic securing action of the stabilizing cylinders.

If the residual stroke is not sufficient, this may result in serious damage to the shield under unfavorable leverage conditions.

Fig. 18: Shield with extremely inclined canopy

α1

s1

s

2

α

2

M

M = height of the set shield α = inclination angle of the canopy S = residual stroke of the stabilizing cylinder

CAUTION! Ensure sufficient residual stroke of the stabilizing cylinders especially in the case of a tendency to roof fall-outs and/or extremely soft floor.

This applies especially if the shield control unit is equipped with an automatic positive setting function. Under unfavorable conditions for example, soft floor and in addition, perhaps a tendency to roof fall-outs - the automatic positive setting function could lead to the stabilizing cylinders not having sufficient residual stroke or being extended or retracted completely. Therefore, operate the shield in such or similar cases without automatic positive set.

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M

Operation of the shield CAUTION! Avoid an excessive inclination of the canopy by filling roof fallouts or by supporting minor fall-outs with the shield in horizontal position.

At this point, we explicitly emphasize again that any damage caused by the non-compliance with these instructions is possibly not covered by the guarantee.

CAUTION! Do not exceed the angles of inclination of the canopy (angle between shield canopy and caving shield) specified in chapter 6 ”Technical data”. If the angles are exceeded, this will cause damage to props and hydraulic cylinders, their arresting elements as well as the articulations of the components.

Since changes in the angles result in considerable changes in height at the ends of the canopy or skids, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the floor and roof, or fill cavities in the roof.

DBT GmbH, Lünen 2005

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Never set the tip of the canopy of two-leg shields with stabilizing cylinder in a cavity (figure 19) if the stabilizing cylinder is fully extended. There must always be sufficient stroke available for decreasing dynamic loads from the roof by the hydraulically protected stabilizing cylinder.

Fig. 19: W r o n g, by no means must the tip of the canopy be set in a cavity, if the stabilizing cylinder is fully extended.

Cavities in the roof can be overcome by placing crib blocks onto the tip of the canopy (see Fig. 20) or by leveling off the canopy.

By these measures the roof will be supported during the next step.

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5.11

Operation of the shield Fig. 20: C o r r e c t, overcome a cavity by placing crib blocks onto the tip of the canopy

Care must be taken that a canopy which is sloping downwards at a step in the roof does not obstruct the pass of the mining machine.

The closed height of the shields must be suitable for the lowest seam height.

The shield must be operated such as to ensure that there is always sufficient residual stroke available for lowering. If not, the shield might get jammed between the roof and the floor and may be heavily damaged by sudden load peaks - for example caused by a mountain bump. Load peaks cannot be cushioned hydraulically when there is not enough hydraulic fluid under the piston of the prop or the piston already has reached its bottom dead center position.

The minimum residual stroke required for lowering the shield can be maintained by J keeping the seam opening sufficiently large by means of the

mining machine J avoiding the accumulation of debris and fine coal on the floor J removing accumulated dirt from the canopies

Before the shields are advanced, the floor must be clear of coarse debris so that the shields can be advanced by the full length of the stroke without obstruction and subsequent advance of the conveyor is not impeded. Besides, a clean floor facilitates corrections in the attitude of the shields.

If the seam height increases considerably and the hydraulic stroke is not sufficient the props have to be extended in time or replaced by props with a larger stroke. You are only allowed to use approved components.

When extending the props or retracting the extensions, the canopy must be secured in position. Make sure that the prop which has been separated from the canopy cannot turn over.

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range of adjustment / changing seam thickness

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Accumulation of dirt on the canopies can be avoided by advancing the shields under roof contact. In some cases it is possible to let the dirt fall onto the conveyor or to clear it away after lowering the tips of the canopies for a short time.

Operation of the shield inclined faces

Particularly in inclined workings sliding and canting of the shields must be avoided by correcting their attitude in time by means of the side seals and steering devices. This is to prevent a shield from getting under the canopy of its adjacent shield, often causing considerable damage.

Since in inclined workings shield advance starts as a rule in the lower section of the face, a correct attitude of the end shields is of importance. For correcting the attitude, hydraulically operated guide beam assemblies and steering devices at the canopy and the base or between canopy and base are used.

The side seals can be used with automatic controls to prevent tilting of a lowered shield during advance. Any corrections in the attitude becoming necessary can be carried out by means of manual control only.

The side seal of the caving shield is only allowed to be used for alignment with respect to the adjacent shield if the two shields have been advanced to the same extent.

On inclined faces, the conveyor has to be secured with anchorages. This measure prevents the conveyor offsetting with respect to the support. It reduces the risk of the shifting unit jamming in the base skid which would make shield advance difficult.

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When pulling up the shields, always observe the specified sequence of steps. If not, the conveyor steering device might be damaged and become unfit for use. Further information, if any, is given in chapter 6, section ”Accessories” and in the operating manual for the conveyor steering device. unfavorable floor conditions

With unfavorable floor conditions, the base frame of the support unit might sink into the floor. In this event, the base frame must be raised during shield advance to make sure that the installation follows the seam line and does not sink into the floor.

Shields which are equipped with a hydraulic base lifting device are raised out of the floor by operating a valve or automatically during shield advance.

Shields without base-lifting device require different procedures, depending on their design: J individual skids of two-leg shields can, as a rule, be lifted

hydraulically by retracting a prop.

J shields with solid bases must be lifted and underlaid by means

usually applied in mines.

IMPORTANT! Both cases require knowledge of the flow plan and skilled personnel. The safety guidelines contained in this manual must strictly be observed.

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5.13

Safe working Safe working For safety of the operator the shields are provided with adjacent controls; i.e. each shield is operated using the controls located in the shield to the left or to the right of the unit to be advanced, or by automated remote batch control.

WARNING! Always stay clear of a shield which is being moved. Circumstances which are not always obvious may lead to unexpected movements of the shield unit which could result in severe injuries or even death.

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

CAUTION! Take care not to damage the push-buttons of the pilot valves.

Jammed push-buttons will cause malfunctions of the valves which may result in accidents.

Always observe these safety rules :

Follow these steps if a shield has failed to advance : 1. Determine reason for failure to advance, there may be: J Malfunctioning of electronic controls J External obstructions:

– shield wedged in between adjacent shields – canopy has tip lodged in roof – floor step or excessive debris in front of base tip 2. In case of malfunction of the automated batch cycles, advance the shield manually in single step mode by use of the control unit of the adjacent shield unit. See separate manual of the electronic control.

3. In case of external obstructions utilize adjacent manual control to overcome the obstruction(s).

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DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

When groups of shields are advanced automatically, nobody is allowed to stay in the area between the operator and the shield to be moved.

E

Keep all parts of your body under the canopy of a set shield and away from the shield in motion or about to be advanced.

Operation of the shield hydraulics Operation of the shield hydraulics WARNING! During normal operation, the shield-type support is operated only by means of the control unit of the electrohydraulic adjacent control system. Observe the separate manual for the control unit.

Location of hydraulic components on the shield The following table applies to all support variants.

DBT GmbH, Lünen 2005

E

Tab. 6: Hydraulic components Item 1 2 3 5 6 7 8 11

Qty. 1 2 1 2 2 1 - / 1 1) 3

Description electrohydraulic control unit prop check valve shifting ram check valve pressure relief valve, 462 bar pressure relief valve, 470 bar check valve check valve twin check valve

12 13 14 15 16 17 18

1 1 1 1 1 1 6 / 71)

pressure gauger hose lines water spray system retainers and accessories manifold pipe accumulator cartridge pressure relief valve

19 20 21

1 1 4

water spray valve dual filter, back flush type high-pressure ball valve

22 23 24 25 26

2 1 1 2 - / 11)

27 28

2 1

high-pressure ball valve high-pressure ball valve in-line-filter screwed socket high-pressure ball valve, X type manifold connection plate

32

- / 11)

33

- / 11)

S1 Z1 Z2 Z3 Z4 Z5 Z6

1 2 1 1 4 1 1

hose lines and fittings for pusher cylinder hose lines and fittings for side flipper pressure sensor prop shifting ram stabilizing cylinder seal cylinder lift cylinder flipper cylinder

Location front lemniscatic link prop, gobside L.H. front lemniscatic link prop, gobside stabilizing cylinder manifold pipe gobside side flipper cylinder a) mounted to flipper cylinder b) mounted to stabilizing cylinder c) flanged to connection plate item 28 for flipper extension cylinder prop check valve, left

front lemniscatic link electrohydraulic control unit a) 2 x at twin check valve (11a) b) 1 x at shifting ram check valve c) 1 x under canopy, R.H. d) 1 x at side flipper cylinder e) 2 x flipper extension cylinder front lemniscatic link, inside front lemniscatic link a) under canopy b) R.H. front lemniscatic link c) manifold pipe d) manifold pipe prop check valve manifold pipe manifold pipe prop head underneath the PM4-control unit under the canopy under twin check valve under canopy

Remark at holder

high flow rate type return line side flipper

subassembly subassembly subassembly at holder a) -flipper cylinder b) -shifting ram c) seal cylinder pisten rod circuit d) e) -twin check valve manual operated, at holder a) at manifold (27) b) at water spray valve (19) c) to spring valve d) water hose prop, piston side pressure supply water supply at holder in seal cylinder circuit for flipper extension cylinder subassembly subassembly

at prop check valve, only R.H.

1) deviating quantity for end shield variants with pusher cylinder and / or side flipper

Doc. No.: 7420 152 000 BA 00

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5.15

Operation of the shield hydraulics Item Z7 Z8 Z9

Qty. 2 2 1

Description flipper extension cylinder side flipper cylinder pusher cylinder

Location

Remark only shield variants 01 und 02

Shield hydraulics

18b 22

2 12

Note: The components marked in “blue” are optionally applicable at the end shield variants 03 and 06.

5.16

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

20 3

E

Fig. 21: Shield hydraulics, arrangement (1), key, see table 6

Operation of the shield hydraulics Fig. 22: Shield hydraulics, arrangement (2) key, see table 6 18e 11c

14

18a 11a

28

B

27 21a

13

16 7 23 18c

18a 18d

8 33 B

B-B 25

DBT GmbH, Lünen 2005

E

19 21b

25

6 11b

15 21c, 21d 24 17

26 32 5 1 Note: The components marked in “blue” are optionally applicable at the end shield variants 03 and 06.

Doc. No.: 7420 152 000 BA 00

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5.17

Operation of the shield hydraulics

DBT GmbH, Lünen 2005

E

Fig. 23: Functions of electrohydraulic control unit, symbol plates shield variants 01 and 02

14 functions

Tab. 7: Electrohydraulic control units with 14 functions, allocation of functions function no.

