PDF Operation Manual CAT 12502780 Roof Support Shield - 2 MB
This operation manual provides critical guidance for the CAT 12502780 / 2X3056 / 1500 Shield Support system used in mining.
It outlines the correct procedures for operating and maintaining the roof support for maximum safety and effectiveness.
Understanding this manual is essential for underground mining crews to prevent accidents and ensure operational stability.
It is a key document for site safety protocols.
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BI622821
Operating Manual
Shield support
1250/2780-2X3056-1500
Doc. no.: 7420 165 000 BA 00
Bucyrus Europe GmbH
Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: [email protected]
D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com
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BI622821
Safety instructions
If you raise the conveyor in the area of several shields, the shields
to which lifting gear is attached must not be located next to one
another.
For raising the conveyor, use only:
J high-strength, undamaged chain slings,
J the lifting points provided for the purpose.
Check that the points of attachment are undamaged before
attaching a load.
J lifting tackle of adequate load-carrying capacity.
Maintenance
Make sure that all safety and protective equipment of the shield
support units are complete and functional. If the safety and protec-
tive equipment is included in the Bucyrus scope of delivery, refer to
chapter 6, “Technical data”, for its location.
Be sure to observe the intervals specified for maintenance and
inspection. See chapter 5, section “Maintenance”.
Check the shield at least once every shift for externally visible
damage.
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Inform the supervisory personnel and the face crew about mainte-
Bucyrus Europe GmbH, Lünen 2009
nance and repair work. Provide them with information on the
intended work and its probable duration.
Secure your working area over a wide range, in order to avoid
endangering other persons.
Immediately replace damaged components affecting safety. Stop
and lockout the respective shield immediately if component
damage creates a hazard and immediate repair is not possible. If
there is a safety hazard, secure this area and notify the entire face
crew and responsible foreman without delay.
Use only replacement parts which conform to the specified techni-
cal requirements. This is best ensured by using original Bucyrus
replacement parts.
Please refer to the replacement parts catalog provided for the
equipment for the order nos. for the required replacement parts.
Do not make modifications or carry out conversions which might
impair the safety of the shield. Bucyrus must be informed of all con-
versions and modifications to check whether they have any effect
on the approval or whether it is necessary to apply for a revised
approval.
Any modifications carried out without authorization invalidate the
Bucyrus declaration of conformity and a new conformity test will be
required.
During work on the relay bar assembly, isolate the working area for
the mining equipment.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
2.11
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BI622821
Transport
Transport
Load units; dimensions and weights
It is imperative that you observe the transport sheets. They include
information on:
J dimensions,
J weight,
J lifting points and
J centers of gravity.
Where technically possible, the load units have suitable lifting
pointsfor transport and installation.
Warning!
Use only load handling devices which comply with the tech-
nical and legal regulations for transporting loads.
Falling components can cause serious injury and death.
Use only suitable load handling devices.
Before transport
Before transporting the equipment at temperatures below freezing,
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freezing temperature
Bucyrus Europe GmbH, Lünen 2009
all hydraulic components operated with by emulsion (HFAE and
HFAS) must be completely drained and filled with a corrosion inhib-
itor (e.g. CV 50).
It is only permitted to transport equipment at temperatures of -21C
to -40C if certain requirements for these conditions have been
taken into account during the design and production of the equip-
ment. Nevertheless, the individual parts and devices of this equip-
ment must not be subjected to sudden impact loads at such low
temperatures and may only be loaded statically or quasi-statically.
During transport of this equipment with floor conveying devices at
such low temperatures, measures must also be taken to ensure
that the parts and devices are not subjected to sudden impact
loads.
At very low temperatures and on poor roads, the transport vehicle
speed must therefore be limited to maximum 25 km/h for truck
transport.
electrical and Electrical and electronic components must be removed for over-
electronic components seas transport or prolonged storage outdoors, unless these com-
ponents or the complete equipment is protected against harmful en-
vironmental influences by suitable packaging.
The electrical cables remain in the equipment. They must be care-
fully protected against transport damage and the connections pro-
tected against dirt.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
3.5
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BI622821
Pre-assembly of the support units
Installation
In this chapter, you will be given information about installing the
support units. Please pay special attention to the warnings and tips.
Warning!
In addition to the safety instructions given in this manual, also
make sure you observe the special safety instructions and ope-
ration instructions which apply to the operation of the mine.
