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Amendmentsandalterationstothispublicationarenotsubjectto notification.DBTGmbH(DBT)reservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws,bothdomesticandinternational.Nopartofthispublicationmaybereproducedortransmittedinanywayorformwithoutthepriorwrittenapprovalofthe DBT.

DBTdeclinesallliabilityfordirectorindirectconsequencesofprintingerrors.

Wereservetherighttointroducemodificationsobtainedby technicaldevelopmentwithoutpreviousnotice!

DBTGmbH,Lünen2005 E

1.Aboutthismanual

2.Yoursafety

3.Storageandtransport

4.Installation

5.Operationandmaintenance

Basicrequirements5.3 .............................. Conditionsforoperation5.3 Safetyrequirements5.6 ................................ Operationoftheshield5.9 ........................... Safeworking5.14 .................................... Operationoftheshieldhydraulics5.15 ................ Locationofhydrauliccomponentsattheshield5.15 Operationofthedualbackflushfilter5.27 .................. Repairandemergencyoperation5.28 Operationandfunctionsofthecontrolvalveblock5.30

Maintenance5.34 .................................... Specialmeasures5.34 .................................. Dailyinspection5.35 Weeklyinspection5.35 Tobedoneeverysixmonths5.35 Assessmentofdamageaccordingtoschedule5.35

Troubleshooting5.36 ................................ Faultfindingonshieldhydraulicsystem5.36 Faultlocalization5.36 ................................... 3/2-Wayvalveorpilotvalve5.39 Pilot-operatedcheckvalves5.39 Internalby-passinprops5.40 ............................ Faultypressurereliefvalve5.40 Defectiveorblockedfilter5.40 ...........................

6.Technicaldata

Shieldvariants6.3 .................................. Mainsubassemblies6.5 Basewithlemniscaticlinksandcentralshiftingunit6.8 Shieldcanopy6.12 Cavingshield6.17 ...................................... Sideseal6.18 Technicaldataoftheshield,steelstructure6.20 Hydraulicsystem6.23 ................................ Double-telescopicprop6.29 Function6.30 .......................................... Hydrauliccylinder,doubleandsingleacting6.31 Stabilizingcylinder6.32 ................................. Baseliftcylinder6.32 Shiftingcylinder6.33 Technicaldataofhydrauliccylinders6.34 .................. Pressurereliefvalves6.38

Electrohydrauliccontrolsystem6.40 .................. Electronicshieldcontrol6.41 Anglesofinclinationofthecanopy6.43 ...............

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthesymbolsused.

Beforestartingwork

Takecaretoensurethattheoperatingmanualavailabletoyouis applicablefortheshieldsupportused.Comparethedatagivenbelowwiththedataonthetypeplateoftheshield.Wheretofindthe typeplateontheshieldisdescribedinchapter7ofthisoperating manual.

Thisoperatingmanualisdesignedfor: DBT-shield2550/5500-2x3926-1750

andisonlypermittedtobeusedforshieldsofthistype.Onlyuse theoperatingmanualapplicabletotherespectiveshield.Ifyou don’tyouwillendangeryourselfandothers.

Tab.1:TypespecificationforDBT-shield2550/5500-2x4319-1750

identificationno.propforce yearof construction application

742014000000 01 2x3926kN 2005 faceshield

742014000000 02 2x3926kN 2005 transitionshield

742014000000 03 07 2x3926kN 2005 faceendshield

Itisabsolutelynecessarytoensurethatallpersonsworkingwithor onthesupporthaveaccesstothecontentsoftheapplicableoperatingmanualsfortheshieldsatanytimeandwithoutanyrestrictions.

Personsforwhomtheoperatingmanualisintended

Thisoperatingmanualisintendedforthosepersonswhoworkwith orontheshields.

Thisincludespersonswho:

J areinchargeoftransport, J preparetheriseheading, J performassembly/disassemblywork, J operatetheshields, J correctmalfunctions, J performdailyroutineworkontheface, J monitor/lookafterthehydraulicsystem,

J performmaintenancework, J performrepairwork;

J supervisorypersonnelwho –initiateand/or –supervise theactivitiesjustindicated.

Everybodyworkingontheshieldsupportmusthavereadthisoperatingmanualbeforehand.

Anypersonsvisitingorinspectingthefacemusthavereceivedadequateinstructions.

Purposeofthisoperatingmanual

Thisoperatingmanualcontainsgeneralinformationonthesafeand economicalhandlingofshieldsupportsandprovidesyouwithimportantinstructionsontheworkperformeddirectlyonorwiththe shields.

Therefore,readthisoperatingmanualcompletelyandatease.Pay specialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthemeaningofthesafetyandinstructionsymbols. Shouldyouhaveanyquestions,pleasecontactourservicedepartment.Contactdetailsaregiveninchapter7ofthisoperating manual.

Readthechapter”Foryoursafety”withspecialattention.This chaptercontainsimportantinformationindicatingpossiblehazards. Observetheinformationgivenandfollowtheproceduralinstructions.

Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationintheoperatingmanual. Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare: damagetotheshieldordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.

Itemsinlistsaremarkedwithblacksquares. Pointsinsub-listsaremarkedwithalongdashatthestartofthe line.

Thesymbolofthehandasksyoutodosomething.Severalsuccessiveparagraphsmarkedwiththesymbolofthehandrepresenta stringofactionswhichmustbeexecutedintheorderspecified.Followtherespectiveinstructionsstep-by-steptoperformthework safelyandefficiently.

Yoursafety

Thischapterprovidesvitalinformationforyoursafety.

Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsand toperformthenecessaryworkassafelyaspossible.

Theshieldhasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. However,acertainriskremainswhichmightgetyouintohazardous situationswhenworkingwithorontheshields.Thesemay,forexample,becausedbyunforeseeableexternalinfluences,machine damageoroperatingerrors.

Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.

Observethesafetyandaccidentpreventionregulations:

J oftheminingcompany,

J oftheminingauthority,and

J oftheminers’accidentinsuranceassociation.

Personnel

Personsemployedintheoperation,repair,andoverhaulofhydraulicand/orelectrohydraulicshieldsupportsmusthavespecialqualifications.Inadditiontohavingreceivedtraininginminingskillsthe followingminimumrequirementsshallbemet.

Operationandmaintenance

Operationandmaintenanceoftheshieldsisonlyallowedtobeperformedbytrainedpersonnel.

Thetrainingshallbematchedtothetypeofshieldactuallyused. Theelectrohydraulicandhydrauliccontrolsystemsshallbe operatedonlybypersonnelwhohavebeenadequatelytrainedtooperatethepresentcontrolsystem.Thecontentofthe operating manual,especiallythechapteronsafety,shallconstituteapartof thistraining.

Theyshallpossessandfurnishproofofadequatefamiliaritywith the

J mechanical, J hydraulic,and J controlsystems.

Repair

Ingeneral,repairworkshallbeperformedonlybypersonswho havetherespectiveknowledgeandskillstomeetthespecialrequirementsandhavebeenadequatelytrainedintherepairofthe equipment.Repairworkonandoverhaulof

J safetydevices,

J hydraulicpropsandcylinders

J controlblocks,valves,andfilters shallbeperformedonlybyDBTservicetechniciansorbyspecially trainedpersonneloftheminingcompany.

Conditionsofoperation

Useinconformancewithspecifications

Theshieldhasbeendesignedandmanufacturedexclusivelyfor useasasupportunitforlongwallfaces.

Usetheshieldonlyinconformancewithspecifications!

Useinconformancewithspecificationsincludes:

J proppingtheroofagainstthefloor;

J ensuringanadequatetravelway;

J thefollowingshieldoperations: –lowering, –pullingup, –alignment,and –setting;

J thefollowingconveyoroperations: –advancing, –retracting;

J forminganabutmentfor: –theconveyorandtheminingmachine, –conveyorsteeringdevices, –devicesforraisingtheconveyor, –conveyorsteeringcylinders;

Usecontrarytospecifications

Useswhicharenotexpresslystatedasconformingwithspecificationsarecontrarytospecificationsandarenotpermissiblewiththe shield.

Usescontrarytospecificationsinclude,amongothers:

J pushingtheshieldbackintothecavingarea,

J raisingoftheconveyorbymeansofthehydraulicforceofthe shield,

J settingofthecanopyinareasofrooffracture.Furtherinformationinthisrespectisgiveninthesection”Operation”ofthis chapterandinchapter5ofthismanualinthesection”Operationoftheshield”.

DBTassumesnoliabilityfordamageswhichresultfromusecontrarytospecifications.

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Safetyinstructions

Basicprinciples

Alwaysconcentrateonyourwork.

Familiarizeyourselfwithyourworkingenvironment. Alwayswearyourpersonalprotectiveclothingandequipment.

Informyourcolleaguesof:

J yourexactlocation,

J theworkwhichyouareperforming,

J thetimewhichyouwillprobablyrequire. Employonlyshieldswhichareinatechnicallyflawlesscondition. Alwayskeepoutofanyshieldwhichisnotset. Maintainthelightingsystemsinafunctionalcondition.

Maintainthesignalling systemsandprotectivedevicesinafunctionalcondition.

Observetheacousticandvisualstartwarnings.Payspecialattentiontothestartwarningsfortheconveyorandfortheminingmachine.

Presstheemergencystopswitchimmediatelyintheeventofmalfunctionsorirregularitiesinoperation.Notifyyourforemanofany peculiarity,inorderthatnecessaryactionbetakenimmediately. Onlyapplicableforshieldsprovidedwithelectrohydrauliccontrol systems.

Actuatethesupportlock-outswitch(repairswitch)beforeperforming.

J maintenancework,

J inspectionwork,

J repairwork,andbefore

J prolongedpresenceintheshield. Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe:

J baseskids,andshiftingunits

J canopies,

J links,

J sideseals,

J frontcantilevers,

J hydraulicpropsandcylinders,

J steeringdevices.

Inautomaticmode,thesupportunitsofalongwallfacearecontrolledbyanautomaticprogrammewithoutanyhumaninterference. Whentravellingthefaceyoushouldthereforealwayskeepinmind thatthesupportunitsmaymoveautomatically.Thereforeitisvital thatyouobservethewarningsatthefaceentriesaswellasthe visualandacousticwarningsignalssentbythecontrolunitinthe supportcurrentlyoperated.

Storageandtransport

Forthispurpose,thoroughlyreadchapter3,”Storageandtransport”.

Nevergounderunsecuredorsuspendedloads.

Observethespecifiedstoragetimelimitsandthestorageinstructions.

Neverstorematerialsofanykindinthetravelwayorinyourworkingarea.

Defectivecomponentsshouldbeimmediatelytransportedaway fromtheface,inordertoavoidinterferencewiththefacecrew. Moreover,thismeasurepreventsinadvertentreinstallationofthese componentselsewhere.

Informthepersonsconcernedabouttheintendedtransportroute andtheprobabledurationoftransport.

Ensurethatthetransportsecuringdeviceshavebeencorrectly installed.Inparticular,ensurethatthefollowingaresecuredfor transport:

J thesideseal,

J theflipper,

J theadvancingbeam(faceandgobsides).

Connectthehoistinggearonlyatthepointsofattachmentprovided forthepurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsfortransportgivenonthe sparepartsdrawingswhichareincludedinthesparepartscatalog. Non-standardtransportassembliesareshownonspecialdrawings whichareaddedintheannextothemanual,ifrequired.

Donotdamagethepolishedsurfacesofthecylindersandprops. Damageofthiskindnecessitateselaborateandexpensiverepair work.

Forroundcomponentssuchascylindersandpropswhicharenot providedwithliftingeyesusetransportstraps,only..Neveruse chainsorsteelcablesforthispurpose.

Onlyusemeansofattachmentwhichareingoodconditionand havebeendesignedfortheloadsconcerned.

Firmlysecureallcomponentswhichmightstartmoving.

Observethepositionofthecenterofgravity,especiallyduring transportwithfloor-mountedequipment.Thecenterofgravitymust beaslowaspossible,inordertopreventtippingofthetransport unit.

Safetyinstructions

Installation

Employappropriateloadingequipmentforsafetransferofthe transportunits.

Priortocommencinganyworkontheshieldmakesurethatthe shieldhasbeensecuredtopreventitretractingautomatically.

Mechanicallysecurethecavingshieldagainstloweringduring:

J installationofthepropsandcylinders, J installationofthecanopy, J workontheopenhydraulic system,

Forsecuringtheshield,hardwoodwedges,forinstance,canbe placedbetweenthepairsoflinks.

Fig.1:Securingbymeansofhardwoodwedges

Iftheshieldisprovidedwithmovablesidesealsthesearepretensionedbyspringforce.Thereforedonotuseforcetoremovethe transportsecuringdeviceofthesideseals.Usethehydrauliccontrolsystemtoadjustthesidesealcylinderssuchthatthelocking pinseitherdropdownorcanbepulledoutwithouttheuseofphysicalforce.

Whenremovingthetransportsecuringdeviceoftheflipperensure thatnobodyispresentintheswivellingareaofthelatterastheflippermayswingdownward.

Makesurethattheminimumdimensionsspecifiedforthetravelway withintheshieldaremaintainedunderanycircumstances.The minimumdimensionsare:

J width:600mm

J height:400mm

Anydevicesaddedtotheshieldlatersuchasforexamplesteering devicesarenotallowedtoreducetheminimumtravelway.Itmay benecessarytoinstalladditionaldeviceslimitingthelowering heightinordertoensurethattheminimumtravelwayismaintained.

Operation

Checktodeterminewhetherallprotectivedevicesontheshieldare presentandfunctional.Inautomaticmode,thesupportunitsofa longwallfacearecontrolledbyanautomaticprogrammewithout anyhumaninterference.Whentravellingthefaceyoushouldthereforealwayskeepinmindthatthesupportunitsmaymoveautomatically.Thereforeitisvitalthatyouobservethewarningsattheface entriesaswellasthevisualandacousticwarningsignalssentby thecontrolunitinthesupportcurrentlyoperated.

Checktodeterminewhetherallprotectivedevicesontheshieldare presentandfunctional.

Operatetheshieldcontrolsystemonlyifyouhaveaprofound knowledgeofthecontrolelementsandtheirfunctions.Itisnecessarythatyouhavebeentasktrainedontherespectivecontrolsystemandknowthecontentsoftherespectiveoperatingmanual. Carefullyreadtheinstructionsforoperatingthecontrol system used.

Donotstayintheshieldwhosefunctionsyouaretooperate.Alwaysoperatetheshieldonlyfromtheadjacentshield.

Makesurethatnopersonsarepresentintheareaoftheshieldbeingactuated.

Whenoperatingtheshieldmanuallytheoperatorhastowatchthe shieldmovementareaconstantlybeforeandwhileoperatingthe shieldinordertoavoidpotentialhazardsbycautiousbehavior. Alwayssettheshielduntilfullsettingpressurehasbeenreached sinceagoodsupportoftheroofcanonlybeensuredinthismanner.