5.18

advance shield

1

set both props

2

advance conveyor

3

activate “water curtain”

4

stabilizing cylinder, extend

5

stabilizing cylinder, retract

6

seal cylinder, extend

7

seal cylinder, retract

8

flipper cylinder, extend

9

flipper cylinder, retract

10

flipper extension cylinder, extend

11

flipper extension cylinder, retract

12

lift cylinder, extend

13

lower both props actively

14

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield hydraulics

DBT GmbH, Lünen 2005

E

Fig. 24: Functions of electrohydraulic control unit, symbol plates shield variants 03 to 06

16 functions

Tab. 8: Electrohydraulic control units with 16 functions, allocation of functions function, description

Doc. No.: 7420 152 000 BA 00

function no. shield variant 04 and 05

03 and 06

advance shield

1

1

set both props

2

2

advance conveyor

3

3

activate “water curtain”

4

4

stabilizing cylinder, extend

5

5

stabilizing cylinder, retract

6

6

seal cylinder, extend

7

7

seal cylinder, retract

8

8

flipper cylinder, extend

9

9

flipper cylinder, retract

10

10

-

-

-

-

side flipper cylinder, extend

-

13

side flipper cylinder, retract

-

14

lift cylinder, extend

15

15

lower both props actively

16

16

VIVR / 01

5.19

Operation of the shield hydraulics Fig. 25: Shield hydraulics, shield variants 01 and 02 key, see table 6

17 16 DN 50 R DN 40-SS P DN 25

W

1 7 23

21d 21c 20

24

21a 27

19 6

Z4

Z4

14

Z3

Z4

11b

6

13

Z2

18c

DBT GmbH, Lünen 2005

E

21b

3

Z4 18b 5

5

Z5 22

22

12 S1 Z1

Z1 2 2 25

28

25

11a

18e

18e 18a Z6

11c

18a Z7

5.20

Z7

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield hydraulics Fig. 26: Shield hydraulics, shield variants 03 to 06 key, see table 6

17 16 DN 50 R DN 40-SS P DN 25

W

1

7 23

21d 21c 20 24

21a

E

27

6

DBT GmbH, Lünen 2005

Z4

32 26 Z9

Z4

Z3

19

8 Z8

21b

18d Z4

11b 6

33 Z2

18c

3

14

13

Z4

Z8 18b

5

Z5

5

22

22

12 S1 Z1

Z1 2 2

18a

25

25

11c

18a Note: The components marked in “blue” are optionally applicable at the end shield variants 03 to 06.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.21

Operation of the shield hydraulics

Z4

18c K R

Fig. 27: Hydraulic lines, overview, shield variants 01 and 02 key, see table 6 20

23 7

21d

24 21c

Z4

DN 10

1

19

3

K R

21b

13

11

9

7

5

3

18b

T P

14

12

10

8

6

4

2

1

2

11b

DBT GmbH, Lünen 2005

E

Z3

6 Z4

K R

21a

Z2

27

R K

Z5

11c

5 S1

12

RK R K K

PAAA BPB A PBPA

28

18c

22

PAA BPB PBPAAA

2

2

18c

18a 22

25

Z7

5.22

Z4

18a

K R

11a

Z1

R

Z1 K

25

R K

K R

Z6

Z7

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield hydraulics

Z4

18c K R

Fig. 28: Hydraulic lines, overview, shield variants 03 to 06 key, see table 6 20

23 7

24

21d

21c

Z4

1 3

15

19

K R

21b

18b

13

11

9

7

5

3

T P

16

14

12

10

8

6

4

2

1

Z3

2

E

11b

21a

Z4

K R

DBT GmbH, Lünen 2005

6

Z2

27

R K

Z5

2

12 22

S1

A BPBPA PBPAAA

BPBPAA PBPAAA

5 2

18a 22

Z6

Z1

Doc. No.: 7420 152 000 BA 00

VIVR / 01

18a

Z4

K R

11a

Z1

R

25 K

25

5.23

Operation of the shield hydraulics Fig. 29: Pusher cylinder, hose lines and fittings key, see table 6

T 9

DN 25

8

7

6

5

4

3

2

26

P

1

2

32

P

12

11

10

R

14

13

B

A

R

A retract pusher cylinder B extend pusher cylinder

K

Z9 NOTE: The components marked in “blue” are optionally applicable at the end shield variants 03 to 06.

T

P

13 11 15

16 14 12 10

9

8

7

6

5

4

3

2

1

2

DBT GmbH, Lünen 2005

E

Fig. 30: Side flipper, hose lines and fittings key, see table 6

8 PA

A

PA

PB

18d Z8

Z8

NOTE: The components marked in “blue” are optionally applicable at the end shield variants 03 and 06.

5.24

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield hydraulics Fig. 31: Shield

4

2 1

DBT GmbH, Lünen 2005

E

3 1 manifold pipe 2 PM 4 control unit

3 control valve block 4 dual filter

Fig. 32: View on the manifold pipe

b

16

21c

P 21d R W

a

16 manifold pipe 21d high-pressure ball valve, auxiliary water line, closed as shown 21c high-pressure ball valve, supply line to water spray system, open as shown

Doc. No.: 7420 152 000 BA 00

VIVR / 01

a protective cover for electrohydraulic control unit b protective cover for dual filter, R return line, DN 50 P pressure line, DN 40SS W water line, DN 25

5.25

Operation of the shield hydraulics Fig. 33: View on the dual filter, protective cover open

21b

20

23 16

23 high-pressure ball valve, serves to isolate the shield hydraulics from pressure supply, open as shown

DBT GmbH, Lünen 2005

E

16 manifold pipe 20 dual filter, back flush type 21b high pressure ball valve, serves to isolate the water supply to the “water curtain”, open as shown

Fig. 34: PM4 control unit fitted at adjustable holder

a

c b

a PM4 control unit b holder for PM4 control unit c control valve block

5.26

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Operation of the shield hydraulics Fig. 35: Adjustable holder for electronic control unit PM4

B 6, 9

6, 9

11

A

E

6 hex. head bolt M16x35 - 8.8, recommended tightening torque 195 Nm 9 washer

11 securing spring A height adjustable link B adjustable hinge fitted link

DBT GmbH, Lünen 2005

Prior to putting the shield unit into operation, the retainer for the PM4 control unit must be fitted in suitable working position.

. Fix height of the retainer (A) at both sides in working position using the securing springs (11).

. Adjust angle (B) in working position and retighten bolts (6) with the recommended tightening torque.

Fig. 36: High-pressure ball valve (26) to operate the pusher cylinder

a A C

26

Doc. No.: 7420 152 000 BA 00

VIVR / 01

B

26 high-pressure ball valve not available at shield variants 01 and 02 a holder C height adjustable link A extend pusher cylinder B retract pusher cylinder

5.27

Operation of the shield hydraulics Fig. 37: High-pressure ball valve (26) to operate the pusher cylinder

A B C B a 26

26 high-pressure ball valve not available at shield variants 01 and 02 a holder

C height adjustable link A extend pusher cylinder

Fig. 38: L.H. prop, gobside view

22 2

5.28

5

12

2 prop check valve 5 pressure relief valve 12 pressure gauge port (pressure gauge to be installed before commissioning)

22 high-pressure ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

B retract pusher cylinder

Operation of the shield hydraulics Fig. 39: R.H. prop, gobside view, protective cover removed

22 2

DBT GmbH, Lünen 2005

E

S1

5

2 prop check valve 5 pressure relief valve S1 pressure sensor port (pressure sensor to be installed before commissioning)

Doc. No.: 7420 152 000 BA 00

VIVR / 01

22 high-pressure ball valve, serves to isolate the prop piston chamber from pressure supply, open as shown

5.29

Operation of the shield hydraulics Operation of the dual backflush filter WARNING! Do not put the filter into operation, before making sure that all connections have been made properly. normal operation

flushing

The filter works, if both backflush levers are in parallel position. The filter needs to be backflushed after contamination accumulates to the point of increased pressure drop and restricted flow.

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

WARNING! Never put both levers into backflush position simultaneously, because the emulsion flow will be completely shut off and backflushing will be impossible.

Only one filter element must be backflushed at a time by simply turning the lever 90 degrees for about two seconds and then returning the lever to the working position. Repeat procedure for the other filter element.

Fig. 40: View on the dual filter and the rear manifold pipe, protective cover open

B

20

A

20 dual filter, back flush type A normal operation: both levers in position “A”

5.30

B

A

B back-flushing: one of the levers in position “B”

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

Effective backflushing requires flow in excess of 70 I/min (19 GPM).

Operation of the shield hydraulics Repair and emergency operation This section contains information on the functions and the operation of the hydraulic control which may only be used in exceptional situations, i.e. during repairs and emergencies. It is assumed here that the shield has been previously installed correctly and that all the shut-off valves are open as for normal operation.

The operation of the control unit of the electronic control system is not described here but in a separate operating manual. If the control unit is part of the DBT scope of supply you will find the corresponding operating manual in the DBT documentation on the system.

The fundamental design of the shield unit and the control system is described in chapter 6, ”Technical description”, of this manual.

It has also been assumed that the reader is familiar with the fundamental principles of the hydraulic shield-type support and the operation of the control unit.

DBT GmbH, Lünen 2005

E

WARNING! The control elements on the control valve block may only be used in an emergency and during repairs and only in compliance with the special operating instructions of the mine for that purpose. They are not allowed to be used for normal operation as otherwise hazardous situations may arise which might result in very serious injuries.

During normal operating mode, the shield is operated exclusively by means of the electronic control. In this respect it is imperative that you observe the separate operating manual of the control unit. If the electronic control is part of the scope of supply of DBT the respective operating manual will be included in the DBT documentation provided for the installation.

Fig. 41: Control devices

a

c b

a PM4 control unit b holder for PM4 control unit

Doc. No.: 7420 152 000 BA 00

VIVR / 01

d

b electrohydraulic control c symbol plate

5.31

Operation of the shield hydraulics Figure 41 shows the arrangement of the PM4 control unit and the control valve block.

How to use the PM4 control unit is not described in this manual.

See separate manual for the PM4 control unit.

Fig. 42: Control valve block (14 functions) fitted at holder between the front lemniscatic links

e d

c

a 1

1 electrohydraulic control 17 accumulator cartridge a push button b pilot valve

c connecting cable d solenoid driver e cover (open)

Fig. 43: Symbol plate for 14 function control valve block

Fig. 44: Symbol plate for 16 function control valve block

The symbol plate is located at the control valve block underneath the pilot control valves. The symbols on the plate correspond directly to the functions activated by the respective push buttons.

The meaning of the symbols and the functions is described in the following.

5.32

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

b

E

17

Operation of the shield hydraulics Operation and functions of the control valve block This section contains information on the functions of the control valve block. Please be sure also to observe the operating instructions for the hydraulic control valve block and the electronic control unit.

WARNING! You are only allowed to operate the controls of the control valve block when you know exactly which effects the functions have with respect to the shield. Therefore you should have received adequate training. If not, there is a risk of operating errors involved which might cause severe injuries to persons, possibly resulting in death.

Control of the shield is particularly dangerous during repair operation as you then operate the shield under which you are standing direct. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

No other persons are allowed to remain in the movement area of the shield as long as you are operating the shield using the repair mode.

DBT GmbH, Lünen 2005

E

There are two push-buttons on the cover of every single pilot control valve. When you press a button, the corresponding working valve is operated directly.

The function stops as soon as you release the push-button.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or death to the operator.

Therefore, never fix the push buttons and take care to ensure that damaged pilot valves are always replaced without delay.

WARNING! The manual operation of a push button on one of the pilot valves causes the direct execution of the respective function.

In this case, dependencies between the individual functions will not be considered. This could lead to dangerous situations if, for example, functional sequences are initiated in the wrong order. For example, the function ”advance shield” can be activated without the functions ”retract side seal” and ”actively lower shield” having been actuated before. This could cause hazardous situations resulting in very severe injuries.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.33

Operation of the shield hydraulics 1

Advance shield Before this function is initiated, the side seal of the shield must be released and the function ”lower prop” must have been executed for both props.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

As long as the function is activated, the pilot-operated check valve sealing off the annulus of the shifting ram is automatically held open.

2

Set both props Before operating this function ensure that the shield canopy has been aligned correctly. The baselift cylinder retracts automatically.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

3

Advance conveyor

Activate “water curtain” The function is performed as long as the button is held depressed.

5

Extend stabilizing cylinder CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

This function causes the canopy tip to raise and serves to correct the attitude of the canopy. It is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

After the attitude of the canopy has been corrected the props will have to be set again.

6

Retract stabilizing cylinder CAUTION! Do not exceed permissible canopy angle!

Observe value for minimum residual stroke.

Before initiating this function ensure that the adjacent shields are completely set.

The function causes the canopy tip to lower and serves to correct the attitude of the canopy. It is performed as long as the button is held depressed or until the end position has been reached After the attitude of the canopy has been corrected the props will have to be set again.

7

Extend seal cylinders This function is designed to correct the attitude of a shield with respect to its adjacent shield. The seal cylinders are extended as

5.34

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

4

E

Before initiating this function, ensure that the shield has been completely set to the roof.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

Operation of the shield hydraulics long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached. When not activated, the side seal is pressed outwards by the force of the pressure springs.

8

Retract seal cylinders This function is designed to correct the attitude of a shield with respect to its adjacent shield. The seal cylinders are retracted as long as the button is held depressed or until the end position has been reached. When not activated, the side seal is pressed outwards by the force of the pressure springs.

9

Extend flipper cylinder The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

10

Retract flipper cylinder The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

11

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

E DBT GmbH, Lünen 2005

Extend flipper extension cylinder

12

Retract flipper extension cylinder The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

13

Extend side flipper cylinders Not applicable to shield variants 01, 02, 04 and 05.

The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

14

Retract side flipper cylinders Not applicable to shield variants 01, 02, 04 and 05.

The function is performed as long as the button is held depressed or until the end position has been reached.