Failure to do so can lead to extremely serious accidents which
may be fatal.
Caution!
Before the hydraulic connections are joined with one another,
the coupling sockets and nipples of the plug-O connections
must be treated with the molybdenum disulfide-free B3 lubrica-
ting paste in accordance with EWN 7068. See Chapter 6, Sec-
tion “Lubricating greases and pastes”.
Caution!
All of the slide surfaces must be treated with the molybdenum
disulfide-free B6 lubricating paste in accordance with
EWN 7068 before the transport subassemblies of the steel
structure are connected with one another. See Chapter 6, Sec-
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Bucyrus Europe GmbH, Lünen 2009
tion “Lubricating greases and pastes”.
Pre-assembly of the support units
The support units are delivered completely pre-assembled. Accor-
dingly, no further pre-assembly is required on the mechanics and
hydraulics of the support units.
The installation parts that are mounted externally such as the
side flap, protective wall and relay bar assembly are delivered indi-
vidually.
Installation of the side flaps
The side flaps are delivered as a complete unit. For installation the
brackets (see Fig. 16, item 2) must be removed from the complete
unit.
. Remove the locking clips (7) and the pins (5) which connect the
hydraulic cylinders with the brackets.
. Remove the locking clips (6) and the pins (4).
. Fasten the three brackets (2) on the side seal using hammer
head bolts (9), washers (8) and hex. nuts (10).
. Install the side flap (1) on the brackets (2) using six pins (4)
and secure the pins with locking clips (6).
. Re-install the hydraulic cylinder using pins (5) securing them
with locking clips (7).
Doc. no.: 7420 165 000 BA 00 SSVI / 03
4.3
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BI622821
Requirements for the face hydraulic system
Requirements for the face hydraulic system
hydraulic medium The hydraulic medium must meet the following conditions for all hy-
draulics components included in the Bucyrus scope of delivery:
Contamination Class 18/14 pursuant to ISO 4406.
Pressure fluids in accordance with the Section “Permissible media”
in Chapter 6 of this operating manual.
pressure, permissible Nominal pressure: . . . . . . . . . . . 320 bar
Admissible tolerance: . . . . . . . . . ± 10% of nominal pressure
If the face hydraulics are designed such that they are unstable or
too weak, there could be a temporary pressure drop during opera-
tion.
In the event that the pressure falls to 180 bar or less, there is a risk
of malfunctions occurring in the electrohydraulic control system.
Valve functions might not be executed. It may even result in valves
starting to vibrate which could lead to valve damage.
Caution!
If there is a pressure drop, dangerous situations may arise,
leading to accidents involving damage to property and/or inju-
ries to personnel.
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Make sure that the system pressure can never fall below
Bucyrus Europe GmbH, Lünen 2009
180 bar anywhere in the face hydraulic system.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
4.13
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BI622821
Requirements
Fig. 24: W r o n g , support advanced too late
Fig. 25: R i g h t , support advanced in time
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Bucyrus Europe GmbH, Lünen 2009
When taking down a step in the roof, a shield canopy which is an-
gled downwards must not get in the way of mining equipment pas-
sing by.
Before a support unit can be pulled up, the flipper must be comple-
tely folded in. Under no circumstances may the support be advan-
ced against the coal face with the flipper extended. Failure to ob-
serve this can lead to serious damage, especially to the flipper
cylinders and the flipper suspension.
When advancing the support, make sure that the shield canopy
doesn't get under the side seal of a neighboring shield. The side
seal of the neighboring shield can otherwise be seriously damaged.
control system, hydraulics Do not operate the shield control system incorrectly.
The symbol plates on the control units indicate the functions of the
shield control system. They should be legible at all times and may
not be removed or damaged.
Hoses must remain free to move. They may not be squeezed or
overstretched. Make sure the hose lines are bundled properly.
Damaged hydraulic hoses and hose connections must be replaced
immediately. This work may only be carried out by skilled person-
nel.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
5.7
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BI622821
Operation of the shield hydraulics
Shield hydraulics
Fig. 31: Shield hydraulics, arrangement (1)
Image caption: see Table 6
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Bucyrus Europe GmbH, Lünen 2009
39 3 10b
Fig. 32: Shield hydraulics, arrangement (2)
Image caption: see Table 6
a b
Z6 Z6 Z6
Doc. no.: 7420 165 000 BA 00 SSVI / 03
5.17
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BI622821
Operation of the shield hydraulics
Twin check valve for flipper cylinder
The check valve for the flipper cylinder is located in front of the
right hand prop below the canopy.
Fig. 44: View of the twin check valve from below the canopy
7
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Bucyrus Europe GmbH, Lünen 2009
7 twin check valve for flipper cylinder
Pressure relief valves for flipper cylinder
Fig. 45: View of the flipper cylinder from below the canopy
11c 11c
Z5
11c PRV, 380 bar Z5 flipper cylinder
Doc. no.: 7420 165 000 BA 00 SSVI / 03
5.27
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BI622821
Operation of the shield hydraulics
Warning!
Manual actuation of a button on one of the pilot solenoid val-
ves initiates the direct execution of the corresponding func-
tion. Dependencies between the individual functions are not
taken into account. Dangerous situations could arise if functio-
nal sequences are initiated in an incorrect order. For example,
the function “pull shield” can be activated without previously
activating the functions “retract side seal” and “actively lower
support”. This can cause dangerous situations which can re-
sult in very serious injury.
Advance shield
1
Before this function can be performed, Function 3 “Prop, retract on
the right” and Function 4 “Prop, retract on the left” must be carried
out.
The function is executed as long as the button is pressed until
there is a balance of forces or until the end position is reached.
As long as the function is activated, the pilot-operated check valve
(14), which hydraulically shuts-off the annular space of the shifting
ram, is opened automatically.
Set props
2
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Bucyrus Europe GmbH, Lünen 2009
Before this function is actuated, the shield canopy must be cor-
rectly aligned. The function is executed as long as the button is
pressed until there is a balance of forces or until the end position is
reached.
3 Prop, retract on the right
Before initiating this function, it must be made sure that the neigh-
boring shields are completely set.
The function is executed as long as the button is pressed or until
the end position is reached.
4 Prop, retract on the left
Before initiating this function, it must be made sure that the neigh-
boring shields are completely set.
The function is executed as long as the button is pressed or until
the end position is reached.
5 Advance conveyor
Before initiating this function, ensure that the support unit is com-
pletely set.
The function is executed as long as the button is pressed until
there is a balance of forces or until the end position is reached.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
5.37
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BI622821
Troubleshooting
Internal by-pass in props
If an internal by-pass in the prop is suspected, this procedure
should be followed:
. Set the prop until the set pressure has been reached.
. Make sure that the annular space of the prop is depressurized.
. Release the hose of the prop annular space connection at the
prop.
. Actuate the “Set prop” function from the neighboring support.
If there is an internal by-pass in the prop, for example due to dama-
ged piston packing, fluid will flow out of the prop lower connection.
If this happens, the prop must be replaced. If fluid escapes from the
detached hose lines, the piloted check valve is defective.
Pressure relief valve defective
Leaking pressure relief valves can normally be detected by the di-
scharge of fluid, or a pressure drop is displayed on the pressure
gauge. If fluid is already discharged at working pressure, the pres-
sure relief valve is defective or the discharge pressure setting of
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the valve used is too low.
Bucyrus Europe GmbH, Lünen 2009
In the hydraulic circuit of a support unit, various models of pressure
relief valves are used. For example, pressure relief valves are used
on the props which have a high flow rate. While the pressure relief
valves for securing shifting rams, stabilizing cylinders etc. are desi-
gned for a lower flow.
Pressure relief valves for different cylinders of for the piston and
ring sides of a cylinder can be set to different maximum pressure
values. Please refer to the information in the hydraulic circuit dia-
grams or the spare parts catalogue.
Defective or blocked filter
Operation of the shield is slow although the system pressure lies in
the normal range.
It is also possible that the hydraulic system has been contami-
nated, for example during repair work on the hydraulic system.
. Check the filters in the hydraulic system.
Backflush filters can be cleaned by backflushing. The filter ele-
ments must be replaced on fine-mesh filters, such as on the elec-
trohydraulic control unit.
Doc. no.: 7420 165 000 BA 00 SSVI / 03
5.47
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BI622821
Description
Relay bar assembly
The relay bar assembly unit is used to push the conveyor and ad-
vance the shield. To do this, it is telescopically extended or retrac-
ted using the shifting ram. The shifting ram functions directly. This