Extendtheflippertowardsthecoalfaceasfaraspossibletopreventcoalorsurroundingrockfromfallingintothetravelway. Cleanthecontrolelementsofthecontrolunitsregularly.Cleanthe controlequipmentatregularintervals.Ensurethattheoperating symbolsareclearlyrecognizable.Thismeasureavoidsfaultyoperationandresultingaccidents.

Keepthefloorascleanaspossible.Keepthefloorfreefromdebris. Thiswayyouwillbeabletoextendtheshiftingunitwithouthindranceandtoadvancetheconveyorwithoutproblems.

Ensurethatthewaterspraysystemrespondsduringadvancement. Securetheconveyorbyanchorages.Thismeasureisrequiredto preventdisplacementoftheconveyorwithrespecttotheshieldand theshiftingunitjamminginthebaseskid.Oninclinedfacesitmay benecessarytoanchortheconveyorwithrespecttothesupport. Thismeasurehelpstopreventlateraldisplacementbetweenthe conveyorandtheshield.Anditreducestheriskoftheshiftingunit jammingbetweentheskids.

Hydraulicanchoragesmustalwaysbesuppliedwiththespecified workingpressuresinceonlythusasufficientanchoragebetween shieldandconveyorisensured.

Whenpullinguptheshields,alwaysobservethespecifiedsequenceofstepstopreventtheshieldsfromcollidingwiththeanchoragecylinders.

Oninclinedfaces,alwaysadvancetheshieldsfromthebottomto thetop.Thisgivesyouabetterviewofyourworkingarea.Operate theshieldtobeadvancedalwaysfromwithintheadjacentshield above.Thisreducestheriskforyoutogethurtbyfallingrocksand alsogivesyouabetterviewoftheadvancingoperation.

inclined faces

Safetyinstructions

Settheshieldsinsuchawaythatthecanopiesandthebaseskids areparallelwiththoseoftheadjacentshield.Theshieldsmustbe alignedatrightangleswithrespecttotheconveyorandparallel withrespecttoeachother.Usethesteeringdevicesortheside sealsforaligningtheshields.

Aligntheshieldsassoonaspossible.Alignmentinduetimeprevents:

J gettingunderthecanopyoftheadjacentshield, J cantingoftheshields, J slippingoftheshields, J andensuresanearlysupportofthenewlyminedroof Preventrooffallsbysupportingthenewlyminedroofasearlyas possible.

Neversetthetipofthecanopyintoarooffall-outsuchthat –themax.admissibleangleofinclinationofthecanopyisexceeded –thestabilizingcylinderlocks –thecanopywillbeloadedexcessivelyinlongitudinaldirection asthismaycausedamageduetoexcessivestressandstrainon thecomponents.

Duringtemporarysupportofarooffall-outensurethatthedrooping canopydoesnotgetinthewayofthepassingminingmachine. Ensurethatsufficientresidualstrokeisstillpresentintheprops whentheseamthicknessdecreases.Thispreventsthepropsfrom goingsolidbetweentheroofandfloor.

Ifpossible,pulltheconveyorbackbyoperatingtherespectivefunctionsoftheelectronicshieldcontrolunit.Ifthisisnotpossible,do asspecifiedintherespectiveoperatinginstructionsofthemine.

Securetheentireminingmachineagainstunauthorizedstarting. Isolateyourplaceofworksuchastopreventanyunauthorizedpersonsenteringthisarea.

Checktodeterminewhethertheshieldsaresetsufficientlytightbetweentheroofandfloor.

Secureyourworkingareaagainstrockfall.Thismeasureisespeciallyimportantiftheconveyormustbeliftedonthecoalfaceside. Onlyusethepointsofattachmentintendedforthatpurpose.Never attachloadstohydrauliccylindersortheirfasteningpoints. Resetallshieldsintheareawheretheconveyoristoberaised. Checkthesettingpressureagain.Bynomeans,disengagethe canopyfromtheroof.Itmustalwaysbeincontactovertheentire length.

Ifyouraisetheconveyorintheareaofseveralshields,thesupportstowhichliftingtackleisattachedmustnotbelocatednextto oneanother.

Forraisingtheconveyor,onlyuse:

J high-strengthundamagedroundlinksteelchains, J thefasteningpointsprovidedforthepurpose.Checkthatthe fasteningpointsareundamagedbeforeattachingaload, J liftinggearwithsufficientpermissibleload-bearingcapacity.

pullingbacktheconveyor

raisingof conveyor

Maintenance

Makesurethatallsafetyandprotectivedevicesoftheshieldsupportsarecompleteandfunctional.IfthesafetyandprotectivedevicesareincludedintheDBTscopeofsupply,refertochapter6for theirlocation.

Examinetheshieldatleastoncepershiftforexternallyvisibledamage.Seechapter5,section”Maintenance”.

Informthesupervisorypersonnelandthecoalfacecrewabout maintenanceandrepairwork.Providethemwithinformationonthe intendedworkandtheprobableduration.

Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.

Replacedamagedcomponentsaffectingsafetyimmediately.Immediatelyshutdowntheshieldconcerned,ifimmediaterepairisnot possible.Stopandlockouttherespectiveshieldimmediatelyifthe componentdamageentailsahazardandanimmediaterepairisnot possible.Securethisareaandnotifytheentirecoalfacecrewand theresponsibleforemenwithoutdelay,ifthereisasafetyhazard.

Useonlysparepartswhichconformwiththespecifiedtechnicalrequirements.Thisisbestensuredbytheuseoforiginalspareparts fromDBT.Astotheordernumbersfortherequiredspareparts pleaserefertothesparepartscatalogprovidedfortheequipment.

Donotperformanyconversionsormodificationswhichmightimpair thesafetyoftheshield.DBTmustbenotifiedofallconversionsand modificationstocheckwhethertheyhaveanyeffectontheapprovalorwhetheritisnecessarytoapplyforarevisedapproval.

AnymodificationscarriedoutwithoutauthorizationresultinthecertificateofconformityofDBTbecominginvalidandrequireanew conformitytest.

Duringworkontheshiftingunit,isolatetheworkingareaforthe miningmachine.

Workinginthewinningtrackispermissibleonlyif

J theroofhasbeensecuredagainstrockfall,

J thecoalfacehasbeensecuredagainstslopingdown,and

J theminingmachineandconveyorhavebeenshutdownand securedagainstrestartingorifyouhaveensuredbyother meansthatthecontinuationoftheminingworkdoesnotaffect thesafeperformanceoftherepairwork.

Beforedisconnectingtheshieldfromtheconveyor,youmust:

J arrangethattheminingoperationiseitherstoppedcompletely orisonlydoneoutsidetherequiredsafetyarea,

J relievetheloadonthecomponentswhichareunderhydraulic pressureormechanicalstress.

Immediatelydiscontinueworkontheshield,ifconveyingandcrushingoperationsareinprogressinyourworkingarea.

Whenperforminganyworkwhichmightentailtheriskofthesupportretractingautomaticallysecuretheshieldmechanicallytopreventitloweringbyitself.

Safetyinstructions

Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulicfluidpenetratingtheskincancauseseriousinfections. Oninclinedfacessecurethecomponentstobereplacedagainst slippingbyusinge.g.chainsorliftinggear.

Immediatelyaftercompletionofthework,reinstallprotectivedeviceswhichhavebeenremoved,andcheckthemforcorrectfunctioning.

Hydraulics

Itisvitalthatyouobservetheoperatingmanualofthemineforthe hydraulicfluidused.Anyadditionalinformation,ifrequired,canbe takenfromthesafetydatasheetofthehydraulicfluidproducer. Neverusehydraulicfluidsforrinsingorcleaning.

Onlypersonswhohaveandcandemonstrateaspecialknowledge ofhydraulicsareallowedtoworkonthehydraulicsystem.

Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Inparticular,payattentionthat:

J thehosesarenotpinchedortrapped.

J thehoseshavenobubblesorblisters.

J thehosesortheoutersheathesofthehosesarenotabnormallyrigidorhard.

J theoutersheathofthehosesisnotdamaged.

J theconnectorsaresecurelyinsertedintothesockets.

J theconnectionsareleak-tight.

Ensurethatnodirtentersthehydraulicsystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamageinthewhole system!Flushoutthehydrauliclinesthoroughlybeforeconnecting.

Ifhydraulichosecouplersaredifficulttodisconnectorcannotbe disconnected,thehydrauliclinemaystillbepressurized.Besureto depressurizethelinebeforedisconnectingcouplers.

Securetheconnectorsofthehydraulicelementsonlywiththe propercouplingclamps.Alwaysfastentheclampscompletelyand withbothsides.Neverusenails,wireorsimilarmaterialsforsecuring.

Aftercompletionofanyrepairwork,checkthedepressurizedsystemfirsttomakesureallconnectionsarecorrect.Next,applypressuretothehydraulicsystemandcheckthattheinstallationisleakproofandfunctioningproperly.

Useonlyhydraulichosesapprovedfortheprevailingpressures.

Donotuseanyhydraulichoseswithdamagedconnectorsorworn O-rings.

Replacehydraulichosesonlywithhosesofthesameorahigher quality.

Observethedateofmanufacturestampedonthehydraulichoses. Neverusehydraulichoseswhicharemorethan2yearsold,evenif theyhavenovisiblesignsofdamage.Neverinstallhydraulichoses whicharemorethan2yearsold,eveniftheydon’tshowanyvisible signsofdamage.

installationof hydraulichoses

Fig.2:Example:4SPhydraulichose,designation

1hosetype

2nominaldiameter

3dateofmanufacture

4manufacturer

5flame-resistantandantistatic 6standard

Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.

Nevertrytorepairdamagedhydraulichoses.Immediatelyreplace damagedhydraulichoses.

Replacehydraulichosesatthefirstsuspicionofdamage.

Laythehydraulichosesproperlybehindthebracketsandclamps providedforthem.

Alwayslayhydraulichosessothatthey: J alwayshavealittleslack.

Fig.3:Layingofhydraulichoselines,slack RIGHT WRONG

J arenottwisted.

Fig.4:Layingofhydraulichoselines,twist RIGHT WRONG

Safetyinstructions

J arenotbentdirectlybehindtheconnections (distancemin.1.5xnominaldiameter).

Fig.5:Layingofhydraulichoselines,bend RIGHT WRONG

J cannotchafe.

Fig.6:Layingofhydraulichoselines,crossing RIGHT WRONG

J arenotkinked.

J donothavetowithstandtensilestrains.

J areprotectedagainstthermalradiation.

J areaccessibleatalltimes.

Pushhydraulichosesintothesocketsonlybyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagetheconnections.

Wheninstallingthehydraulichoses,ensurethattheycannotbe:

J tornout,

J kinked,

J crushed,

J drivenoveror

J twisted bythemovementofthemachine(Fig.:7).

Fig.7:Layingofhydraulichoselines,connectionsatmovableparts

Overviewofthesafetyinstructions

Thisisasummaryofallsafetyinstructionsgivenintheindividual chaptersofthisoperatingmanual.Asthesesafetyinstructionsare citedoutoftheircontextthemeaningisnotalwaysobvious.

Chapter3:Storageandtransport

WARNING!

Useonlyloadhandlingdevicescomplyingwiththetechnical andlegalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.

CAUTION!

Transportsafetydevicesmaygetdamagedduringtransportto themine,forexamplewhenloadingandunloadingthetransportunits.Therefore,checkalltransportsafetydevicesfor damageandreplacedamagedonesbeforeallowingtransport oftheunitsinthemineshaft.Damagedtransportsafetydevicesmaybethecauseofseriousdamagetothetransportunit ortothetransportshaftifloadunitsaretransportedsuspendedunderthecagewithdamagedorinadequatetransport safetydevices.

CAUTION!

Ifthepointsofattachmentonthecavingshieldaretobeused fortransportingtheassembledsupportunit,canopyandbase skidmustbeconnectedmechanicallybymeansofanadditionaltransportsafetydevicetopreventthemmovingapart.

Chapter4:Installation

DANGER!

Damagedhosesmightburstandhydraulicfluidcouldescape underhighpressure.Thiscouldseverelyinjureorevenkillyou orothers.

Makesurethatthemovementsoftheshielddonotcauseany damagetothehoselines. Laythehoselinescorrectlybehindtheretainersprovidedfor thatpurpose.

WARNING!

Whenperforminganywork,observethesafetyinstructions giveninthismanualandalsothespecialsafetyinstructions andoperatingmanualsprovidedbytheminemanagement. Failuretocomplycanleadtomostseriousaccidentswhich mightevenresultindeath.

Overviewofthesafetyinstructions

WARNING

Thefirststart-upandthetestrunshouldonlybeperformedby awell-trainedandexperiencedcrewwhoarefamiliarwiththe specialconditionsprevailingin undergroundminesandthe safetyregulations.Thecrewmustalsobeskilledinhandling theequipmentproperlyandknowthecontentoftherespective operatingmanuals.

WARNING

Thefirststart-upandthetestrunshouldonlybeperformedby awell-trainedandexperiencedcrewwhoarefamiliarwiththe specialconditionsprevailingin undergroundmines,particularlywiththesafetyregulations.Thecrewmustalsobeskilled inhandlingtheequipmentproperlyandknowthecontentof therespectiveoperatingmanuals.

WARNING

Canopiesmustnotbeslopingdownwardsandreachintothe trackfortheminingmachine.

WARNING

Donotinstallshut-offvalvesintothereturnlinesfortheshield hydraulicsasotherwiseadangerouslyhighpressuremay buildupwhichcoulde.g.causehoselinestoburst.Thismay resultinseriousinjuriestopersonsorevendeath.

CAUTION!

Priortoassembly,socketsandnipplesoftheplug-typeconnectorsmustbetreatedwithlubricatingpasteB3toEWN7068 whichdoesnotcontainmolybdenumdisulfide.Seechapter6, section”Recommendedlubricatinggreasesandpastes”.

CAUTION!

Priortoassembly,theslidingsurfacesofthetransportunitsof thesteelstructuremustbecoatedwithlubricatingpasteB6to EWN7068whichdoesnotcontainmolybdenumdisulfide.See chapter6,section”Recommendedlubricatinggreasesand pastes”.

CAUTION!

Fortransportundergroundonlytheattachmentpointsdetailed inchapter3”Transport”areallowedtobeused.Furtherinformationisgiveninchapter3”Transport”.Failuretocomply mayleadtopersonalinjuryanddamagetoproperty.

CAUTION!

Facehydraulicsystemswhichareunstableornotamplydimensionedcouldcausetemporarypressuredropsduringoperation.

Apressuredropdownto180barorlessentailsthedangerof malfunctionsoftheelectrohydrauliccontrolsystem.Possibly, valvefunctionswillnotbeexecuted.Itmayevenresultin valvesstartingtovibratewhichcouldleadtovalvedamage. Underunfortunateconditionsthiscouldresultinhazardous situationswithaccidentsentailinginjurytopersonsanddamagetoproperty.

Therefore,takeallmeasuresrequiredtoensurethatthesystempressurecannotdroptolessthan180baranywhereinthe facehydraulicsystem.

NOTICE!

Makesurethatallsecuringelementsneededduringtransportationhavebeenremoved.Seechapter3,section”Transport”.

NOTICE!

