operating manual m-1437c en

Operating Manual

M-1437C

Control Container

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 Version:0

M-1437COverview Operating Manual

Chapter

I) Introduction, