DOWNLOAD PDF CAT DBT Testing Device for Hydraulic Props & Vents Operating Manual

EM026966-0 (EN-US)

Operating manual Testing Device for Hydraulic Props and Vents Doc. no.: 6819 070 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

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

EM026966-0 (EN-US)

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

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

We reserve the right to introduce modifications due to technical development without previous notice.

DBT GmbH, Lünen 2006E

EM026966-0 (EN-US)

1

About this manual

EM026966-0 (EN-US)

EM026966-0 (EN-US)

Contents

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

1.3

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

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

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

1.3 1.3 1.4

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

2.3

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

Repairs and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

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

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

2.4 2.4

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

2.5

DBT GmbH, Lünen 2006

3. Operation Function of the testing device . . . . . . . . . . . . . . . . . . . . . . . .

3.3

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

3.3

Lever positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the testing device . . . . . . . . . . . . . . . . . . . . . . .

Checking the pressure relief valve . . . . . . . . . . . . . . . . . . . .

3.4 3.4 3.5 3.8

4. For your information

Doc. no.: 6819 070 000 BA 00

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

4.3

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

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

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

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

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

4.3 4.4 4.4 4.4 4.4

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Contents

DBT - Testing Device for Hydraulic Props and Vents

EM026966-0 (EN-US)

Before starting work

About this manual This chapter contains important information making it easier for you to use this manual. It provides you with information on the structure of the manual and the symbols used.

Before starting work Allocation

Take care to ensure that the operating manual available to you is applicable for the type of testing device used. Failure to do so can result in a safety hazard for yourself and others.

The present manual is a component part of the Testing Device for Hydraulic Props and Vents - with the device number 6819 070 000 00 00 and is only permitted to be used with testing devices of this type.

Only use the manual applicable to the testing device. Otherwise, you may cause harm to yourself and others.

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Accessibility of the manual

It must be ensured without fail that all personnel who work with the testing device or who are involved in work at the shield support have access at all times and without restriction to the contents of the current operating manual for the testing device.

DBT GmbH, Lünen 2006

Persons for whom the operating manual is intended This operating manual is for all personnel who J install J maintain J repair J operate and J dismantle the control unit

In addition, the supervisory personnel who assign and/or supervise the above mentioned tasks must also observe these operating instructions.

Purpose of this operating manual operating manual

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

Therefore, read this operating manual completely and at leisure.

Pay special attention to the safety instructions.

Try to memorize the appearance and the meaning of the safety and instruction symbols.

questions?

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

safety

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

Observe this information and follow the procedural instructions.

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

Try to memorize the symbols and their meanings.

Danger!

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

Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

Caution!

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

Important!

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

1.4

J

Items in lists are marked with bullets.

–

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

.

The hand symbol prompts you to carry out an action.

When several sequential paragraphs are each marked with the hand symbol, then this represents the steps in a sequence of actions. These must be performed in the sequence specified. Follow these instructions step-by-step in order to perform the work safely and efficiently.

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Notice!

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

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2

Your safety

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Personnel

Your safety This chapter provides vital information about safety.

Pay special attention to this chapter. The safety instructions and rules of behavior will assist you in avoiding hazardous situations and carrying out the required tasks as safely as possible.

Residual risk

Nevertheless, the residual risk that still remains could cause you to become involved in hazardous situations while working with the test device. These could for example be triggered because of unforeseeable external influences, machinery damage or operator error.

Supplementary regulations

In addition to the specifications contained in this text, also do not fail to observe the respective legal rules and regulations for the prevention of accidents valid in the country in which the equipment is used.

Also take into account the safety and accident prevention regulations: J of the mine J of the Mines Inspectorate

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J of the mining supervisory authorities.

DBT GmbH, Lünen 2006

Personnel Personnel who are responsible for the operation, repair and servicing of hydraulic and/or electrohydraulic components must be specially qualified. In addition to having training in mining operations, the following minimum requirements listed below must also be fulfilled.

Operation and maintenance Qualification

The testing device may not be operated or serviced by anyone other than trained personnel.

The contents of the operating manual, especially the chapter on safety, must be made a part of this training.

You must have an adequate knowledge of the J mechanics J hydraulics

and must be able to prove this knowledge.

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Operating conditions Repairs and servicing Generally speaking, repair and servicing work is only to be performed by personnel who are able to meet the special requirements involved as the result of their knowledge and abilities and who have been trained for repairing and servicing the device.