Takecaretoensurethatalltransportsafetydevicesrequired fortransporthavebeenremoved.Seechapter3,section ”Transport”.

IMPORTANT!

Wheninstallingtheshieldsintheface,besuretoobservethe shieldnumbers.Sincetheindividualshieldsmightbeprovided withdifferentfunctionstheymustbearrangedinthespecified order.

IMPORTANT!

Fordetails,pleaserefertotherespectiveseparateoperating manualofthemanufacturer.

Chapter5:Operationandmaintenance

DANGER!

Youareonlyallowedtooperatetheshieldcontrolifyouhavea profoundknowledgeofthecontrolelementsandofthewaythe controlsystemworks.Youmusthavebeentask-trainedonthe presentcontrolsystemandshouldhavepracticedtodeepen yourknowledge.Shouldthisnotbethe caseyouarenotallowedtooperatethecontrol.Informyoursuperiorimmediately andaskfortherequiredtraining.

DANGER!

Pushbuttonsthatarejammedorfixedcouldleadtouncontrolledmovementsoftheshield.Thesemaycausesevereinjuriesordeathtotheoperator. Therefore,neverfixthepushbuttonsandtakecaretoensure thatdamagedpilotvalvesarealwaysreplacedwithoutdelay.

WARNING!

Ignoringthesafetyregulationswillcause accidentsandmay resultinseriousbodilyinjuriesordeath. Theregulationsaboutsafeworkingofyourminemustbefollowedstrictly.Applythefollowinginstructionsanalogouslyin additionandinaccordancewiththeindividualsafetyregulationsofthemine.

WARNING

Alwaysstayclearofashieldwhichisbeingmoved.Circumstanceswhicharenotalwaysobviousmayleadtounexpected movementsoftheshieldunitwhichcouldresultinsevereinjuriesorevendeath.

Forexample,theshieldcanopymayjerkfreeduringloweringif itwasstuckbetweenthecanopiesoftheadjacentshields.

WARNING

Duringnormaloperation,theshield-typesupportisoperated onlybymeansofthecontrolunitoftheelectrohydraulicadjacentcontrolsystem.

WARNING

Thecontrolelementsonthecontrolvalveblockmayonlybe usedinanemergencyandduringrepairsandonlyincompliancewiththespecialoperatinginstructionsoftheminefor thatpurpose.Theyarenotallowedtobeusedfornormalop-

Overviewofthesafetyinstructions

erationasotherwisehazardoussituationsmayarisewhich mightresultinveryseriousinjuries.Duringnormaloperating mode,theshieldisoperatedexclusivelybymeansoftheelectrohydrauliccontrol.Inthisrespectitisimperativethatyou observetheseparateoperatingmanualofthecontrolunit.If theelectroniccontrolispartofthescopeofsupplyofDBTthe respectiveoperatingmanualwillbeincludedintheDBTdocumentationprovidedfortheinstallation.

WARNING

Youareonlyallowedtooperatethecontrolsofthecontrol valveblockwhenyouknowexactlywhicheffectsthefunctions havewithrespecttotheshield.Thereforeyoushouldhavereceivedadequatetraining.Ifnot,thereisariskofoperatingerrorsinvolvedwhichmightcausesevereinjuriestopersons, possiblyresultingindeath.

WARNING

Themanualoperationofapushbuttonononeofthepilot valvescausesthedirectexecutionoftherespectivefunction. Inthiscase,dependenciesbetweentheindividualfunctions willnotbeconsidered.Thiscouldleadtodangeroussituations if,forexample,functionalsequencesareinitiatedinthewrong order.Forexample,thefunction”advanceshield”canbeactivatedwithoutthefunctions”retractside seal”and”actively lowershield”havingbeenactuatedbefore.Thiscouldcause hazardoussituationsresultinginvery severeinjuries.

WARNING

Whentheoperatingsafetyisatriskanydamagedcomponents mustbereplacedwithoutdelay.Ifthisisnotpossible,stopthe shieldoperationatonceandsecuretheshield.Immediately informthecompletefacecrewandyoursuperior.

WARNING

Troubleshootingonhydraulic systemsentailsanincreased accidenthazard.Particularlybymalfunctionsofthehydraulic systemandhydraulicmediumescapingathighpressuresevereinjuriescouldbecaused. Thereforeyouarerequiredtobeverycautiousandwearthe specifiedprotectiveequipment.Failuretocomplywiththese instructionscouldcausesevereinjuries.

CAUTION!

Neverexceedthemax.permissibleanglesofinclinationofthe canopy.Exceedingthepermissibleanglesofinclinationofthe canopystatedinchapter6, section”Technicaldata”canresult indamagetotheshield.Thisdoesparticularlyapplytothestabilizingcylinders,theirfasteningelementsandpointsofattachmenttoshieldcanopyand cavingshield.

CAUTION!

Neverextendorretractthestabilizingcylindersoftheshield completely.Theymustalwayshavesufficientresidualstroke. Standardvalue:min.20mm!

Thesameappliesanalogouslyfortheswivelcanopycylinders.

CAUTION!

Ensuresufficientresidualstrokeofthestabilizingcylinders especiallyinthecaseofatendencytorooffall-outsand/orextremelysoftfloor.

CAUTION!

Avoidanexcessiveinclinationofthecanopybyfillingrooffalloutsorbysupportingminorfall-outswiththeshieldinhorizontalposition.

Atthispoint,weexplicitlyemphasizeagainthatanydamage causedbythenon-compliancewiththeseinstructionsispossiblynotcoveredbytheguarantee.

CAUTION!

Donotexceedtheanglesofinclinationofthecanopy(angle betweenshieldcanopyand cavingshield)specifiedinchapter 6”Technicaldata”.Iftheanglesareexceeded,thiswillcause damagetopropsandhydrauliccylinders,theirarrestingelementsaswellasthearticulationsofthecomponents.

CAUTION!

Takecarenottodamagethepush-buttonsofthepilotvalves. Jammedpush-buttonswillcausemalfunctionsofthevalves whichmayresultinaccidents.

CAUTION!

Donotexceedpermissiblecanopyangle! Observevalueforminimumresidualstroke.

CAUTION!

Donotexceedpermissiblecanopyangle! Observevalueforminimumresidualstroke.

NOTICE!

Itisimportantthatthecontrolsymbolsarelegibletoavoidthe riskofoperatingerrorsandresultantaccidents.

IMPORTANT!

Bothcasesrequireknowledgeoftheflowplanandskilledpersonnel.Thesafetyguidelinescontainedinthismanualmust strictlybeobserved.

Chapter6:Technicaldata

WARNING!

Riskofgettingsqueezedbetweenmovingpartsoftheshifting unitandtheshield.

Keepawayfromadvancingshieldunitsorsuchwhicharegoingtobeadvanced.

Overviewofthesafetyinstructions

WARNING

Duringnormaloperatingmodethepushbuttonsatthepilot valvesofthecontrolvalveblocksmustnotbeusedforoperatingthefunctions.Failuretoobservethiswarningcanresultin unexpectedandhazardoussituations,for exampleiffunctional linksbecomeinvalid.

Thepushbuttonsofthepilotvalvesareonlyallowedtobeoperatedinspecifiedexceptionalcircumstances,forexamplefor repairormaintenancepurposes.Inthesecasesitisimperative toobservetheapplicablespecialsafetyregulations.

WARNING

Riskofseriousbodilyinjuriesduetopressurefluidsuddenly escapingathighpressureandburstinghydraulichoselines causedbydangerousoverpressure.

Neverclosetheloweringportsof double-actingpropspressure-tight!Ifyoudo,apressuremightbuildupintheannulus whenextendingthepropwhichisamultipleofthesetting pressure.

WARNING

Riskofseriousbodilyinjuriesduetopressurefluidsuddenly escapingathighpressureandburstinghydraulichoselines causedbydangerousoverpressure.

Neverclosetheloweringportsof double-actingpropspressure-tight!Ifyoudo,apressuremightbuildupintheannulus whenextendingthepropwhichisamultipleofthesetting pressure.

WARNING

CAUTION!

Topreventoverloadingofthestabilizingcylinderwhenthe canopyissetina cavity,caremustbetakentoensurethatthe max.angleofinclinationofthecanopy(anglemaincanopycavingshield)willnotbeexceeded.

CAUTION!

Thepressuresettingmustnotbechanged.

CAUTION!

Ifthemax.anglesstatedareexceeded,damagewillbecaused tothepropsandcylindersaswellastotheirarrestingelementsandtothearticulations.

NOTICE!

Thetechnicaldataofthecylindersaregiveninthesection “Technicaldata”oftheshieldused.

NOTICE!

Newsealsmustbefittedwheneverapressurereliefvalveis replaced.

NOTICE!

HowtooperatethePANZERMATIC® controlunitisnotsubject ofthismanual.Seeseparateoperatinginstructions.

NOTICE!

UseonlyhydraulicfluidsapprovedbyDBT! ThesefluidshavebeentestedatDBTandguaranteeareliable operationofthehydraulicsystem.

IMPORTANT!

Weexpresslypointoutthattheapprovalofthelistedproducts relatesonlytothepuretechnicaluseinourhydraulicsystems. Theresponsibilityfortheconstituentsusedinthehydraulic concentratesliessolelywiththerespectivemanufacturer.

IMPORTANT!

Besuretoobservethemanufacturer’sinstructionsforuse.

IMPORTANT!

FurtherinformationiscontainedinDIN24320.

IMPORTANT!

Thegreaseslistedinthesametablecanbemixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethatthey areequivalent. Differentlycomposedlubricatinggreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmay alsobedangeroustouselubricatinggreaseshavingthesame saponificationbasebutdifferentorigins. Incaseof doubt,themanufacturerofthelubricatinggreaseto beusedshouldbecontactedastothecompatibilityofthe greaseinquestion.

IMPORTANT!

Theinstructionsfortheuseofthelubricatinggreasesgiven under”important”alsoapplytothelubricatingpastes.

IMPORTANT!

Thetighteningtorquesstatedinthesparepartslistshavetobe observed,aswell,forinstallationandmaintenance.

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Storageandtransport

Thischaptercontainsimportantinformationonthecorrectstorage andtransportoftheshields.

Observanceoftheinstructionsandtipswillincreasetheservicelife oftheshields.Youwillalsobeabletocarryoutthetransportwork quickerandmoresafely.

Carefulattentiontothepointsinthischapterwillhelpyoutosimplifyyourday-to-daywork.

Storage

Storageofnewequipment

Thesurfacesoftheequipmentareprovidedwithatemporarycorrosionprotection.Ifstoredproperly,theequipmentpartswillbeprotectedforsixmonthsreferredtothedateofdelivery.

Priortodeliverythehydraulicallyoperatedequipmentwillbetested andoperatedattheDBTsiteusingtheanticorrosiveandanti freezingfluidHYDROCOR®CV50*.Thisfluidremainsinthehydraulicsystemfortransportandafollowingshort-timestorageperiod.

HYDROCOR®CV50isfreeze-proofdownto-40degreesCelsius andprotectsinsidemetallicmaterialsagainstcorrosion.

HYDROCOR®CV50isequippedwithacolorindicator,whichis responsiveonthepH-valueofthefluid.Thecolorofthefluidwill changefrom”red”to”yellow”incasethepH-valuedropsdown.A yellowcoloredfluidindicatesinsufficientcorrosionprotection. ForfurtherparticularsonthepropertiesofHYDROCOR®CV50 pleaserefertotherespectivedatasheetofthemanufacturer.

Water-bearingpartsoftheequipmentsuchasforexamplethecomponentsbelongingtothewaterspraying systemofashieldshould becompletelyemptiedor,ifrequired,befilledwithanantifreezing fluid.

Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponents neednotberemoved.Suchcomponentsmust,however,beparticularlyprotectedagainstenvironmentalinfluences,includinghigh temperatures,forexamplebysuitablecoversorsheathingsforthe controlsandbyadditionallycoveringtheequipment.Iftheequipmentistobestoredformorethanfourweeksadditionalspecial measuresmayhavetobetaken,dependingontheenvironmental conditions.Itmay,forexample,benecessarytoremovetheelectroniccontrolunitinordertostoreitadequately.

Iftheequipmentistobestoredformorethan6months,thecavitiesinthehydrauliccomponentsmustbecompletelyfilledwitha preservingfluidsuchase.g.HYDROCOR®CV50.Thisfluidmust havecorrosion-protectionpropertiesandshouldbefrost-proof withintherespectivetemperaturerangeoftheapplication.Allports mustbesealedwithdurableandsuitableplugs. Itishighlyrecommendednottostoretheequipmentoutdoorsbutin awellventilatedroom.Ifitisnotpossibletostorethecomplete equipmentindoors,removethehydraulicandelectroniccomponentsandstorethemseparately.

*HYDROCOR®CV50isatradenameofTheunissen,ChemischeFabriken GmbH,Wuppertal/Germany

Storage

Equipmentpartsstoredoutdoorsmustbeprotectedagainstdirect sunlight,precipitationanddirt-forexamplebyusingtarpaulins. Thesepartshavetobestoredsuchthatfluidwillnotbeallowedto collectincavities.Fluidsenteringanycavitiesduringtransportor loading/unloadingmustbeabletoflowofffreely.

Asageneralrule,electricalequipment,electroniccomponents, sparepartsmadeofrubberorplastic-suchassealsandhosesaswellaspressurefluidshavetobestoredinclosedroomsat15 °C.to25°C.protectedagainstdirectsunlight.Exceptions:see ”Short-termstorage”.

Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Astorageperiodofapprox.twoyearsisthereforequoted asanindicativevaluefortheseparts.

Equipmentpartsstoredoutdoorsforalongerperiodoftimemustbe protectedagainstdirectsunlight,precipitation,anddirt,forexample byusingtarpaulins.

Protectallhydraulicelementsduringstorageinasuitablemanner againsttheingressofdirtandmoisture.Theconnectingsurfacesof thehydrauliccomponentsmustbeprotectedagainstcorrosionand closedwithblindplates.Hydraulicplug-typeconnectionsandthe connectorsoftheelectriccablesmustbeclosedwithsuitablecaps orplugs.

Whenstoringassemblies-suchaspropsandcylinders-containing contactingjoints,sealingelementsmaysufferplasticdeformation astheyareconstantlysubjectedtostaticunilateralloadsduetothe weightofthecomponents.Thismayrenderthesealsuselessor reducethelifeofthesealingelement.Thiseffectisgreatlyinfluencedbythesizeanddurationoftheloadandtheprevailing temperature.

Therefore,props,cylindersandsimilarcomponentsshouldonlybe storedinanuprightposition.Thisespeciallyappliesifthecomponentsaretobestoredforalongerperiodoftime. Ifyouintendtostoreamachinecontaininganyoftheabove-mentionedcomponentsyoumayhavetodismantlesuchcomponentsin ordertostorethemadequately.

Afterastorageperiodofapprox.twoyears,arandomsampleinspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyDBT.Thecostwill bebornebythemine.

WithrespecttothestorageofHFAfluidsorconcentratesforthe productionofHFAfluidsinanycasetheregulationsofthe manufacturerorsupplierofthosemediahavetobeobservedfirst. Supplementaryinformationisgiveninthesection”Pressurefluids ofgroupHFA”inthismanual.

Takecaretoensurethatnewsuppliesarestoredseparatelyfrom existingstockandthatremovaltakesplaceonthe”firstin,firstout” principle.Markthecontainersaccordingly.

Usedequipment

Ifthereisanyneedtostorehydraulicequipmentthathasbeenin usebeforetheitemsspecifiedaboveapplyanalogously,withthe exceptionoftheitemcorrosionprotection.

Incasethehydraulicsystemistobeputoutof operationtemporarilythecompletesystemhastobeflushedthoroughlyandfilled withasuitablepreservingfluid(e.g.HYDROCOR®CV50).Ifthisis notdone,considerabledamagetothehydrauliccomponentsmay becausedwithinashorttimesincethepropertiesofthemedium usedmaychangeveryfastandnegatively,e.g.duetomicrobial attack.

Transport WARNING!

Useonlyloadhandlingdevicescomplyingwiththetechnical andlegalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.

Inconsultationwiththecustomerandtakingintoconsiderationthe localconditionsprevailingatthesitetransportunitswerespecified asfollows:

Theshieldsaredeliveredascompletelypre-assembledunits.

Asfarastechnicallypossible,theloadunitsareprovidedwithsuitableandfixedpointsofattachmentfortransportandassembly.If not,adequatethreadedholesorotherprovisionsareavailablefor thetemporaryattachmentofparts.Detailsonthearrangementand load-carryingcapacityoftheattachmentpointsaregiveninthe sparepartscatalogoronthespecialdrawingsfortransportassemblieswhichareaddedintheannextothismanual,ifrequired.

Beforetransportingtheequipmentattemperaturesbelowfreezing, allhydrauliccomponentsoperatedwithamediumsensitivetofrost, forexample,anoil-in-wateremulsion(HFAE)havetobecompletely drainedandthenfilledwithafrost-proofpreservingfluid,e.g.HYDROCOR®CV50.If,fortechnicalreasons,thefluidcannotbe drainedcompletelychooseapreservingfluidwhichcanbemixed withthemediumoriginallyusedandensurethatthemediaareadequatelymixed.

Transportofequipmentattemperaturesbetween-21°Cand-40° C isonlypermissiblewhencertainmeasuresweretakentomeet theseconditionsatthedesignandmanufacturingstages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandare onlyloadedstaticallyorquasi-statically.Externalforcesareonly allowedtobeintroducedviathepointsofattachmentandabsorptionsurfacesindicatedonseparatedrawings,ifany.

Theequipmentisnotallowedtobetransportedattemperaturesbelow-40°C.

Duringtransportofthisequipmentwithfloor-mountedvehiclesat suchlowtemperatures,measuresmustalsobetakentoensure thatthepartsanddevicesarenotsubjectedtosuddenimpact loads.

Atverylowtemperaturesandonpoorroads,thetransportvehicle speedmustthereforebelimitedtomax.25km/hfortrucktransport.

Electricalandelectroniccomponentsmustberemovedforoverseastransportorprolongedstorageoutdoorsunlessthesecomponentsorthecompleteequipmentisprotectedagainstharmfulenvironmentalinfluencesbysuitablepackaging. Theelectricalcablesremainintheequipment.Theymustbecarefullyprotectedagainsttransportdamageandsoilingoftheconnections.

Ashieldcanbetransportedasacompletelyassembledunitordividedintotransportunits.Ifdismantlingintotransportunitsisnecessary,thisisplannedandlaiddowninclosecooperationwiththe costumer.

Tab.2:Transportunits

DesignationTransportposition Remarks supportunitcomplete 1) asfornormaluse sidecanopy hydrauliccylindersontop

Forthepurposeofensuringsafetyduringtransport,themovable partsofeachtransportunitmustbefastenedsuchastoprevent theirchangingtheirpositioninadvertently,ifrequiredinadditionto thestandardsecuringdevices,e.g.onsidesealsandflipper.The followingtransportsafetydevicesareprovidedonthetransport units:

Tab.3:Transportsafetydevices

PartTransportsafetydevice

protectionplugs

CAUTION!

Fig.8:Transportofshieldsascompleteunit

S3 slothole,2xonthecoalfaceendofthebase,load-bearingcapacity:15000kg

S4 slothole,2xonthegobsideendofthebase,load-bearingcapacity:15000kg

X1,X2 securingelementstofixtherelaybarduringtransport,facesideandgobside

X3 securingelementstofixtheflipper

X4 securingelementstofixthemoveablesideseals

X5 transportsafetydevicesatthesidecanopy

Y transportsafetydevicebetweencanopyandbase notincludedinthescopeofdelivery

So centerofgravity

Tab.4:Shieldsupport742014000000.., dimensionsandweightsofvariants

Specialmeasures

sprayingsystemadaptor atrearlink

Specialmeasures

Beforeloweringtheshieldtoitsminimumheight-forexamplefor transport-thetwosprayingsystem adaptorsfittedtotherearlink havetoberemoved.SeeFig.9.Iftheadaptorsareleftinplace theymaybedamaged.

Thesprayingsystem adaptorshavetobefittedagainbeforereleasingtheshieldforregularoperation.

Fig.9:Sprayingsystemadaptoratrearlink

1sprayingsystemadaptor 2hex.headboltM12x40-A4-70, widthacrossflats19 3waterportDN10

4 Installation

Installation

Thischaptercontainsinformationontheinstallationoftheshield units.Pleasepayparticularattentiontothewarningsandtips.

WARNING!

CAUTION!

Pre-assemblyoftheshieldunits

Theshieldsaredeliveredascompletelypre-assembledunits. Hence,nofurtherpre-assemblyisrequiredforthemechanicaland hydraulicsystemsoftheshields.

Installationoftheshieldunits

CAUTION!

Theshieldsareinstalledinthelongwallfaceincorrespondence withtheinstallationplanofthemine.

IMPORTANT!

Wheninstallingtheshieldsintheface,besuretoobservethe shieldnumbers.Sincetheindividualshieldsmightbeprovided withdifferentfunctionstheymustbearrangedinthespecified order.

Tofacilitateidentificationforassemblyandinstallationintheface theshieldsorthetransportunitsshouldbeprovidedwithconsecutivenumbers.Thisnumberingshould,forexample,correspondto theorderinwhichtheshieldsaretobearrangedintheface.The numbersshouldbewrittenonthesurfaceofthecomponentswitha clearlyvisiblecolor.

Theshieldnumberisanidentificationfeature.Allshieldsarenumberedconsecutively.Firmlyattachedplaquesshowingtherespectiveshieldnumberareprovidedatthebaseskid,atthefrontlinks, andattheclevispointforthestabilizingcylinderatthecanopyof eachshield.

Installationoftheshieldunits

Fig.10:Shieldnumberatthebase,example

Tab.5:Allocationofshieldnumbers shieldno.orderno application 7...124,129 74201400000001 faceshield 6,125 74201400000002 transitionshield 1 74201400000003 endshield

4,5and130 74201400000004 endshield 126and127 74201400000005 endshield 128 74201400000006 endshield 2and3 74201400000007 endshield

Supplyconnections

Duringfirststart-upaswellasduringnormaloperationthesupplyto thesupportshieldunitproceedsexclusivelybymeansofthemanifoldpipe.

16manifoldpipe

20dualfilter,backflushtype 21ehigh-pressureballvalve,auxiliarywaterline,openasshown 21dhigh-pressureballvalve,supplylinetowaterspraysystem, openasshown 23high-pressureballvalve, pressuresupply,openas shown

aprotectivecoverforelectrohydrauliccontrolunit

bprotectivecoverfordualfilter, openasshown Rreturnline,DN50

Ppressureline,DN40 Wwaterline,DN50

Fig.12:Viewontherearmanifoldpipeandthedualfilter,protectivecover removed

16manifoldpipe

20dualfilter,backflushtype 21chighpressureballvalve,servesto

isolatethewatersupplytothe “watercurtain”,openasshown 23high-pressureballvalve,servesto isolatetheshieldhydraulicsfrom pressuresupply,openasshown

Fig.11: Viewonthemanifoldpipe

Couplingbetweentheconnections

Thehydraulicconnectorsareplug-typeconnectorsaccordingto DIN20043.

Amanifoldpipefortheshieldhydraulicsystemislocatedbetween thefrontlemniscaticlinksofeachshieldunit.Thispipeprovidesthe hydraulicsupplytotheindividualshieldunit.Themanifoldpipesof adjacentshieldunitsareconnectedwiththeuseofthreehose lines:Apressureline(DN40),areturnline(DN50)andawaterline (DN50).Seethehydraulicblockdiagraminchapter6.

Theshieldunitsareequippedwithanelectroniccontrolunitoftype PM4.Theconnectionbetweenthecontrolunitandtheelectrohydrauliccontrolblockisprovidedbyasolenoiddrivermodule.The connectingcablesrequiredforthispurposeareincludedinthe scopeofsupplyofthePM4control system.Howtoconnectthe controlunitisdescribedintheseparateoperatingmanualforthe PM4controlsystem.Anoverviewofthedesignofthecontrolis alsogiveninchapter6ofthisoperatingmanualinthesectiontitled ”shieldcontrol”.

Provisionismadeontheshieldunitstoallowtheattachmentof additionalequipmentwhichisnotincludedinDBT’sscopeofsupply,asforexample:

–lightingsystem

–two-wayintercomsystem

Forinformationontheinstallationoftheadditionalequipment, pleaserefertothepertinentoperatingmanualoftherespective manufacturer.

Requirementstothefacehydraulicsystem

Forallhydrauliccomponentsincludedinthescopeofsupplyof DBT,thehydraulicmediummustmeetthefollowingrequirements:

Pressurefluidaccordingtolistofapprovedproducts,seesection ”Operatingmedia”inchapter6ofthismanual.

Purityclass18/14toISO4406

nominalpressure320bar

admissibletolerance 10%ofnominalpressure

CAUTION!

Facehydraulicsystemswhichareunstableornotamplydimensionedcouldcausetemporarypressuredropsduringoperation.

Therefore,takeallmeasuresrequiredtoensurethatthesystempressurecannotdroptolessthan180baranywhereinthe facehydraulicsystem.

Start-up

WARNING!

NOTICE!

Takecaretoensurethatalltransportsafetydevicesrequired fortransporthavebeenremoved.Seechapter3,section ”Transport”.

Tobeobservedpriortostart-up

Start-upmustbeperformedbytrainedandqualifiedpersonnel.If themineusestheshieldsupportforthefirsttime,itisimperative thattheDBTfieldserviceispresentduringstart-up.

Pleaseobservethefollowingitems:

J Mechanics

. Checktomakesurethatalltransportsafetydeviceshavebeen removed

. Checkallmechanicalconnectionsontheshields

. Checkattachmentoftheshiftingunit Onshiftingunitswithadjustablecrawlpanmakesurethatthe crawlpanhasbeenattachedproperly.Neverusethelastslot forconnection.

J Hydraulicsystem

. Testtheentirehydraulicsystemforleaks.Sealanyconnectionsthatareleaking.

. Checkwhethershieldmovements,particularlyinthelinks, couldcausedamagetohoses.

DANGER!

Damagedhosesmightburstandhydraulicfluidcouldescape underhighpressure.Thiscouldseverelyinjureorevenkillyou orothers.

Makesurethatthemovementsoftheshielddonotcauseany damagetothehoselines. Laythehoselinescorrectlybehindtheretainersprovidedfor thatpurpose.

. Checkthehydraulicsupplypressure.

. Checksupportingpoweroftheprops.(observepressuregauge reading)Theactualpressureunderthepistonofapropcanbe readoffthePM4controlunit.Youcaneitherreadoffthepressureofanadjacentsupportorofthesupportwhereyouare currentlylocated.Thepressuregaugeatthepropcheckvalve indicatesthepressuredirect..

Start-up

. Checkalloperatingelementstomakesurethatthecorrect functionisexecutedwhenactuatingtherespectiveoperating element.

J Signallingandlighting systems

IMPORTANT!

Fordetails,pleaserefertotherespectiveseparateoperating manualofthemanufacturer.

. Checkallsignalling systems.

. Checkthatthefaceisilluminatedsufficiently.

. Checkthatthefacearea,especiallythetravelway,isprovided withallsignsrequired.Itisimperativethatyouobservetheregulationsoftheresponsibleminingauthority.

J Emergencystop systems

. Checkthatallemergencystop systemsfunctionproperly.

J Miningandconveying

. Checkallfunctionsofthelongwall systembeforestart-up.

. Checkcorrectinteractionofthecompletelongwall system(miningmachine,conveyorsystem,shields).

WARNING!

Canopiesmustnotbeslopingdownwardsandreachintothe trackfortheminingmachine.

Start-upoftheshields

Bringtheshieldsintoinitialposition,whichmeans: –shieldsandconveyorarealignedinastraightline, –theshieldsarealignedatrightangleswithrespecttotheconveyor,

–theshieldcanopiesareparalleltothefloor.

Checktheshieldsforanyinstallationerrorsoranyothersourcesof errors.

. Checkalllineconnectionsmadeduringtheinstallationofthe shields,particularlythesupplylinesforthehydraulic systemof theshields,tomakesuretheyarecompleteandcorrect.

WARNING!

. Checkthefunctionofthehydraulicandwatersupply systems fortheface.

. Checkallfunctionsoftheshieldcontrolsystem.

Donotallowtheshieldtobeoperateduntilalldefectshavebeen eliminatedandtheshieldisfullyfunctional.

Corrosionprotectionofhydrauliccomponents

Beforedelivery,DBThydrauliccomponentsareprovidedwithacorrosionpreventingmediumfortestingpurposes.

Therearenospecialmeasuresrequiredtoremoveremnantsofthe testingfluidbeforeputtingthehydrauliccomponentsintooperation. Thetestingfluidisfullycompatiblewiththepermissiblemedialisted inthe“Approvallist”,seesection“HydraulicFluidsofGroupHFA”in chapter6.

5 Operation

Operationandmaintenance

Thischapterprovidesgeneralinformationontheoperationand maintenanceoftheshields.Thisinformationistoberegardedas preparationoforadditiontohands-ontraining.Readingofthis chapterisrecommendedinadditiontothetrainingmeasures,butit innowayreleasetheoperatorfromparticipatinginthetraining.

DANGER!

WARNING!

Ignoringthesafetyregulationswillcause accidentsandmay resultinseriousbodilyinjuriesordeath.

Theregulationsaboutsafeworkingofyourminemustbefollowedstrictly.Applythefollowinginstructionsanalogouslyin additionandinaccordancewiththeindividualsafetyregulationsofthemine.

Basicrequirements

Conditionsforoperation

Thefacecrewmustbeinformedaboutpossibledangersituations. Thesafetymeasurestobetakenmustbelaiddowninwritingand mustbemadeknowntothefacecrew.

Thefacecrewmustbeinstructedtostopthefaceconveyorimmediatelyincaselargelayersofcoalandrockhavefallenontothe conveyor.Thisalsoappliesincaseofaccumulationofdebris.

