DOWNLOAD PDF CAT DBT-shield 1020 2200-2X2771-1750 Operating Manual

Operating manual DBT-shield 1020/2200-2X2771-1750 Doc. no.: 7420 176 000 BA 00

DBT GmbH Industriestraße 1 Telephone: +49 (0) 23 06 / 709 - 0 Email: infodbt@dbt.de D-44534 Lünen 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. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of 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 2007E

Contents

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

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

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

2.3 2.4

Conditions for 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 . . . . . . .

4.7

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

4.8

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

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

4.8 4.9

Corrosion protection of hydraulic components . . . . . 4.10

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Contents 5. Operation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

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

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

5.3 5.6

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

5.9

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

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

Shield components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5.15 5.16 5.22 5.33 5.35 5.38 5.39 5.40 5.41 5.41 5.41

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 Fault finding on shield hydraulic system . . . . . . . . . . . . . . .

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

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

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

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

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

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

5.42 5.42 5.45 5.45 5.46 5.46 5.46

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

6.3

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

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

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

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

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

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

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

6.4 6.5 6.7 6.13 6.16 6.17 6.20

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 Shield hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.22 6.28

Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Alignment cylinder (seal cylinder) . . . . . . . . . . . . . . . . . . . .

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

6.30 6.31 6.31 6.32 6.32

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

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

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

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

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

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

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39

Contents Pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Electrohydraulic control system . . . . . . . . . . . . . . . . . . 6.36 Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.36 6.37

Angles of inclination of the canopy . . . . . . . . . . . . . . . 6.41 Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.42 6.45

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

6.47

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7. For your information

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

7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

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

7.6

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

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

7.6 7.7

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

7.8

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

Referenced European standards and guidelines . . . . . . . .

7.8 7.8

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Contents

DBT-shield 1020/2200-2X2771-1750

1

About this manual

Before starting work

About this manual This chapter contains important information making it easier for you to use this manual. It provides you with 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 to the shield support being used. Compare the data given below with the data given 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 1020/2200-2X2771-1750 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 1020/2200-2X2771-1750 Year of Application Order number Prop force construction

availability of operating manual

7420 176 000 00 01 2X2771 kN

2006

Face shield

7420 176 000 00 02 2X2771 kN

2006

Transition shield

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 for the hydraulic system J perform maintenance work J perform repair 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.

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1.3

Before starting work 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 shield support.

Therefore, read this operating manual completely and at leisure.

Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

questions?

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

safety

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

Observe this information and follow the procedural instructions.

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

Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

Caution!

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

Notice!

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

Important!

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

J

Items in lists are marked with bullets.

–

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

.

1.4

The hand symbol prompts you to take action. Several successive paragraphs marked with the hand symbol represent a sequence of actions which must be executed in the order specified. Follow these instructions step-by-step in order to perform the work safely and efficiently.

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

Danger!

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

E

Try to memorize the symbols and their meanings.

2

Your safety

Personnel

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

The shield support was manufactured in accordance with state of the art and generally recognized safety standards and regulations.

However, a residual risk still exists which may involve you getting 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.

supplementary regulations

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

Observe the safety and accident prevention regulations: J of the mining company, J of the mines inspectorate, and J of the mining supervisory authorities.

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Personnel Persons employed in the operation, repair and overhaul of hydraulic and/or electrohydraulic shield supports must be specially qualified.

In addition to having had training in mining technology the following minimum requirements must be met.

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

The training must be specially tailored to the type of shield actually being used. The electrohydraulic or hydraulic control may only be actuated by people trained on the control at hand. The contents of the operating manual, especially the chapter on security, must be a component of this training.

They must 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 may only be performed by persons who have the knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment.

Repair work on and overhaul of J safety devices, 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 1020/2200-2X2771-1750

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

Use the shield only as intended!

Intended uses are: J propping the roof against the floor, J ensuring an adequate travel way, J the following shield operations:

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

– advancing, E

– returning, DBT GmbH, Lünen 2007

J forming an abutment for:

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

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

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

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

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

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 work with utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment.

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

prerequisite

Employ only shields which are in a technically flawless condition.

Always keep out of any shield which is not set.

lighting system signaling systems and protective devices

Maintain the lighting systems in a functional condition.

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

support lock-out switch

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 can be taken immediately.

- Only applicable for shields provided with electrohydraulic shield control systems: Actuate the support lock-out switch (repair switch) before performing: J maintenance work, J inspection work, J repair work and 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 bases and shifting units, J canopies, J lemniscatic links, J side seals, J front cantilevers, J hydraulic props and cylinders, J steering devices.

automatic mode

2.6

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield units may move automatically. Therefore it is vital that you observe the warnings at the face entries as well as the visual and acoustic signals sent by the control unit in the shield currently operated.

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

EMERGENCY STOP

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

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

Never stand under unsecured or suspended loads.

Observe the specified storage time limits and the storage instructions.

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

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

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

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

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J the flipper, J the relay bar (face and gob sides). transporting

connect the hoisting gear only at the attachment points 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 the props. Damage of this kind necessitates elaborate and expensive repair work.

For round components such as cylinders and props which are not provided with lifting 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 Use appropriate loading equipment for safe transfer of the transport units.

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

Mechanically secure the caving shield against 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 lemniscatic 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 safety device of the side seals. Use the hydraulic control system to adjust the 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 swiveling area of the latter as the flipper may swing downward.

travel way

Make sure that the minimum dimensions specified for the travel way with the shield are maintained at all times. The minimum dimensions are: J Width: 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 travel way. It may be necessary to install additional devices limiting the lowering height in order to ensure that the minimum travel way is maintained.

2.8

DBT-shield 1020/2200-2X2771-1750

Safety instructions Operation shield control

In automatic mode, the shield units of a longwall face are controlled by an automatic program without any human intervention. When traveling the face you should therefore always keep in mind that the shield 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 shield currently operated.

Check to determine whether all protective devices on the shield are present and functional. Also see chapter 6 “Technical data”.

You may only operate the shield control system if you have an extensive knowledge of the control elements and their functions. It is necessary that you have been trained on the respective control system and know the contents of the respective operating manual.

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

Always operate the shield only from an adjacent shield.

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

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During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the shield support is being moved, and prevent any hazards by acting with caution.

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

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

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

Keep the floor as clean as possible. Prevent debris from collecting.

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

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

On an inclined face, the conveyor must be anchored adjacent to the support, if necessary. This way you can prevent the conveyor from shifting to the side with respect to the support. And it reduces the risk of the shifting unit jamming between the bases.

Hydraulic anchorages must always be charged to the specified working pressure since only thus is a sufficient anchorage between shield and conveyor 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 of you getting 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 another. Use the steering devices or the side seals for aligning the shields.

Align the shields as soon as possible. Use the steering devices or the side seals for aligning the shields. Early alignment prevents: J getting under the canopy of the adjacent shield, J canting of the shields, J slipping of the shields, J delays in supporting the newly mined roof.

roof falls

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

Never set the tip of the canopy into a roof fall so that J the max. admissible angle of inclination of the canopy is exJ the stabilizing cylinder locks 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, ensure that the sloping canopy does not get in the way of the passing mining equipment. residual stroke

pulling back the conveyor

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

If possible, pull the conveyor back by operating the respective functions of the electronic shield control unit. If this isn’t 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 to prevent any unauthorized persons entering this area.

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

raising the 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 only 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 full contact over the entire length.

2.10

DBT-shield 1020/2200-2X2771-1750

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ceeded

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 adequate load-carrying capacity. attaching loads

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

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 delivery, refer to chapter 6, “Technical data,” for their location.

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

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

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

Secure your working area over a wide range, in order to avoid endangering other persons.

Immediately replace damaged components affecting safety. Stop and lockout the respective shield immediately if the component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible foreman without delay.

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

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

Do not make modifications or carry out conversions which might impair the safety of the shield. DBT must be informed 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 invalidate the DBT declaration of conformity and a new conformity test will be required.

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

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2.11

Safety instructions You may only carry out work in the mining area 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 otherwise ensured that the continuation of the mining work does not affect the safe performance of the repair work.

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

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

pressure or mechanical stress.

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

The support must be mechanically secured, for all work where there is a danger of the support retracting automatically.

Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infections.

hydraulic system protective equipment

When dismantling protective devices that contain hydraulic components, keep in mind that these components may be pressurized.

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

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

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

maintenance, repair

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

pressure relief valves

Make sure that pressure relief valves always have protective caps.

Replace defective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: J the hoses are not pinched or trapped, J the hoses have no bubbles or blisters, J the hoses or the outer sheathes of the hoses are not abnormal-

lyrigid or hard,

2.12

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DBT GmbH, Lünen 2007

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

E

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

Safety instructions 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.

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

Secure the connectors of the hydraulic elements only with the proper staples. 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.

DBT GmbH, Lünen 2007

E

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 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. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

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

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2.13

Safety instructions laying hydraulic hoses

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted Fig. 4:

Laying hydraulic pipes, twisting RIGHT

DBT GmbH, Lünen 2007

E

WRONG

J are not bent directly behind the connections

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

laying hydraulic hoses, bending RIGHT

WRONG

J cannot chafe Fig. 6:

2.14

Laying hydraulic hoses, crossing RIGHT

WRONG

DBT-shield 1020/2200-2X2771-1750

Safety instructions J are not kinked J do not have to withstand tensile loads J are protected against thermal radiation J are accessible at all times.

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, J driven over or J twisted (Fig. 7).

Fig. 7:

Laying hydraulic hoses, connections on moving parts WRONG

DBT GmbH, Lünen 2007

E

RIGHT

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2.15

Overview of the safety instructions Overview of the safety instructions This is a summary of all safety instruction given in the individual chapters of this operating manual. As these safety instructions are cited out of 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 transporting loads.

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

Use only suitable load handling devices.

Important!

For transporting, use the four lifting eyes S1 and S2.

Chapter 4: Installation Danger!

Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others can be seriously injured or even killed!

Make sure that hydraulic hoses can’t be damaged by movements of the support.

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

Warning!

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

The first start-up and test run may only be carried out by a welltrained and experienced crew which is familiar with the special conditions in subsurface mining, especially with the safety requirements. The crew must also be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

2.16

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DBT GmbH, Lünen 2007

If the attachment points on the caving shield are to be used to transport the assembled head drive, the canopy and base must first be mechanically connected to each other using an additional transport safety device so that they cannot move apart.

E

Caution!

Transport safety devices may get damaged during transport to the mine, for example when loading the 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 Bent support canopies may not project into the mining area.

Shut-off valves may not be installed into the return lines for the shield hydraulics as otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in persons being seriously injured or even killed.

Caution!

Before the hydraulic connections are joined, the coupling sleeves and nipples of the plug-O connections must be lubricated with molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, “Lubricating greases and pastes” section.

Before putting the transport units of the steel structure together, all slide surfaces must be lubricated with molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, “Lubricating greases and pastes” section.

For transport underground only the attachment detailed in chapter 3 “Transport” may be used. Further information about this can be found in chapter 3 “Transport”. Failure to comply can lead to personal injury and damage to property.

DBT GmbH, Lünen 2007

E

If the face hydraulics are designed such that they are unstable or too weak, there could be a temporary pressure drop during operation.

In the event that the pressure falls to 180 bar or less, there is a danger of malfunctions occurring in the electrohydraulic control.

Valve functions might 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 properly.

For this reason, take all necessary precautions to make sure that the system pressure cannot drop to below 180 bar anywhere in the face hydraulics.

Notice!

Make sure 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 some shield units may be provided with different functions, their set-up on the longwall is not arbitrary.

For further information, please see the corresponding separate operating manual of the respective 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 extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control and have consolidated your knowledge during a corresponding training session on the object. Should this not be the case you are not allowed to operate the control. Inform your superior immediately and ask for the required training.

Jammed or locked buttons can cause uncontrolled movements of the shield. Seriously injuring or even killing you.

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

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

The actuators on the control valve block should only be used in an emergency and for repair work and only in compliance with the special operating instructions of the mine. During normal operation they should not be used. Otherwise, dangerous situations could arise which could result in very serious injury. The shield support is operated in normal operation exclusively by means of the electronic control. It is imperative that you observe the instructions in the control unit’s separate operating manual. If the control unit is included in the DBT scope of delivery, the respective operating manual will be included in the DBT documentation provided for the installation.

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 support. You must have attended a special training course to this purpose. Otherwise, there is a risk of incorrect operation. This could result in serious injury and even fatal accidents.

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DBT GmbH, Lünen 2007

Never be on a support which is currently being moved. Circumstances which are not always obvious may lead to unexpected movements in the shield units. This could result in serious injury or even death.

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

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 Manual actuation of a button on one of the pilot valves initiates direct execution of the corresponding function. Dependencies between the individual functions are not taken into account. Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”. This can cause dangerous situations which can result in very serious injury.

If the operational safety is endangered, damaged components must be replaced immediately. If this is not possible, you must immediately shut down the shield and secure it. Immediately notify the entire face crew and your superiors.

There is a heightened risk of accidents when performing trouble shooting work on hydraulic systems. In particular malfunctions in the hydraulic system and hydraulic medium escaping at high pressure can cause serious injury.

Therefore take special care and always wear the specified protective clothing.

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

DBT GmbH, Lünen 2007

E

Caution!

Never exceed the permissible angle of inclination of the canopy.

Exceeding the permissible angle of inclination of the canopy specified in chapter 6 of the section “Technical data” can lead to the support becoming damaged. This especially applies to stabilizing cylinders whose fastening elements and fulcrum points are on the shield canopy and caving shield.

Never extend or retract the stabilizing cylinders of the shield completely!

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm!

The same applies analogously for the adjusting cylinder of the front cantilever.

Ensure that the stabilizing cylinder has sufficient residual stroke when there is a tendency toward roof falls and/or an extremely soft floor.

Avoid the canopy being excessively inclined by filling out the roof falls, for example, or by underpinning smaller roof falls with a horizontally positioned shield.

At this point, we again explicitly emphasize that any damage caused by not complying with these instructions, is not covered by the warranty.

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield) specified in Chapter 6, section “Technical data” of this manual, is exceeded, this could lead to damage to props, hydrocylinders and their fastening elements, as well as to the part hinges.

Take care not to damage the pilot valve buttons. Sticking buttons might lead to malfunctions and cause an accident.