15 / 13

Extend base lift cylinder The function is performed as long as the button is held depressed, until equilibrium of forces has been obtained or until the end position has been reached.

16 / 14

Actively lower both props Before this function is initiated, ensure that the adjacent shields have been set completely.

This function is performed as long as the button is held depressed or until the end position has been reached.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.35

Maintenance Maintenance WARNING! When the operating safety is at risk any damaged components must be replaced without delay. If this is not possible, stop the shield operation at once and secure the shield. Immediately inform the complete face crew and your superior. electronic control

See separate original operating instructions for the PM4 control unit.

hydraulic control

Special measures

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 getting clogged. This 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.

5.36

piston rods

All shields equipped with a water spraying system require the piston rods of those cylinders which are usually only rarely extended or retracted completely, for example, props and and stabilizing cylinders, to be thoroughly cleaned approximately every 6 months. A suitable preservative should be applied afterwards.

filter cartridges

The filter cartridges of the manifold block and the control valve block of the shield control unit are designed to protect the downstream hydraulic components against damage due to dirt in the hydraulic medium. They have to be replaced regularly only if the filtration in the face supply line is insufficient.

Therefore, it is vital that you see to quality in the treatment of the hydraulic medium.

If problems occur in the preparation of the medium there will be an increased risk of failures due to clogged filters. To maintain operational reliability of the installation, additional measures may then be required. For example, the filters mentioned above should be regularly inspected for contaminations on a random basis. It may be necessary to replace the filter cartridges regularly as a precaution.

pressure relief valve

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

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

E

One week after start-up, at the latest, the filter cartridges of the electrohydraulic control valve blocks of the shield control units on the complete longwall must be checked for dirt on a random basis.

If this inspection reveals that there is a high probability of failures due to dirty filters all filter cartridges on the face must be replaced.

DBT GmbH, Lünen 2005

One week after start-up

Maintenance Pressure-relief valves with nitrogen filling must be inspected at regular intervals to check that they function correctly. We recommend to perform sample tests once every three months. hydraulic high-pressure hoses

dual back flush filter

For reasons of safety and to maintain the installation operative all hydraulic high-pressure hoses must be replaced regularly at least after two years of operation, irrespective of whether they show any signs of damage. If this deadline cannot be met because the end of the section planned to be mined will only be reached shortly after the deadline, the hoses can by way of exception be replaced after the respective section has been completed.

Since the operating time between backflushing depends on the contamination of the emulsion (HFA fluid) the frequency of backflushing cannot be predetermined. In general, however, each filter should be backflushed once every shift.

Daily inspection hydraulics

. Check all shield units by visual inspection for hydraulic fluid escaping on the: – hose lines, – control valve blocks, – valves

DBT GmbH, Lünen 2005

E

– props, – shifting ram and lift cylinder – stabilizing cylinder, steering and flipper cylinders.

. Check pressure gauges at the props for any visible signs of damage and correct functioning. steel structure

. Check all shield units by visual inspection for damage to the steel structure, for instance: – on the shifting unit, – bolt connections and retainers – on the side seals, – on holders, etc.

Weekly maintenance control unit

. Check the control unit for correct function. . Replace defective control units or individual components immediately.

. Clean the control units, especially the control panel.

NOTICE! It is important that the control symbols are legible to avoid the risk of operating errors and resultant accidents.

To be done every six months

. Apply a preservative to the piston rods of the hydraulic cylinders. Details are given in this chapter under the heading ”Special measures”.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.37

Maintenance Assessment of damage according to schedule

DBT GmbH, Lünen 2005

E

We recommend to keep records of the damages found. These records should be evaluated regularly, say once a month, and summarized in a damage report. Frequently recurring failures can thus be detected early and the source of the failure eliminated. This will improve the availability of the installation and help to reduce operating cost.

5.38

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Trouble shooting Trouble shooting Fault finding on shield hydraulic system The hydraulic circuits of the shields contain a number of modules and components, identified in the schematic drawings. See ”Operating the shield hydraulics” in this chapter or the spare parts catalog.

Faults can occur on any of the components. The main cause on hydraulic valves is a by-pass which in most cases is audible to the operator.

The following information will assist you in the detection and elimination of faults.

WARNING! Trouble shooting on hydraulic systems entails an increased accident hazard. Particularly by malfunctions of the hydraulic system and hydraulic medium escaping at high pressure severe injuries could be caused.

Therefore you are required to be very cautious and wear the specified protective equipment. Failure to comply with these instructions could cause severe injuries.

DBT GmbH, Lünen 2005

E

Fault localization failure to lower the shield

Doc. No.: 7420 152 000 BA 00

possible cause

check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shut-off valve in feed line to prop piston chamber is closed.

Open shut-off valve.

Lines to piston chamber and annulus of prop must be open.

Canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

Pilot piston in the prop check valve is not operating.

Check if there is enough pressure to operate the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit. Replace hoses if required. Make sure hoses are laid properly.

Props are damaged.

Check prop for damage or leakage (if damaged, replace prop).

VIVR / 01

5.39

Trouble shooting failure to set the shield

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shut-off valve in feed line to prop piston chamber is closed.

Open shut-off valve.

Lines to piston chamber and annulus of prop must be open.

Canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot piston in the prop check valve Check if there is enough pressure to operate is not operating. the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

Check for damaged or kinked hoses in prop circuit. Replace hoses if required. Make sure hoses are laid properly.

Props are damaged.

Check prop for damage or leakage (if damaged, replace prop).

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shield is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free shield.

failure to advance the shield

Step on roof or floor preventing ad- Lower canopy sufficiently to clear the step or vance. put baselift function to ”ON”.

5.40

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot piston in the pilot-operated check valve is not operating.

Check if there is enough pressure to operate the piston (minimum approx. 80 bar).

Prop check valve may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in shifting ram circuit. Replace hoses if required.

Make sure hoses are laid properly.

Shifting ram is defective.

Check - shifting ram for damage - that POCV works correctly.

Disconnect hose on piston side and operate function ”advance panline”. If pressure fluid escapes replace shifting ram.

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

Damaged or trapped hoses.

Trouble shooting failure to maintain the prop pressure after setting the support

Check / measure required

Faulty prop check valve.

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

Props are damaged.

Check props for damage (if damaged, replace prop).

Disconnect hose from prop lower port and check if pressure fluid escapes without large prop movement. If so: piston packing defective. Replace prop

Faulty pressure relief valve.

Check pressure gauge reading. Is pressure relief valve weeping?

If so, replace pressure relief valve and check functions.

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shield canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot-operated check valve is not operating.

Check if there is enough pressure to operate the valve (minimum 80 bar).

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop circuit.

Stabilizing cylinder is damaged.

Check cylinder for damage (if damaged, replace cylinder).

Possible cause

Check / measure required

The shut-off valve for pressure supply at the supply block of the shield is closed.

Open shut-off valve.

Feed line must be open to allow pressure to the shield hydraulics.

Shield canopy is trapped by adjacent shields.

Find cause. If necessary, lower or align adjacent shields to free canopy.

System pressure is too low for operation.

Check that - hydraulic system works correctly.

- all shut-off valves are open - system pressure is sufficient.

Pilot-operated check valve is not operating.

Check if there is enough pressure to operate the valve (minimum 80 bar).

POCV may be faulty.

Damaged or trapped hoses.

Check for damaged or kinked hoses in prop and/or stabilizing cylinder circuits.

Stabilizing cylinder is damaged.

Check cylinder for damage (if damaged, replace cylinder).

DBT GmbH, Lünen 2005

E

failure to operate the tip up function

Possible cause

failure to operate the tip down function

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.41

Trouble shooting 3/2-Way valve or pilot valve The valve sticks or a by-pass has formed due to internal leakages.

On the directional valves of the control valve block the latter mainly shows by a clearly audible hissing noise.

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

Defective pilot valves are difficult to recognize as there is no medium escaping at the valve bank. Therefore, there are no obvious signs of a defect, as e.g. fluid escaping.

The 3/2-way valve or the pilot valve may also be defective. valve sticks

. Try to eliminate the problem by operating the functions on the control unit or the control valve block several times.

internal leakage

. Try to locate the defective valve by operating the individual functions one after the other.

If the noise stops while a function is operated the respective valve is faulty.

You may be required to hold the push-button for the defective function for some seconds before the noise stops. manifold pipe.

. Operate the functions manually to depressurize the system. . Replace the 3/2-way valve or the pilot valve.

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

. Try to eliminate the problem by operating the functions on the control unit or the control valve block several times.

If the problem still exists, the valve may be faulty.

. Check valve and replace, if defective.

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

. Set the props until setting pressure has been reached. . Detach the ”set props” hose line at the POCV. If fluid escapes at the POCV port the valve is defective.

5.42

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

E

. Close the main shut-off valve in the pressure feed line at the DBT GmbH, Lünen 2005

valve replacement

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

. Pump props up to roof at set pressure. . Isolate the annulus side of the prop to be checked. To this end, detach the hose line at the prop annulus ports (located at the prop head and the prop cylinder) temporarily and admit pressure to the control port (extend prop) of the POCV.

. Operate the ”set prop” function.

If there is an internal by-pass in the prop, for example due to damaged piston packings, fluid will flow out of the prop lower port. If this happens, the prop must be replaced. If fluid escapes from the detached hoses the POCV is defective.

If no fluid flows from the annulus side hoses or the POCV, the POCV is defective, too.

Faulty pressure relief valve

DBT GmbH, Lünen 2005

E

A faulty pressure relief valve can usually be seen to be weeping or a check on the pressure gauge reveals it is not holding pressure. If pressure fluid still flows out at operating pressure, the pressure relief valve is defective or the discharging pressure setting of the valve used is too low.

Pressure relief or pressure relief valves of various types are used in the hydraulic circuit of a shield. pressure relief valves used on props, for example, have a high flow rate while the pressure relief valves used on shifting rams, stabilizing cylinders etc. are designed for a lesser flow rate.

The pressure relief valves for different cylinders or for the piston and ring sides of a cylinder may have different max. value settings.

Please observe the information given in the hydraulic flow plans or in the spare parts catalog.

Defective or blocked filter Operation of the shield is slow although pressure is known to be normal operating pressure. Contamination is assumed to have occurred in the hydraulic system, e.g. after repair work.

. Check the filters in the hydraulic system. Backflush filters may be cleaned by backflushing. On fine-mesh filters which are, for example, used on the control valve blocks, the filter elements must be replaced.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

5.43

DBT GmbH, Lünen 2005

E

Trouble shooting

5.44

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

6

Technical data

Shield description

Technical data This chapter contains important and useful information on the design and a technical description of the shield and its main components.

Shield description Type

2550/5500-2x4319-1750 und 2400/5000-2x4319-1750

The two-leg shield units basically comprise the following main components: J base with lemniscatic links, shifting unit and baselift cylinder J canopy with flipper J caving shield J side seal, moveable at R.H. side only J hydraulic props J hydraulic equipment with hose lines and controls

E

Six different versions of the same type of shield will be supplied: DBT GmbH, Lünen 2005

Tab. 9: Variants of the shield (1) Variant

Application

Order-no.

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

Weight approx. in kg

01

face shield

7420 152 000 00 01 6090 x 18501) x 5500 7020 x 1650 x 2550

27200

02

transition shield

7420 152 000 00 02 6590 x 18501) x 5500 8020 x 1650 x 2550

28400

03

face end shield, right with side flipper and sidewall

7420 152 000 00 03 7000 x 25503)4) x 5000 8225 x 22152) x 2400

30400

04

face end shield, right

7420 152 000 00 04 7000 x 18501) x 5000 8225 x 1650 x 2400

28800

05

face end shield, left

7420 152 000 00 05 7000 x 18501) x 5000 8225 x 1650 x 2400

28800

06

face end shield, left with side flipper and sidewall

7420 152 000 00 06 7000 x 27501)3) x 4500 8225 x 22152) x 2400

30400

Tab. 10: Variants of the shield (2) Variant

Application

Shield no.

Special features

01

face shield

5 to 175

shifting ram dia. 150 mm, short relay bar, short canopy (4230 mm),with flipper extension

02

transition shield

4 and 176 shifting ram dia. 150 mm, short relay bar, prolonged canopy (4730 mm), with flipper extension 1) side seal fully extended 2) side flipper fully retracted 3) side flipper fully extended 4) side seal fully retracted

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.3

Shield description

Variant

Application

Shield no.