Thefacemustbeilluminatedsufficiently.

Towarnthefacecrewandforcommunicationofthecrew,intercommunicationsystemsmustbeprovided.

Thefaceconveyormustbeequippedwithapre-startwarningsystemandashut-downandlock-outdevice.

Largelayersofcoalandrockmustbebrokenuptopreventspillage andjammingundershieldcanopies.Compressed-airpickshaveto bekeptonhandforthispurpose.Thefaceconveyormustbeata standstillduringtheprocessofbreakingupthelayersofrockand coal.

Incaselargelayersofrockandcoalcannotbebrokenupasrequiredtheymayonlybetransportedwhenitisensuredthatnobody willbeputindanger.Anyworkonthefacemustbestoppeduntil thetransportoftherockandcoallayershasbeenfinished.

Theminimumdimensionsforthetravelwayspecifiedmustbemaintained.

IntheFederalRepublicofGermany,thefollowingvaluesapplywith respecttotheminimumdimensionsofthetravelway:

Width:600mm

Height:400mm

IfthesupportisusedincountriesotherthantheFederalRepublic ofGermanytherespectiveregulationsapplicableinthosecountries mustbeobserved.

Debrisorobjectslyinginthetravelwaymustberemovedimmediately.Thisdoesespeciallyapplyforlowseamheights.

Ifcrawlpansareusedwhoselengthisadjustable,carehastobe takenthatasafetravelwayofadequatewidthremains.

Iftheheightofthetravelwayisrestrictedbytheuseofadditional equipment,e.g.forconveyoralignment,carehastobetakenthata safetravelwayofadequateheightremains.

Iftheareabehindthefrontpropsistobeusedastravelway,e.g.in caseofthickseams,steeplyinclinedfaces,oriftheshieldcanbe moveduptotheconveyor,thetravelwaymustbemarkedatthe faceendsbyasign.

Caremustbetakenthatthefillingsectionofthefaceconveyorremainsunobstructed.Thismeansthatthecanopiesoftheshields mustbesetagainsttheroofimmediatelyaftertheshieldshave beenloweredandadvanced.

Workintheminingtrackmayonlybecarriedoutfromasafeposition.Theconveyorandtheminingmachinemustbeatastandstill andlocked-outtopreventrestarting.

Theconveyorandthespaceabovetheconveyormayonlybeenteredifthereisaprotectionagainstfallofrockfromtheroof. Inthickseamsthecoalfacemustalsobeprotectedagainstslabbingintheseplaces.Onfacesequippedwithshieldsthisisbest donebyusingflippers.

Caremustbetakenthattheflippersarealwaysextendedtowards thecoalfacefarenoughtoachievethedesiredprotection.This doesnotapplyduringshieldadvance.

Ifflippersarenotused,someotherkindofprotectionmustbeappliedtoshieldtheminingtrackfromtherestoftheface,e.g.extrahighspillplates,wiremesh,nets,etc.orthelike.

Workwhichhastobeperformedintheimmediatevicinityofthe faceconveyoratorabovethespillplatesmayalsoonlybecarried outaftertheplaceofworkhasbeensecuredagainstfallofrock andfallingcoallayers.

Oninclinedfacestheconveyormustadditionallybeprovidedwith barriers,forexampleaircushions,whichhavetobefittedabove theplacewheretheworkhastobecarriedout.Theirnumberand typedependsonthegradientandotherlocalconditions.

Beforestartinganyworkonthehydraulicsystemtakecaretoensurethattherespectivesectionofthesystemhas beendepressurized.Inaddition,youshouldtakeadequatemeasurestoprevent anyunauthorizedpersonsfromrestoringpressure.

Ifsupportunitsaretobedetachedfromtheconveyor,stoptheminingoperationcompletelyorensurebyothermeansthatthemining workcontinuesonlyoutsidethesafetyzonerequiredtosafelyperformtherepairwork.

Componentswhicharesubjecttomechanicalstressorhydraulic tensionareonlyallowedtobeloosenedorremovedaftertheyhave beenrelievedoftheirtensionorstress,forexamplebyaligning, liftingorlowering.

If,inexceptionalcases,thetensionorstresscannotberelieved completely,itshouldbereducedasfaraspossibleandtherespectivecomponentbesecuredbysuitablemeanssuchasforexample chainsorlockingelementstopermitthetensionstobeabsorbed safelywhentheyoccur.Anyworkinthisareaisonlyallowedtobe performedfromasafeposition.

Protectionequipmentincreasessafety;itisonlyallowedtoberemovedifthisisrequiredforperformingthework.Aftercompletion ofthework,theprotectionequipmentshouldimmediatelybe installedagainproperly.

Thewatersprayingsystemisdesignedfortheactivesuppression ofdust.Theshieldsupportisequippedwithseveralnozzleswhich spraywaterasandifrequired.Dependingontheoperatingmodeof theinstallation,thesprayingsystemwillbeactivatedfromtimeto time,forexamplewhenadvancingthesupportandwhenthemining machinepassesthesupport.Operationofthesprayingvalvesis program-controlledviatheelectronicshieldcontrolordirectbythe hydraulicshieldcontrolsystem.

Oninclinedfaces,theconveyorhastobesecuredbyanchorages, ifrequired.Thismeasureisrequiredtopreventtheconveyoroffsettingwithrespecttothesupport.Itreducestheriskoftheshifting unitjamminginthebaseskid.

Hydraulicanchoragesmustalwaysbesuppliedwiththespecified workingpressure.Onlythusisasufficientanchoragebetweensupportandconveyorensured.

Whenpullinguptheshields,alwaysobservethespecifiedsequenceofsteps.Ifnot,theanchoragedevicemightbedamaged andbecomeunfitforuse.

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Safetyrequirements

Exercisespecialcareandcautionwhentravellingafacethatisoperatedautomatically.Besuretoobservethewarningsattheface entryandtherespectivesafetyregulationsofthemine.

Youmustalwaysbepreparedfortheshieldwhichyouareinbeing addressedbytheautomatic system.Thereforeitisvitalthatyou observetheacousticandopticalwarningsignalssentbythecontrol unitofashieldwhichisjustbeingoperated.

Operatethe”supportlock-outswitch”whenyouhavetostayina shieldforalongerperiodoftime.

Ashieldmustalwaysbeoperatedfromasafepositionandfrom withinanadjacentshield.

Nevereverstayunderashieldwhichhasnotbeenset.

Takecarethatnopartofyourbodyevergetsbetweenthecanopy andtheroof,thebaseandthefloor,skidandshiftingunitorbetweenthesidesealsofadjacentshields.

Whenoperatingtheshieldmanuallytheoperatorhastoalways watchtheareaofmovementoftheshieldbeforeandwhileoperatingtheshieldinordertopreventpotentialhazardsbycautiousbehavior.

Nobodyisallowedtostayinashieldwhichisbeingadvanced.

Youarenotallowedtoloweroradvanceashieldaslongasapersonisintheimmediatevicinityofthesupportunitorinthesupport unit.

Youarenotallowedtoloweroradvanceashieldmanuallywhen theminingmachineisbeforeorintherangeofactionofthesupportunit.

Oninclinedfaces,shieldadvanceshouldbestartedinthelower section.Sincetheshieldsaretobeoperatedbyadjacentcontrol, theoperatorcanoperateandobservetheunittobeadvancedfrom asafepositionwithintheadjacentshield.

Thepropsoftheshieldsmustalwaysbesetuntilthesettingpressurehasbeenreachedtoensuregoodroofsupportandincaseof shieldswithspecialfunctions,e.g.shieldsservingasabutmentsfor conveyoralignmentsystems,sufficientanchoringbetweenroofand floor.

Theshieldsmustbeadvancedassoonaspossibletopreventthe potentialdangerofrooffall-outs.

Acanopywhichisslopingdownwardsatastepintheroofmustnot obstructthepassingoftheminingmachine.

Theflippermustbefoldedbackcompletelypriortoadvancingthe shieldunit.Neveradvanceashieldagainstthecoalfacewitha folded-outflipper.Otherwisetheflippercylindersandthelinkjoints oftheflipperwillbedamagedseriously.

Whileadvancingashieldunitspecialcaremustbetakenthatthe shieldcanopydoesnotgetunderthesidesealofanadjacent shield.Otherwisethesidesealoftheadjacentshieldwillbedamagedseriously.

Takecaretoavoidmisoperationoftheshieldcontrol.

Thesymbolplatesonthecontrolunitsshowthefunctionsofthe shieldcontrol.Theyshouldbelegibleatalltimesandmustnotbe removedordamaged.

Hosesmustremainfreetomove.Theymustnotbesqueezedor overstretched.Caremustbetakenthattheyareproperlybundled. Damagedhydraulichosesandhoseconnectionsmustbereplaced atonce.Thisworkmustonlybecarriedoutbytrainedpersons.

Fig.13: Wrong ,shieldshavenotbeenadvancedintherighttime

Fig.14: Correct,shieldshavebeenadvancedintime

Basicrequirements

Hoselinesbetweenpilot-operatedcheckvalvesandpropsorcylinders,whichhaveaload-acceptingfunction,e.g.stabilizingcylindersorswivelcanopycylinders,mayonlybereplacedafterthe canopyandthecavingshieldhavebeensecuredinpositionmechanically.Thisalsoappliestotheworkonthearticulations.

Shut-offvalvesmustnotbeinstalledinthereturnline.

Topreventdamageincasethereturnlineisclosedsafetyvalves ofnominaldiameter32relievingtoatmosphereshouldbeinstalled additionallyintothereturnline,spacedabout40mapart.Relief pressure25bar.

damages,spareparts

Specialobservations,inparticularconcerningdefectsordamage, havetobereportedimmediately.

Machinepartsandhydraulicelementsmayonlybereplacedby genuinespareparts.

Operationoftheshield

Agoodtrainingoftheoperatingpersonnel,knowledgeandobservanceofthesafetyregulationsandoftheoperatinginstructions listedafterwardslargelyhelptopreventtheoccurrenceofhazardoussituations.Moreover,theyaregoodprerequisitesforareliable interactionofshieldandminingmachinewithinthelongwall system.

Iftheshieldisequippedwithanelectrohydrauliccontrol system,a profoundknowledgeoftheseparateoperatingmanualforthiscontrolsystemisabsolutelynecessaryforshield operation.

Theshieldsmustbesetuntilthesettingpressurehasbeen reachedtoensuregoodroofsupportand,incaseofshieldswith specialfunctions,e.g.shieldsservingasabutmentsforanchorages,sufficientanchoringbetweenroofandfloor.

Itisageneralrulethattheshieldsshouldbeadvancedassoonas possibletoachieveanearlysupportofthenewlyminedroof.

Thesupportunitsmustbealignedatrightangleswithrespectto theconveyor.

Theshieldsmustalwaysbesetinsuchawaythatthecanopies andthebasesareasparallelaspossible.Withinthemaximum anglesgiveninthetechnicaldatasheetitispossible,however,to adaptthecanopytostepsintheroofandtoovercomestepsinthe floor,ifrequiredbygeologicaloroperationalconditions.

CAUTION!

Fig.15:Shieldinthenormalposition

Operationoftheshield

CAUTION!

Neverextendorretractthestabilizingcylindersoftheshield completely.Theymustalwayshavesufficientresidualstroke. Standardvalue:min.20mm!

Thesameappliesanalogouslyfortheswivelcanopycylinders.

Thisistheonlywayofcushioninghighpeakloads,whichmayoccursuddenly,bythehydraulicsecuringactionofthestabilizingcylinders.Iftheresidualstrokeisnotsufficient,thismayresultinseriousdamagetotheshieldunderunfavorableleverageconditions.

Fig.16:Shieldwithextremelyinclinedcanopy

M=heightofthesetshield

α =inclinationangleofthecanopy

S=residualstrokeofthestabilizingcylinder

CAUTION!

Ensuresufficientresidualstrokeofthestabilizingcylinders especiallyinthecaseofatendencytorooffall-outsand/orextremelysoftfloor.

Thisappliesespeciallyiftheshieldcontrolunitisequippedwithan automaticpositivesettingfunction.Underunfavorableconditionsforexample,softfloorandinaddition,perhapsatendencytoroof fall-outs-theautomaticpositivesettingfunctioncouldleadtothe stabilizingcylindersnothavingsufficientresidualstrokeorbeing extendedorretractedcompletely.Therefore,operatetheshieldin suchorsimilarcaseswithoutautomaticpositiveset.

CAUTION!

Avoidanexcessiveinclinationofthecanopybyfillingrooffalloutsorbysupportingminorfall-outswiththeshieldinhorizontalposition.

Atthispoint,weexplicitlyemphasizeagainthatanydamage causedbythenon-compliancewiththeseinstructionsispossiblynotcoveredbytheguarantee.

CAUTION!

Sincechangesintheanglesresultinconsiderablechangesin heightattheendsofthecanopyorskids,thenecessityoftaking appropriatecountermeasurescanberecognizedatanearlystage, evenwithoutameasuringinstrument.Forinstance,itmaybenecessarytoripandleveloffstepsinthefloorandroof,orfillcavities theroof.

Never setthetipofthecanopyoftwo-legshieldswithstabilizing cylinderinacavity(figure17)ifthestabilizingcylinderisfullyextended.Theremustalwaysbesufficientstrokeavailablefordecreasingdynamicloadsfromtheroofbythehydraulicallyprotected stabilizingcylinder.

Fig.17: Wrong,bynomeansmustthetipof thecanopybesetinacavity, ifthestabilizingcylinderisfullyextended.

Cavitiesintheroofcanbeovercomebyplacingcribblocksontothe tipofthecanopy(seeFig.18)orbylevelingoffthecanopy. Bythesemeasurestheroofwillbecaughtduringthenextstep.

Operationoftheshield

Fig.18: Correct,overcomeacavitybyplacingcribblocksontothe tipofthecanopy

rangeof adjustment / changingseamthickness

Caremustbetakenthatacanopywhichisslopingdownwardsata stepintheroofdoesnotobstructthepassoftheminingmachine.

Accumulationofdirtonthecanopiescanbeavoidedbyadvancing theshieldsunderroofcontact.Insomecasesitispossibletolet thedirtfallontotheconveyorortoclearitawayafterloweringthe tipsofthecanopiesforashorttime.

Theclosedheightoftheshieldsmustbesuitableforthelowest seamheight.

Theshieldmustbeoperatedsuchastoensurethatthereisalways sufficientresidualstrokeavailableforlowering.Ifnot,theshield mightgetjammedbetweentheroofandthefloorandmaybe heavilydamagedbysuddenloadpeaks-forexamplecausedbya mountainbump.Loadpeakscannotbecushionedhydraulically whenthereisnotenoughhydraulicfluidunderthepistonofthe proporthepistonalreadyhasreacheditsbottomdeadcenterposition.

Theminimumresidualstrokerequiredforloweringtheshieldcan bemaintainedby

J keepingtheseamopeningsufficientlylargebymeansofthe miningmachine

J avoidingtheaccumulationofdebrisandfinecoalonthefloor

J removingaccumulateddirtfromthecanopies

Beforetheshieldsareadvanced,thefloormustbeclearofcoarse debrissothattheshieldscanbeadvancedbythefulllengthofthe strokewithoutobstructionandsubsequentadvanceoftheconveyor isnotimpeded.Besides,acleanfloorfacilitatescorrectionsinthe attitudeoftheshields.