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

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2.19

Overview of the safety instructions Notice!

It is important that the control symbols are easily legible. This prevents the risk of incorrect operation and any resulting accidents.

Important!

Familiarity with the circuit diagram and skilled personnel are required for both procedures. Make sure that you observe the safety regulations under all circumstances.

Every third shield is equipped with a PMC®-R control unit. The other two shields receive a shield locking switch or a breakout box.

See the “Conveyor steering equipment” manual for detailed information on the “Raise prop” and “Lower prop” functions.

Chapter 6: Technical data

Risk of injury! The moveable side seal is under spring pressure.

Secure the side seal using clamps before dismantling the side seal cylinders and their guiding pins.

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

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

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

Never close the lowering connections on double-acting props pressure-tight. Otherwise, pressure might build up in the ring space when extending the prop which is several times more than the set pressure.

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

Never close the lowering ports of double-acting props pressuretight.

Otherwise, pressure that is several times higher than the set pressure can build up in the ring space when extending the cylinder.

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DBT GmbH, Lünen 2007

Risk of injury due to unexpected movements of the side seal. The moveable side seal is under spring pressure. Never remove connecting elements of the side seal before the side seal is pulled together and secured using clamp clips.

E

Warning!

Risk of being crushed. Body parts which get between moving parts of the shifting unit and stationary parts of the support can be crushed. For this reason, make sure that you keep a distance from shields which are being advanced or are to be advanced soon.

Overview of the safety instructions During normal operation the buttons on the pilot valves of the electrohydraulic control unit should not be used to activate functions.

Failure to observe this warning can result in unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

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

Caution!

To avoid overloading the stabilizing cylinder, you must make sure that the setting angle of the shield canopy doesn’t exceed the maximum permissible value, e.g. when the canopy is set in a roof fall.

Before putting the support unit into operation, the transport safety devices (see Fig. 69 marked with a *) of the side seal must be removed.

For the transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured with staples.

DBT GmbH, Lünen 2007

E

The set pressure of pressure relief valves should not be changed!

Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system’s circuit diagram. Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

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

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

When putting the transport safety devices into operation, remove items (27*, 46*) and (28*, 44*) on the movable side seal. Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

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

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2.21

Overview of the safety instructions Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

The technical data for the cylinders can be found in section “Technical data, hydraulic cylinders” of the used shield unit.

Always fit new seals when replacing a pressure relief valve. Ignoring this can lead to leakage at the coupling and impair the operational safety of the hydraulic system.

Please observe the separate operating manual for the PMC®-R control unit.

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

Important!

When the support is extended or retracted as far as possible, the “Canopy - Caving shield” crosspoint moves correspondingly when the canopy is raised or engaged.

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

The tightening torques stated in the spare parts lists must be observed for installation and maintenance work!

2.22

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DBT GmbH, Lünen 2007

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

E

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

3

Storage and transport

Storage

Storage and transport This chapter contains important information concerning the proper storage and transport of the shield.

Observance of the instructions and tips will increase the service life of the shield. In addition, you will be directed to perform the tasks involved with transport safely and efficiently.

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

Storage Storage of new equipment corrosion protection

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

DBT GmbH, Lünen 2007

E

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

The fluid remains in the hydraulics system for the purpose of transport and (if required) subsequent storage. HYDROCOR® CV50 is frost-free to -40 °C and protects the metallic materials used from corrosion. It contains a color indicator which reacts when the pH value drops. The color of the medium changes from “red” to “yellow” here. The yellow coloration indicates that the anticorrosion protection is no longer adequate.

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

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

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

*

Doc. no.: 7420 176 000 BA 00

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

VSVA / 01

3.3

3.4

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

Do not store the equipment outdoors. It should be stored in a dry, well ventilated room. If this is not possible for the entire shield unit, for example, then the hydraulic and electronic components might have to be dismantled and separately stored.

storage outdoors

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

electrical equipment, rubber and plastic parts

Electrical equipment, electronic components, replacement parts made of rubber or plastic - such as seals and hoses - and pressure fluids must generally be stored in closed spaces at 15 °C to 25 °C, and 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 approximately two years is therefore specified for these parts as an indicative value.

moisture and dirt

All hydraulics elements must be protected appropriately against penetration by dirt and moisture during storage. The connection surfaces of the hydraulics components that remain in the device must be protected against corrosion and sealed with blind plates.

Hydraulic plug connections and electrical cables must be sealed with suitable caps or plugs.

plastic deformation

When storing subassemblies, such as props and cylinders, which contain sealed contact joints, sealing elements can be plastically deformed as they are permanently subjected to unilateral loads due to the weight of the parts. This can render the sealing element useless or reduce its service life considerably. This effect is mainly influenced by the size and duration of the acting force and the temperature at the time.

For this reason, only store the props, cylinders and similar parts in an upright position. This especially applies when the parts are to be stored for a relatively long period of time. If you want to store a machine which contains the above-named parts, you might have to dismantle such parts for the purpose of proper storage.

random sample inspection

Random sample inspections must be carried out after a storage period of approximately two years. This makes it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

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

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DBT GmbH, Lünen 2007

long term storage

E

Storage

Transport HFA fluids

The regulations stipulated by the manufacturer or of the supplier take precedence in every instance involving the storage of HFA fluids and/or concentrates for the production of HFA fluids. Supplementary information can also be found in the section “Permissible media” in this operating manual.

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

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

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

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

DBT GmbH, Lünen 2007

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Transport Warning!

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

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

Use only suitable load handling devices. transport units

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

points of attachment

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

temperatures below freezing

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

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

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically. Here, the external forces are only to be applied to the attachment points and retainer surfaces as specified in special drawings, if available.

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3.5

Transport The equipment may not be transported at temperatures below -40 °C. During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

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

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

Unless these components or 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 it is necessary to disassemble it into transport units, this is planned and laid down in close co-operation with the customer.

Tab. 2: Transport units As for normal use

Remarks E

Transport position

Complete shield unit

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

Tab. 3: Transport safety devices Part

Transport securing devices

Side seal, movable

Pin and retaining clip

4

Transport rod

1

Hydraulic connections not used are protected by protective caps or plugs

-

Quantity

Relay bar Face side Hydraulics

3.6

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transport safety devices

Designation

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 attachment points on the caving shield are to be used to transport the assembled head drive, the canopy and base must first be mechanically connected to each other using an additional transport safety device so that they cannot move apart.

Fig. 8:

Transporting the shield support as a complete unit

S3

SY

H

SO

S1

Sx

E

S2

X2

L S3

S4

880 b

DBT GmbH, Lünen 2007

X1

S4

S3

S1 Bore, 2x on the coal face end in the base, capacity: 15 000 kg S2 Bore, 2x on the gob side of the base, capacity: 15 000 kg S3 Slot, 2x on the canopy, capacity: 15 000 kg S4 Transport ring, 2x on the caving shield, capacity 8 000 kg X1, X2 Securing elements to fix the relay bar during transport, face side So Center of gravity

Important!

For transporting, use the four lifting eyes S1 and S2.

Tab. 4: Shield support 7420 176 000 00 01 and 7420 176 000 00 02, Dimensions and weight Variant

Doc. no.: 7420 176 000 BA 00

Order number

Length L in mm

01 7420 176 000 00 01

5293

02 7420 176 000 00 02

5893

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Width B in mm

Height H in mm

Sx/Sy in mm

Weight in kg

1650

1020 1225/593

15200

1650

1020 1091/600

15750

3.7

Transport Transport safety device, shifting unit Fig. 9:

Transport safety device, shifting unit (coal face side)

135 133 134

133 Chain 6 x 42 134 Hex. head screw M 12x45-8.8 135 Hex. nut M 12-8.8

Fig. 10: Shifting unit (gob side) without transport safety device Z-Nr.:

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130 Transport rod 131 Spring clips 2x

131

DBT GmbH, Lünen 2007

130

Transport Transport safety device, side seal For the transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured using staple locks see also chapter 6, “Side seal” section.

Fig. 11: Transport safety device, side seal

b

DBT GmbH, Lünen 2007

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a

a Pin b Staple locks

Supply hoses Fig. 12: Arrangement of supply hoses during transport

135 134

133 a

133 Chain 6 x 42 134 Hex. head screw M 12x45-8.8

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135 Hex. nut M 12-8.8

3.9

Transport Shield during transport

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Fig. 13: Shield during transport

3.10

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4

Installation

Pre-assembly of the shield units

Installation In this chapter, you will receive information about installing the shield units. Please pay special attention to the warnings and tips.

Warning!

In addition to the safety information given in this manual, also make sure you observe the special safety information and operation instructions which apply to the operation of the mine.

Failure to do so can lead to extremely serious accidents which may be fatal.

Caution!

Before the hydraulic connections are joined, the coupling sleeves and nipples of the plug-O connections must be lubricated with molybdenum disulfide-free B3 lubricating paste in accordance with EWN 7068. See chapter 6, “Lubricating greases and pastes” section.

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Caution!

Before putting the transport units of the steel structure together, all slide surfaces must be lubricated with molybdenum disulfide-free B6 lubricating paste in accordance with EWN 7068. See chapter 6, “Lubricating greases and pastes” section.

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

Installation of the shield units Caution!

For transport underground only the attachment detailed in chapter 3 “Transport” may be used. Further information about this can be found in chapter 3 “Transport”. Failure to comply can lead to personal injury and damage to property. installation plan

The shield units are installed in the longwall according to the installation plan of the mine.

Important!

When installing the shields in the face, be sure to observe the shield numbers. Since some shield units may be provided with different functions, their set-up on the longwall is not arbitrary.

identification for installation in the face

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In order to identify the shield units or their transport units more easily for the purpose of assembling and installing in the face, they should be labeled with a sequential number. They should correspond to the order in which the shield units are to be arranged in the face, for example. The numbers should be written in color so that they are clearly visible on the surface of the parts.

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4.3

Installation of the shield units shield number

The shield number serves as an identification feature. All shields are numbered sequentially. Firmly attached tags with the respective shield number are on the left base of the shield.

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Fig. 14: Shield number on the base, example

Tab. 5: Allocation of the shield numbers

4.4

Utilization

Shield number

Order no.

4 to 110

7420 176 000 00 01 Face shield

1 to 3 111 to 113

7420 176 000 00 02 Transition shield

DBT-shield 1020/2200-2X2771-1750

Installation of the shield units Supply connections The shield is always supplied through the connections on the supply block during initial start up as well as normal operation.

Fig. 15: View underneath the supply block 12

26 16b

P

R

W

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27

12 Pressure release valve, 80 bar 16b Plug cap DN 10 with pressure relief 26 Supply block DN40SS-DN50

27 Supply block DN25-20 P Pressure line, DN 40SS R Return line, DN 50 W Water line, DN 25

Fig. 16: View of the water filter

34

37

34 HP ball valve DN 25, interrupts the main line to the shield 37 Pipeline filter

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4.5

Installation of the shield units Coupling between the connections The hydraulic connections on the shield units are designed as plug connections in accordance with DIN 20043, which is standard for German mining. hydraulic system

The supply block for supplying the shield hydraulics is located on the side, in front of the right props. The connection to the supply block of the neighboring support is made using three hose pipes: one pressure line (DN 40SS), one return line (DN 50) and one water line (DN 25), see also Fig. 15 and the hydraulic circuit diagrams in chapter 6 of this manual.

Fig. 17: Connection between the connections

c

26 a

b

26 Supply block DN40SS-DN50 27 Supply block DN25-20 control unit

additional equipment

a Electrohydr. control unit b PMC®-R c Solenoid driver board

The support units are equipped with a type PMC®-R electronic control unit. The control unit and the electrohydraulic control unit are connected via a solenoid driver board. The connection cables required for this are included in the delivery of the PMC®-R control.

For more details on how to connect the control unit, please refer to the separate operating manual for the PMC®-R control. An overview of the design of the control is also given in chapter 6 of this operating manual in the section “shield control”.

The shield units are prepared for having additional equipment attached which are not included in the scope of delivery of the DBT. For example: J illumination, J two-way intercom system.

The information required for the installation of additional equipment can be found in the corresponding operating manual of the respective manufacturer.

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27

Requirements for the face hydraulic system Requirements for the face hydraulic system hydraulic medium

The hydraulic medium must meet the following conditions for all hydraulic components included in the DBT scope of delivery: Contamination Class 18 /14 in accordance with ISO 4406.

Pressure fluids according to “Permissible media” section in chapter 6 of this operating manual.

permissible pressure

Nominal pressure:

320 bar

Admissible tolerance: ± 10 % of nominal pressure

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Caution!

If the face hydraulics are designed such that they are unstable or too weak, there could be a temporary pressure drop during operation.

In the event that the pressure falls to 180 bar or less, there is a danger of malfunctions occurring in the electrohydraulic control. Valve functions might 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 properly.

For this reason, take all necessary precautions to make sure that the system pressure cannot drop to below 180 bar anywhere in the face hydraulics.

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4.7

Start-up Start-up Warning!

The first start-up and test run may only be carried out by a well-trained and experienced crew which is familiar with the special conditions in subsurface mining, especially with the safety requirements. The crew must also be well-practiced in handling the equipment and be familiar with the content of the associated operating manuals.

Notice!

Make sure that all transport safety devices required for transport have been removed.

See chapter 3, section “Transport”.

To be observed prior to start-up Start-up may only be carried out by trained and qualified personnel.

If the support is being used for the first time, the start-up absolutely it is imperative that is carried out under the direction of the DBT installation service.

Please observe the following items:

moved.

. Position the symbol bar on the brackets of the control valve block so that the symbols are clearly legible.

. Check all mechanical connections on the shield units. . Check the plugs of the shifting unit.

When the shifting unit is designed with a plug-in crawl pan, ensure that the crawl pan is plugged in correctly. Under no circumstances may the crawl pan be plugged in for normal operation in the “lowering position” 1).

J Hydraulic system:

. Check the entire hydraulic system for leaks. Seal any leaky connections immediately.

. Especially check whether hinges and hoses can be damaged due to movements of the support.

Danger!

Damaged hoses can burst and hydraulic fluid can escape under high pressure.

As a result, you or others can be seriously injured or even killed!

Make sure that hydraulic hoses can’t be damaged by movements of the support.