Repair and servicing tasks involving: J safety components such as pressure relief valves, etc.

may only be carried out by DBT service engineers or by specially trained personnel of the mining company.

Operating conditions Intended use Only use the testing device as intended.

The intended use is: J The testing device is only for checking functions of built-in pres-

sure relief valves on props and cylinders of shield supports.

Such unauthorized use includes: J Using the test device for other hydraulic components, without

shutoff function (pressure relief valves).

Danger!

Unauthorised usages endanger both you and others. This could result in serious injury to you or even death.

Only connect the testing device to a secure hydraulic circuit.

Only use the testing device as intended.

DBT rejects any liability for the consequences of unauthorized use.

2.4

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All usages that are not expressly listed as being intended uses are to be considered unauthorised.

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Unauthorized use

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Safety instructions Safety instructions The following basic rules apply: General

Always work with full concentration.

In addition, do not fail to observe the operating manual for the support.

Before beginning work, always familiarize yourself with your working environment first.

Never stand in an insecure shield.

Always wear your personal protective gear.

Observe the acoustic and visual start-up warnings. Observe in particular the start-up warnings of the conveyor and of the mining equipment.

Only use testing devices that are in perfect technical working condition.

EMERGENCY STOP

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Report any peculiarities to your superior so that necessary measures can be taken immediately.

Shield support blocked switch

If the shield is equipped with an electrohydraulic control unit, you have to block the shield by activating the shield locking switch (repair switch). This secures the shield from being activated by the control unit.

DBT GmbH, Lünen 2006

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Requirements

Activate the shield locking switch for: J maintenance work J inspection work J repair work J remaining in the shield for long periods of time Moving parts

Never place limbs or other body parts between components that could move. This applies in particular for the: J gap coverings J runners J shifting units J control arm (lemniscates) J hydraulic props and cylinders J caps and J carbon bumpers

Storage and transport Do not store materials in the travel path or in your working area.

Immediately remove any faulty components from the face in order not to hinder the face crew or put them in danger.

Do not store defective components next to ones that are still intact.

That way you can avoid unintentional reinstallation of defective components. Pass defective components on for servicing.

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Safety instructions Maintain the prescribed storage periods and observe the instructions for storage.

Installation Secure all moveable components mechanically before you depressurize the hydraulics system.

As a rule, do not work on hydraulics systems at all unless they have been depressurized.

Make sure that no dirt finds its way into the hydraulics system.

Wait to remove the protective caps for the connections until just before connecting the testing device.

Operation Check that all protective devices are installed on the shield and in proper functioning order.

Make sure that no personnel are within range of the actuated shield.

Watch the area of movement of the shield in order to recognise dangers and avert them promptly.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the expected duration.

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

Close off the working area for the mining equipment or disenable the mining equipment and the conveyor and secure the system from being turned on again.

Secure the shield before work mechanically against unintended sinking, e.g. due to: J supporting or bracing the canopy J wooden wedges between the control arms (lemniscates).

Stop work on the shield when conveyor and mining operations are being carried out.

Refit any dismantled safety equipment immediately after completion of work and check that it works properly.

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Maintenance

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Safety instructions Original parts

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

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

Do not carry out any conversions or modifications. Conversions and modifications must be approved by DBT. Hydraulics

Handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

Protective equipment Hydraulic system

When dismounting protective devices covering hydraulic components, keep in mind that these components may be under pressure.

You could be severely injured by hydraulic fluid being expelled in an uncontrolled manner. Therefore it is essential that you depressurize the hydraulic components before removing the protective equipment.

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

Maintenance, repair

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Pressure relief valves

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

Ensure that the pressure relief valves are always protected with caps. Replace any defective caps without delay.

DBT GmbH, Lünen 2006

Inspect all the hydraulic components at regular intervals. In particular check that: J The hoses are not pinched J The hoses have no bubbles or blisters J The hoses or the outer sheaths of the hoses are not abnormally

rigid or hard J The outer sheathing of the hoses is not damaged J The connectors are securely inserted in the plug-type connec-

tions J The connections are leak-tight.

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

Dirt in the hydraulic system can cause serious damage to the entire system. Flush the hydraulic lines thoroughly before connecting.

Before you remove the staples to release the hydraulic hoses, you must first check whether the line is still under pressure by rotating the hose at the plug connection. If the hose cannot be rotated at all, or only with difficulty, then the line is still under pressure. Be sure to depressurize the line.