Iftheseamheightincreasesconsiderablyandthehydraulicstroke isnotsufficientthepropshavetobeextendedintimeorreplaced bypropswithalargerstroke.Youareonlyallowedtouseapproved components.

Whenextendingthepropsorretractingtheextensions,thecanopy mustbesecuredinposition.Makesurethatthepropwhichhas beenseparatedfromthecanopycannotturnover.

Particularlyininclinedworkingsslidingandcantingoftheshields mustbeavoidedbycorrectingtheirattitudeintimebymeansofthe sidesealsandsteeringdevices.Thisistopreventashieldfrom gettingunderthecanopyofitsadjacentshield,oftencausingconsiderabledamage.

Sinceininclinedworkingsshieldadvancestartsasaruleinthe lowersectionoftheface,acorrectattitudeoftheendshieldsisof importance.Forcorrectingtheattitude,hydraulicallyoperatedguide beamassembliesandsteeringdevicesatthecanopyandthebase orbetweencanopyandbaseareused.

Thesidesealscanbeusedwithautomaticcontrolstopreventtiltingofaloweredshieldduringadvance.Anycorrectionsintheattitudebecomingnecessarycanbecarriedoutbymeansofmanual controlonly.

Thesidesealofthecavingshieldisonlyallowedtobeusedfor alignmentwithrespecttotheadjacentshieldifthetwoshieldshave beenadvancedtothesameextent.

Oninclinedfaces,theconveyorhastobesecuredwithanchorages.Thismeasurepreventstheconveyoroffsettingwithrespect tothesupport.Itreducestheriskoftheshiftingunitjamminginthe baseskidwhichwouldmakeshieldadvancedifficult.

Whenpullinguptheshields,alwaysobservethespecifiedsequenceofsteps.Ifnot,theconveyoranchoragedevicemightbe damagedandbecomeunfitforuse.Furtherinformation,ifany,is giveninchapter6,section”Accessories”andintheoperating manualfortheconveyoranchoragedevice.

Withunfavorablefloorconditions,thebaseframeofthesupport unitmightsinkintothefloor.Inthisevent,thebaseframemustbe raisedduringshieldadvancetomakesurethattheinstallationfollowstheseamlineanddoesnotsinkintothefloor.

Shieldswhichareequippedwithahydraulicbaseliftingdeviceare raisedoutofthefloorbyoperatingavalveorautomaticallyduring shieldadvance.

Shieldswithoutbase-liftingdevicerequiredifferentprocedures,dependingontheirdesign:

J Individualskidsoftwo-legshieldscan,asarule,beliftedhydraulicallybyretractingaprop.

J shieldswithsolidbasesmustbeliftedandunderlaidbymeans usuallyappliedinmines.

IMPORTANT!

Bothcasesrequireknowledgeoftheflowplanandskilledpersonnel.Thesafetyguidelinescontainedinthismanualmust strictlybeobserved.

unfavorable floorconditions

Safeworking

Forsafetyoftheoperatortheshieldsareprovidedwithadjacent controls;i.e.eachshieldisoperatedusingthecontrolslocatedin theshieldtotheleftortotherightoftheunittobeadvanced,orby automatedremotebatchcontrol.

WARNING!

Alwaysstayclearofashieldwhichisbeingmoved.Circumstanceswhicharenotalwaysobviousmayleadtounexpected movementsoftheshieldunitwhichcouldresultinsevereinjuriesorevendeath.

Forexample,theshieldcanopymayjerkfreeduringloweringif itwasstuckbetweenthecanopiesoftheadjacentshields.

CAUTION!

Takecarenottodamagethepush-buttonsofthepilotvalves. Jammedpush-buttonswillcausemalfunctionsofthevalves whichmayresultinaccidents.

Alwaysobservethesesafetyrules:

Keepallpartsofyourbodyunderthecanopyofasetshieldand awayfromtheshieldinmotionorabouttobeadvanced.

Whengroupsofshieldsareadvancedautomatically,nobodyisallowedtostayintheareabetweentheoperatorandtheshieldtobe moved.

Followthesestepsifashieldhasfailedtoadvance:

1.Determinereasonforfailuretoadvance,theremaybe:

J Malfunctioningofelectroniccontrols

J Externalobstructions: –shieldwedgedinbetweenadjacentshields –canopyhastiplodgedinroof –floorsteporexcessivedebrisinfrontofbasetip

2.Incaseofmalfunctionoftheautomatedbatchcycles,advance theshieldmanuallyinsinglestepmodebyuseofthecontrolunitof theadjacentshieldunit.Seeseparatemanualoftheelectroniccontrol.

3.Incaseofexternalobstructionsutilizeadjacentmanualcontrolto overcometheobstruction(s).

ItemQty. Description

Operationoftheshieldhydraulics

WARNING!

Duringnormaloperation,theshield-typesupportisoperated onlybymeansofthecontrolunitoftheelectrohydraulicadjacentcontrolsystem.Payattentiontotheseparatemanualof theelectroniccontrolsystem.

Locationofhydrauliccomponentsattheshield

Tab.6:Hydrauliccomponents

Location

Remark

1 1 electrohydrauliccontrolunit frontlemniscaticlink atholder

2 2 propcheckvalve prop,gobside

3 1 shiftcylindercheckvalve L.H.frontlemniscaticlink

5 2 pressurereliefvalve,420bar prop,gobside highflowratetype

6 2 pressurereliefvalve,420bar stabilizingcylinder

7 1 checkvalve manifoldpipe returnline

8 -/1 1) checkvalve gobsidesidecanopycylinder sidecanopy

10 1 compensatingvalve R.H.prop,gobside

11 3 twincheckvalve

a)flippercylinder

b)stabilizingcylinder c)underthecanopy,belongsto flipperextensioncylinder

12 2 pressuregauger propcheckvalve

13 1 hoselines subassembly

14 1 waterspraysystem subassembly

15 1 retainersandaccessories subassembly

16 1 manifoldpipe frontlemniscaticlink atholder

17 1 accumulatorcartridge electrohydrauliccontrolunit

18 6/71) pressurereliefvalve

a)2xattwincheckvalve(11a) b)2xattwincheckvalve(11c)

c)1xatshiftcylindercheckvalve d)1xundercanopy,R.H. e)1xatsidecanopycylinder a)b)c)d)sealcylindercircuit e)-

19 1 watersprayvalve frontlemniscaticlink,inside

20 1 dualfilter,backflushtype frontlemniscaticlink manualoperated,atholder

21 5 high-pressureballvalve

a)R.H.prop,gobside

b)undercanopy

c)R.H.fontlemniscaticlink d)manifoldpipe e)manifoldpipe

a)atcompensatingvalve(10) b)atmanifold(27)

c)atwatersprayvalve(19) d) e)

22 2 high-pressureballvalve propcheckvalve prop,pistonside

23 1 high-pressureballvalve manifoldpipe pressuresupply

24 1 in-line-filter manifoldpipe watersupply

25 2 screwedsocket prophead

26 -/11) high-pressureballvalve,Xtype underneaththePM4-controlunit atholder

27 2 manifold underthecanopy insealcylindercircuit

28 1 connectingplate attwincheckvalve(11b)

29 1 plug-insocketwithrelief manifoldpipe returnline

30 1 watersprayvalve R.H.frontlemniscaticlink

32 -/11) hoselinesandfittingsfor pushercylinder subassembly

33 -/11) hoselinesandfittingsforside canopy subassembly

S1 1 pressuresensor atpropcheckvalve,onlyL.H.

Z1 2 prop

Z2 1 shiftcylinder

Z3 1 stabilizingcylinder

Z4 4 sealcylinder

Z5 1 liftcylinder

Z6 1 flippercylinder

Z7 2 flipperextensioncylinder

Z8 2 sidecanopycylinder

Z9 1 pushercylinder

1) deviatingquantityforendshieldvariantswithpushercylinderand/orsidecanopy

Operationoftheshieldhydraulics

Shieldhydraulics

Fig.19:Shieldhydraulics,arrangement(1), key,seetable6

Note:Thecomponentsmarkedin“blue”areoptionallyapplicableattheendshieldvariants03...07.

Fig.20:Shieldhydraulics,arrangement(2) key,seetable6

18a18b11c2821a2721b29723

Note:Thecomponentsmarkedin“blue”areoptionallyapplicabletotheendshieldvariants03...07.

Operationoftheshieldhydraulics

Fig.21:Electrohydrauliccontrolunits,symbolplates 16functions

14functions

Tab.7:Electrohydrauliccontrolunitswith14/16functions, allocationoffunctions

function,descriptioncontrolunit p 14funct. 16funct advanceshield

flippercylinder,extend

flippercylinder,retract 10 10 flipperextensioncylinder,retract 11 11 flipperextensioncylinder,extend 12 12 sidecanopycylinder,extend - 13 sidecanopycylinder,retract - 14 liftcylinder,extend 13 15 lowerbothpropsactively 14 16

Fig.22:Shieldhydraulics key,seetable6

Note:Thecomponentsmarkedin“blue”areoptionallyapplicabletotheendshieldvariants03...07.

Operationoftheshieldhydraulics

Fig.23:Hydrauliclines,overview key,seetable6

Fig.24:Pushercylinder,hoselinesandfittings key,seetable6

Aretractpushercylinder Bextendpushercylinder

NOTE:Thecomponentsmarkedin“blue”arenotincludedinthescopeofsupplyof thefaceshieldvariants01and02.

Fig.25:Sidecanopy,hoselinesandfittings key,seetable6

NOTE:Thecomponentsmarkedin “blue” arenotincludedinthescopeofsupplyof thefaceshieldvariants01and02.

Operationoftheshieldhydraulics

1manifoldpipe

2PM4controlunit

3controlvalveblock

Fig.27: Viewonthemanifoldpipe

16manifoldpipe

20dualfilter,backflushtype

21ehigh-pressureballvalve,auxiliarywaterline,openasshown

21dhigh-pressureballvalve,supplylinetowaterspraysystem, openasshown

23high-pressureballvalve, pressuresupply,openas shown

aprotectivecoverforelectrohydrauliccontrolunit

bprotectivecoverfordualfilter, openasshown

Rreturnline,DN50

Ppressureline,DN40

Wwaterline,DN50

Fig.26:Shield

Fig.28: Viewonthedual filterandtherearmanifoldpipe,protectivecover removed

16manifoldpipe

20dualfilter,backflushtype 21chighpressureballvalve, servestoisolatethewater

supplytothe“watercurtain”, openasshown 23high-pressureballvalve, servestoisolatetheshieldhydraulicsfrompressuresupply, openasshown

Fig.29:PM4controlunitfittedatadjustableholder

aPM4controlunit bholderforPM4controlunit ccontrolvalveblock

Operationoftheshieldhydraulics

Fig.30:AdjustableholderforelectroniccontrolunitPM4

6hex.headboltM16x35-8.8, recommendedtighteningtorque 195Nm 9washer

11securingspring

Aheightadjustablelink

Badjustablehingefittedlink

Priortoputtingtheshieldunitintooperation,theretainerforthe PM4controlunitmustbefittedinsuitableworkingposition.

. Fixheightoftheretainer(A)atbothsidesinworkingposition usingthesecuringsprings(11).

. Adjustangle(B)inworkingpositionandretightenbolts(6)with therecommendedtighteningtorque.

Fig.31:High-pressureballvalve(26)tooperatethepushercylinder

26high-pressureballvalve notavailableatshieldvariants 01and02 aholder

Cheightadjustablelink

Aextendpushercylinder Bretractpushercylinder

Fig.32:Props,gobsideview,protectivecoverassembled

Fig.33:L.H.prop,gobsideview,protectivecoverremoved

2propcheckvalve 5pressurereliefvalve 12pressuregauge

22high-pressureballvalve, servestoisolatetheproppiston chamberfrompressuresupply, openasshown

Operationoftheshieldhydraulics

Fig.34:R.H.prop,gobsideview,protectivecoverremoved

2propcheckvalve

5pressurereliefvalve

10compensatingvalve

12pressuregauge

21ahigh-pressureballvalve,enables /disablescanopyautoaligning function,enabledasshown

S1pressuresensor

22high-pressureballvalve,serves toisolatetheproppistonchamberfrompressuresupply,open asshown

Operationofthedualbackflushfilter

WARNING!

Donotputthefilterintooperation,priormakingsurethatall connectionshavebeenmadeproperly.

Thefilterworks,ifbothbackflushleversareinparallelposition.The filterneedstobebackflushedaftercontaminationaccumulatesto thepointofincreasedpressuredropandrestrictedflow.

Sincetheoperatingtimebetweenbackflushing dependsonthe contaminationoftheemulsion(HFAfluid)thefrequencyofbackflushingcannotbepredetermined.Ingeneral,however,eachfilter shouldbebackflushedonceeveryshift.

WARNING!

Neverputbothleversintobackflushpositionsimultaneously, becausetheemulsionflowwillbecompletelyshutoffand backflushingwillbeimpossible.

Onlyonefilterelementmustbebackflushedatatimebysimply turningthelever90degreesforabouttwosecondsandthen returningthelevertotheworkingposition.Repeatprocedureforthe otherfilterelement.

Effectivebackflushingrequiresflowinexcessof70I/min(19GPM).

Fig.35: Viewonthedual filterandtherearmanifoldpipe,protectivecover removed

Operationoftheshieldhydraulics

Repairandemergencyoperation

Thissectioncontainsinformationonthefunctionsandtheoperation ofthehydrauliccontrolwhichmayonlybeusedinexceptionalsituations,i.e.duringrepairsandemergencies.Itisassumedherethat theshieldhasbeenpreviouslyinstalledcorrectlyandthatallthe shut-offvalvesareopenasfornormaloperation.

Theoperationofthecontrolunitoftheelectroniccontrol systemis notdescribedherebutinaseparateoperatingmanual.IfthecontrolunitispartoftheDBTscopeofsupplyyouwillfindthecorrespondingoperatingmanualintheDBTdocumentationonthesystem.

Thefundamentaldesignoftheshieldunitandthecontrol systemis describedinchapter6,”TechnicalDescription”,ofthismanual. Ithasalsobeenassumedthatthereaderisfamiliarwiththefundamentalprinciplesofthehydraulicshield-typesupportandtheoperationofthecontrolunit.

WARNING!

Thecontrolelementsonthecontrolvalveblockmayonlybe usedinanemergencyandduringrepairsandonlyincompliancewiththespecialoperatinginstructionsoftheminefor thatpurpose.Theyarenotallowedtobeusedfornormaloperationasotherwisehazardoussituationsmayarisewhich mightresultinveryseriousinjuries.Duringnormaloperating mode,theshieldisoperatedexclusivelybymeansoftheelectrohydrauliccontrol.Inthisrespectitisimperativethatyou observetheseparateoperatingmanualofthecontrolunit.If theelectroniccontrolispartofthescopeofsupplyofDBTthe respectiveoperatingmanualwillbeincludedintheDBTdocumentationprovidedfortheinstallation.

Fig.36:Controldevices

aPM4controlunit belectrohydrauliccontrol

Figure36aboveshowsthearrangementofthePM4controlunit andthecontrolvalveblock. HowtousethePM4controlunitisnotdescribedinthismanual. SeeseparatemanualforthePM4controlunit.

Fig.37:Controlvalveblock(14functions)fittedatholderbetweenthefront lemniscaticlinks

1electrohydrauliccontrol 17accumulatorcartridge apushbutton bsymbolplate, hiddenbythepilotvalves

cpilotvalve dconnectingcable esolenoiddriver

Fig.38:Symbolplatefor14functioncontrolvalveblock

Fig.39:Symbolplatefor16functioncontrolvalveblock

Thesymbolplateislocatedatthecontrolvalveblockunderneath thepilotcontrolvalves.Thesymbolsontheplatecorresponddirectlytothefunctionsactivatedbytherespectivepushbuttons. Themeaningofthesymbolsandthefunctionsisdescribedinthe following.

Operationoftheshieldhydraulics

Operationandfunctionsofthecontrolvalveblock

Thissectioncontainsinformationonthefunctionsofthecontrol valveblock.Pleasebesurealsotoobservetheoperatinginstructionsforthehydrauliccontrolvalveblockandtheelectroniccontrol unit.

WARNING!

Controloftheshieldisparticularlydangerousduringrepairoperationasyouthenoperatetheshieldunderwhichyouarestanding direct.Itisthereforeextremelyimportantthatyouknowandunderstandtheinterrelationshipsbetweenthefunctionsandmovements oftheshield.

Nootherpersonsareallowedtoremaininthemovementareaof theshieldaslongasyouareoperatingtheshieldusingtherepair mode.

Therearetwopush-buttonsonthecoverofeverysinglepilotcontrolvalve.Whenyoupressabutton,thecorrespondingworking valveisoperateddirectly.

Thefunctionstopsassoonasyoureleasethepush-button.

DANGER!

WARNING!

Advanceshield

Beforethisfunctionisinitiated,thesidesealoftheshieldmustbe releasedandthefunction”lowerprop”musthavebeenexecuted forbothprops.

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Aslongasthefunctionisactivated,thepilot-operatedcheckvalve sealingofftheannulusoftheshiftingramisautomaticallyheld open.

Setbothprops

Beforeoperatingthisfunctionthecanopymustbecorrectlyaligned manuallyifthe”aligncanopyautomatically”functionhasbeendeactivated.

Whilethe”setbothprops”functionisoperatedthebaseliftcylinder isactivelyretractedautomaticallyandthegobsidespraying system isactivated.Atthesametime,thecanopyisautomaticallyaligned withrespecttotheroofprovidedshut-offvalve21aisopen.The followingfigure40showsthepositionofshut-offvalve21a.The shut-offvalveisopenwhenthehandlepointsinthedirectionof flow.Itisclosedwhenthehandleisatrightanglestothedirection offlow.

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Aligncanopyautomatically Ifthecanopyswivelangleistoosteepandshut-offvalve21ais opentheattitudeofthecanopywithrespecttotheroofwillbeautomaticallycorrectedduringthesettingoperation.Thebalancing valve10causesthepressurelimitatthepistonsideofthestabilizingcylindertobetemporarilyreducedto200baraslongasthe pressureinthepistonchamberoftheR.H.propdoesnotexceed 100bar.Result:shouldthecanopycontacttheroofonlyinthefront areathestabilizingcylinderwillretractuntilequilibriumofforces hasbeenachieved.

Fig.40:R.H.prop,gobsideview,protectivecoverremoved

Operationoftheshieldhydraulics

Advanceconveyor

Beforeinitiatingthisfunction,ensurethattheshieldhasbeencompletelysettotheroof.

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Activate“watercurtain”

Thefunctionisperformedaslongasthebuttonishelddepressed.

Extendstabilizingcylinder

CAUTION!

Donotexceedpermissiblecanopyangle! Observevalueforminimumresidualstroke.

Thisfunctioncausesthecanopytiptoraiseandservestocorrect theattitudeofthecanopy.Itisperformedaslongasthebuttonis helddepressed,untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached. Aftertheattitudeofthecanopyhasbeencorrectedthepropswill havetobesetagain.

Retractstabilizingcylinder

CAUTION!

Donotexceedpermissiblecanopyangle! Observevalueforminimumresidualstroke.

Beforeinitiatingthisfunctionensurethattheadjacentshieldsare completelyset.

Thefunctioncausesthecanopytiptolowerandservestocorrect theattitudeofthecanopy.Itisperformedaslongasthebuttonis helddepressedoruntiltheendpositionhasbeenreached Aftertheattitudeofthecanopyhasbeencorrectedthepropswill havetobesetagain.

Extendsealcylinders

Thisfunctionisdesignedtocorrecttheattitudeofashieldwithrespecttoitsadjacentshield.Thesealcylindersareextendedas longasthebuttonishelddepressed,untilequilibriumofforceshas beenobtainedoruntiltheendpositionhasbeenreached.When notactivated,thesidesealispressedoutwardsbytheforceofthe pressuresprings.

Retractsealcylinders

Thisfunctionisdesignedtocorrecttheattitudeofashieldwithrespecttoitsadjacentshield.Thesealcylindersareretractedaslong asthebuttonishelddepressedoruntiltheendpositionhasbeen reached.Whennotactivated,thesidesealispressedoutwardsby theforceofthepressuresprings.

Extendflippercylinder

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Retractflippercylinder

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Extendflipperextensioncylinder

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Retractflipperextensioncylinder

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Extendsidecanopycylinders

Notapplicabletoshieldvariants01,02,04and05. Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Retractsidecanopycylinders

Notapplicabletoshieldvariants01,02,04and05. Thefunctionisperformedaslongasthebuttonishelddepressed oruntiltheendpositionhasbeenreached.

Extendbaseliftcylinder

Thefunctionisperformedaslongasthebuttonishelddepressed, untilequilibriumofforceshasbeenobtainedoruntiltheendpositionhasbeenreached.

Activelylowerbothprops

Beforethisfunctionisinitiated,ensurethattheadjacentshields havebeensetcompletely. Thisfunctionisperformedaslongasthebuttonishelddepressed oruntiltheendpositionhasbeenreached.

Maintenance

WARNING!

Whentheoperatingsafetyisatriskanydamagedcomponents mustbereplacedwithoutdelay.Ifthisisnotpossible,stopthe shieldoperationatonceandsecuretheshield.Immediately informthecompletefacecrewandyoursuperior.

. SeeseparateoriginaloperatinginstructionsforthePM4control unit.

Specialmeasures

Oneweekafterstart-up,atthelatest,thefiltercartridgesofthe electrohydrauliccontrolvalveblocksoftheshieldcontrolunitson thecompletelongwallmustbecheckedfordirtonarandombasis. Ifthisinspectionrevealsthatthereisahighprobabilityoffailures duetodirtyfiltersallfiltercartridgesonthefacemustbereplaced.

Whenextensiveworkhasbeenperformedonthehydraulic system orafterstart-upofanewfacethereisanincreasedriskofdirthavingenteredthehydraulicsystem.Dependingonthedegreeofcontaminationthismayleadtothefiltercartridgesgettingclogged.This resultsinthefunctionsbeingoperatedslowerornotatall.We thereforerecommendthatyoutakethemeasuredescribedabove inordertopreventfailuresoccurringduringoperationoftheshield hydraulics.

Allshieldsequippedwithawaterspraying systemrequirethepistonrodsofthosecylinderswhichareusuallyonlyrarelyextended orretractedcompletely,forexample,propsandandstabilizingcylinders,tobethoroughlycleanedapproximatelyevery6months.A suitablepreservativeshouldbeappliedafterwards.

Thefiltercartridgesofthemanifoldblockandthecontrolvalve blockoftheshieldcontrolunitaredesignedtoprotectthedownstreamhydrauliccomponentsagainstdamageduetodirtinthehydraulicmedium.Theyhavetobereplacedregularlyonlyifthefiltrationinthefacesupplylineisinsufficient. Therefore,itisvitalthatyouseetoqualityinthetreatmentofthe hydraulicmedium.

Ifproblemsoccurinthepreparationofthemediumtherewillbean increasedriskoffailuresduetocloggedfilters.Tomaintainoperationalreliabilityoftheinstallation,additionalmeasuresmaythenbe required.Forexample,thefiltersmentionedaboveshouldberegularlyinspectedforcontaminationsonarandombasis.Itmaybe necessarytoreplacethefiltercartridgesregularlyasaprecaution.

Allpressurereliefvalvesshouldbesubjectedtoafunctiontestafteroneyearofoperationatthelatestorwhenmovingtheequipmenttoanotherface.Ifitisnotpossibletokeepthisdeadlinebecausetheendofthesectionplannedtobeminedwillonlybe reachedshortlyafterthedeadline,thepressurereliefvalvescanby wayofexceptionbecheckedaftertherespectivesectionhasbeen completed.

Pressure-reliefvalveswithnitrogenfillingmustbeinspectedatregularintervalstocheckthattheyfunctioncorrectly.Werecommend toperformsampletestsonceeverythreemonths.

Forreasonsofsafetyandtomaintaintheinstallationoperativeall hydraulichigh-pressurehosesmustbereplacedregularlyatleast aftertwoyearsofoperation,irrespectiveofwhethertheyshowany signsofdamage.Ifthisdeadlinecannotbemetbecausetheendof thesectionplannedtobeminedwillonlybereachedshortlyafter thedeadline,thehosescanbywayofexceptionbereplacedafter therespectivesectionhasbeencompleted.

Dailyinspection

. Checkallshieldunitsbyvisualinspectionforhydraulicfluidescapingonthe: –hoselines, –controlvalveblocks, –valves –props, –shiftingramandliftcylinder –stabilizingcylinder,sealandflippercylinders.

. Checkpressuregaugesatthepropsforanyvisiblesignsof damageandcorrectfunctioning.

. Checkallshieldunitsbyvisualinspectionfordamagetothe steelstructure,forinstance: –ontheshiftingunit, –boltconnectionsandretainers –onthesideseals, –onholders,etc.

Weeklyinspection

. Checkthecontrolunitforcorrectfunction.

. Replacedefectivecontrolunitsorindividualcomponentsimmediately.

. Cleanthecontrolunits,especiallythecontrolpanel.

NOTICE!

Itisimportantthatthecontrolsymbolsarelegibletoavoidthe riskofoperatingerrorsandresultantaccidents.

Tobedoneeverysixmonths

. Applyapreservativetothepistonrodsofthehydrauliccylinders.Detailsaregiveninthischapterundertheheading”specialmeasures”.

Assessmentofdamageaccordingtoschedule Werecommendtokeeprecordsofthedamagesfound.Theserecordsshouldbeevaluatedregularly,sayonceamonth,andsummarizedinadamagereport.Frequentlyrecurringfailurescanthus bedetectedearlyandthesourceofthefailureeliminated.Thiswill improvetheavailabilityoftheinstallationandhelptoreduceoperatingcost.

Troubleshooting

Faultfindingonshieldhydraulicsystem

Thehydrauliccircuitsoftheshieldscontainanumberofmodules andcomponents,identifiedintheschematicdrawings.See”operatingtheshieldhydraulics”inthischapterorthesparepartscatalog.

Faultscanoccuronanyofthecomponents.Themaincauseon hydraulicvalvesisaby-passwhichinmostcasesisaudibletothe operator.

Thefollowinginformationwillassistyouinthedetectionandeliminationoffaults.

WARNING!

Faultlocalization

possiblecausecheck/measurerequired

Theshut-offvalveforpressure supplyatthesupplyblockofthe shieldisclosed.

Shut-offvalveinfeedlinetoprop pistonchamberisclosed.

Canopyistrappedbyadjacent shields.

Pilotpistoninthepropcheckvalve isnotoperating.

Damagedortrappedhoses.

Propsaredamaged.

Nopressureatcontrolvalveblock output.

Openshut-offvalve. Feedlinemustbeopentoallowpressureto theshieldhydraulics.

Openshut-offvalve. Linestopistonchamberandannulusofprop mustbeopen.

Findcause.Ifnecessary,loweroralignadjacentshieldstofreecanopy.

Checkifthereisenoughpressuretooperate thepiston(minimumapprox.80bar). Propcheckvalvemaybefaulty.

Checkfordamagedorkinkedhosesinprop circuit.Replacehosesifrequired.

Checkpropfordamageorleakage(ifdamaged,replaceprop).

Disconnecthoseatloweringportofprop. Checkforanymediumleaking.Ifnot,disconnecthoseatcontrolvalveblock.Ifnoleakage,checkfeedlinetocontrolvalveblock.

Troubleshooting

PossiblecauseCheck/measurerequired

Theshut-offvalveforpressure supplyatthesupplyblockofthe shieldisclosed.

Shut-offvalveinfeedlinetoprop pistonchamberisclosed.

Canopyistrappedbyadjacent shields.

Systempressureistoolowforoperation.

Pilotpistoninthepropcheckvalve isnotoperating.

Openshut-offvalve. Feedlinemustbeopentoallowpressureto theshieldhydraulics.

Openshut-offvalve. Linestopistonchamberandannulusofprop mustbeopen.

Findcause.Ifnecessary,loweroralignadjacentshieldstofreecanopy.

Checkthat -hydraulicsystemworkscorrectly. -allshut-offvalvesareopen -systempressureissufficient.

Checkifthereisenoughpressuretooperate thepiston(minimumapprox.80bar). Propcheckvalvemaybefaulty.

Damagedortrappedhoses. Checkfordamagedorkinkedhosesinprop circuit.Replacehosesifrequired.

Propsaredamaged. Checkpropfordamageorleakage(ifdamaged,replaceprop).

PossiblecauseCheck/measurerequired

Theshut-offvalveforpressure supplyatthesupplyblockofthe shieldisclosed.

Canopyistrappedbyadjacent shields.

Steponrooforfloorpreventingadvance.

Systempressureistoolowforoperation.

Pilotpistoninthepilot-operated checkvalveisnotoperating.

Openshut-offvalve. Feedlinemustbeopentoallowpressureto theshieldhydraulics.

Findcause.Ifnecessary,loweroralignadjacentshieldstofreecanopy.

Lowercanopysufficientlytoclearthestepor putbaseliftfunctionto”ON”.

Checkthat -hydraulicsystemworkscorrectly. -allshut-offvalvesareopen -systempressureissufficient.

Checkifthereisenoughpressuretooperate thepiston(minimumapprox.80bar). Propcheckvalvemaybefaulty.

Damagedortrappedhoses. Checkfordamagedorkinkedhosesinshiftingramcircuit.Replacehosesifrequired.

Shiftingramisdefective.

Check -shiftingramfordamage -thatPOCVworkscorrectly. Disconnecthoseonpistonsideandoperate function”advancepanline”.Ifpressurefluid escapesreplaceshiftingram.