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

1) Maximum possible plug-ins

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. Make sure that all transport safety devices have been re-

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J Mechanics:

Start-up . Check the hydraulic supply pressure. . Check the load carrying function of the prop. The current pressure under the piston of a prop can be queried on the PMC®-R control unit. Here, you can query the pressure for a neighboring support or the support in which you are currently located. The pressure gauge on the prop control valve of the prop indicates the pressure directly.

. Check all operation elements to make sure they are working properly. Test whether the function is correctly executed when the corresponding operating element is activated.

J Signaling and lighting systems, information plates:

Important!

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

. Check all signaling systems. . Make sure that the face lighting is sufficient. . Check whether the face area, especially the travel way, is suffiDBT GmbH, Lünen 2007

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ciently signed. It is imperative that you observe the regulations of the responsible mining inspectorate.

J Emergency stop systems:

. Check that all EMERGENCY STOP systems function properly.

J Mining and conveying:

. Before start-up, check all functions of the face system. . Test to make sure the entire face system (mining equipment, conveying system, supports) is working together perfectly.

Warning!

Bent support canopies may not project into the mining area.

How to put the support into operation Move the shield units to their original positions, i.e.: J Shields and conveyors are aligned in a straight line J The shields are aligned at right angles to the conveyor.

J The shield canopies are aligned parallel to the floor.

Check the shield for any installation errors or other sources of error:

. Check all line connections made during the installation of the shields for completeness and correctness, especially all supply lines of the shield hydraulics.

Warning!

Shut-off valves may not be installed into the return lines for the shield hydraulics. As otherwise a dangerously high pressure may build up which could, for example, cause hose lines to burst.

This may result in persons being seriously injured or even killed.

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4.9

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

. Check all functions of the shield control unit.

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

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

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When these components are put into operation, no special measures have to be taken with regard to corrosion protection since the used testing and anticorrosion medium is completely compatible with the approved operation fluids of the group HFA. See section “Permissible media” in chapter 6 of this operating manual.

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5

Operation

Requirements

Operation This chapter provides general information on the operation and maintenance of the shields. This information is to be regarded as preparation of or addition to hands-on training. It is recommended that you read this chapter in addition to the training, 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 extensive knowledge of the control elements and of the way the control system works. You must have had instruction on the actual control and have consolidated your knowledge during a corresponding training session on the object. Should this not be the case you are not allowed to operate the control. 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.

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 accumulations 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 completed.

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5.3

Requirements travel way

The minimum dimensions for the travel way specified must be maintained.

In the Federal Republic of Germany, the following values apply with respect to the minimum dimensions of the travel way: 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 travel way must be removed immediately. This applies particularly for low seam heights.

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

roof supporting work

Roof supporting work must be carried out so 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 area

Work in the mining area may only be carried out from a safe position. The face 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 the roof has been secured against falling rock.

In thick seams the coal face must also be protected against slabbing in these places. On faces equipped with shield supports this is the 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 unit advance.

If flippers are not used, some other kind of protection must be applied to shield the mining area from the rest of the face, e.g. extrahigh spill plates, wire mesh, nets, 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.

In longwalls of the inclined face, additional barricades, such as air cushions, must be set up above the work area in the conveyor to protect against the following material. The design and amount of required safety equipment depends on the local conditions.

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DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

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

E

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

Requirements repair work

Before you start work on the hydraulic system, you must always first make sure that the respective section of the system has been depressurized. Also, take suitable measures to prevent the pressure from being reactivated by unauthorized personnel.

If the shield units are to be detached from the conveyor, mining must either be completely stopped or it must be otherwise ensured that mining can only be continued outside of the safety zone required for safely carrying out repair work.

Parts which are under mechanical or hydraulic tension must be relieved before they can be released or dismantled. The pretension can be relieved, for example, by aligning, lifting or lowering.

If in exceptional cases, the pretension cannot be relieved completely, it must be reduced as far as possible and the respective part must be secured by suitable means, such as chains or locking elements, so that the tension can be safely absorbed as it is released. All work in this area may only be carried out from a safe position.

Protective equipment increases the safety and may only be removed if it is required for carrying out work. After completion of work, the protective equipment should immediately be installed.

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water spraying system

conveyor steering devices

The water spraying system serves to actively fight against the dust.

Usually several nozzles are attached to the shield support via which water can be sprayed. The water spraying system is activated only temporarily depending on the operating state of the system, for example when pushing the shield and when the mining machine passes the support. The water spraying valves are controlled by the program of the electronic shield control or directly by means of the hydraulic shield control.

On an inclined face, the conveyor must be anchored adjacent to the support, if necessary. This way you can prevent the conveyor from shifting to the side with respect to the support. With this, you lower the risk that the shifting system will get stuck in the base.

The intended working pressure must always be applied to the hydraulic conveyor steering device. This is the only way to guarantee that there will be sufficient bracing between the support and conveyor.

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

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5.5

Requirements Safety requirements automatic mode

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

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

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

shield unit operation

The shield unit must always be operated from a safe position and from a neighboring shield unit.

Never stand in a shield unit which hasn’t been set.

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

You may not withdraw or retighten a support unit if there are persons in the vicinity of or inside the support unit.

You may not lower or advance a shield unit manually if the mining equipment is directly in front of or in the range of action of the support.

Advancing should be started in the lower section in longwalls with an inclined face. The neighboring control offers the operator in the above-lying shield unit protection and allows the shield unit being pulled up to be monitored.

The prop of the shield units must always be set until the set pressure is reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as abutments for conveyor steering equipment.

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

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No one may be in a shield unit while it is being advanced.

E

During manual operation, the operator must always keep an eye on the movement range of the shield unit before and while the shield support is being moved, and prevent any hazards by acting with caution.

Requirements Fig. 18: W r o n g , support advanced too late

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Fig. 19: R i g h t , support advanced in time

When taking down a step in the roof, a shield canopy which is angled downwards must not get in the way of mining equipment passing by.

Before a shield unit can be pulled up, the flipper must be completely folded in. Under no circumstances may the support be advanced against the coal face with the flipper extended. Failure to observe this can lead to serious damage, especially to the flipper cylinders and the flipper suspension.

When advancing the support, make sure that the shield canopy doesn’t get under the side seal of the neighboring shield. The side seal of the neighboring shield can otherwise be seriously damaged. hydraulics, controls

Do not operate the shield control incorrectly.

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

Hoses must remain free to move. They may not be squeezed or overstretched. Make sure the hose pipes are bundled properly.

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

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5.7

Requirements The shield canopy and caving shield must be mechanically secured against falling when hose lines between piloted check valves and props or other cylinders or adjusting cylinders lying in the flow of force are to be exchanged. Analogously, this also applies for work on the hinges of the shield unit.

Shut-off valves may not be installed in the return lines.

To make sure the return lines can’t be closed, safety valves must be installed in the return line (see hydraulic layout, if prepared by DBT). If the layout was prepared by the operator, we recommend safety valves be installed at 50 m intervals in the return line. The valves should be set to 25 bar and spray in the atmosphere. damage, replacement parts

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

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

5.8

DBT-shield 1020/2200-2X2771-1750

Operation of the shield Operation of the shield Well trained operating personnel, knowledge and compliance with the safety regulations, as well as the operating instructions listed below largely prevent dangerous situations from arising, and are good preconditions for the fail-safe interaction of the support and mining within the longwall system.

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

The shield units must always be set until the setting pressure has been reached in order to achieve good roof support and to ensure sufficient bracing between the roof and the floor for shield units with special functions, such as abutments for anchorages.

In general, the supports should be advanced to support the exposed roof surface as quickly as possible.

The shield units must be aligned at right angles to the conveyor.

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canopy adjustment

The shield units should always be set so that the shield canopy and base are aligned as parallel to each other as possible. Within the framework of the maximum inclination and swivel angles named on the technical data sheet, however, steps on the roof can be underpinned and steps on the floor can be overcome by bending the shield canopy accordingly if the geological or operational conditions require this.

Caution!

Never exceed the permissible angle of inclination of the canopy.

Exceeding the permissible angle of inclination of the canopy specified in chapter 6 of the section “Technical data” can lead to the support becoming damaged. This especially applies to stabilizing cylinders whose fastening elements and fulcrum points are on the shield canopy and caving shield.

Fig. 20: Shield support in normal position

α=0 M

M = Height of the set shield support α = Angle of inclination 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!

Stabilizing cylinders must always have sufficient residual stroke.

Guide value: at least 20 mm!

The same applies to the adjusting cylinder of the front cantilever.

This is the only way that any potential, suddenly occurring load surges can be “cushioned” by the hydraulic safeguard of the stabilizing cylinders.

If there isn’t sufficient residual stroke available, this could result in serious damage to the support under unfavorable conditions - high force and unfavorable lever ratio.

Fig. 21: Shield support with extremely inclined shield canopy.

α1

s1

s2 α2 M

M = Height of the set shield support α = Angle of inclination of the canopy s = Residual stroke of the stabilizing cylinder

Caution!

Ensure that the stabilizing cylinder has sufficient residual stroke when there is a tendency toward roof falls and/or an extremely soft floor.

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

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

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M

Operation of the shield Caution!

Avoid the canopy being excessively inclined by filling out the roof falls, for example, or by underpinning smaller roof falls with a horizontally positioned shield.

At this point, we again explicitly emphasize that any damage caused by not complying with these instructions, is not covered by the warranty.

Caution!

If the permissible angle of inclination of the canopy (angle between the shield canopy and caving shield) specified in Chapter 6, section “Technical data” of this manual, is exceeded, this could lead to damage to props, hydrocylinders and their fastening elements, as well as to the part hinges.

Since angle changes in the shield canopies or base ends involve significant height changes, the necessity of taking appropriate countermeasures can be recognized at an early stage, even without a measuring instrument. For instance, it may be necessary to rip and level off steps in the floor and roof, or fill break outs in the roof.

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Shield canopies of two-prop shields with stabilizing cylinders may never be set with the tip of the canopy in break outs (see Fig. 22), when the stabilizing cylinder is completely extended. There must always be enough residual stroke available so that dynamic loads from the roof can be absorbed by the hydraulically secured stabilizing cylinder.

Fig. 22: W r o n g, do not set the tip of the canopy in the roof fall when the stabilizing cylinder is extended.

WRONG

Roof falls can be overcome by filling them (see Fig. 23) or by setting the shield canopies horizontally. This will underpin the roof in the next step.

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5.11

Operation of the shield Fig. 23: R i g h t, fill out roof falls

RIGHT

When underpinning a step in the roof, ensure that a shield canopy angled downward doesn’t get in the way of the mining equipment passing by.

The retracted height of the shield units must be suitable for the lowest seam height.

The support must be operated so that there is always sufficient residual stroke remaining for lowering the shield unit. Otherwise the shield unit can get stuck between the roof and floor and be seriously damaged by suddenly occurring load surges, caused by a rock burst, for example. Load surges cannot be hydraulically cushioned if there is not sufficient hydraulic fluid under the piston of the prop or if this is already in the lowest end position.

The minimum residual stroke required for lowering the support unit can be maintained by: J keeping the longwall opening sufficiently large using the mining

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

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

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

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

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range of adjustment/changing seam thickness

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Accumulation on the shield canopies can be avoided by advancing the canopy along the roof. In some cases, the piles can also be guided into the conveyor by briefly lowering the tip of the canopy.

Operation of the shield inclined faces

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

Since in inclined workings shield unit advance usually begins in the lower lying part of the face, it is important that the face end shields are well aligned. Usually, hydraulic end supports, as well as alignment devices are used on the shield canopies and bases or between the bases and shield canopies.

Automatic controls can be used for the side seals which prevent a lowered shield unit from tipping over during the exchanging operation. Other aligning operations which might be necessary are only possible using manual control, however.

The side seal of the caving shield may only be used for aligning with respect to the neighboring shield when this has been aligned to the same extent.

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On an inclined face, the conveyor must be anchored with respect to the support. This way you can prevent the conveyor from shifting to the side with respect to the support. This way you lessen the danger of jamming the ram system in the basic frame, which would hinder pulling up and advancing the shield.

When pulling up the shields, you must always comply with the specified sequence of steps. Otherwise, the conveyor steering equipment can become damaged and unfit for use. Further information can be found in chapter 6, section “Accessories”, or in the operating manual for the conveyor steering device, if necessary. unfavorable floor conditions

In the case of unfavorable floor conditions, the base of the shield unit can sink into the floor. Then the base must be lifted when the shield is pulled up so that the system follows the course of the seam and doesn’t sink into the floor.

For shield units which are equipped with a special hydraulic lifting device, it is lifted out by actuating a valve, or automatically during advancing.

For shield units without a lifting device, the procedure is different, depending on the type: J Individual bases on two-prop shields can usually be lifted hy-

draulically by actively retracting a prop.

J Shield units with undivided bases must be lifted and supported

using standard mining methods.

Important!

Familiarity with the circuit diagram and skilled personnel are required for both procedures. Make sure that you observe the safety regulations under all circumstances.

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5.13

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

Warning!

Never be on a support which is currently being moved. Circumstances which are not always obvious may lead to unexpected movements in the shield units. This could result in serious injury or even death.

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

Caution!

Take care not to damage the pilot valve buttons. Sticking buttons might lead to malfunctions and cause an accident.

Observe the following safety regulations:

Follow these steps if a shield has failed to advance: 1. Determine the cause. Check the following possibilities: J Malfunction of the electronic controls J External obstructions:

– shield is wedges in between the neighboring shields.

– tip of the canopy is stuck in the roof.

– floor step or debris is blocking the base.

2. If the automatic function of the electronic control is not working properly, the support can be manually controlled using the individual control of the control unit of a neighboring shield. See the separate operating manual for the electronic control.

3. If the cause is an external obstruction, try to get the shield free by manually moving the neighboring shields.

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

E

Make sure that your body is completely under a set shield. Keep away from shields which are in the process of being moved or which are to be moved soon.

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

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

Location of hydraulic components on the support The following table lists the hydraulic components of the shield support.