Special features

03

face end shield, right with side flipper and sidewall

1

shifting ram dia. 200 mm, long relay bar, long canopy (5230 mm), sideflipper R.H., pusher L.H.

04

face end shield, right

2 and 3

shifting ram dia. 200 mm, long relay bar, long canopy (5230 mm), pusher L.H.

05

face end shield, left

177 and 178

shifting ram dia. 200 mm, long relay bar, long canopy (5230 mm), pusher R.H.

06

face end shield, left with side flipper and sidewall

179

shifting ram dia. 200 mm, long relay bar, long canopy (5230 mm), side flipper L.H., pusher R.H.

The shield is provided with a solid base which has the two interconnected skids separated by a tunnel. What differentiates the base variants from each other is that they are equipped with different shifting cylinders, relay bars of various lengths, and whether or not they are provided with a pusher cylinder. See table 10.

Programmed methods of calculation ensure the best possible support resistance and range of vertical adjustment of the shields.

Props used are telescopic props with equal load acceptance in all stages. They are always double-acting.

The lemniscatic linkage is a mechanism which causes the articulation between the canopy and the caving shield to move on a nearstraight line path over the whole vertical range of the shield, keeping the canopy tip to face distance near-constant.

Unlike the face shield and the transition shield, the end shield variants can be equipped with a side flipper. This can optionally be mounted at the R.H. or the L.H. side. Shield variants 03 and 06 have the side flipper included in the scope of supply and come equipped with L.H. or R.H. side flipper at the side seal of the canopy.

End shield variant 03 requires both side seals to be fixed.

The shield units are equipped with all hydraulic components needed to perform electrohydraulic adjacent control using the PM4 electronic control unit.

The control units for all shield variants are of the same design.

They mainly differ in the number of functions to be operated and the different hose lengths which are due to the differences in canopy lengths.

6.4

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

The canopy transmits the support load of the two hydraulic props into the roof. Connection to the caving shield is via pins and a stabilizing cylinder. All the canopies are equipped with a flipper. The canopy of the transition shield (variant 02) is 500 mm longer than the canopy of the face shield (variant 01). The canopies of the end shields (variants 03, 04, 05 and 06) are 1000 mm longer than those of the face shields (variant 01).

E

The caving shield is a solid steel structure and connected to the base via the lemniscatic links.

Shield description

Main subassemblies Fig. 45: Variants of the shield, dimensions L1 L3

L2

HA

H

HE

L5

DBT GmbH, Lünen 2005

E

L6

L4 L M

M B4

B

B3

M

B

M B

B3

B4

B

B3

B2 B1

B2 B1

B2 B1

B2 B1

variants 01 und 02

variant 03

variant 04 and 05

variant 06

Tab. 11: Variants of the shield, dimensions Var.

L

L1

L2

L3

L4

L5

L6

H

HA

HE

B

B1

B2

B3

B4

01

7020

4075

1165

2910

3520

1050

69

4800

5500

2550

1650

1610

360

200

-

02

8020

4575

1165

3410

3520

1050

69

4800

5500

2550

1650

1610

360

200

-

03

8225

5075

1165

3910

3625

1050

69

4200

5000

2400

1650

1610

360

-

900

04

8225

5075

1165

3910

3625

1050

69

4200

5000

2400

1650

1610

360

200

-

05

8225

5075

1165

3910

3625

1050

69

4200

5000

2400

1650

1610

360

200

-

06

8225

5075

1165

3910

3625

1050

69

4200

5000

2400

1650

1610

360

200

900

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.5

Shield description Fig. 46: Variants of the shield, main components (1) face shield and transition shield, variants 01 and 02 (with flipper extension) 11 or 12 51 31 21 or 23

41

1 end shield, variants 4 and 05 51

13

32

24 3

42

63 3 1 base of shield variant 01 3 base of shield variants 04 and 05 11 canopy, shield variant 01 12 canopy, shield variant 02 13 canopy, shield variants 04 and 05 21 side seal, shield variant 01

6.6

23 side seal, shield variant 02

42 prop shield variants 04 and 05

24 side seal, shield variants 04 and 05

51 stabilizing cylinder

31 caving shield shield variants 01 and 02 32 caving shield shield variants 04 and 05 41 prop shield variants 01 and 02

61 electrohydraulic shield control, shield variant 01 63 electrohydraulic shield control, shield variants 04 and 05 64 electrohydraulic shield control, shield variant 02

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

61 or 64

Shield description

Fig. 47: Variants of the shield, main components (2) end shield, variants 03 und 06 51

13

32

24

42

62

3

DBT GmbH, Lünen 2005

E

81

71

3 base of shield variants 03 and 06 13 canopy shield variants 03 and 06 24 side seal shield variants 03 and 06

Doc. No.: 7420 152 000 BA 00

32 caving shield shield variants 03 and 06 42 prop 51 stabilizing cylinder 62 electrohydraulic shield control shield variants 03, and 06

VIVR / 01

71 protective wall 81 side flipper

6.7

Shield description

Tab. 12: DBT-shield 7420 152 000 00 .. , variants, applicable components item

variants

description

order no.

01 02 03 04 05 06 0001 base

x

x

-

-

-

-

7420.132.300.00.01

weight approx approx. in kg

remarks

8560 shifting ram, dia. 150 8241.233.000.00.00 lift cylinder 8241.189.000.00.00 shifting unit 3422 long 7420.118.330.00.01 pusher cyl. not applicable

0003 base

-

-

x

x

x

x

7420.128.300.00.03

9200 shifting ram, dia.200

8241.234.000.00.00 lift cylinder 8241.189.000.00.00 shifting unit, 3527 long 7420.118 .340.00.01 pusher cyl.

8241.046.000.00.00

0011 canopy 4230 long

x

-

-

-

-

-

7420.152.400.00.01

6940 flipper, 1699 long

7420.152.420.00.00 7420.152.420.00.00 7420.131.420.00.00

-

x

-

-

-

-

7420.152.400.00.02

0013 canopy 5230 long

-

-

x

x

x

x

7420.152.400.00.03

8500 flipper, 1300 long

0021 side seal

x

-

-

-

-

-

7420.132.700.00.01

3020

0023 side seal

-

x

-

-

-

-

7420.132.700.00.03

3170

0024 side seal

-

-

x

x

x

x

7420.128.700.00.03

3030

0031 caving shield

x

x

-

-

-

-

7420.132.800.00.00

4160

0032 caving shield

-

-

x

x

x

x

7420.128.800.00.00

4430

0041 prop

x

x

-

-

-

-

8250.092.000.00.00

1860

0042 prop

-

-

x

x

x

x

8250.101.000.00.00

1716

0051 stabilizing cylinder

x

x

x

x

x

x

8241.212.000.00.00

225

0061 shield control system - 14 functions -

x

-

-

-

-

-

8112.215.000.00.00

175 el.-hydr. control unit

0062 - 16 functions -

-

-

x

-

-

x

8112.217.000.00.00

185 el.-hydr. control unit

0063 - 16 functions -

-

-

-

x

x

-

8112.218.000.00.00

185 el.-hydr. control unit

0064 - 14 functions -

-

x

-

-

-

-

8112.216.000.00.00

175 el.-hydr. control unit

71

protective wall

-

-

x

-

x

7421.001.860.00.00

656

81

side flipper

-

-

x

-

x

7420.078.450.00.00

772

8154.101.000.00.00 hose lines 8112.215.010.00.00 water spray system 8112.159.020.00.00 retainer & accessories 8112.215.030.00.00 8154.098.000.00.00 hose lines 8112.217.010.00.00 water spray system 8112.159.020.00.00 retainer & accessories 8112.217.030.00.00 8154.098.000.00.00 hose lines 8112.217.010.00.00 water spray system 8112.159.020.00.00 retainer & accessories 8112.217.030.00.00 8154.101.000.00.00 hose lines 8112.216.010.00.00 water spray system 8112.159.020.00.00 retainer & accessories 8112.215.030.00.00

1) anti-topple device optional applicable

6.8

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

1)

E

0012 canopy 4730 long

8000 flipper, 1699 long

Shield description

Base with lemniscatic links and central shifting unit

DBT GmbH, Lünen 2005

E

The solid base transmits the shield load of the hydraulic props into the floor. The props are supported in an articulated manner in ball sockets welded to the base and secured by bolted prop retainers.

The links of the lemniscate system are hinge-connected with the base by pins.

The type of base described is characterized by having the shifting unit and its guiding device arranged between the skids. The shifting unit is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reverse-mounted shifting unit, the force of the piston surface area is utilized to advance the shield and the smaller force of the ring surface area to advance the pan line. The connection to the conveyor is provided via a universal joint.

A baselift cylinder serves for raising the base out of a soft floor during shield advance.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.9

Shield description

DBT GmbH, Lünen 2005

E

Fig. 48: Base, shield variants 01 and 02

1 base lift cylinder ZE-125/90-240 2 shifting ram ZE-150/100-960 7 shifting unit 11 base 13 front lemniscatic link, R.H. 14 front lemniscatic link, L.H. 15 rear lemniscatic link, RH 16 rear lemniscatic link, LH 17 base lift cylinder bearing

6.10

18 prop retainer, R.H. 19 prop retainer, L.H. 20 travel path 30 retainer 31 pin 32 pin dia. 50x105 33 screw M 24x90 34 staple DN 10 35 staple DN 40

36 pin dia. 139.3x525 40 locking plate 41 pin dia. 29x57 50 hex. head screw M 24x100-8.8 51 hex. nut M 24-8 55 washer 60 retaining clip 61 retaining clip refer to the spare parts catalog too

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

DBT GmbH, Lünen 2005

E

Fig. 49: Base, shield variants 03 to 06

1 base lift cylinder ZE-125/90-240 3 shifting ram ZE-200/140-960 4 pusher cylinder ZE-135/120-300 8 shifting unit 12 base 13 front lemniscatic link, R.H. 14 front lemniscatic link, L.H. 15 rear lemniscatic link, RH 16 rear lemniscatic link, LH 17 base lift cylinder bearing 18 prop retainer, R.H. 19 prop retainer, L.H. 21 travel path

Doc. No.: 7420 152 000 BA 00

22 cap 23 cap 30 retainer 31 pin 32 pin dia. 50x105 33 screw M24x90 34 staple DN 10 35 staple DN 40 36 pin dia. 70x292 37 washer 38 staple DN 20 39 filler

VIVR / 01

41 pin dia. 29x57 45 lemniscatic pin 139.3x572 46 pin 47 pin 48 locking device 50 hex. head bolt M 24x100-8.8 51 hex. nut M 24-8 52 hex. head bolt M30x45-10.9 53 spring clip dia. 5 55 washer 61 retaining clip refer to the spare parts catalog too

6.11

Shield description

Shifting unit Fig. 50: Shifting unit

H1

1

L1

2

1 relay bar 2 clevis assembly for conveyor others: fastening elements, see spare parts catalog

shifting g unit, order no.

L1

H1

01 and 02

7420 118 330 00 01

3422

230

03 to 06

7420 118 340 00 01

3527

250

dimensions

The variants of the shield are equipped with different types of shifting units. See table 13 above.

The conveyor shifting unit is arranged in the middle of the base frame. It consists mainly of the relay bar, the shifting ram, the baselift cylinder and the necessary fastening elements. It serves to advance conveyor and shield.

The shifting ram is reverse-mounted with the force of the cylinder being transmitted to the conveyor via the relay bar. With a reversemounted shifting ram, the force of the piston surface area is utilized to advance the shield and the smaller force of the ring surface area to advance the pan line.

The base lifting device serves for raising the base out of a soft floor during shield advance.

The baselift cylinder is attached in the center of the base. The component of force produced by the lifting cylinder is transmitted into the floor via the relay bar of the shifting unit.

6.12

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

shield variant

E

Tab. 13: Shifting units, differences

Shield description

Functional description 1. Initial position of shield The shifting ram of the support unit is retracted.

2. Advancing the shield During shield advance the lifting cylinder presses down on the relay bar of the shifting unit causing the base skid to lift.

WARNING! Risk of getting squeezed between moving parts of the shifting unit and the shield.

Keep away from advancing shield units or such which are going to be advanced.