Troubleshooting

failuretomaintaintheprop pressureaftersettingthesupport

failuretooperatethetipup function

PossiblecauseCheck/measurerequired

Faultypropcheckvalve. Checkpropcheckvalvereplacingunit.Continuetroubleshootingifpressurecontinuesto drop.

Propsaredamaged. Checkpropsfordamage(ifdamaged,replace prop).

Disconnecthosefromproplowerportand checkifpressurefluidescapeswithoutlarge propmovement.Ifso:pistonpackingdefective.Replaceprop

Faultypressurereliefvalve. Checkpressuregaugereading.Ispressure reliefvalveweeping? Ifso,replacepressurereliefvalveandcheck functions.

PossiblecauseCheck/measurerequired

Theshut-offvalveforpressure supplyatthesupplyblockofthe shieldisclosed.

Shieldcanopyistrappedbyadjacentshields.

Systempressureistoolowforoperation.

Pilot-operatedcheckvalveisnot operating.

Openshut-offvalve. Feedlinemustbeopentoallowpressureto theshieldhydraulics.

Findcause.Ifnecessary,loweroralignadjacentshieldstofreecanopy.

Checkthat -hydraulicsystemworkscorrectly. -allshut-offvalvesareopen -systempressureissufficient.

Checkifthereisenoughpressuretooperate thevalve(minimum80bar). POCVmaybefaulty.

Damagedortrappedhoses. Checkfordamagedorkinkedhosesinprop circuit.

Stabilizingcylinderisdamaged.

failuretooperatethetipdown function

Checkcylinderfordamage(ifdamaged,replacecylinder).

PossiblecauseCheck/measurerequired

Theshut-offvalveforpressure supplyatthesupplyblockofthe shieldisclosed.

Shieldcanopyistrappedbyadjacentshields.

Systempressureistoolowforoperation.

Pilot-operatedcheckvalveisnot operating.

Openshut-offvalve. Feedlinemustbeopentoallowpressureto theshieldhydraulics.

Findcause.Ifnecessary,loweroralignadjacentshieldstofreecanopy.

Checkthat -hydraulicsystemworkscorrectly. -allshut-offvalvesareopen -systempressureissufficient.

Checkifthereisenoughpressuretooperate thevalve(minimum80bar).

POCVmaybefaulty.

Damagedortrappedhoses. Checkfordamagedorkinkedhosesinprop and/orstabilizingcylindercircuits.

Stabilizingcylinderisdamaged.

Checkcylinderfordamage(ifdamaged,replacecylinder).

3/2-Wayvalveorpilotvalve

Thevalvesticksoraby-passhasformedduetointernalleakages. Onthedirectionalvalvesofthecontrolvalveblockthelattermainly showsbyaclearlyaudiblehissingnoise.

Pilotorcontrolvalveswithasignificantlylowervolumeflowwillbecomenoticeablywarmerduetotheconstantlyflowingmedium.

Defectivepilotvalvesaredifficulttorecognizeasthereisnomediumescapingatthevalvebank.Therefore,therearenoobvious signsofadefect,ase.g.fluidescaping.

The3/2-wayvalveorthepilotvalvemayalsobedefective.

. Trytoeliminatetheproblembyoperatingthefunctionsonthe controlunitorthecontrolvalveblockseveraltimes.

. Trytolocatethedefectivevalvebyoperatingtheindividual functionsoneaftertheother.Ifthenoisestopswhileafunction isoperatedtherespectivevalveisfaulty.Youmayberequired toholdthepush-buttonforthedefectivefunctionforsomesecondsbeforethenoisestops.

. Closethemainshut-offvalveinthepressurefeedlineatthe manifoldpipe.

. Operatethefunctionsmanuallytodepressurizethe system.

. Replacethe3/2-wayvalveorthepilotvalve.

Pilot-operatedcheckvalves

Theformationofaby-passisshownbyadropinpressure.

. Trytoeliminatetheproblembyoperatingthefunctionsonthe controlunitorthecontrolvalveblockseveraltimes.

Iftheproblemstillexists,thevalvemaybefaulty.

. Checkvalveandreplace,ifdefective.

Troubleshooting

Internalby-passinprops

Ifaninternalby-passinthepropissuspected,thisprocedure shouldbefollowed:

. Pumppropsuptoroofatsetpressure.

. Isolatetheannulussideoftheprop.Tothisend,detachthe controllineatthepilot-operatedcheckvalve(item11,seehydraulicflowplan)temporarilyandadmitpressuretothecontrol portofthePOCV.

. Removethepilot-operatedcheckvalve(item11,seehydraulic flowplan)temporarilytoopentheannulusportoftheprop.

. Operatethe”setprop”functionfromadjacentshield.

Ifthereisaninternalby-passintheprop,forexampleduetodamagedpistonpackings,fluidwillflowoutoftheproplowerport.Ifthis happens,thepropmustbereplaced.

Faultypressurereliefvalve

Afaultypressurereliefvalvecanusuallybeseentobeweepingor acheckonthepressuregaugerevealsitisnotholdingpressure.If pressurefluidstillflowsoutatoperatingpressure,thepressurereliefvalveisdefectiveorthedischargingpressuresettingofthe valveusedistoolow.

Pressurerelieforpressurereliefvalvesofvarioustypesareusedin thehydrauliccircuitofashield.pressurereliefvalvesusedon props,forexample,haveahighflowratewhilethepressurerelief valvesusedonshiftingrams,stabilizingcylindersetc.aredesigned foralesserflowrate.

Thepressurereliefvalvesfordifferentcylindersorforthepiston andringsidesofacylindermayhavedifferentmax.valuesettings. Pleaseobservetheinformationgiveninthehydraulicflowplansor inthesparepartscatalog.

Defectiveorblockedfilter

Operationoftheshieldisslowalthoughpressureisknowntobe normaloperatingpressure.Contaminationisassumedtohaveoccurredinthehydraulicsystem,e.g.afterrepairwork.

. Checkthefiltersinthehydraulicsystem.Backflushfiltersmay becleanedbybackflushing.Onfine-meshfilterswhichare,for example,usedonthecontrolvalveblocks,thefilterelements mustbereplaced.

6 Technicaldata

Technicaldata

Thischaptercontainsimportantandusefulinformationonthedesignandatechnicaldescriptionoftheshieldanditsmaincomponents.

Shieldvariants

Type2550/5500-2x3926-1750

Thetwo-legshieldunitsbasicallycomprisethefollowingmaincomponents:

J basewithlemniscaticlinks,shiftingunitandbaseliftcylinder

J canopywithflipper

J cavingshield

J sideseal,moveableatR.H.sideonly

J hydraulicprops

J hydraulicequipmentwithhoselinesandcontrols

Sevendifferentversionsofthesametypeofshieldwillbesupplied:

Tab.8:Variantsoftheshield(1)

VariantApplication Order-no. Dimensions max./min.,LxWxH inmm Weight approx. inkg

01 faceshield 74201400000001 6090x18501) x5500 7520x1650x2550

02 transitionshield 74201400000002 6590x18501) x5500 8020x1650x2550

04,05 endshield 74201400000004 74201400000005 7090x18501) x5500 8520x1650x2550 31000

03,06 endshield 74201400000003 74201400000006 7090x27501)3) x5500 8520x22152) x2550 31480 07 endshield 74201400000007 7090x18501) x5500 8520x1650x2550 31000

Tab.9:Variantsoftheshield(2)

VariantApplication Shieldno. Specialfeatures

01 faceshield 5....124 and129 shiftingramdia.150mm, shortrelaybar,shortcanopy(4075mm)

02 transition shield 6,125 shiftingramdia.150mm, shortrelaybar,prolongedcanopy(4575 mm)

03 endshield 1 shiftingramdia.200mm, longrelaybar,longcanopy(5075mm),side canopyR.H.,pusherL.H.

04 endshield 4,5and 130 likevariant03,butsidecanopyoptionalapplicable

05 endshield 126and 127 likevariant04,butpusherR.H.

06 endshield 128 likevariant05,butsidecanopyfittedL.H.

07 endshield 2,3 likevariant06,butwithoutsidecanopyand pusherL.H.fitted

1sidesealfullyextended

2.sidecanopyfullyretracted

3.sidecanopyfullyextended

Whatdifferentiatesthebasevariantsfromeachotheristhatthey areequippedwithdifferentshiftingcylinders,relaybarsofvarious lengths,andwhetherornottheyareprovidedwithapushercylinder.Seetable9above.

Thecavingshieldisasolidsteelstructureandconnectedtothe baseviathelemniscaticlinks.Thecavingshieldsofallvariantsare identical.

Thecanopytransmitsthesupportloadofthetwohydraulicprops intotheroof.Connectiontothecavingshieldisviapinsandastabilizingcylinder.Allthecanopiesareequippedwithaflipper.The canopyofthetransitionshield(variant02)is500mmlongerthan thecanopyofthefaceshield(variant01).Thecanopiesoftheend shields(variants03...07)are1000mmlongerthanthoseofthe faceshields(variant01).

Programmedmethodsofcalculationensurethebestpossiblesupportresistanceandrangeofverticaladjustmentoftheshields. Propsusedaretelescopicpropswithequalloadacceptanceinall stages.Theyarealwaysdouble-acting.

Thelemniscaticlinkageisamechanismwhichcausesthearticulationbetweenthecanopyandthecavingshieldtomoveonanearstraightlinepathoverthewholeverticalrangeoftheshield,keepingthecanopytiptofacedistancenear-constant.

Unlikethefaceshields,transitionandendshieldscanbeequipped withasidecanopy.Thiscanbefittedoptionallyattheright-handor attheleft-handside.Forshieldvariants03and06,thesidecanopy isincludedinthescopeofsupplyandisattachedattheright-hand (03)/left-hand(06)sideatthesidesealofthecanopy.

Theshieldunitsareequippedwithallhydrauliccomponentsneeded toperformaelectrohydraulicadjacentcontrolsystemusingthe PM4electroniccontrolunit.

Theelectrohydrauliccontrolunitforshieldvariants01,02,04and 05isthesameandincludesfourteenfunctions.Theelectrohydrauliccontrolunitfortheshieldvariants03to07hassixteenfunctions asithastwoadditionalfunctionsfortheoperationofthesidecanopyorauxiliaryfunctions.

Thecontrolunitsforallshieldvariantsareofthesamedesign. Theymainlydifferinthenumberoffunctionstobeoperatedand thedifferenthoselengthswhichareduetothedifferencesincanopylengths.

Mainsubassemblies

Fig.41:Variantsoftheshield,dimensions

faceshield,variant01

5500extendedheight 2550retractedheight

transitionshield,variant02

5500extendedheight

4800

2550retractedheight

endshield,variants03to07

7520transportlength

5500extendedheight

4800

2550retractedheight

7520transportlength

Shieldvariants

Fig.42:Variantsoftheshield,maincomponents

faceshieldandtransitionshield,variants01and02

endshield,variants03to07

1baseofshieldvariants01,02

3baseofshieldvariants03...07

11canopy,shieldvariant01 12canopy,shieldvariant02 13canopy,shieldvariants03...07 14canopy,shieldvariants04...06 21sideseal,shieldvariant01

23sideseal,shieldvariants02..07

31cavingshield

41prop

51stabilizingcylinder

61electrohydraulicshieldcontrol, shieldvariant01

62electrohydraulicshieldcontrol, shieldvariant02

63,electrohydraulicshieldcontrol, shieldvariant03

64electrohydraulicshieldcontrol, shieldvariants04and05

65electrohydraulicshieldcontrol, shieldvariants06and07

71protectivewall

81sidecanopy

Tab.10:DBT-shield742014000000..,variants,applicablecomponents itemdescription

0001

shiftcylinder,dia.1508241.233.000.00.00 liftcylinder8241.189.000.00.00 shiftingunit3438long7420.140.330.00.01 pushercyl.notapplicable

0065

Basewithlemniscaticlinksandcentralshiftingunit

Thesolidbasetransmitstheshieldloadofthehydraulicpropsinto thefloor.Thepropsaresupportedinanarticulatedmannerinball socketsweldedtothebaseandsecuredbyboltedpropretainers. Thelinksofthelemniscatesystemarehinge-connectedwiththe basebypins.

Thetypeofbasedescribedischaracterizedbyhavingtheshifting unitanditsguidingdevicearrangedbetweentheskids.Theshifting unitisreverse-mountedwiththeforceofthecylinderbeingtransmittedtotheconveyorviatherelaybar.Withareverse-mounted shiftingunit,theforceofthepistonsurfaceareaisutilizedtoadvancetheshieldandthesmallerforceoftheringsurfaceareato advancethepanline.Theconnectiontotheconveyorisprovided viaauniversaljoint.

Abaseliftcylinderservesforraisingthebaseoutofasoftfloorduringshieldadvance.

Fig.43:Grundrahmen

1baseliftcylinderZE-125/90-240

2) 2shiftcylinderZE-150/100-960

1) 3shiftcylinderZE-200/140-960

1) 4pushercylinderZE-135/120-300

2) 7shiftingunit

1) 8shiftingunit

2) 11base

1) 12base

13frontlemniscaticlink,R.H. 14frontlemniscaticlink,L.H. 15rearlemniscaticlink

17baseliftcylinderbearing 18propretainer,R.H. 19Propretainer,L.H.

21travelpath

22,23cap

30retainer

31pin

32pindia.50x105

33boltM24x90-10.9

34stapleDN10

35stapleDN40

36pindia.70x292

37washer

1) 38stapleDN20

39fillerpiece

40pin

41collardpindia.29x57

45lemniscaticpindia.139,3x525

1) 46pindia.30/40x180

47pin

48lockingdevice

51washer

52hex.headboltM30x45-10.9

53springclipdia.5

55washer

61retainingclip

refertothesparepartscatalogtoo

1) onlyapplicabletoshieldvariants03...07

2) onlyapplicabletoshieldvariants01...02

Shiftingunit

Fig.44:Shiftingunit

1relaybar 2clevisassemblyforconveyor others:fasteningelements,seesparepartscatalog

Tab.11:Shiftingunits,differences shieldshiftingunit, dimensions variant g order-no. L1 H1 01and02 74201403300000 3438 230 03....07 74201403400000 3543 225

Thevariantsoftheshieldareequippedwithdifferenttypesofshiftingunits.Seetable11above.

Theconveyorshiftingunitisarrangedinthemiddleofthebase frame.Itconsistsmainlyoftherelaybar,theshiftingram,thebaseliftcylinderandthenecessaryfasteningelements.Itservestoadvanceconveyorandshield.

Theshiftingramisreverse-mountedwiththeforceofthecylinder beingtransmittedtotheconveyorviatherelaybar.Withareversemountedshiftingram,theforceofthepistonsurfaceareaisutilized toadvancetheshieldandthesmallerforceoftheringsurfacearea toadvancethepanline.

Thebaseliftingdeviceservesforraisingthebaseoutofasoftfloor duringshieldadvance.

Thebaseliftcylinderisattachedinthecenterofthebasetoathrust piece.Thecomponentofforceproducedbytheliftingcylinderis transmittedintothefloorviatherelaybaroftheshiftingunit.

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