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Tab. 6: Hydraulic components Item 01 02

Pcs. 1 1

03

2

04 05

1 1

06

1

08

1

10

4

11

4

12 14

1 1

15

1

16

3

21 22 23 25

1 1 1 2

26

1

27

1

30

1

31

1

32

1

34

1

36 37

1 1

39

2

Designation Arrangement Electrohydraulic control unit 10x In the center between the props Water valve unit Left next to the electrohydraulic control unit Prop CV, NG 13 On prop respectively, face side Twin CV Flanged on stabilizing cylinder (Z3) Throttle CV, DN 12 Under the canopy behind the electrohydraulic control unit CV, NW 25 At the supply block (item 26), above right CV, NW 20 Under the canopy behind the water valve (2) Pressure relief valve, 450 bar a) 2x on the stabilizing cylinder at the twin CV (4) b) On prop respectively, face side Pressure relief valve, 400 bar a) At distributor (25), below the canopy behind the right prop b) On piloted CV (14) c) On gob side prop respectively Pressure relief valve, 80 bar Over the supply block (26) CV, DN 12 piloted At the two-way valve (15) below the canopy Two-way valve DN 12 At the center below the canopy, behind electrohydraulic control unit (1) Plug cap DN 10 with pressure a) At CV (3) respectively, at prop relief b) At the supply block Hose pipes Water spraying system Holder and accessories Distributor Under the canopy behind the right prop Supply block In front of the right prop DN 40SS-DN 0 Supply block Behind the supply block (26) DN 25-20 HP ball valve DN 10 At the distributor in annular space red handle of the side seal HP ball valve DN 10 Behind the water valve unit (2) blue handle HP ball valve DN 20 Next to supply block (27) and filter blue handle (36) HP ball valve DN 25 In front of supply block at right red handle (26, 27) Filter Next to supply block Pipeline filter At right next to supply block, behind HP ball valve (34) Glycerine pressure gauge At prop CV (3) respectively NG 50

Remarks In brackets

Throttles the speed of the relay bar In the return line

a) For piston and annular space respectively a) For ring space side seal b) For shifting ram c) In the ring space In the return line For shifting rams For shifting rams

Pressure relief valve Subassembly group Subassembly group Subassembly group In the circuit of the side seal In a holder In a holder For side seal, compl.

For flushing and cleaning the nozzles Used for blocking the water supply Interrupts main pressure line to shield In water circuit In high pressure circuit

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.15

Operation of the shield hydraulics Item S1 Z1 Z2 Z3 Z4

Pcs. 2 2 1 1 3

W1

Designation Pressure sensor Prop Shifting ram Stabilizing cylinder Seal cylinder

Arrangement On prop respectively, face side

Remarks

Roof timbering sprinkling system Water curtain

W2

Functions of the HP ball valves The following ball valves are open during normal operation: J 30, 32, 34

The following ball valves are closed during normal operation: J 31

Color

Designation

30

Red

HP ball valve DN 10

31

Blue

HP ball valve DN 10

32

Blue

HP ball valve DN 20

34

Red

HP ball valve DN 25

Function Used for blocking the ring chambers of the seal cylinder Used for blocking the supply for the flushing and cleaning water spraying system Used for blocking the water supply Is used for blocking the pressure supply line to the shield

Utilization Close when transporting the shield, so that the side seal doesn’t extend and the mechanical interlock can be installed For flushing and cleaning the nozzles In order to deactivate the function of the water spraying system During maintenance and repair work on the shield

Fig. 24: HP ball valve, shown opened and closed

Open

Closed

through-flow for medium enabled

5.16

through-flow for medium stopped

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

Pos.

E

Tab. 7: HP ball valves

Operation of the shield hydraulics Shield hydraulics Fig. 25: Shield hydraulics, arrangement (1) Image caption: see Table 6

Z

16b 21 39 10b 16a

16a

3 39 10b

DBT GmbH, Lünen 2007

E

3

View Z

14

11c

5

11c

15

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.17

Operation of the shield hydraulics Fig. 26: Shield hydraulics, arrangement (2) Image caption: see Table 6

22

26

23

34 32 37

2

36

31 8

1 25

11b

30 11a

4 10a

5.18

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

12 27

E

6

Operation of the shield hydraulics Fig. 27: Functions of the electrohydraulic control unit, symbol plates

DBT GmbH, Lünen 2007

E

1

10 Functions leg raise

leg lower

conveyor push

1

3

5

canopy tip up

7

2

4

6

leg raise

leg lower

shield advance

8 canopy tip down

extending seal-cyl.

9 10 retracting seal-cyl.

Tab. 8: Electrohydraulic control unit with 10 functions, allocation of functions Function, designation Raise prop 1 Raise prop 2 Lower prop 1 Lower prop 2 Advance conveyor Advance shield Stabilizing cylinder, extend Stabilizing cylinder, retract Seal cylinder, extend Seal cylinder, retract

Function no.

1 2 3 4 5 6 7 8 9 10

Fig. 28: Functions of the water valve unit, symbol plates water spray gob

W2 W1 Water curtain

Tab. 9: Water valve unit with 2 functions, allocation of functions Function, designation Water curtain Roof timbering sprinkling system

Doc. no.: 7420 176 000 BA 00

VSVA / 01

Function no.

W1 W2

5.19

Operation of the shield hydraulics Fig. 29: Shield hydraulics, Image caption: see Table 6

Z4 Water curtain

Water curtain

2 21

8

31

1

10b

39

14

3

11b 3

15 5

16a 11c

Z5

16a 11c

37 34 16b 26

6

12

Z1

Z1

R = 50 P = 40 SS

W = 25 25 25 27

36 32

30 11a

22

4 10a

Z4

Z3

Z4

5.20

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

39

E

10b

Operation of the shield hydraulics Fig. 30: Hydraulic lines Image caption: see Table 6

10a 10a

4

Z2

Z3

Z4

E

Z4

30

a

11b

21

15

5

25

X

DBT GmbH, Lünen 2007

11a

14

31 11c

Z1

11c

Z1 8

W2

3

6

7

5

4 3

2 1

S1

32

27

8

37

9

39

3

10

16a

10b W1

S1

36

34

10b

1

2

16a

W = 25 P = 40 SS R = 50

R4P4 6

26

39

12

Z4 22

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.21

Operation of the shield hydraulics Shield components Shield support Fig. 31: Shield, side view 21 51

11, 12

31 c b 41 a

d 61

1 Base 11,12 Canopy 21 Side seal 31 Caving shield 41 Prop 51 Stabilizing cylinder

61 Hydraulic system a PMC®-R control unit b Electrohydraulic control unit c Supply block d Shifting ram

Fig. 32: Shield, rear view

140

140 Rubber covering

5.22

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

E

1

Operation of the shield hydraulics Supply block Fig. 33: View of the supply block from below

26 ??

P

R

W

34

E

37 DBT GmbH, Lünen 2007

27 32

26 Supply block DN40SS-DN50 27 Supply block DN25-20 32 HP ball valve DN 20, blocks water supply

Doc. no.: 7420 176 000 BA 00

VSVA / 01

36

34 HP ball valve DN 25, interrupts main pressure line to shield 36 Filter 37 Pipeline filter DN 25 P Pressure line, DN 40SS R Return line, DN 50 W Water line, DN 25

5.23

Operation of the shield hydraulics Fig. 34: View of the supply block from the front

26 16b

12 34

P

R 27

W

12 Pressure release valve, 80 bar 16b Plug cap DN 10 with pressure relief 26 Supply block DN40SS-DN50 27 Supply block DN25-20

5.24

34 HP ball valve DN 25, interrupts the main line to the shield 37 Pipeline filter DN 25 P Pressure line, DN 40SS R Return line, DN 50 W Water line, DN 25

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

E

37

Operation of the shield hydraulics Pipeline filter Fig. 35: View of the pipeline filter

34

E

37

DBT GmbH, Lünen 2007

34 HP ball valve DN 25, interrupts the main line to the shield 37 Pipeline filter

Check valve, piloted Fig. 36: View of the piloted CV

11b

??

15

14 37

5

5 Throttle CV, DN 12 11 Pressure release valve, 400 bar

Doc. no.: 7420 176 000 BA 00

VSVA / 01

14 CV, piloted 15 Two-way valve

5.25

Operation of the shield hydraulics Control unit Fig. 37: Control units

c b

a 31

31 HP ball valve DN 10, for flushing and cleaning the nozzles

a PMC®-R control unit b Symbol plate c Solenoid driver module

The face shields consist of three different variants that are equipped with a PMC®-R control unit, a shield locking switch and a breakout box respectively.

Important!

Every third shield is equipped with a PMC®-R control unit. The other two shields receive a shield locking switch or a breakout box.

Fig. 38: View beneath the control unit

2 32 1

1 Elektrohydr. control unit 2 Water valve unit

5.26

32 HP ball valve DN 20 blocks water supply

DBT-shield 1020/2200-2X2771-1750

E

1 Electrohydraulic control unit 2 Water valve unit

2

DBT GmbH, Lünen 2007

1

Operation of the shield hydraulics Brackets Fig. 39: Holder for control unit

c

16

1

14

3

4

DBT GmbH, Lünen 2007

E

11

a b 1 Retaining plate 3 Symbol plate 10x 4 Symbol plate 2x 11 Hex. head screw M 12x40-A 4-70 14 Hex. nut, M 12-A 4-80

Doc. no.: 7420 176 000 BA 00

VSVA / 01

d

16 Hex. nut M 12-A 4-80 a Electrohydr. control unit b Water valve unit c Solenoid driver board d HP ball valve DN 10 for flushing and cleaning the nozzles

5.27

Operation of the shield hydraulics Fig. 40: Holder for PMC®-R, front and rear views

b

c

a

DBT GmbH, Lünen 2007

E

7

5

a 1

3 1 Tube 25x5 3 Hex. head screw M 12x120-A 4-70 5 Hex. nut M 12-1.4571 7 Washer 12

5.28

a Electrohydraulic control unit b Emergency stop switch c Support lock-out switch

DBT-shield 1020/2200-2X2771-1750

Operation of the shield hydraulics Prop Fig. 41: Left prop, view from the face side

39

S1 10b

16a

3

DBT GmbH, Lünen 2007

E

3 Prop control valve 10b PRV, 450 bar, piston surface side 16a Plug cap with pressure relief, annular space side, covered

39 Pressure gauge S1 Pressure sensor

Fig. 42: Right prop, view from face side

S1 39

10b 16a

3

3 Prop control valve 10b PRV, 450 bar 16a Plug cap with pressure relief, covered

Doc. no.: 7420 176 000 BA 00

VSVA / 01

39 Pressure gauge S1 Pressure sensor

5.29

Operation of the shield hydraulics Fig. 43: Left and right props, view from the gob side

DBT GmbH, Lünen 2007

E

11c

11c PRV, 400 bar

Plug cap with pressure relief The shield has three plug caps DN 10 with pressure relief: J on the supply block, J on the respective prop.

Fig. 44:

Plug cap on the supply block

16b 12

12 Pressure release valve, 80 bar

5.30

16b Plug cap with pressure relief

DBT-shield 1020/2200-2X2771-1750

Operation of the shield hydraulics Fig. 45:

Plug cap on the prop

16a

39

3

DBT GmbH, Lünen 2007

E

3 Prop CV 16a Plug cap with pressure relief 39 Pressure gauge

Canopy and side seal Fig. 46: View beneath the canopy, center

8 1

15

2 31

11b

14 5

1 Elektrohydr. control unit 2 Water valve unit 5 Throttle CV, DN 12 8 CV, NW 20

Doc. no.: 7420 176 000 BA 00

VSVA / 01

11 Pressure release valve, 400 bar 14 CV, piloted 15 Two-way valve DN 12 31 HP ball valve DN 10, for flushing and cleaning the nozzles

5.31

Operation of the shield hydraulics Fig. 47: View beneath the canopy, right rear 30

25

11a

25 Distributor for side seal

E

11a PRV, 400 bar 30 HP ball valve DN 10, for side seal, complete

DBT GmbH, Lünen 2007

Fig. 48: View into the side seal, right

25

11a 11a PRV, 400 bar

5.32

25 Distributor

DBT-shield 1020/2200-2X2771-1750

Operation of the shield hydraulics Fig. 49: View of stabilizing cylinder

a

10a

4

a Stabilizing cylinder 4 Twin CV

10a Pressure release valve, 450 bar

DBT GmbH, Lünen 2007

E

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

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

Operation of the control unit of the electronic control is not described here, but in a separate operating manual for the control unit instead. If the control unit is included in the DBT scope of delivery, the respective operating manual will be included in the DBT documentation provided for the installation.

The fundamental design of the shield unit and the shield control is shown in chapter 6, “Technical data”, “Description” section of this manual.

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

Warning!

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

The shield support is operated in normal operation exclusively by means of the electronic control. It is imperative that you observe the instructions in the control unit’s separate operating manual. If the control unit is included in the DBT scope of delivery, the respective operating manual will be included in the DBT documentation provided for the installation.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.33

Operation of the shield hydraulics Fig. 50 shows the layout of the PMC®-R control unit and the electrohydraulic control unit on the support.

Operation of the PMC®-R control unit is not described in this operating manual. For information on this, please refer to the separate operating manual for the PMC®-R control unit.

Fig. 50: Control units

d

c b

e

a 1

2

d Emergency stop switch

b Symbol plate

e Shield locking switch E

a PMC®-R control unit

c Solenoid driver module

DBT GmbH, Lünen 2007

1 Electrohydraulic control unit 2 Water valve unit 31 HP ball valve DN 10, for flushing and cleaning the nozzles

31

Fig. 51: Electrohydraulic control unit, 10 functions

d

f

b c 1

e 2

a

1 Electrohydraulic control unit 2 Water unit a Pilot valve b Symbol plate 10x

5.34

c Symbol plate 2x d Solenoid driver e Button f Connecting cable

DBT-shield 1020/2200-2X2771-1750

Operation of the shield hydraulics Symbol plate Fig. 52: Symbol plate for electrohydraulic control unit with 10 functions leg raise

leg lower

1

3

2

4

leg raise

leg lower

conveyor push

5

6 shield advance

canopy tip up

extending seal-cyl.

7

9

8

10

canopy tip down

retracting seal-cyl.

The symbol plate is located on the electrohydraulic control unit above the pilot valves. The symbols correspond to the various functions which are initiated by actuating the respective button. The meaning of the symbols and functions are described below.

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

DBT GmbH, Lünen 2007

E

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 support. You must have attended a special training course to this purpose. Otherwise, there is a risk of incorrect operation. This could result in serious injury and even fatal accidents.

Controlling the shields during repair operation is especially dangerous since you are operating the shield you are on. It is therefore extremely important that you know and understand the interrelationships between the functions and movements of the shield.