If it is difficult or impossible to pull out the staple locks, the hydraulic line may still be pressurized. Be sure to depressurize the line.

Secure the plug-type connections of the hydraulic elements only with the proper staple locks. Always insert the staple locks completely, using both points.

Never use nails, wire or similar materials for securing.

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

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Safety instructions Permissible hoses

Only use hydraulic hoses approved for the pressures that occur.

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

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses that are more than 2 years old, even if they have no visible signs of damage.

Fig. 1:

Example: 4SP hydraulic hose, designation 3 2 1

6

4

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4 Standard 5 Nominal diameter 6 Flame-resistant and antistatic

Never try to hold a pulsing hydraulic hose. Depressurize the section in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

Laying hydraulic hoses

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

Always lay hydraulic hoses so that they: J always have a little slack Fig. 2:

Laying hydraulic hoses, slack RIGHT

2.8

WRONG

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1 Manufacturer 2 Hose type 3 Date of manufacture, 1st quarter 2002

5

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Safety instructions J are not twisted Fig. 3:

Laying hydraulic pipes, twisting RIGHT

WRONG

J Are not bent directly behind the connections

(distance min. 1.5 x nominal diameter) Fig. 4:

Laying hydraulic hoses, bending WRONG

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RIGHT

J cannot chafe Fig. 5:

Laying hydraulic hoses, crossing RIGHT

WRONG

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

Only insert hydraulic hoses in the sockets by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: J torn out J kinked J crushed J driven over J turned out of position (see fig.: 6).

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Safety instructions Fig. 6:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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3

Operation

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Operation

Operation This chapter provides you with information concerning the operation of the testing device. It is imperative to additionally observe the shield support operating manual, specifically the hydraulics diagram.

Function of the testing device The testing device is a pressure intensifier that can check the function of the pressure relief valves. The pressure relief valve is charged via the pressure intensifier of the testing device with the setting pressure of the pressure relief valve in order to check the function (pressure release by expelling).

Operation The pressure relief valve is charged with pressure that constantly increases until reaching the discharge pressure via the lever.

Fig. 7:

Testing device

DBT GmbH, Lünen 2006

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c

e

d

G

b a

a connector b lever c manometer

F

f hydraulic hose g connection for pressure supply

d cap nut e testing device body

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Operation Lever positions The testing device has three lever positions. The pump fills up with hydraulic fluid depending on the lever position and presses it with a 1.75 fold higher pressure into the prop of the pressure relief valve that is to be tested.

Fig. 8:

Lever positions

3

1

Preparation

. Set the prop, on which the pressure relief valve is to be tested, to the setting pressure.

. Dismount the protective plate from the prop in order to access the manometer connection.

Fig. 9:

Protective plate on the prop

Prop with protective plate

3.4

Prop without protective plate

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Lever position 1) Pump fills up with hydraulic fluid Lever position 2) Pump entrance and pressure intensification = zero Lever position 3) Hydraulic fluid is pressed into the pressure relief valve (pressure intensifier)

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Operation Warning!

Risk of injury due to escaping pressurized hydraulic fluid.

This could result in serious injury to you or even death.

Do not fail to depressurize the hydraulics circuit before you perform any work on it.

Do not carry out any work on a hydraulics circuit if you are not certain that it is depressurized.

. Check to see whether residual pressure is still present in the hydraulics circuit. Residual pressure can, for example, build up from external loads on the props or cylinders.

Important!

It is imperative to observe chapter 5, “Operating shield hydraulics”, found in the shield support operating manual.

If the hydraulics circuit is depressurized, then you can begin with the next step.

Connecting the testing device

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Notice!

Before connecting the testing device to the manometer connection on the prop, dismount the pre-mounted connector. The pre-mounted connector does not fit on the manometer connection on the prop.

If the pre-mounted connector is not removed, both the premounted connector and the manometer connection can be damaged.

. Remove the staple lock (1) and pull the hose connector (2) out of the connection.

Notice!

Contamination in the hydraulics system can cause serious damage in the overall installation!

Always take care to ensure that your working area is clean.

Fig. 10: Connection on the testing device (as delivered)

1 2

Before the testing device can be connected, the lever must be in position 1 (see fig. 8, lever positions).

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Operation . Twist off the protective cap from the manometer connection.

Protective cap on the manometer connection

. Carefully place the booster connector (fig. 12) into the manometer connection and turn the screw until it is hand-tight.

Fig. 12: Booster connector (included in scope of delivery)

. Now attach the hose connector on the testing device to the booster connector.