3. Setting the shield After shield advance the props are to be set. The lifting cylinder yields during the process of setting.

DBT GmbH, Lünen 2005

E

4. Advancing the pan line The shifting ram is switched to ”retract”.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.13

Shield description

Shield canopy The canopy of a shield has the hydraulic props connected in an articulated manner. It transmits the support load of the props into the roof. The canopy is connected with the caving shield by a locking hinge. Stability for the articulation is provided by a stabilizing cylinder.

CAUTION! To prevent overloading of the stabilizing cylinder when the canopy is set in a cavity, care must be taken to ensure that the max. angle of inclination of the canopy (angle main canopy caving shield) will not be exceeded.

The canopies of all shield variants are equipped with an adjustable side seal at the R.H. side and a flipper.

Tab. 14: Canopy, differences shield

canopy, py

variant

order-no.

01

7420 152 400 00 01 total length : 4230 mm 1)

02

7420 152 400 00 02 total length : 4730 mm 1)

03 to 06

total length : 5230 mm 1) 7420 152 400 00 03 slot holes to attach - anti-topple device “canopy - canopy” DBT GmbH, Lünen 2005

E

features

Fig. 51: Canopy of face shield, variant 01

1 canopy, subassembly 4 flipper 5 prop head retainer 6 pin dia. 24.3x156

7 retaining clip 8 pin dia. 53x155 9 staple DN 40 10 pin dia. 138.5x540

11 retainer 12 pin 13 retaining clip

1) with the flipper folded back to the canopy

6.14

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

DBT GmbH, Lünen 2005

E

Fig. 52: Canopy of transition shield, variant 02

2 canopy, subassembly 4 flipper 5 prop head retainer 6 pin dia. 24:3x136

7 retaining clip 8 pin dia. 53x155 9 staple DN 40 10 pin dia. 138.5x540

11 retainer 12 pin 13 retaining clip

Fig. 53: Canopy of end shield, variant 03 to 06

3 canopy, subassembly 4 flipper 5 prop head retainer 6 pin dia. 24.3x136

Doc. No.: 7420 152 000 BA 00

7 retaining clip 8 pin dia. 53x155 9 staple DN 40 10 pin dia. 138.5x540

VIVR / 01

11 retainer 12 pin 13 retaining clip

6.15

Shield description

Fig. 54: Befestigung des Stempelkopfes A-A

5 9

6, 7

8

5 prop head retainer 6 pin dia. 24.3x156 7 retaining clip 5x32

8 pin dia. 53x155 9 staple DN 40

DBT GmbH, Lünen 2005

E

Fig. 55: Flipper of shield variants 01 and 02

1 hydraulic cylinder ZE-165/100-500 2 hydraulic cylinder ZE-80/63-215

12 support element 13 pin dia. 58.5x 300

6 extension 7 flipper, subassembly

14 pin dia. 58.5x240 15 pin dia. 58.5x170

9 fork link 11 link

16 pin dia. 38.5x115 17 pin dia. 28.5x152

6.16

23 pin dia. 43.5x141 24 fork 25 locking device 26 bolt dia. 34.5x150 others: fastening elements please, refer also to the spare parts catalog

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

DBT GmbH, Lünen 2005

E

Fig. 56: Flipper of shield variants 03 to 06

1 hydraulic cylinder ZE- 165/100-500-KO-BN 7 flipper, subassembly 9 fork link 11 link

Doc. No.: 7420 152 000 BA 00

13 pin Ø58.5x300 14 pin Ø58.5x240 15 pin Ø58.5x170 23 pin Ø43.5x141 24 fork

VIVR / 01

25 locking device 26 pin Ø34.5x150 others: fastening elements please, refer also to the spare parts catalog

6.17

Shield description

Fig. 57: Side flipper, applicable only to shield variants 03 and 06

DBT GmbH, Lünen 2005

E

1 hydraulic cylinder 2 side flipper, subassembly 3 bracket others: fastening and securing elements please, refer also to the spare parts catalog Fig. 58: Protective wall, R.H. design

x

1 protective wall 2 holder 3 collared pin 4 locking clip x position of items 2, 3 and 4 for L.H. design please, refer also to the spare parts catalog

6.18

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

Caving shield The caving shield shields the face area towards the gob. It is connected to the canopy by a hinge link and to the base by the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the main canopy to provide stability for the articulation.

DBT GmbH, Lünen 2005

E

Provision is made on the caving shield for the attachment of the cylinders and guide pins of the side seal.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.19

Shield description

DBT GmbH, Lünen 2005

E

Fig. 59: Caving shield, shield variants 01 and 02

S2

S2

S1 1 caving shield, subassembly 2 lemniscatic pin dia. 139.3x525 3 pin dia. 53x155 4 locking plate 5 pin dia. 12x120/115 6 staple DN 40 7 retaining clip S1 lifting eye, load-carrying capacity: 3000 kg S2 lifting eye, load-carrying capacity: 8000 kg

6.20

S1

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

DBT GmbH, Lünen 2005

E

Fig. 60: Caving shield, shield variants 03 to 06 Z-Nr.: 7420 128 800 00 001

S2

S2

S1 1 caving shield, subassembly 2 lemniscatic pin dia. 139.3x525 3 pin dia. 53x155 4 locking plate 5 pin dia. 12x120/115 6 staple DN 40 7 retaining clip S1 lifting eye, load-carrying capacity: 3000 kg S2 lifting eye, load-carrying capacity: 8000 kg

Doc. No.: 7420 152 000 BA 00

VIVR / 01

S1

6.21

Shield description

Side seal Fig. 61: Side seal of the face shield variants 01 and 02

DBT GmbH, Lünen 2005

E

L

1 hydraulic cylinder ZE-119-63/50-215 2 side seal, canopy R.H. 3 side seal, canopy L.H. 4 side seal, caving shield R.H. 5 side seal, caving shield L.H. 8 guide pin dia. 90 9 pin dia. 34x329 10 guide pin 11 guide pin 12 cover 13 guide pin 14 compression spring

15 guide pin 16 compression spring 17 torque support 18 bush 20 pin dia. 34x64 21 pin dia. 22x196 22 pin dia. 28x74 23 pin dia. 24x59 24 transport safety device 25 pin 26 pin dia. 28x93 27 torque support

28 locking device 29 pin 30 pin dia. 12x165 37 clip pin 38 staple DN 12 39 staple DN 25 42 washer 43 locking clip 45 pin dia. 22x135 others fastening and securing elements please, refer also to the spare parts catalog

NOTICE! Remove transport securing devices, items 24, 38 and 45, 37 at moveable side before putting the shield into operation.

All sliding surfaces and joints coated with lubricating paste B6 to EWN 7068

6.22

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

Tab. 15: Side seal of the face shield variants 01 and 02 description

variants order no.

01 02 0

length g L in mm

weight approx. in kg

side seal

x

-

7420.132.700.00.01

2680

3020

side seal

-

x

7420.132.700.00.03

3180

3170

DBT GmbH, Lünen 2005

E

Fig. 62: Side seal of the face shield variants 03 to 06

1 hydraulic cylinder ZE-119-63/50-215 2 side seal, canopy R.H. 3 side seal, canopy L.H. 4 side seal, caving shield R.H. 5 side seal, caving shield L.H. 8 guide pin dia. 90 9 pin dia. 34x329 10 guide pin 11 guide pin 12 cover 13 guide pin 14 compression spring

Doc. No.: 7420 152 000 BA 00

15 guide pin 16 compression spring 17 torque support 18 bush 20 pin dia. 34x64 21 pin dia. 22x196 22 pin dia. 28x74 23 pin dia. 24x59 24 transport safety device 25 pin 26 pin dia. 28x93 27 torque support 28 locking device

VIVR / 01

29 pin 30 pin dia. 12x165 37 clip pin 38 staple DN 12 39 staple DN 25 42 washer 43 locking clip 45 pin dia. 22x135 weight 3030 kg others fastening and securing elements please, refer also to the spare parts catalog

6.23

Shield description

DBT GmbH, Lünen 2005

E

NOTICE! Remove transport securing devices, items 24, 38 and 45, 37 at moveable side before putting the shield into operation.

All sliding surfaces and joints coated with lubricating paste B6 to EWN 7068

6.24

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Shield description

Technical data of the shield, steel structure

DBT GmbH, Lünen 2005

E

face shield, variant 01 permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . deg

15

closed height . . . . . . . . . . . . . . . . . . . . . . . mm

2550

extended height . . . . . . . . . . . . . . . . . . . . mm

5500

height adjustment of shield . . . . . . . . . . . mm

2950

advance stroke . . . . . . . . . . . . . . . . . . . . . mm shifting ram stroke . . . . . . . . . . . . . . . . . . mm

865 960

distance of prop centers (inclination) . . . mm

900

forepole of canopy . . . . . . . . . . . . . . . . . . mm

2910

rear projection of canopy . . . . . . . . . . . . . mm

1165

width of canopy incl. side seals . . . . . . . mm

1650

length of canopy . . . . . . . . . . . . . . . . . . . . mm

4075

inclination of caving shield, shield closed . . . . . . . . . . . . . . . . . . . . . . . deg. shield extended . . . . . . . . . . . . . . . . . . . . . deg.

14.1 58.3

width of caving shield, incl. side seals . . mm

1650

width of base . . . . . . . . . . . . . . . . . . . . . . . mm

1610

total area of base . . . . . . . . . . . . . . . . . . . cm2

33776

shield center distance . . . . . . . . . . . . . . . mm

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4000 5819 8534

specific support resistance per square meter of roof area at an average seam height of . . . . . . . . . . . . . . mm 4800 a) at 315 bar setting pressure . . . . . . . . kN/m2 718 b) at 462 bar yield pressure (distance canopy tip to face low / high) . kN/m2 887 /1053

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.25

Shield description

6.26

15

closed height . . . . . . . . . . . . . . . . . . . . . . . mm

2550

extended height . . . . . . . . . . . . . . . . . . . . mm

5500

height adjustment of shield . . . . . . . . . . . mm

2950

advance stroke . . . . . . . . . . . . . . . . . . . . . mm shifting ram stroke . . . . . . . . . . . . . . . . . . mm

865 960

distance of prop centers (inclination) . . . mm

900

forepole of canopy . . . . . . . . . . . . . . . . . . mm

3410

rear projection of canopy . . . . . . . . . . . . . mm

1165

width of canopy incl. side seals . . . . . . . mm

1650

length of canopy . . . . . . . . . . . . . . . . . . . . mm

4575

inclination of caving shield, shield closed . . . . . . . . . . . . . . . . . . . . . . . deg. shield extended . . . . . . . . . . . . . . . . . . . . . deg.

14.1 58.3

width of caving shield, incl. side seals . . mm

1650

width of base . . . . . . . . . . . . . . . . . . . . . . . mm

1610

total area of base . . . . . . . . . . . . . . . . . . . cm2

33776

shield center distance . . . . . . . . . . . . . . . mm

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4800 5819 8534

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . deg

E

transition shield, variant 02

Shield description

DBT GmbH, Lünen 2005

E

end shield, variants 03 to 06

Doc. No.: 7420 152 000 BA 00

permissible inclination, omnidirectional up to . . . . . . . . . . . . . . . . deg

15

closed height . . . . . . . . . . . . . . . . . . . . . . . mm

2400

extended height . . . . . . . . . . . . . . . . . . . . mm

5000

hydraulic height adjustment of shield . . mm

2600

advance stroke . . . . . . . . . . . . . . . . . . . . . mm shifting ram stroke . . . . . . . . . . . . . . . . . . mm

865 960

distance of prop centers (inclination) . . . mm

900

forepole of canopy . . . . . . . . . . . . . . . . . . mm

3910

rear projection of canopy . . . . . . . . . . . . . mm

1165

width of canopy incl. side seals . . . . . . . mm

1650

length of canopy . . . . . . . . . . . . . . . . . . . . mm

5075

inclination of caving shield, shield closed . . . . . . . . . . . . . . . . . . . . . . . deg. shield extended . . . . . . . . . . . . . . . . . . . . . deg.