While actuating the shield using repair mode, no other persons may stand in the shield’s area of movement.

There are two push-buttons on the cover of each individual pilot valve. When you actuate a button, the corresponding work valve is operated immediately.

The function stops as soon as you release the button.

Danger!

Jammed or locked buttons can cause uncontrolled movements of the shield. Seriously injuring or even killing you.

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

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.35

Operation of the shield hydraulics Warning!

Manual actuation of a button on one of the pilot valves initiates direct execution of the corresponding function. Dependencies between the individual functions are not taken into account.

Dangerous situations could arise if functional sequences are initiated in an incorrect order. For example, the function “advance shield” can be activated without previously activating the functions “retract side seal” and “actively lower support”.

This can cause dangerous situations which can result in very serious injury.

Raise prop 1

1

Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

2

Raise prop 2 2

3

Lower prop 1 Before initiating this function, it must be made sure that the neighboring shield is completely set.

The function is executed as long as the button is pressed or until the end position is reached.

4

Lower prop 2 Before initiating this function, it must be made sure that the neighboring shield is completely set.

The function is executed as long as the button is pressed or until the end position is reached.

Important!

See the “Conveyor steering equipment ” manual for detailed information on the “Raise prop” and “Lower prop” functions.

5

Advance conveyor Before initiating this function, ensure that the shield unit is completely set.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

5.36

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

E

Before this function is actuated, the shield canopy must be correctly aligned. The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

Operation of the shield hydraulics Advance shield

6

Before this function is executed, the side seal of the shield unit must be released and the “Lower prop 1” (function 3) and “Lower prop 2” (function 4) functions must have been executed for both props.

The function is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

As long as the function is activated, the hydraulically piloted check valve (14) which is blocking the annular space of the shifting ram is opened automatically.

7

7

Stabilizing cylinder, extend The function lifts the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed until there is a balance of forces or until the end position is reached.

After the canopy has been correctly aligned, the props must be reset.

DBT GmbH, Lünen 2007

E

Caution!

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

8

Stabilizing cylinder, retract Before initiating this function, it must be made sure that the neighboring shield is completely set.

The function lowers the tip of the canopy and is for aligning the canopy. It is executed as long as the button is pressed or until the end position is reached. After the canopy has been correctly aligned, the props must be reset.

Caution!

Do not exceed permissible inclination!

Observe the value for minimum residual stroke.

9

Seal cylinder, extend The function serves to align the shield unit to the adjacent support.

The seal cylinders continue to extend out as long as the button is held down, until there is a balance of forces or until the end position is reached.

In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

10

Seal cylinder, retract The seal cylinders continue to retract as long as the button is held down or until the end position is reached.

In idle status, the side seal is always pushed outwards due to the resistance of the compression springs.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.37

Operation of the shield hydraulics Functions of the water valve unit Fig. 53: Functions of the water valve unit, symbol plates Water spray gob

W2 W1 Water curtain

W2

Water spray canopy The function is executed as long as the button is pushed.

W1

Water curtain

DBT GmbH, Lünen 2007

E

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

5.38

DBT-shield 1020/2200-2X2771-1750

Maintenance Maintenance Warning!

If the operational safety is endangered, damaged components must be replaced immediately. If this is not possible, you must immediately shut down the shield and secure it. Immediately notify the entire face crew and your superiors. electronic control

Refer to the separate original operating manual for the PMC®-R control unit.

hydraulic control

Special measures

one week after start-up

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

E DBT GmbH, Lünen 2007

At the latest one week after start-up, the filter cartridges on the electrohydraulic control units of the control system in the entire face must be spot checked for contamination. If inspection shows that the probability of malfunctions caused by contaminated filter elements is high, all filter cartridges along the face must be replaced.

piston rods

The piston rods of cylinders, which are usually only rarely extended and retracted completely, for example props and stabilizing cylinders, must be thoroughly cleaned every 6 months and then treated with a suitable corrosion inhibitor on all shields which are equipped with a water spraying system.

filter cartridges

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

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

If problems occur in the preparation of the preparation of the medium there will be an increased risk of failures due to clogged filters. Additional measures may be necessary to ensure reliable and safe operation. For example, the filters described above should be spot checked regularly for contamination. If necessary the filter cartridges must be replaced regularly as a precautionary measure.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.39

Maintenance pressure relief valves

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

Pressure relief valves which are pre-tensioned with gas pressure must be additionally spot checked at regular intervals to ensure their correct function. We recommend such spot checks at 3-monthly intervals.

high-pressure hydraulic hoses

All high-pressure hydraulic hoses must be replaced irrespective of any visible damage at the latest after two years of operation for safety reasons and to ensure correct function of the system. If this deadline cannot be met because the end the section planned to be minded will only be reached shortly after this deadline, the hose pipes, can as an exception, be replaced after the respective section has been completed.

dual filter, can be backflushed

Since the intervals between backflushing depends on the degree of contamination of the emulsion used (HFA fluid) the frequency of backflushing cannot be predetermined. We recommend backflushing both filters regularly once per shift

. Check all shields by visually inspecting them for escaping hydraulic fluid: – hose pipes, – electrohydr. control unit, – valves, – props, – shifting ram and baselift cylinder, – link, steering and flipper cylinders.

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

. Check all shields by visually inspecting them for damage to the steel structure, for instance: – on the ram system, – bolt connections and retaining devices, – on the side seals, – on brackets, etc.

5.40

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

hydraulics

E

Daily inspection

Maintenance Weekly maintenance control unit

. Check each 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 easily legible. This prevents the risk of incorrect operation and any resulting accidents.

Carry out every six months

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

Assessment of damage according to schedule

DBT GmbH, Lünen 2007

E

We recommend keeping a record of damage determined. The records should be evaluated regularly, for example every month, and combined in a damage report. This will enable you to detect frequently occurring damage and take preventative action. This will heighten system availability and lower operating costs accordingly.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.41

Troubleshooting Troubleshooting Fault finding on shield hydraulic system The shield hydraulics of a shield unit consist of a multitude of individual components. The linking of the components with each other is shown in the circuit and hose diagrams for the shield hydraulics.

Also refer to the section “Operating the shield hydraulics” in this chapter or the spare parts catalog.

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

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

Warning!

There is a heightened risk of accidents when performing trouble shooting work on hydraulic systems. In particular malfunctions in the hydraulic system and hydraulic medium escaping at high pressure can cause serious injury.

Therefore take special care and always wear the specified protective clothing. Failure to comply with these instructions can result in serious injury.

5.42

Possible cause

Check/measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the prop piston chamber is closed.

Open the shut-off valve.

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

Control piston on the prop control valve isn’t working.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked prop hose pipes. Replace the hoses, if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

support cannot be lowered

E

Fault localization

Troubleshooting Possible cause

Check/measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shut-off valve in the supply line to the prop piston chamber is closed.

Open shut-off valve!

Lines to the piston and annular space of the prop must be open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Control piston on the prop control valve isn’t working.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked prop hose pipes. Replace the hoses, if necessary. Make sure hoses are laid properly.

Prop is defective.

Check the prop for damage and leakage.

Replace the prop, if necessary.

Possible cause

Check/measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The support is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

Step on roof or floor preventing advance.

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

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

The control piston on the pilot-operated check valve does not work.

Check whether the pressure is sufficient to control the valve. Minimum approx. 80 bar.

The prop control valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked shifting ram hose pipes. Replace the hoses, if necessary.

Make sure hoses are laid properly.

Shifting ram is defective.

Check whether the - shifting ram is damaged - the piloted check valve is working properly.

Remove hose from the connection on the piston side and execute the “Advance conveyor” function. If pressure fluid escapes, replace the shifting ram.

DBT GmbH, Lünen 2007

E

support cannot be set

support cannot be advanced

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.43

canopy cannot be positioned

canopy cannot be lowered

5.44

Possible cause

Check/measure required

Prop control valve is defective.

Replace prop control valve. Continue trouble shooting in the pressure continues to drop.

Props are damaged.

Check prop for damage and replace, if necessary.

Remove hose from prop lowering connection and check whether pressure fluid is escapes although the prop no longer extends. If applicable: Piston packing defective, replace prop.

Pressure relief valve defective.

Monitor pressure drop on the pressure gauge.

Is pressure fluid leaking from the pressure relief valve? If applicable: Replace the pressure relief valve and retest the function.

Possible cause

Check/measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Piloted check valve isn’t working.

Check whether the pressure for controlling the valve is sufficient. Minimum is approx. 80 bar.

The check valve may be defective.

Damaged or trapped hoses.

Check for damaged or kinked prop hose pipes.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and exchange, if necessary.

Possible cause

Check/measure required

The shut-off valve for the shield supply on the supply block is closed.

Open the shut-off valve.

Valves can only be switched when the supply line is open.

The shield canopy is stuck between the neighboring supports.

Find the cause. If required, lower neighboring supports and align them in order to free the canopy.

The pressure of the hydraulic supply is too low.

Check whether - the hydraulic supply is working properly - all shut-off valves are open - the system pressure is sufficient.

Piloted check valve isn’t working.

Check whether the pressure for controlling the valve is sufficient. Minimum is about 80 bar.

The check valve may be defective.

Damaged or trapped hoses.

Check hose lines for controlling the prop / stabilizing cylinder.

Stabilizing cylinder is defective.

Check stabilizing cylinder for damage and exchange, if necessary.

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

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

E

Troubleshooting

Troubleshooting 3/2-way or pilot valve The valve is jammed or a by-pass has formed due to internal leakages. The latter can normally be detected on the work valves of the electrohydraulic control unit by an easily audible hissing noise.

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

Defective pilot valves are difficult to detect as no medium is discharged on the valve terminal. There is therefore no obvious indication of faults, for example discharged fluid.

The 3/2-way valve or the pilot valve can therefore be faulty. valve sticks

. Try to solve the problem by initiating the function several times on the control unit or the control valve block.

internal leakage

. Locate the faulty valve by actuating the functions individually in sequence.

If the noise stops while a function is being actuated, this valve is faulty.

You may have to press the button for the faulty function for several seconds before the noise ceases.

valve replacement

. Close the main shut-off valve in the pressure feed line at the

DBT GmbH, Lünen 2007

E

pipe distributor.

. Then operate the functions manually to depressurize the system.

. Replace the 3/2-way valve or pilot valve.

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

. Try to solve the problem by initiating the function several times on the control unit or the control valve block.

If the problem occurs once more, the valve may be defective.

. Check the valve and replace if defective.

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

. Set the prop until the set pressure has been reached. . Remove the “Set prop” hose pipe on the piloted check valve.

If fluid escapes from the connection of the piloted check valve, it is defective.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

5.45

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

. Set the prop until the set pressure has been reached. . Depressurize the annular space side of the prop to be checked.

To do this, vent the plug cap (item 16a, see Fig. 41/42) on the piloted check valve (item 3, see Fig. 41/42) using the screw (screw in).

Important!

Before restarting the prop or after installing a new prop, the venting screw must be screwed out far enough that the plug cap is sealed again.

. Release the hose of the prop annular space connection at the prop.

Pressure relief valve defective Leaking pressure relief valves can normally be detected by the discharge of fluid, or a pressure drop is displayed on the pressure gauge. If fluid is already discharged at operating pressure, the pressure relief valve is defective or the discharge pressure setting of the valve used is too low.

In the hydraulic circuit of a shield unit, various types of pressure relief valves are used. For example, pressure relief valves are used on the props which have a high flow rate. While the pressure relief valves for securing shifting rams, stabilizing cylinders etc. are designed for a lower flow.

Pressure relief valves for different cylinders of for the piston and ring sides of a cylinder can be set to different maximum pressure values. Please refer to the information in the hydraulic circuit diagrams or the spare parts catalog.

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

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

. Check the filters in the hydraulic system.

Backflush filters can be cleaned by backflushing. On fine-mesh filters such as on the control valve block, the filter elements must be replaced.

5.46

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

If there is an internal by-pass in the prop due to damaged piston packing for example, fluid will flow out of the prop lower connection.

In this happens, the prop must be replaced. If fluid escapes from the detached hose lines, the piloted check valve is defective.

E

. Actuate the “Set prop” function from the neighboring support.

6

Technical data

Description

Technical data This chapter contains the technical description of the support and its main subassemblies as well as the technical data for the described subassemblies.

Description Type 1020/2200-2x2771-1750 The two-prop shield mainly consists of the following listed main subassemblies: J basic frame with lemniscatic links and ram system, J canopy, J caving shield, J side seal, moveable on right side, J hydraulic prop, J hydraulic equipment with hose pipes and control.

Tab. 10: Shield support (1) Dimensions, L x W x H max. / min. in mm

Application

Order number

Face shield

7420 176 000 00 01

4900 x 18501) x 2200 5293 x 16502) x 1020

15200

Transition shield

7420 176 000 00 02

5500 x 18501) x 2200 5893 x 16502) x 1020

15750

E DBT GmbH, Lünen 2007

Approximate weight in kg

Tab. 11: Shield support (2) Application

Order number

Shield no.

Special equipment

Face shield

7420 176 000 00 01

4 to 110

Canopy 3595 mm long

7420 176 000 00 02

1 to 3 111 to 113

Canopy 4195 mm long

Transition shield

The two-prop shield is equipped with a two-part basic frame. It consists of two single bases that are connected on the gobside through the yoke of the ram system. The ram system is centrally located between the bases. The shifting ram functions directly.

The caving shield is a one-piece steel construction, connected to the basic frame by the lemniscatic links.

The canopy transmits the support load of the props into the roof.

The connection to the caving shield is flexible by means of pin connections. The hinge is reinforced by the stabilizing cylinder.

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

The multi-stage hydraulic props have the same capacity at all stages and act on both sides.

The lemniscatic link system has the effect that the distance between the tip of the canopy and the coal face is nearly constant over the entire adjusting range of the shield.

1) 2)

Doc. no.: 7420 176 000 BA 00

Side seal full extended Side seal fully retracted

VSVA / 01

6.3

Description The shield units are equipped with all components required for implementing electrohydraulic neighboring control with the electronic PMC®-R control unit.

Main subassemblies Fig. 54: Main subassemblies 21 51

31

11, 12 e b 41 a

f 1

1 Base 11, 12 Canopy 21 Side seal 31 Caving shield 41 Prop

51 Stabilizing cylinder

c Supply block

61 Hydraulic system

d Baselift cylinder

a

PMC®-R control unit

e Supply block

b Electrohydraulic control unit

f Shifting ram

Tab. 12: DBT shield 7420 176 000 00 01/02, main subassemblies Order no.