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Fig. 11:

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Operation Fig. 13: Connecting the testing device

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. Secure the booster connector and the hose connector with

DBT GmbH, Lünen 2006

the staple lock.

Check to see if the staple lock is tight.

Fig. 14: Connecting the testing device

. Connect the pressure supply from the shield support to the connection (g) on the testing device. Now secure the connection with a staple lock.

Once the testing device has been connected, you can begin with the next step.

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Operation Checking the pressure relief valve Warning!

Risk of injury due to escaping pressurised hydraulic fluid.

Wear appropriate safety glasses to protect yourself from being harmed. Please observe that no other people are in immediate range of the shield support.

Caution!

The measured setting and opening pressure may not exceed the desired value of the setting pressure by more than 5%. The measured closing pressure may not exceed the setting pressure by more than 10%. If the values deviate, then the pressure relief valve is defect.

. Activate the lever alternately between position 1 and 3. The pressure can be read on the manometer.

The pressure in the prop is constantly increased by activating the lever between position 1 and 3. Repeat the procedure until the test pressure of the pressure relief valve is expelled.

The pressure relief valve is completely functional when hydraulic fluid is expelled. If this is not the case, the pressure relief valve is defect and must be replaced.

. Place the lever back in position 1 after the testing procedure. . Depressurize the pressure supply and disconnect the connection to connection (g).

. Disconnect the testing device from the manometer. . Screw the protective caps back onto the manometer connection.

. Mount the protective cover back over the prop.

Once you have removed the testing device, you can check the next pressure relief valve.

3.8

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Important!

If necessary, tighten or loosen the throttling screw (see fig. 7 pos. d) in order to decrease or increase the flow rate.

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For your information

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Service addresses

For your information If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (Homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Headquarters) Industriestraße 1 D-44534 Lünen, Germany Tel: Fax: E-mail:

Great Britain

+49 / 23 06 70 9 - 0 +49 / 23 06 70 9 - 1421 infodbt@dbt.de

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

DBT GmbH, Lünen 2006

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Tel: Fax: E-mail:

+44 / 11 59 51 - 2500 +44 / 11 59 32 - 9683 martin.daldrup@dbtgb.com

DBT GB Limited Engineering Pioneer House 2 Renshaw Place Europoint Office Park Eurocentral Lanarkshire, ML1 4UF Scotland Phone: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax: E-mail:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509 dbtpolska@dbtpolska.com

DBT Moscow Office Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: Fax: E-mail:

+7 / 49 56 23 - 5396 +7 / 49 59 24 - 8363 dbt@co.ru

OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: Fax: E-mail:

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+7 / 38 43 35 - 3441 +7 / 38 43 35 - 3442 office@dbtrus.ru

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Service addresses North America, Canada, South America USA

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

+1 / 72 47 43 - 1200 +1 / 72 47 43 - 1201 info@dbtamerica.com

DBT America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Australia DBT Australia Pty Ltd / DBT Diesel Pty Ltd 537 Lake Road Argenton, New South Wales 2284

+61 / 24 95 8 - 3133 +61 / 24 95 8 - 5754 tim.clark@dbtaustralia.com

DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

Africa South Africa

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: Fax: E-mail:

+ 27 / 11 82 5 - 8212 + 27 / 11 82 5 - 7389 zelda.stephens@dbtafrica.com

Asia China

DBT China Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: Fax: E-mail:

4.4

+86 / 10 65 88 - 2998 +86 / 10 65 88 - 6570 Info.beijing@dbtchina.com

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Tel: Fax: E-mail:

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P.O. Box 102 Boolaroo, New South Wales 2284

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Service addresses DBT (Langfang) Mine Technik Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: Fax: E-mail:

+ 86 / 31 66 08 6 - 840 (& 841, 842, 843) + 86 / 31 66 08 6 - 845 Info.langfang@dbtchina.com

DBT Tangshan Machinery Ltd. No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: Fax: E-mail:

+86 / 31 53 20 - 3117 (& 3445, 3404) +86 / 31 53 20 - 3438 Info.tangshan@dbtchina.com

Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209

DBT GmbH, Lünen 2006

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Tel: Fax: E-mail: India

+86 / 47 78 28 - 7245 (& 7514, 7290) +86 / 47 78 28 - 7431 Info.shenhua@dbtchina.com

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

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+91 / 33 24 2 - 0272 +91 / 33 24 2 - 8684

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Service addresses

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