14.0 56.8

width of caving shield, incl. side seals . . mm

1650

width of base . . . . . . . . . . . . . . . . . . . . . . . mm

1610

total area of base . . . . . . . . . . . . . . . . . . . cm2

33776

shield center distance . . . . . . . . . . . . . . . mm

1750

support resistance at average seam height of . . . . . . . . . . . . . mm a) at 315 bar setting pressure . . . . . . . . . kN b) at 462 bar yield pressure . . . . . . . . . . kN

4200 5847 8575

VIVR / 01

6.27

Hydraulic system Hydraulic system The following section gives an overview of the hydraulic system installed on the shield units. For additional information please refer to the spare parts catalog. variants, differences

The design of the electrohydraulic control units for the different shield variants is largely identical. It mainly differs in the number of functions to be operated. The control units for the end shield variants 03 and 06 allow the operation of sixteen (16) functions while the control units for shield variants 01 and 02 are designed for only fourteen (14) functions. The subassemblies ”lines” and ”retainers” are also different because of the differences in length of the canopies as well as the different number of functions and equipment with devices. The subassembly ”spraying system” is the same for all shield variants. Table 16 provides a survey of the differences of the different variants of the shield control unit.

Tab. 16: Electrohydraulic(EH) shield control system, differences and use applicable to shield control no.

8112.xxx.000.00.00

shield variant 7420 152 000 00 xx

215

216

217

218

EH-control unit, 14 functions

8154 101 000 00 00

x

x

-

-

01 and 02

EH-control unit, 16 functions

8154 098 000 00 00

-

-

x

-

03 and 06

EH-control unit, 16 functions

8154 098 000 00 00

-

-

-

x

04 and 05

hose lines

8112 215 010 00 00

x

-

-

-

01

8112 216 010 00 00

-

x

-

-

02

8112 217 010 00 00

-

-

x

x

03 to 06

water spray system

8112 159 020 00 00

x

x

x

x

all

retainers and accessories

8112 215 030 00 00

x

x

-

-

01 and 02

8112 217 030 00 00

-

-

x

x

03 to 06

normal and exceptional operation

During normal operation the functions of the shield units are to be operated by use of the PM4 control unit only.

The individual pilot valves of the control valve block are equipped with facilities for manual operation. The functions of the directional control valves are shown on the symbol plate.

WARNING! During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

6.28

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

E

order no.

DBT GmbH, Lünen 2005

subassemblies description

Hydraulic system Shield hydraulics The following table applies to all support variants.

Tab. 17: Hydraulic components Qty. 1 2 1 2 2 1 - / 1 1) 3

Description electrohydraulic control unit prop check valve shifting ram check valve pressure relief valve, 462 bar pressure relief valve, 470 bar check valve check valve twin check valve

12 13 14 15 16 17 18

1 1 1 1 1 1 6 / 71)

pressure gauger hose lines water spray system retainers and accessories manifold pipe accumulator cartridge pressure relief valve

DBT GmbH, Lünen 2005

E

Item 1 2 3 5 6 7 8 11

19 20 21

1 1 4

water spray valve dual filter, back flush type high-pressure ball valve

22 23 24 25 26

2 1 1 2 - / 11)

27 28

2 1

high-pressure ball valve high-pressure ball valve in-line-filter screwed socket high-pressure ball valve, X type manifold connection plate

32

- / 11)

33

- / 11)

S1 Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9

1 2 1 1 4 1 1 2 2 1

hose lines and fittings for pusher cylinder hose lines and fittings for side flipper pressure sensor prop shifting ram stabilizing cylinder seal cylinder lift cylinder flipper cylinder extension flipper cylinder side flipper cylinder pusher cylinder

Location front lemniscatic link prop, gobside L.H. front lemniscatic link prop, gobside stabilizing cylinder manifold pipe gobside side flipper cylinder a) mounted to flipper cylinder b) mounted to stabilizing cylinder c) flanged to connection plate item 28 for flipper extension cylinder prop check valve, left

front lemniscatic link electrohydraulic control unit a) 2 x at twin check valve (11a) b) 1 x at shifting ram check valve c) 1 x under canopy, R.H. d) 1 x at side flipper cylinder e) 2 x flipper extension cylinder front lemniscatic link, inside front lemniscatic link a) under canopy b) R.H. front lemniscatic link c) manifold pipe d) manifold pipe prop check valve manifold pipe manifold pipe prop head underneath the PM4-control unit under the canopy under twin check valve under canopy

Remark at holder

high flow rate type return line side flipper

subassembly subassembly subassembly at holder a) -flipper cylinder b) -shifting ram c) seal cylinder pisten rod circuit d) e) -twin check valve manual operated, at holder a) at manifold (27) b) at water spray valve (19) c) to spring valve d) water hose prop, piston side pressure supply water supply at holder in seal cylinder circuit for flpper extension cylinder subassembly subassembly

at prop check valve, only R.H.

only shield variants 01 und 02

1) deviating quantity for end shield variants with pusher cylinder and / or side flipper

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.29

Hydraulic system Shield hydraulics Fig. 63: Shield hydraulics, arrangement (1), key, see table 17

20 3 18b

2 12

Note: The components marked in “blue” are optionally applicable at the end shield variants 03 and 06.

6.30

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

22

Hydraulic system Fig. 64: Shield hydraulics, arrangement (2) key, see table 17 18e 11c

14

18a 11a

28

B

27 21a

13

16 7 23 18c

18a 18d

8 33 B

B-B 25

DBT GmbH, Lünen 2005

E

19 21b

25

6 11b

15 21c, 21d 24 17

26 32 5 1 Note: The components marked in “blue” are optionally applicable to the end shield variants 03 and 06.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.31

Hydraulic system

DBT GmbH, Lünen 2005

E

Fig. 65: Functions of Electrohydraulic control unit, symbol plates for schildvariants 01 and 02

14 Functions

Tab. 18: Electrohydraulic control units with 14 functions, allocation of functions function, description

6.32

function no.

advance shield

1

set both props

2

advance conveyor

3

activate “water curtain”

4

stabilizing cylinder, extend

5

stabilizing cylinder, retract

6

seal cylinder, extend

7

seal cylinder, retract

8

flipper cylinder, extend

9

flipper cylinder, retract

10

flipper extension cylinder, extend

11

flipper extension cylinder, retract

12

lift cylinder, extend

13

lower both props actively

14

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Hydraulic system

DBT GmbH, Lünen 2005

E

Fig. 66: Functions of electrohydraulic control unit, symbol plates for schildvariants 03 to 06

16 functions

Tab. 19: Electrohydraulic control units with 16 functions, allocation of functions function, description

04 and 05

03 and 06

advance shield

1

1

set both props

2

2

advance conveyor

3

3

activate “water curtain”

4

4

stabilizing cylinder, extend

5

5

stabilizing cylinder, retract

6

6

seal cylinder, extend

7

7

seal cylinder, retract

8

8

flipper cylinder, extend

9

9

flipper cylinder, retract

10

10

-

-

-

-

-

13

side flipper cylinder, retract

-

14

lift cylinder, extend

15

15

lower both props actively

16

16

side flipper cylinder, extend

Doc. No.: 7420 152 000 BA 00

function no. shield variant

VIVR / 01

6.33

Hydraulic system Fig. 67: Shield hydraulics, shield variants 01 and 02 key, see table 17

17 16 DN 50 R DN 40-SS P DN 25

W

1 7 23

21d 21c 20

24

21a 27

19 6

Z4

Z4

14

Z3

Z4

11b

6

13

Z2

18c

DBT GmbH, Lünen 2005

E

21b

3

Z4 18b 5

5

Z5 22

22

12 S1 Z1

Z1 2 2 25

28

25

11a

18e

18e 18a Z6

11c

18a Z7

6.34

Z7

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Hydraulic system Fig. 68: Shield hydraulics, shield variants 03 to 06 key, see table 17

17 16 DN 50 R DN 40-SS P DN 25

W

1

7 23

21d 21c 20 24

21a

E

27

6

DBT GmbH, Lünen 2005

Z4

32 26 Z9

Z4

Z3

19

8 Z8

21b

18d Z4

11b 6

33 Z2

18c

3

13

Z4 18b

14

Z8 5

Z5

5

22

22

12 S1 Z1

Z1 2 2

18a

25

25

11c

18a Note: The components marked in “blue” are optionally applicable at the end shield variants 03 to 06.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.35

Hydraulic system Double-telescopic prop The prop described is a double-telescopic prop with equal loadbearing capacity at both stages. Equal load-bearing capacity of the two stages is ensured by a pilot-operated check valve which is installed in the piston pipe.

Bottom and top end of the prop are designed as a globe joint. This allows to join the prop to the base and the canopy with angular articulation. The cams at the bottom end of the prop will be fixed at the base using bolted arresting devices.

The prop head is fastened to the canopy using special securing elements.

The technical data of the hydraulic prop are to be found in section “Technical data, hydraulic cylinders”.

Fig. 69: Double telescopic prop, type SD-4300-345-1985/4875-CR und SD-4300-345-1820/4375-CR

b2 b1

E

21 DBT GmbH, Lünen 2005

e 2

a

d

1 c 1 prop bottom end 2 piston pipe 21 piston rod a valve connection plate b1 piston pipe annulus port

b2 piston rod annulus port c cam d pressure relief valve port e load ring 3000 kg

Tab. 20: Telescopic prop of shield variants length in mm

6.36

stroke in mm

order no. telescopic prop

shieldvariants

retracted

extended

upper stage

lower stage

8250 092 000 000 00 00

01 und 02

1985

4875

1450

1440

8250 101 000 000 00 00

03 bis 06

1820

4375

1250

1305

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Hydraulic system WARNING! Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic hose lines caused by dangerous overpressure.

Never close the lowering ports of double-acting props pressure-tight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

Function prop setting

Pressure fluid is admitted under the piston of the center prop through the piston chamber connection. The center prop will extend first and the pressure fluid displaced from the annulus is passed into the return line. If the piston of the center prop contacts the threaded bush before the canopy comes to rest against the roof, the inner prop will extend. Pressure fluid is admitted through the check valve.

Loading props a) Center prop extended only

DBT GmbH, Lünen 2005

E

Load is transmitted mechanically from the canopy to the inner prop via the prop head and, then, to the valve housing installed in the inner prop. The further transmission of load is hydraulically via the pressure fluid under the center prop into the foot of the prop and from there mechanically into the base.

The hydraulic pressure under the center prop cannot exceed the pre-determined value as a pressure relief valve is installed in the respective control valve. When the preset pressure is exceeded, the pressure relief valve will open and permit fluid to escape and the prop yields with the rated prop resistance. b) Center prop and inner prop extended Load is transmitted mechanically from the canopy to the inner prop via the prop head. The inner prop bears on the pressure fluid under its piston. This fluid is trapped by the check valve. The further course of load transmission is as described under a). prop lowering

The pressure fluid under the center prop is connected to the return by means of the prop control valve.

Both stages of the prop can be power lowered. The inner prop will start to close when the center prop is closed completely and the check valve is opened by the tappet.

Just a few millimeters before the piston pipe ”touches down” the check valve is opened by the tappet with the pressure fluid under the piston pipe acting as a spring lifting the piston pipe to close the valve again. When the prop is lowered over the complete stroke this procedure is repeated several times.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.37

Hydraulic cylinder

Hydraulic cylinder Design design

The following figure shows the main components of a hydraulic cylinder. The cylinders differ mainly by the arrangement of the connections. They can be roughly divided into two groups: Type a) arrangement of connections at the outer cylinder Type b) arrangement of connections at the piston rod Fig. 70:

Hydraulic cylinder, typical example

Typ a)

2

1

3

5

4

2

1 outer cylinder 2 cylinder bottom 3 piston rod

3

1

4

6

4 guide bush 5 connection 6 connection

NOTICE! The technical data of the cylinders are given in the section “Technical data, hydraulic cylinder” of the shield used.

WARNING! Risk of serious bodily injuries due to pressure fluid suddenly escaping at high pressure and bursting hydraulic hose lines caused by dangerous overpressure.

Never close the lowering ports of double-acting props pressure-tight! If you do, a pressure might build up in the annulus when extending the prop which is a multiple of the setting pressure.

The end of the piston rod can either be attached directly or it is designed in such a way that the means of attachment - e.g. rod head or fork head - can be screwed on and secured against working loose by clamping screws or a spring dowel sleeve.

The pressure fluid is either fed through the connections at the outer cylinder (type a) or through the connections at the piston rod (type b).