Approximate weight in kg

7420 176 000 00 01 Basic frame/ base

7420 176 300 00 01

4665

Shifting ram Ø 150 ram system, 3942 long

8241 335 000 00 00 7420 176 330 00 00

02

7420 176 000 00 02 Basic frame/ base

7420 176 300 00 01

4665

Shifting ram Ø 150 ram system, 3942 long

8241 335 000 00 00 7420 176 330 00 00

11

01

7420 176 000 00 01 Canopy

7420 176 400 00 01

4038

12

02

7420 176 000 00 02 Canopy

7420 176 400 00 02

4038

21

01

7420 176 000 00 01 Side seal

7420 176 700 00 01

1738

21

02

7420 176 000 00 02 Side seal

7420 176 700 00 01

1738

31

01

7420 176 000 00 01 Caving shield

7420 176 800 00 01

2615

31

02

7420 176 000 00 02 Caving shield

7420 176 800 00 01

2615

41

01

7420 176 000 00 01 Hydraulic prop

8250 133 000 00 00

561

41

02

7420 176 000 00 02 Hydraulic prop

8250 133 000 00 00

561

51

01

7420 176 000 00 01 Stabilizing cylinder

8241 270 000 00 00

226

51

02

7420 176 000 00 02 Stabilizing cylinder

8241 270 000 00 00

226

61

01

7420 176 000 00 01 Shield control system -10 functions -

8112 241 000 00 00

127

Electrohydr. control unit Lines Water spraying system Holders

8154 133 000 00 00 8112 241 010 00 00 8112 241 020 00 00 8112 241 030 00 00

61

01

7420 176 000 00 02 Shield control system -10 functions -

8112 241 000 00 00

127

Electrohydr. control unit Lines Water spraying system Holders

8154 133 000 00 00 8112 241 010 00 00 8112 241 020 00 00 8112 241 030 00 00

Item

Variants

1

01

1

6.4

For device number

Description

Remarks

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

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61

Description Main dimensions Fig. 55: DBT face shield, dimensions L1 L3

L2

461 409

HE

H

HA

400

1497

DBT GmbH, Lünen 2007

E

L M

B3

B

a b a d a d a

aa a b

a b cc b a

340 X 880

Doc. no.: 7420 176 000 BA 00

VSVA / 01

HA Height, extended HI Height, retracted L Transport length B Width M Support center distance x Number plate

6.5

Description Fig. 56: DBT transition shield, dimensions L1 L2

HE

H

HA

L3

DBT GmbH, Lünen 2007

E

L

900 1) HA Height, extended HI Height, retracted L Transport length B Width M Support center distance

450 1)

1)

Rod extension

Tab. 13: Shield variants, dimensions

6.6

Var.

Order no.

L

L1

L2

L3

M

H

HA

HE

B

B3

01

7420 176 000 00 01

5293

3450

950

2500

1750

1500

2200

1020

1650

200

02

7420 176 000 00 02

5893

4050

950

3100

1750

1500

2200

1020

1650

200

DBT-shield 1020/2200-2X2771-1750

Description Base with lemniscatic links and shifting unit The bearing strength of the hydraulic props is transmitted to the floor through both bases. The props are simply supported in the ball sockets in the bases and are held on both sides by prop retainers.

Both pairs of lemniscatic links are hinged to the basic frame with a pin connection.

The ram system is located between the two bases in the center.

The yoke connects both bases to each other on the gob side and to the ram system. The bases are not connected to each other on the face side. The shifting ram functions directly. That means that the force generated by the piston surfaces is used to advance the conveyor. The lower force of the ring surface is used to advance or pull up a shield. The shifting ram can be equipped with a reed-switch rod for measuring forward movement.

DBT GmbH, Lünen 2007

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The ram system is fastened to the conveyor using the clevis assembly on the crawl pan. The hemispherical shell in the front area of the crawl pan is the thrust bearing for the hydraulic cylinder of the boom steering system that stabilizes the hinge between the crawl pan and the conveyor.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.7

Description Fig. 57: Base (basic frame) for face and transition shield 13 48 34

535

15

829.5

3038

11

25 27 47

18

26 28 47

36

35 46 45

12

17

DBT GmbH, Lünen 2007

E

5

1

1460

1 Shifting ram ZE-135/80-930 5 Shifting unit 11 Base, right 12 Base, left 13 Lemniscatic link, front 15 Lemniscatic link, rear 17 Prop retainer, left

18 Prop retainer, right 25 Lemniscatic link pin Ø133,5x512 26 Lemniscatic link pin Ø98,5x487 27 Locking plate 28 Locking plate 34 Pin, 35/29x66 35 Bolt 75/60x125

36 Washer 45 Hex. nut, M 10-A 4-80 46 Hex. head screw M 10x140-A 4-80 47 Locking clip 5,6 48 Locking clip 4

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.8

DBT-shield 1020/2200-2X2771-1750

Description SHIFTING UNIT The ram system advances the conveyor and pulls up the shield. To do this, it is telescopically extended or retracted using the shifting ram. The shifting ram functions directly. This means that the greater force that is generated by the piston surface is used to advance the conveyor.

Fig. 58: Ram system for face shield

60

70

3953

46 10

35 32

18

40

17 45

3

42

1

8

2 9

DBT GmbH, Lünen 2007

E

1155

41

15 50 16 1083.5

20 19 582

34

667

1275 31 30

3607.5

1 Securing device 2 Cylinder bearing 3 Cylinder receptacle 8 Yoke 9 Guiding rod 10 Crawl pan 15 Round head screw 16 Hemispherical shell 17 Bolt 40/30x87

18 Fastening bolts 28x126 19 Pin, 30/23x95 20 Washer 30 Pin, Ø50x85 31 Protective plug U11 32 Protective plug U2 34 Staple DN 12 35 Staple DN 20 40 Hex. head screw M6x85-A2-70

41 Hex. head screw M10x140-A4-80 42 Hex. head screw M20x40-A2-70, MA=380Nm 45 Hex. nut M6-A 4-80 46 Hex. nut M10-A 4-80 47 Hex. nut M20-10 18 Washer

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.9

Description description

The shifting unit is located in the middle of the base. It primarily consists of the gobside journal bearing (2), the yoke (8), the cylinder bearing seat (3) with the guiding rods (9) and the crawl pan (10), the shifting ram and the required connecting elements.

The gobside part of the ram system, the cylinder receptacle (3), is attached to the base of the basic frame by the yoke (8). The piston rod of the shifting ram affects the cylinder receptacle (3).

The guiding rods (9) can be replaced. They are attached to the cylinder receptacle (3) with bolts and are guided into the gobside journal bearing (2) in the longitudinal direction.

The absolute length of the ram system is variable within limits since the cylinder receptacle (3) can be fastened to the guiding rods (9) in a variety of positions. With respect to the lengths represented in Fig. 58, the ram system can be lengthened and shortend by approx. 150 mm.

E

Fig. 59: Ram system with crawl pan

3

DBT GmbH, Lünen 2007

a

2

1

9

1 Securing device 2 Cylinder bearing 3 Cylinder receptacle

6.10

9 Guiding rod a Shifting ram

DBT-shield 1020/2200-2X2771-1750

Description Functions of the ram system Warning!

Risk of being crushed. Body parts which get between moving parts of the shifting unit and stationary parts of the support can be crushed. For this reason, make sure that you keep a distance from shields which are being advanced or are to be advanced soon. advance conveyor

The shield is used as the thrust bearing, meaning that the shield must be set. The gobside part of the ram system, the journal bearing (2), supports itself with the yoke (8) on the set shield. The face side part of the ram system moves in the direction of the face when the shifting ram is extended. The conveyor is advanced. The power required for advancing the conveyor is generated by the piston surface of the shifting ram.

pull shield

The conveyor is used as the thrust bearing, meaning that the shield must be withdrawn. The face side part of the ram system, the crawl pan (10), supports itself at the conveyor. The gobside part of the ram system moves in the direction of the face when the shifting ram is retracted. The conveyor is pulled up. The power required for pulling up the shield is generated by the annular surface of the shifting ram.

DBT GmbH, Lünen 2007

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Fig. 60: Ram system with conveyor

d

a

c

b

a Conveyor b Shield

Doc. no.: 7420 176 000 BA 00

VSVA / 01

c Conveyor steering equipment d Crawl pan at ram system

6.11

Description Ram system transition shield The ram system of the transition shield can be equipped with ram system extensions of 450 or 900 mm.

Fig. 61: Ram system with extension

DBT GmbH, Lünen 2007

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a

a Ram system extension Fig. 62: Ram system with extension, transport

6.12

DBT-shield 1020/2200-2X2771-1750

Description Canopy The canopy transfers the supporting force of the prop to the roof. It is articulated and connected to the caving shield with bolts. The hinge between the canopy and the caving shield is stabilized by the stabilizing cylinder. The heads of the props are fastened to the canopy and can be rotated.

Caution!

To avoid overloading the stabilizing cylinder, you must make sure that the setting angle of the shield canopy doesn’t exceed the maximum permissible value, e.g. when the canopy is set in a roof fall.

The canopies of all shield variants are equipped with moveable side seals on the right side.

DBT GmbH, Lünen 2007

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880

1610

Fig. 63: Canopy for the face shield

14

7

5

4

8

6

9

10

11

480

1

950 3595 12 13

1 Canopy 4 Pin Ø24, 3x131 5 Pawl R 80 6 Pin Ø24, 3x180

Doc. no.: 7420 176 000 BA 00

7 Spring clip, 5x32 9 Pin, Ø53x175 11 Securing device 12 Pin, 15/12x120

VSVA / 01

13 Locking clip 2,5 14 Spring cotter 5

6.13

Description

14 7

5

4

6

8

9

10

11

480

1

1610

880

Fig. 64: Canopy for the transition shield

1 Canopy 4 Pin Ø24, 3x131 5 Pawl R 80 6 Pin Ø24, 3x180

7 Spring clip, 5x32 8 Pin, Ø53x175 9 Locking element 10 Joint pin Ø108x467

E

950 12 13

11 Securing device 12 Pin, 15/12x120 13 Locking clip 2,5 14 Spring cotter 5

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.14

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

4195

Description Prop head Fig. 65: Prop head attachment

5 5 Pawl R80 6 Retaining bolt Ø24, 3x180

6, 7 7 Spring clip, 5x32

DBT GmbH, Lünen 2007

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Fig. 66: Prop head

7

6

5

5 Pawl R80 6 Retaining bolt Ø24, 3x180

Doc. no.: 7420 176 000 BA 00

VSVA / 01

7 Spring clip, 5x32

6.15

Description Caving shield The caving shield protects the face area toward the gob. It is connected to the shield canopy and with the basic frame via the front and rear lemniscatic links. A stabilizing cylinder is arranged between the caving shield and the shield canopy to provide stability for the articulation.

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

Fig. 67: Caving shield for face and transition shield 230

300

180

580

300

1

880

16

DBT GmbH, Lünen 2007

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14

8

4

1981

9 15

5

3

350

360

520

360

1610

1 Caving shield, subassembly 3 Securing device 4 Lemniscatic link pin Ø133, 5x512

5 Lemniscatic link pin Ø98, 5x487 8 Pin, Ø53x175 9 Pin, 15/12x120

14 Locking element 15 Locking clip 2,5 16 Spring cotter 5

Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.16

DBT-shield 1020/2200-2X2771-1750

Description Fig. 68: Caving shield, load rings

S1

S2

S1

S2 S1 Load ring, capacity: 8 000 kg

S1 Load ring, capacity: 3 000 kg

Side seal DBT GmbH, Lünen 2007

E

The side seals seal the gap between adjacent shield units. In addition, they are also used to align a shield unit to the adjacent shield units.

The left side (viewed in the shifting direction) of the side seal is permanently welded to the shield canopy or caving shield. The right side is attached so that it is movable. It is guided through using guiding pins and pressed permanently against the neighboring shield using compression springs. The side seals can be extended and retracted using hydraulic cylinders.

Warning!

Risk of injury due to unexpected movements of the side seal.

The moveable side seal is under spring pressure. Never remove connecting elements of the side seal before the side seal is pulled together and secured using clamp clips.

Caution!

Before putting the support unit into operation, the transport safety devices (see Fig. 69 marked with a *) of the side seal must be removed.

For the transport, the moving side seals are retracted and mechanically locked with pins. The pins are secured with staples.

The same side seal is used for face shields and transition shields.

Notice!

When putting the transport safety devices into operation, remove items (27*, 46*) and (28*, 44*) on the movable side. Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.17

Description Notice!

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

Warning!

Risk of injury! The moveable side seal is under spring pressure. Secure the side seal using clamps before dismantling the side seal cylinders and their guiding pins.

DBT GmbH, Lünen 2007

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Notice!

Apply lubricant B6 EWN7068 to all connecting points and slide surfaces.