If a double-acting cylinder is to be used as single-acting cylinder only, the annulus connection must be provided with a screw with filter element to avoid contamination by dirt. If the cylinder is used without the seals which seal off the annulus, the grooves for the seals have to be filled with lubricating grease.

6.38

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

Typ b)

Hydraulic cylinder

Stabilizing cylinder Fig. 71: Hydraulic cylinder, type ZE-200/140-520-EC-CR

a

b

11

d

55

55 L

c

1

c pressure relief valve port, piston chamber d load ring 1000 kg L retracted 935 - extended 1455

1 cylinder tube a valve connection plate b pressure relief valve port, annulus

Baselift cylinder Fig. 72: Hydraulic cylinder ZE-125/90-240-LI-CR 3 a b 295

DBT GmbH, Lünen 2005

E

11 piston rod

1

L

2

1 cylinder tube 2 wearing bottom 3 piston rod

Doc. No.: 7420 152 000 BA 00

VIVR / 01

a piston chamber port b annulus port L retracted 518 - extended 758

6.39

Hydraulic cylinder

Shifting ram Fig. 73: Hydraulic cylinder type ZE-150/100-960-SC-W-CR, in use with face shield (variant 01) and transition shield (variant 02) only 21

d 62

70 L b c

1

2 24 a

Fig. 74: Hydraulic cylinder type ZE-200/140-960-SC-W-CR in use with the end shield variants 03 to 06 only 3

62

70 L d

b 1

2 6

1 cylinder tube 2 reed contact rod 3 piston rod 6 screw rod a annulus port

6.40

a c

b piston chamber port c shifting unit adapter d load ring 3000 kg L retracted 1404 - extended 2364

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

b piston chamber port c shifting unit adapter d load ring 3000 kg e journal L retracted 1299 - extended 2259

1 cylinder tube 2 reed contact rod 21 piston rod 24 screw joint a annulus port

E

e

Hydraulic cylinder

Flipper cylinder Fig. 75: Hydraulic cylinder type ZE-165/100-500-KO-CR

2 a

35 Ø70 L

b 1 c

E DBT GmbH, Lünen 2005

b pressure relief port, piston chamber c load ring 1000Kg L retracted 815 - extended 1315

1 cylinder tube 2 piston rod a valve connecting plate

Pusher cylinder Fig. 76: Hydraulic cylinder type ZE-135/120-300-PU 2 a

35

b

L

1

1 cylinder tube 2 piston rod a piston chamber port

Doc. No.: 7420 152 000 BA 00

VIVR / 01

b annulus port L retracted 620 - extended 920

6.41

Hydraulic cylinder

Technical data of hydraulic cylinders

shifting ram double-acting, el. connection, reverse-mounted

6.42

prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1985

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

4875

hydraulic stroke . . . . . . . . . . . . . . . . . . . . . mm

2890

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

345 / 250

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

320 / 230

piston surface area . . . . . . . . . . . . . . . . . . cm2

934.8 / 490.9

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

130.6 / 75.4

prop force at 315 bar setting pressure . kN

2944.6

prop force at 462 bar yield pressure . . . kN

4318.84

retracting force at 315 bar . . . . . . . . . . . . kN

411.4

Type SD-4300-345-1820/4375-CR, drawing no. 8250 101 000 00 00 in use with shield variants 03 to 06 E

double telescopic prop, double-acting - 2 stages

Type SD-4300-345-1985/4875-CR, drawing no. 8250 092 000 00 00 in use with shield variants 01 and 02

prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

1820

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

4375

hydraulic stroke . . . . . . . . . . . . . . . . . . . . . mm

2555

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

345 / 250

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

320/230

piston surface area . . . . . . . . . . . . . . . . . . cm2

934.8/490.9

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

130.6 / 75.4

prop force at 315 bar setting pressure . kN

2944.6

prop force at 462 bar yield pressure . . . kN

4318.84

retracting force at 315 bar . . . . . . . . . . . . kN

411.4

Type ZE-150/100-960-SC-W-CR, drawing no. 8241 233 000 00 00, equipped with reed contact rod, in use with base variant 01 and 02 only stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

960

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

150

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

100

piston surface area . . . . . . . . . . . . . . . . . . cm2

176.7

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

98.2

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

556.6

pulling force at 315 / 380 bar . . . . . . . . . kN

309.3 / 373.1

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

double telescopic prop, double-acting - 2 stages

Hydraulic cylinder

shifting ram double-acting, el. connection, reverse-mounted

DBT GmbH, Lünen 2005

E

stabilizing cylinder, double-acting

baselift cylinder, double-acting

side seal cylinder, double-acting

Doc. No.: 7420 152 000 BA 00

Type ZE-200/140-960-SC-W-CR, drawing no. 8241 234 000 00 00, equipped with reed contact rod, in use with base variants 03 to 06 only

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

960

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

200

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

140

piston surface area . . . . . . . . . . . . . . . . . . cm2

314.2

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

160.2

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

989

pulling force at 315 / 380 bar . . . . . . . . . kN

504.6 / 608.8

Type ZE-200/140-520-EC-BN, drawing no. 8241 212 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

520

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

200

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

140

piston surface area . . . . . . . . . . . . . . . . . . cm2

314.2

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

160.2

thrust at 315 / 470 bar . . . . . . . . . . . . . . . kN

989.7 / 1476.7

pulling force at 315 / 470 bar . . . . . . . . . kN

504.6 / 752.9

Type ZE-125/90-240-LI-CR, drawing no. 8241 189 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

240

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

125

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

90

piston surface area . . . . . . . . . . . . . . . . . . cm2

122.7

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

59.1

thrust at 315 / --- bar . . . . . . . . . . . . . . . . kN

386.5 / ---

pulling force at 315 / --- bar . . . . . . . . . . . kN

186.2 / ---

Type ZE-119-63/50-215-N, drawing no. 9571 191 200 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

63

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

50

piston surface area . . . . . . . . . . . . . . . . . . cm2

31.2

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

11.5

thrust at 315 / --- bar . . . . . . . . . . . . . . . . kN

98.3 / ---

pulling force at 315 / 380 bar . . . . . . . . . kN

36.2 / 43.7

VIVR / 01

6.43

Hydraulic cylinder

flipper cylinder, double-acting

stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

500

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

165

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

100

piston surface area . . . . . . . . . . . . . . . . . . cm2

213.8

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

135.3

thrust at 315 / 380 bar . . . . . . . . . . . . . . . kN

673.5 / 812.4

pulling force at 315 / 380 bar . . . . . . . . . kN

426.2 / 514.2

Type ZE-80/63-215-KO-CR, drawing no. 8241 235 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

80

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

63

piston surface area . . . . . . . . . . . . . . . . . . cm2

50.3

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

19.1

thrust at 315 / 380 bar . . . . . . . . . . . . . . . kN

158.5 / 191.1

pulling force at 315 / 380 bar . . . . . . . . . kN

60.2 / 72.6

pusher cylinder, double-acting

side flipper cylinder, double-acting

6.44

Type ZE-135/120-300-PU-CR, drawing no. 8241 046 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

300

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

135

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

120

piston surface area . . . . . . . . . . . . . . . . . . cm2

143.1

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

30

thrust at 315 bar . . . . . . . . . . . . . . . . . . . . kN

450.8

pulling force at 315 bar . . . . . . . . . . . . . . kN

94.5

Type ZE-90/60-280, drawing no. 7370 953 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

280

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

90

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

60

piston surface area . . . . . . . . . . . . . . . . . . cm2

63.6

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

35.3

thrust at 315 / --- bar . . . . . . . . . . . . . . . . kN

200.4 / ---

pulling force at 315 / --- bar . . . . . . . . . . . kN

111.2 / ---

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

flipper extension cylinder, double acting

Type ZE-165/100-500-KO-CR, drawing no. 8241 232 000 00 00

Pressure relief valves hydraulic cylinder of anti-topple device double-acting

DBT GmbH, Lünen 2005

E

hydraulic cylinder of anchoring device base - base double-acting

Type ZE-80/50-600, drawing no. 8241 066 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

600

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

80

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

50

piston surface area . . . . . . . . . . . . . . . . . . cm2

50.3

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

30.6

thrust at 315 / --- bar . . . . . . . . . . . . . . . . kN

158.4 / ---

pulling force at 315 / --- bar . . . . . . . . . . . kN

96.3 /---

Type ZE-110/70-900-AB-CR, drawing no. 8241 192 000 00 00 stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

900

piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm

110

piston rod dia. . . . . . . . . . . . . . . . . . . . . . . mm

70

piston surface area . . . . . . . . . . . . . . . . . . cm2

95

ring surface area . . . . . . . . . . . . . . . . . . . . cm2

56.5

thrust at 315 bar . . . . . . . . . . . . . . . . . . . kN

299

pulling force at 315 bar . . . . . . . . . . . . . . kN

177.9

Pressure relief valves Pressure relief valves protect the hydraulic equipment, such as props and cylinders, connected with them from overload. When the set pressure is reached, the valve opens and the pressure fluid is discharged to atmosphere.

For the type of valve used please see the following table, the hydraulic flow plan or the spare parts catalog.

Tab. 21: Pressure relief valves, use of different types set pressure in bar

order no.

general application, spring-loaded not for props and stabilizing cylinders

380

7337 486 380 00 00

only at stabilizing cylinder

spring-loaded

420

8220 027 420 00 00

only at stabilizing cylinder

spring-loaded

470

8220 027 470 00 00

only at props

spring-loaded

420

0000 000 416 99 68

only at props

gas pressure

462

7337.611.462.00.00

only at props

gas pressure

472

7337 611 472 00 00

application

type

CAUTION! Do not change the pressure setting of pressure relief valves!

Only use pressure relief valves which have been factory-set to the required value and are provided with the relevant color code.

Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.45

Pressure relief valves CAUTION! Always replace pressure relief valves with valves which are as new and have the same properties. Refer to the hydraulic flow plan in this respect. Failure to comply with this impairs the operational safety of the hydraulic system and may lead to severe damage to and the destruction of components.

NOTICE! Always fit new seals when replacing a pressure relief valve.

Failure to comply may result in leakages at the plug-type connection and impair the operational safety of the hydraulic system. code system

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

The letter code includes the following details: J Set pressure, target value J Week setting was made J Year setting was made J Last setting made by

09

03

xy

set pressure

week

year

made by last

The color code may consist of one or two colors. It characterizes the setting pressure range. The following figure 77 shows a pressure relief valve provided with a blue-white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 77: Typical pressure relief valve

a color code b protection cap b

a

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

Tab. 23: Color codes for pressure relief valves, overview color

pressure range (bar)

black

0 - 49

black / white brown

6.46

50 - 99 100 - 149 1) Setting pressure according to DIN 21557: 1/10 x nominal pressure in bar, ”42” equals 420 bar, ”08” equals 80 bar

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

420 or 42 1)

E

Tab. 22: Typical letter code

Pressure relief valves color

pressure range (bar)

brown / white

150 - 199

green

200 - 249

green / white

250 - 299 300 - 349 350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow /white

550 - 599

orange

600 - 649

orange / white

650 - 699

DBT GmbH, Lünen 2005

E

blue blue / white

Doc. No.: 7420 152 000 BA 00

VIVR / 01

6.47

Electrohydraulic control system Electrohydraulic control system Electrohydraulic control units Fig. 78: Electrohydraulic control, 14 functions

a 2

1

4

3

a connecting accumulator cartridge 1 control valve block

DBT GmbH, Lünen 2005

E

2 pilot control valve for electromag netic operation

3 push-button for manual operation 4 plug contact, electrical connection to the control unit

Fig. 79: Electrohydraulic control, 16 functions

a 4 1 2

3

a connecting accumulator cartridge 1 control valve block 2 pilot control valve for electromag netic operation

6.48

3 push-button for manual operation 4 plug contact, electrical connection to the control unit

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Electrohydraulic control system WARNING! During normal operating mode the push buttons at the pilot valves of the control valve blocks must not be used for operating the functions. Failure to observe this warning can result in unexpected and hazardous situations, for example if functional links become invalid.

The push buttons of the pilot valves are only allowed to be operated in specified exceptional circumstances, for example for repair or maintenance purposes. In these cases it is imperative to observe the applicable special safety regulations.

Electronic shield control PANZERMATIC® PM4 NOTICE! How to operate the electronic shield control unit type is not subject of this manual. See separate operating instructions.

Fig. 80: Control unit type Panzermatic® PM4, Eingangsbelegung PM4 inputs A1 = L.H. adjacent unit A2 = not used B1 = infrared transmitter/receiver B2 = not used C1 = pressure sensor C2 = not used D1 = not used

DBT GmbH, Lünen 2005

E

front view

rear view

Doc. No.: 7420 152 000 BA 00

A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

VIVR / 01

D2 = shifting ram sensor E1 = not used E2 = not used F1 = R.H. adjacent unit F2 = solenoid driver module of unit

6.49

Electrohydraulic control system Fig. 81: Electronic shield control unit type Panzermatic® PM4, schematic diagram for shield variants 01 and 02 rear view A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

1

A L.H. adjacent support, port F1

R.H. adjacent support, port A1 3

3

5

6

a

DBT GmbH, Lünen 2005

E

B 127V AC 12V DC

PA

F1

R.H. adjacent support, port A1

A electronic shield control, components B support with power adapter (PA) C support with isolation adaptor (IA)

C R.H. adjacent support, port A1

6.50

IA

F1

1 single control unit (SCU) 3 solenoid driver 5 pressure sensor 6 infrared transmitter/receiver a reed rod, shifting ram other: see spare parts catalog

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Electrohydraulic control system Fig. 82: Electronic shield control unit type Panzermatic® PM4, schematic diagram for shield variants 03 to 06 SCU, rear view

A

A2

B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

1

R.H. adjacent support, port A1

L.H. adjacent support, port F1

3

5 6

DBT GmbH, Lünen 2005

E

a

B

127V AC 12V DC

PA

F1

R.H. adjacent support, port A electronic shield control, components B support with power adapter (PA) C support with isolation adaptor (IA)

A1

C R.H. adjacent support, port A1

IA

Doc. No.: 7420 152 000 BA 00

F1

VIVR / 01

1 single control unit (SCU) 3 solenoid driver 5 pressure sensor 6 infrared transmitter/receiver a reed rod, shift ram other: see spare parts catalog

6.51

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15° unless limited by the closed or extended condition of props or stabilizing cylinders or by the limited articulation of the hinged joint between canopy and caving shield.

Fig. 83: Angles α 1 / α 2

α1 α2

Tab. 24: Angles α 1 / α 2 at height M Inclination α at height M

Shield Order-no.

7420 152 000 00 xx

7420 152 000 00 xx

Variant 01 to 02

03 to 06

α1 in °

α2 in °

M in mm

14

12

2550 bis 2850

15

15

>2850 bis <5200

14

12

5200 bis 5500

14

13.5

2400 bis 2700

15

15

>2700 bis <4700

14

13.5

4700 bis 5000

CAUTION! If the max. angles stated are exceeded, damage will be caused to the props and cylinders as well as to their arresting elements and to the articulations.

6.52

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

E

M

Accessories Accessories Anti-topple device “canopy - canopy” The anti-toppling device ”canopy-canopy” according to drawing number 7420 066 470 00 00 can only be used on the following shield support variants: Tab. 25: Anti-topple device “canopy - canopy” order no. 7420 066 470 00 00, suitable shield supports Application of shield support

Order-no.

end shield, right with side flipper and protective wall

7420 152 000 00 03

end shield, right

7420 152 000 00 04

end shield, left

7420 152 000 00 05

end shield, left with side flipper and protective wall

7420 152 000 00 06

Prior to alignment, the respective shield must be lowered. The adjacent shield to which the steering cylinder is attached must be set.

By operating (pushing or pulling) the lever ”Z” (fig. 85) the respective steering cylinder is retracted pulling up the shield.

It may be necessary to use the respective side seal or the pusher cylinder in addition to assist in a precise alignment.

DBT GmbH, Lünen 2005

E

Fig. 84: Anti-topple device “canopy - canopy”

27

28

5 26

19

1 hydraulic cylinder 5 chain shackle 6 chain connector 10 anchoring bracket 15 pin

Doc. No.: 7420 152 000 BA 00

VIVR / 01

24 10

6

1

25 16

17

15 18

18-19 pin 16, 17 universal joint 24 chain 29 control unit other fastening and securing elements

6.53

Accessories WARNING! Be sure that the misalignment between shield 1 and shield 2 does not exceed the max. permissible value.

If this dimension is exceeded the steering cylinders or their holders could be heavily damaged. You may be severely injured or even killed by falling parts. The misalignment is never allowed to exceed 300 mm.

CAUTION! An incorrect sequence of steps when pulling up the shields could cause severe damage to the shields.

Advance the shields only in the sequence of steps 2-1-3 or 2-3-1.

Fig. 85: Hydraulic control for “canopy - canopy” anti-toppling device

a b R

13 4,7

P 13

T T P

A B

4,7 14

3,7

R 5,7,8

3,7

15 7 D CC

X

Z

1,10 1 hydraulic control unit 3, 4 plug-in socket 5 plug-in reducer 7, 8 staple 10 bolt 13 hose 14 hose

15 hose a piston surface area b ring surface area X lever for operating the end anchorage, see fig. 87 Z lever for operating the anti-toppling device

End anchorage End anchorages are designed for aligning the face-end shields (No. 1 or No. 179). Prior to aligning, the end shield must be lowered.

The shield (No. 3 or No. 177) to which the chain of the end anchorage is attached must be set to the roof.

By operating the lever ”X” fig. 87 the steering cylinder is retracted and the shield advanced.

CAUTION! An incorrect sequence of steps when pulling up the shields could cause severe damage to the shields.

Advance the shields only in the sequence of steps 2-1-3 or 2-3-1.

6.54

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

14 5,7,8

E

14

Accessories End anchorage base - base Fig. 86: End anchorage L. H. (tail gate)

2

3

3

2

1

DBT GmbH, Lünen 2005

E

1

R. H. (head gate)

section “A - A”

1 hydraulic cylinder 10 pin 11 chain shackle 12 washer 13 cylinder protection 14 protective plate

Doc. No.: 7420 152 000 BA 00

section “B - B”

15 pin 16 bush 17 locking device 40 cylinder bracket R.H. 41 cylinder bracket L.H. 42 chain guide

VIVR / 01

section “C - C”

43 chain guide 44 chain attachment 70 chain 71 chain connector other: fastening and securing elements

6.55

Accessories

DBT GmbH, Lünen 2005

E

Fig. 87: Control unit for end anchorage

X

Z

X

Z

a

6.56

a hydraulic control unit 1 angle socket, DN10 2 straight socket, DN10 4 staple, DN10 7 hose

X

lever for operating the end anchorage

Z

lever for operating the anti-toppling device, see fig. 85

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

Accessories Side flipper hydraulics Fig. 88: Hydraulic control for side flipper

15 R

1

8

12

1

8 18e 12 Z8

DBT GmbH, Lünen 2005

E

Z8

8 1 2 18 1

1 F-F plug-in elbow DN 10 2 F-F plug-in cross socket DN 10 3 screw plug

Doc. No.: 7420 152 000 BA 00

VIVR / 01

8 staple 12 hose 15 hose

6.57

Operating media Operating media Hydraulic fluids Permissible hydraulic fluids NOTICE! Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

For the operation of hydraulic components of DBT GmbH generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWM 8350 or an exemption permit of DBT GmbH is available to the respective operator. DBT GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

Suitability test Before the certificate of DBT GmbH is issued for a hydraulic fluid the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by DBT GmbH. For the tests, the criteria as specified in EWN 8350 will be applied. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to J stability J sealing materials J corrosion

In addition, a chemical ”fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

6.58

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

If a mine only uses individual hydraulic components without applying DBT shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid as is used for the existing shield support shall be allowed to be used for these individual components, subject to approval by DBT. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by DBT GmbH upon request.

E

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

Operating media If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive the respective certificate by DBT GmbH. Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of hydraulic systems of DBT GmbH for each product tested. The respective certificate shall be valid for a period of one year and, after a simplified test, can be extended for an additional year each. The certificate shall become invalid if one or several of the prerequisites for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

The following illustration shows a typical certificate.

DBT GmbH, Lünen 2005

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Fig. 89: Typical certificate

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6.59

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

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

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

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

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: < 105 Kol/m In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

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

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following table 26 lists limit values for the essential properties and components of the water.

If the limit values shown are maintained it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not met this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

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

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DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

DBT GmbH, Lünen 2005

J Microbial load

E

– Target value: see certificate

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

Tab. 26: Properties of the process water, limit values Limit value

Appearance, color, smell

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

electrical conductivity

< 1800 µS/cm

pH-value

6,5 ..... 8,5

Na+ - content

not specified

Mg+ - content

not specified

water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content

≤

145 mg/l

NO3- - content

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 Kol/ml

Ratio of solid foreign matter at 1,2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

- / 18 / 14

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Test criterium

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 *) 7068 Tab. 27: Lubricating greases for general application

lubricating greases A2

Flash point in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load. *) EWN = DBT standard

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Operating media Tab. 28: 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.

Lubricating pastes 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.

Supplier

Type

gleitmolybdän

gleitmo 805 *)

Base Li

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Tab. 29: Lubricating pastes free from molybdenum disulfide

NLGI class

Flash point °C

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” lubricating pastes B6

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.

Behavior in the presence of water:

non-soluble in water

Temperature of application:

-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 & 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.

*) The products listed in table 27 are suitable lubricating greases for filling of adjacent cavities.

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DBT GmbH, Lünen 2005

lubricating pastes B3

Tightening torques Tightening torques Screws with ISO metric thread Tab. 30: Recommended tightening torques at µges. = 0.14 Thread 1) (mm)

(mm)

E

MA (Nm) 8.8

10.9

12.9

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

-

1100

-

d

coarse thread

M8

M 24

DBT GmbH, Lünen 2005

Tightening torque 4)

Pitch P

fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3,5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

IMPORTANT! The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

1) dimensions in brackets in exceptional cases only 2) according to works standard (EWN 6110), February 1985 edition 3) only for expansion screws having a reduced shaft cross-section of 24.2 mm 4) the tightening torques comply with EWN 6003 works standard.

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Tightening torques

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DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750

7

For your information

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 - 14 21 E-mail: Internet:

Great Britain

infodbt@dbt.de http://www.dbt.de

DBT GB Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS

DBT GmbH, Lünen 2005

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: Internet: USA

info@dbtgb.com http://www.dbt.de

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: Internet:

Australia

infodbt@dbt.de http://www.dbt.de

DBT Australia (Pty.) Ltd. 537 Lake Road Argenton, NSW 2284 Tel: +61 / 2 49 58 31 33 Fax: +61 / 2 49 58 57 54 E-mail: Internet:

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infodbt@dbt.de http://www.dbt.de

7.3

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: Internet:

Info.beijing@dbtchina.com 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-mail: Internet:

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: Internet: France

infodbt@dbt.de http://www.dbt.de

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: Internet:

Poland

info@dbtfrance.com http://www.dbt.de

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48-32-3170 500 Fax: +48 32 3170 509

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DBT Africa Pty. Ltd.

DBT GmbH, Lünen 2005

South Africa

Info.langfang@dbtchina.com http://www.dbt.de

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

Fig. 90: Identification plate, example

1

DBT GmbH 2 5

6

7

2

12345

E

01/05

4

678

7420 140 311 00 00 3926 kN

1 manufacturer 2 last 5 digits of SAP-no. resp. order-no.

3 month and year of manufacture 4 current component no.

DBT GmbH, Lünen 2005

3

5 drawing no.

6 number of props 7 rated yield force of props

Shield number The shields are numbered consecutively. Plates showing the shield number are fitted at the faceside of the base at the left.

Fig. 91: Shield number at the base, example

Tab. 31: Allocation of shield numbers

Doc. No.: 7420 152 000 BA 00

shield no.

order no

5 to 175

7420 152 000 00 01 face shield

4 and 176

7420 152 000 00 02 transition shield

1

7420 152 000 00 03 face end shield, right with side flipper and sidewall

2 an 3

7420 152 000 00 04 face end shield

177 and 178

7420 152 000 00 05 face end shield

179

7420 152 000 00 06 face end shield, left with side flipper and sidewall

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application

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Identification of shields

7.6

DBT-Shield 2550/5500-2x4319-1750 & DBT-Shield 2400/5000-2x4319-1750