6.18

DBT-shield 1020/2200-2X2771-1750

Description Fig. 69: Side seal for face and transition shield 23 14 46

45 15 41 32 1

3

25 47

17

11

1

45 22 40 33 42 24

420

34

20 43

6

320

310

390

330

1650

5

35

27* 46* 18

30 48

13

4

16 49

44* 28* 46 31 26

10

48

19

50

E

2610

DBT GmbH, Lünen 2007

1800

750

1 Hydraulic cylinder ZE-63/50-215 3 Side seal, canopy, right 4 Side seal, canopy, left 5 Side seal, caving shield, right 6 Side seal, caving shield, left 10 Guiding pin Ø90x1040 11 Guiding pin Ø90x645 13 Guiding pin Ø103x1063 14 Guiding pin Ø103x690 15 Pin, 40/34x188 16 Pin, 30/22x315 17 Pin, 30/22x170

Doc. no.: 7420 176 000 BA 00

18 Cover plate for canopy 19 Cover plate for caving shield 20 Pin, Ø25x175 22 Pin, 40/34x64 23 Pin, Ø22x196 24 Pin, Ø28x74 25 Pin, Ø28x93 26 Pin, Ø22x169 26 Pin, Ø22x150 28 Transport safety device 30 Torque support 31 Torque support 32 Cylinder liner, 103x105 33 Cylinder liner, 92x105

VSVA / 01

34 Compression spring 12x64x621 35 Compression spring 12x79x560 40 Screw pin M 6x8-14 H 41 Screw pin M 10x12-45 H 42 Sprung pin 5x50 43 Staple DN 12 44 Staple DN 12 45 Staple DN 25 46 Spring clip 47 Splint pin, 6,3x40 48 Hex. head screw M 12x20-A 4-80 49 Hex. head screw M 10x80-A 2-70 50 Hex. nut M10-8

6.19

Description Technical data, steel structure Face shield, device number 7420 176 000 00 01

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

1020

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

2200

Height adjustment of shield . . . . . . . . . . . mm

1180

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

850

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

930

Length change of ram system . . . . . . . . mm

2x150

Distance of prop centers (inclination) . . mm

880

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

2500

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

950

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

1650

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

3450

Caving shield inclination:

6.20

Support retracted . . . . . . . . . . . . . . . . . . . degree

10.36

Support extended . . . . . . . . . . . . . . . . . . . degree

45.83

Width of caving shield with side seal retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1650

Basic frame width . . . . . . . . . . . . . . . . . . . mm

1460

Total area of the basic frame . . . . . . . . . . cm2

25659

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

1750

Supporting force of support for average seam of . . . . . . . . . . . . . . . . . . . . mm

1500

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

3562

a) for 450 bar nominal pressure . . . . . . . kN

5010

Support resistance per m2 roof surface for average seam of . . . . . . . . . . . . . . . . . mm

1500

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

528

b) for 450 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

608/742

DBT-shield 1020/2200-2X2771-1750

E

15

DBT GmbH, Lünen 2007

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

Description Transition shield, device number 7420 176 000 00 02

E

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

15

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

1020

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

2200

Height adjustment of shield . . . . . . . . . . . mm

1180

Advance stroke . . . . . . . . . . . . . . . . . . . . . mm

850

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

930

Length change of support/PF connection . . . . . . . . . . . . . . . . . . . . . . . . . mm

2x150

Distance of prop centers (inclination) . . mm

880

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

3100

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

950

Width of canopy with side seals retractedmm

1650

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

4050

DBT GmbH, Lünen 2007

Caving shield inclination:

Doc. no.: 7420 176 000 BA 00

Support retracted . . . . . . . . . . . . . . . . . . . degree

10.36

Support extended . . . . . . . . . . . . . . . . . . . degree

45.83

Width of caving shield with side seal retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

1650

Basic frame width . . . . . . . . . . . . . . . . . . . mm

1460

Total area of the basic frame . . . . . . . . . . cm2

25659

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

1750

Supporting force of support for average seam of . . . . . . . . . . . . . . . . . . . . mm

1500

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

3562

a) for 450 bar nominal pressure . . . . . . . kN

5010

Support resistance per m2 roof surface for average seam of . . . . . . . . . . . . . . . . . mm

1500

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

457

b) for 450 bar nominal pressure (KAKO large/small) . . . . . . . . . . . . . . . . . . kN/m2

539/642

VSVA / 01

6.21

Hydraulic system Hydraulic system The following section provides an overview of the parts of the shield hydraulics. You can find additional information in the spare parts catalog of the shield support.

normal and exceptional operation

During normal operation, the shield functions may only be controlled via the PMC®-R control unit.

The pilot valves of the electrohydraulic control unit are equipped with buttons, which allow the shield functions to be operated manually. A symbol plate shows the function/button allocation.

Warning!

During normal operation the buttons on the pilot valves of the control valve blocks should not be used to activate functions.

Failure to observe this warning can result in unexpected and hazardous situations, for example if interlocking functions are deactivated as a result.

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

The following table lists the hydraulic components of the shield support.

Tab. 14: Hydraulic components Item 01

Pcs. 1

02

1

Designation Electrohydraulic control unit 10x Water valve unit

03 04 05

2 1 1

Prop CV, NG 13 Twin CV Throttle CV, DN 12

06

1

CV, NW 25

08

1

CV, NW 20

10

4

Pressure relief valve, 450 bar

11

4

Pressure relief valve, 400 bar

12 14

1 1

Pressure relief valve, 80 bar CV, DN 12 piloted

15

1

Two-way valve DN 12

16

3

21 22

1 1

Plug cap DN 10 with pressure relief Hose pipes Water spraying system

Arrangement In the center between the props

Remarks In a holder

Left next to the electrohydraulic control unit On prop respectively, face side Flanged on stabilizing cylinder (Z3) Under the canopy behind the electrohydraulic control unit At the supply block (item 26), above right Under the canopy behind the water valve (2) a) 2x on the stabilizing cylinder at the twin CV (4) b) On prop respectively, face side a) On the distributor (25), below the canopy behind the right prop b) On piloted CV (14) c) On gob side prop respectively Over the supply block (26) At the two-way valve (15) below the canopy At the center below the canopy, behind electrohydraulic control unit (1) a) At CV (3) respectively, at prop b) At the supply block

Throttles the speed of the relay bar In the return line

a) For piston and ring space respectively a) For annular space side seal b) For shifting ram c) In the annular space In the return line For shifting rams For shifting rams

Pressure relief valve Subassembly group Subassembly group

CV = Check valve, PRV = Pressure relief valve, HP = High pressure

6.22

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DBT GmbH, Lünen 2007

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Shield hydraulics

Hydraulic system Item 23 25

Pcs. 1 2

Designation Holders and accessories Distributor

26 27 30

1 1 1

Supply block DN 40SS-DN 0 Supply block DN 25-20 HP ball valve DN 10 red handle

31

1

32

1

34

1

36 37

1 1

39

2

S1 Z1 Z2 Z3 Z4

2 2 1 1 3

HP ball valve DN 10 blue handle HP ball valve DN 20 blue hand- Next to supply block (27) and filter le (36) HP ball valve DN 25 red handle In front of supply block at right (26, 27) Filter Next to supply block Pipeline filter At right next to supply block, behind HP ball valve (34) Glycerine pressure gauge At prop CV (3) respectively NG 50 Pressure sensor On prop respectively, face side Prop Shifting ram Stabilizing cylinder Seal cylinder

W2

Under the canopy behind the right prop In front of the right prop Behind the supply block (26) At the distributor in annular space of the side seal Behind the water valve unit (2)

Remarks Subassembly group In the circuit of the side seal In a holder In a holder For side seal, compl.

For flushing and cleaning the nozzles Used for blocking the water supply Interrupts main pressure line to shield In water circuit In high pressure circuit

Roof timbering water spraying system Water curtain

DBT GmbH, Lünen 2007

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W1

Arrangement

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.23

Hydraulic system Shield hydraulics Fig. 70: Shield hydraulics, arrangement (1) Image caption: see Table 14

Z

16b 21 39 10b 16a

16a

3 39 10b

DBT GmbH, Lünen 2007

E

3

View Z

14

11c

5

11c

15

6.24

DBT-shield 1020/2200-2X2771-1750

Hydraulic system Fig. 71: Shield hydraulics, arrangement (2) Image caption: see Table 14

22

26 6

DBT GmbH, Lünen 2007

E

12 27

23

34 32 37

2

36

31 8

1 25

11b

30 11a

4 10a

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.25

Hydraulic system Fig. 72: Functions of the electrohydraulic control unit, symbol plates

10 Functions leg raise

leg lower

conveyor push

1

3

5

canopy tip up

7

2

4

6

leg raise

leg lower

shield advance

8 canopy tip down

extending seal-cyl.

9 10 retracting seal-cyl.

Tab. 15: Electrohydraulic control unit with 10 functions, allocation of functions Function, designation Raise prop 1 Raise prop 2 Lower prop 1 Lower prop 2 Advance conveyor Advance shield Stabilizing cylinder, extend Stabilizing cylinder, retract Seal cylinder, extend Seal cylinder, retract

Function no.

1 2 3 4 5 6 7 8 9 10

Fig. 73: Functions of the water valve unit, symbol plates Water spray gob

W2 W1 Water curtain

Tab. 16: Water valve unit with 2 functions, allocation of functions Function, designation Water curtain Roof timbering water spraying system

6.26

Function no.

W1 W2

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

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1

Hydraulic system Fig. 74: Shield hydraulics, Image caption: see Table 14

Z4 Water curtain

Water curtain

2 21

8

31

1

10b

39

DBT GmbH, Lünen 2007

E

10b 39

14

3

11b 3

15 5

16a 11c

Z5

16a 11c

37 34 16b 26

6

12

Z1

Z1

R = 50 P = 40 SS

W = 25 25 25 27

36 32

30 11a

22

4 10a

Z4

Z3

Z4

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.27

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 piloted check valve which is installed in the piston pipe.

The bottom and top of the prop are designed as a globe joint. This allows the prop to be joined to the support via a rotatable fastening.

The head is fastened using two pegs each that are inserted into the holes in the retainer before the prop head is installed. The pegs are secured in the second slot by a pin and spring clip. After the prop head is installed, the pegs are pushed into the holes of the prop head and secured in the first slot with a pin and spring clip.

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

Fig. 75: Double-telescopic prop, Type SD-2770-280-860/1910-BN

21

DBT GmbH, Lünen 2007

E

2

b

d

a

1

c

1 Prop base 2 Piston pipe 21 Piston rod

a Piston space connection b Ring space connection c Cam

d Load ring 3000 kg

Tab. 17: Telescopic prop Length in mm

6.28

Stroke in mm

ID no.

Telescopic prop

Retracted

Extended

Upper stage

Lower stage

8250 133 000 00 00

860

1910

515

535

DBT-shield 1020/2200-2X2771-1750

Hydraulic system Warning!

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

Never close the lowering connections on double-acting props pressure-tight. Otherwise, pressure might build up in the annular space when extending the prop which is several times more than the set pressure.

Function Pressure fluid is admitted under the piston pipe via the piston space connection. The piston pipe first extends, whereby the pressure fluid in the annular space is conducted away into the return line. If the piston of the piston pipe moves against the stop before the shield canopy has reached the roof, the piston rod extends.

Hereby, the pressure fluid is supplied via the check valve in the bottom of the piston pipe.

prop loading

a) Piston pipe extended only: The force is transferred mechanically from the shield canopy via the prop head to the piston rod and again via the bottom of the piston rod to the bottom of the piston pipe. Further transmission of the force is hydraulically via the pressure fluid under the piston pipe in the prop base and from there, mechanically into the basic frame (base).

DBT GmbH, Lünen 2007

E

prop setting

The hydraulic pressure under the piston pipe is regulated by a pressure relief valve which is installed in the associated prop check valve. If the pressure on the pressure relief valve is exceeded, the pressure fluid flows from the prop and the prop is pushed in under the nominal prop force. b) Piston pipe and piston rod extended: The force is mechanically transferred from the shield canopy via the prop head to the piston rod.

The piston rod supports itself on the pressure fluid, which is blocked by the check valve in the bottom of the piston pipe.

The further course of the force flow up to the setting of the piston pipe is as described under a). props lowering

The pressure fluid is connected to the return under the piston pipe via the prop check valve.

Both stages of the prop can be actively lowered. Only when the piston pipe is completely retracted is the check valve in the bottom of the piston pipe opened by the tappet and the piston pipe can then retract.

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

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.29

Hydraulic cylinder Hydraulic cylinder Design The hydraulic cylinders used mainly differ in the arrangement of their connections. They can be roughly divided into two groups: Type a) Connections arranged on the outer cylinder Type b) Connections arranged at the end of the piston rod Fig. 76: Hydraulic cylinder, typical example Type a)

2 1 Outer cylinder 2 Cylinder bottom 3 Piston rod

3

3

5

4

1

4

6

4 Guide bushing 5 Connection 6 Connection

Notice!

The technical data for the cylinders can be found in section “Technical data, hydraulic cylinders” of the used shield unit.

Warning!

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

Never close the lowering ports of double-acting props pressure-tight.

Otherwise, pressure that is several times higher than the set pressure can build up in the ring space when extending the cylinder.

The end of the piston rod either has its own fastening option or is made so that a fastening option, e.g. rod head or fork head, can be screwed on and can be secured against working loose using clamping screws or a clamping sleeve connection.

The pressure fluid is either fed through the connections at the outer cylinder (type a) or on the piston rod (type b).

If a double-acting cylinder is to be operated as a single-acting cylinder only, the annular space connection must be protected from the penetration of dirt with a filter screw. If the cylinder is used without the annular space seals, the seal grooves are to be filled with grease.

6.30

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

1

Type b)

E

2

Hydraulic cylinder Shifting ram Fig. 77: Hydraulic cylinder type ZE-135/80-930

75 L c

d 1

21

3

a

33

b e

DBT GmbH, Lünen 2007

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1 Cylinder tube 3 Reed-switch rod 21 Piston rod 33 Screw fitting a Ring space connection b Piston space connection

c Ram system adapter d Load ring 1000 kg e Cylinder disk L Extended 1597 retracted 667 Stroke 930

Stabilizing cylinder Fig. 78: Hydraulic cylinder ZE-165/100-330

55

55 L a c

10 b 1 1 Cylinder tube 10 Piston rod a Valve connection plate b Piston space connection

Doc. no.: 7420 176 000 BA 00

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c Load ring 1000 kg L Retracted 770 extended 1100 Stroke 330

6.31

Hydraulic cylinder Alignment cylinder (seal cylinder) Fig. 79: Hydraulic cylinder ZE-63/50-215

a

30 L

1

b

2

a Piston space connection

E

2 Piston rod

b Annular space connection L Retracted 440 extended 655 Stroke 215

DBT GmbH, Lünen 2007

1 Cylinder tube

Technical data, hydraulic cylinder double telescopic prop, double-acting, 2-stage

6.32

Type SD-2770-280-860/1910-BN/CR device no. 8250 133 000 00 00 Prop height a) retracted . . . . . . . . . . . . . . . . . . . . . . . . mm

860

b) extended . . . . . . . . . . . . . . . . . . . . . . . . mm

1910

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

1050

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

200/280

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

260/185

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

615.7 / 314.2

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

84.8 / 45.4

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

1970

Setting pressure, 450 bar . . . . . . . . . . . . kN

2770

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

271.36

DBT-shield 1020/2200-2X2771-1750

Hydraulic cylinder shifting ram double acting, el. connection, reeved arrangement

DBT GmbH, Lünen 2007

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stabilizing cylinder, double-acting

alignment cylinder, double acting

Doc. no.: 7420 176 000 BA 00

Type ZE-135/80-930, device no. 8241 335 000 00 00 version with reed-switch rod Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

930

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

135

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

80

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

50.3

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

92.9

Compressive force at 320/400 bar . . . . kN

160.96 / 201.2

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

297.3

Type ZE-165/100-330, device no. 8241 270 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

330

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

165

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

100

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

213.8

Ring surface . . . . . . . . . . . . . . . . . . . . . . . cm2

135.3

Thrust at 320 / 450 bar . . . . . . . . . . . . . . kN

684/ 962

Pulling force at 320 / 450 bar . . . . . . . . . kN

433 / 609

Type ZE-63/50-215, Dr. no. 8241 352 000 00 00 Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

215

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

63

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

50

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

31.2

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

11.5

Thrust at 320 bar . . . . . . . . . . . . . . . . . . . kN

100

Pulling force at 320 / 400 bar . . . . . . . . . kN

37 / 46

VSVA / 01

6.33

Pressure relief valves Pressure relief valves Pressure relief valves protect the hydraulic components, such as props and cylinders, against damage caused by overloads. When the set pressure is reached, the valve opens and the fluid is discharged.

The pressure relief valves in the following table can be used in the hydraulic circuit of the shield support. Also refer to the hydraulic circuit diagram and spare parts catalog.

Type

Setting pressure in bar

Order no.

For return line

Spring-loaded

80

8220 042 080 00 00

For prop side seal cylinder and shifting ram

Spring-loaded

400

7337 486 400 00 00

For stabilizing cylinder and prop

Spring-loaded

450

7337 486 450 00 00

Caution!

The set pressure of pressure relief valves should not be changed! Only use pressure relief valves which have been factory-set to the required value and which have a corresponding color code.

Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system’s circuit diagram. Non-compliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Ignoring this can lead to leakage at the coupling and impair the operational safety of the hydraulic system.

Code system

Pressure relief valves are color coded according to DIN 21557.

The letter code includes the following information: J set pressure, target value, J week setting was made, J year setting was made, J made by.

6.34

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

Application

E

Tab. 18: Pressure relief valves, use of the various types

Pressure relief valves Tab. 19: Typical letter code 420 or 42 1)

09

03

xy

Set pressure

Week

Year

made by

Color coding is with either one or two colors. It indicates the range within which the set pressure is located. The following Fig. 80 shows a pressure relief valve provided with a blue and white color code. This color code corresponds to the pressure range of 350 to 399 bar.

Fig. 80: Pressure relief valve, example

b

a

a Color code b Protective cap

DBT GmbH, Lünen 2007

E

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

Tab. 20: Color codes for pressure relief valves, overview

1)

Doc. no.: 7420 176 000 BA 00

Color

Pressure range (bar)

black

0 - 49

black / white

50 - 99

brown

100 - 149

brown / white

150 - 199

green

200 - 249

green / white

250 - 299

blue

300 - 349

blue / white

350 - 399

red

400 - 449

red / white

450 - 499

yellow

500 - 549

yellow / white

550 - 599

orange

600 - 649

orange / white

650 - 699

Set pressure according to DIN 21557: 1/10 x nominal pressure in bar, “42” equals 420 bar, “08” equals 80 bar

VSVA / 01

6.35

Electrohydraulic control system Electrohydraulic control system Electrohydraulic control unit The electrohydraulic control unit has 10 functions and is the same for the face shield and transition shield.

Fig. 81: Electrohydraulic control unit, 10 functions

2

1 Distribution block 2 Pilot valve actuated electromagnetically

4

3 Button for manual operation 4 Contact for electrical connection to the control unit

Warning!

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

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

6.36

DBT-shield 1020/2200-2X2771-1750

E

3

DBT GmbH, Lünen 2007

1

Electrohydraulic control system PMC®-R control unit Notice!

Please observe the separate operating manual for the PMC®-R control unit.

Control unit PMC®-R, input allocation; Face shield device number 7420 176 000 00 01 Fig. 82: Control unit PMC®-R, input allocation Front view

Rear view B2

C2

D2

E2

F2

A1

B1

C1

D1

E1

F1

DBT GmbH, Lünen 2007

E

A2

Doc. no.: 7420 176 000 BA 00

PMC®-R inputs A1 = left hand, adjacent unit A2 = not used B1 = not used B2 = not used

D1 = not used

C1 = shifting ram reed-switch rod C2 = pressure sensor, left

F1 = right hand, adjacent unit

VSVA / 01

D2 = pressure sensor, right E1 = sensor, right neighboring shield E2 = sensor, left neighboring shield

F2 = Solenoid driver module

6.37

Electrohydraulic control system Fig. 83: Control unit PMC®-R, diagram Rev. 00 Right-hand neighbor

4

PROP RIGHT PROP LEFT RAM

PROP RIGHT PROP LEFT RAM

Left-hand neighbor

4

4

X3 X2

MINING DIRECTION

X2 X3

21

21

Front view

A1

C1 D1 E1 F1

Rear view E

C2 D2 E2 F2

1 MINING DIRECTION

5b

5a

5a

5b 5b

5a

a

a

Right-hand neighbor

Left-hand neighbor 1 Shield control unit (SCU) 4 Solenoid driver 5a Pressure sensor, left

6.38

a

5b Pressure sensor, right a Reed-switch rod, shifting ram Other components: see spare parts catalog

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

A2

Electrohydraulic control system Fig. 84: Shield group with double power unit, diagram Left-hand neighbor

Right-hand neighbor

**

4

4

** PROP RIGHT PROP LEFT RAM

PROP RIGHT PROP LEFT RAM

**

4

X3 X2

MINING DIRECTION

X2 X3

Front view

21

21

DBT GmbH, Lünen 2007

E

* A2

C2 D2 E2 F2

A1

C1 D1 E1 F1

Rear view

DPU

1

MINING DIRECTION

5a

5b

5a

5b

5a

a

a Left-hand neighbor

a Right-hand neighbor

1 Shield control unit (SCU) 4 Solenoid driver 5a Pressure sensor, left 5b Pressure sensor, right a Reed-switch rod, shifting ram

Doc. no.: 7420 176 000 BA 00

5b

VSVA / 01

*) Coding plug CP1 15K in shield as numbering master unit **) Coding plug CP2 27K in shield with block anchorage

Other components: see spare parts catalog

6.39

Electrohydraulic control system Fig. 85: Shield group with isolation coupler (IC), diagram Right-hand neighbor

Left-hand neighbor

PROP RIGHT PROP LEFT RAM

4

4

** PROP RIGHT PROP LEFT RAM

**

**

4

X3 X2

MINING DIRECTION

X2 X3

21

21

Front view

Rear view

A2

C2 D2 E2 F2

A1

C1 D1 E1 F1

E

IC

1 MINING DIRECTION

5a

5b

a Left-hand neighbor

5a

5b

5a

a

1 Shield control unit (SCU) 4 Solenoid driver module 5a Pressure sensor, left 5b Pressure sensor, right a Reed-switch rod, shifting ram

6.40

5b

a Right-hand neighbor *) Coding plug CP1 15K in shield as numbering master unit **) Coding plug CP2 27K in shield with block anchorage

Other components: see spare parts catalog

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

*

Angles of inclination of the canopy Angles of inclination of the canopy The angles of inclination of the canopy relative to the floor level are at least 15 degrees unless limited by the retracted/extended state of props or stabilizing cylinders or by the limited articulation of the hinged joint between canopy and caving shield.

Fig. 86: Angles α 1 / α 2

α1 α2

DBT GmbH, Lünen 2007

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M

Tab. 21: Change angle α 1 / α 2 for height M Inclination α at height M

Shield Order no.

α1 in °

α2 in °

M in mm

7420 176 000 00 01 7420 176 000 00 02

10

10

1020 to 1300

15

15

1400 to 2200

Caution!

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

Important!

When the support is extended or retracted as far as possible, the “Canopy - Caving shield” crosspoint moves correspondingly when the canopy is raised or engaged.

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.41

Permissible media Permissible media Hydraulic fluids Operating media Notice!

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

For the operation of hydraulic components from 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 using 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. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

In addition, a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

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

6.42

DBT-shield 1020/2200-2X2771-1750

DBT GmbH, Lünen 2007

If a mine only uses individual hydraulic components without using DBT shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by DBT. The same applies for example to hydraulic chain tensioners, hydraulically tensionable drive units etc.

The respective exemption permit will be issued by DBT GmbH on request.

E

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

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of DBT GmbH hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can respectively be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

The following illustration shows a typical certificate.

DBT GmbH, Lünen 2007

E

Fig. 87: Typical certificate

Doc. no.: 7420 176 000 BA 00

VSVA / 01

6.43

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

The operator must draw up a maintenance concept for the hydraulic fluid that relates to the respective conditions of use. 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: see certificate – Target value: ≤ 105 col/ml.

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

The permissible 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 22 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 must provide a sample of the original water to enable the tests required for the issue of the certificate to be performed.

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.

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J Microbial load

Permissible media Tab. 22: Properties of the process water, limit values Test criteria

Limit value

Appearance, color, smell

No peculiarities permissible e.g. turbidity, bad odor, 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 - equivalent (≤ 42° dH)

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

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

≤

10 mg/l

Contamination class according to ISO 4406: 1999

- / 18 / 14

DBT GmbH, Lünen 2007

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Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases general properties

Base:

lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presenceof water: practically non-soluble in water

lubricating grease A1

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 installation (according to EWN *) 7068).

Tab. 23: Lubricating greases for general application Flash point in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

*) EWN = DBT works standard

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Permissible media lubricating grease A2

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

Tab. 24: Lubricating greases with additives Flash point in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

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

Tab. 25: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

Lubricating molybdenum

Gleitmo 805 *)

Li

NLGI class

Flash point in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 according to the DBT works standard EWN 7068 is used: Lubricating molybdenum “Gleitmo 805” lubricating paste B6

Separating agents and lubricants with organic lubricating media in a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders of pin connections and similar connection elements at the shield support.

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

-34 to +120 °C

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

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

*) The products listed in table 23 are suitable lubricating greases for filling of adjacent cavities.

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lubricating paste B3

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Lubricating pastes

Tightening torques Tightening torques Screws with ISO metric thread Tab. 26: Recommended tightening torques at µtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1,25

23

32,5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

DBT GmbH, Lünen 2007

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 must be observed for installation and maintenance work!

1) 2) 3) 4)

Doc. no.: 7420 176 000 BA 00

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

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

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

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

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Tightening torques

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For your information

Service addresses

For your information If you should require replacement parts or if technical problems occur, please contact out after-sales service personnel or contact us directly (Homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Head Office) Industriestraße 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: infodbt@dbt.de

Great Britain

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

DBT GmbH, Lünen 2007

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: martin.daldrup@dbtgb.com DBT GB Limited Engineering Pioneer House 2 Renshaw Place Europoint Office Park Eurocentral Lanarkshire, ML1 4UF Scotland Tel: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48 / 32 31 70 - 500 Fax: +48 / 32 31 70 - 509 E-mail: dbtpolska@dbtpolska.com

Russia

DBT Office Moskow Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: dbt@co.ru OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: office@dbtrus.ru

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7.3

Service addresses North America, Canada, South America USA

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

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

Australia DBT Australia Pty Ltd / DBT Diesel Pty Ltd 537 Lake Road Argenton, New South Wales 2284

Tel: +61 / 24 95 8 - 3133 Fax: +61 / 24 95 8 - 5754 E-mail: tim.clark@dbtaustralia.com DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

Africa South Africa

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: zelda.stephens@dbtafrica.com

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P.O. Box 102 Boolaroo, New South Wales 2284

Service addresses Asia China

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

DBT GmbH, Lünen 2007

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@dbtchina.com Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209 Tel: +86 / 47 78 28 - 7245 (& 7514, 7290) Fax: +86 / 47 78 28 - 7431 E-mail: Info.shenhua@dbtchina.com India

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

Doc. no.: 7420 176 000 BA 00

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+91 / 33 24 2 - 0272 +91 / 33 24 2 - 8684

7.5

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

Fig. 88: Type plate, example

DBT GmbH 2

2

1 Manufacturer 2 SAP/order no.

3 Date of manufacture 4 Serial no.

7.6

4

678

5

7420 176 000 00 00

7

2771 kN

5 Device number 6 Number of props 7 Prop set load

DBT GmbH, Lünen 2007

6

12345 3 01/07

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1

DBT-shield 1020/2200-2X2771-1750

Identification of the shields Shield number The shields are numbered consecutively. Plates with the shield number are fitted at the faceside on the base at the left.

DBT GmbH, Lünen 2007

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Fig. 89: Shield number on the base, example

Tab. 27: Allocation of the shield numbers

Doc. no.: 7420 176 000 BA 00

Use

Shield number

Device no.

4 to 110

7420 176 000 00 01 Face shield

1 to 3 111 to 113

7420 176 000 00 02 Transition shield

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7.7

Referenced standards and guidelines Referenced standards and guidelines Referenced national standards and guidelines Tab. 28: National standards and guidelines, extract

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation system Hydraulic system plug connections Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulphate ash Tensioning force, tightening torques and surface pressure for bolts T-head bolts Lubricating greases & solid lubricants Non metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and guidelines Tab. 29: European standards and guidelines, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 prEN 1710 prEN 1552

Date of issue

Title EC directives of the European Parliament and the Council for Standardizing the Legal and Administrative Guidelines for Machines EC directive for standardizing the legal guidelines of the Member State for Equipment intended for use in Potentially Explosive Atmospheres (ATEX) Safety of machinery Safety of machinery Non-electric equipment for use in potentially explosive atmospheres - Part 1: Basic methods and requirements Electrical apparatus for explosive gas atmospheres - Part 0: General requirements Basic and safety principles for man - machine interface Creating manuals - Structure, content and presentation Petroleum products and bituminous materials - Determination of water - Distillation method Equipment and components for use in areas susceptible to firedamp in mines Mobile extraction machines on the face - safety requirements for shearers and plane systems 1)

7.8

1998-06-22

1994-03-23 2004-04 2004-04 2002-04 2004-12 2000-08 2001-11 2003-02 2003-04 2003-09

EWN = DBT works standard

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Title

DBT GmbH, Lünen 2007

Designation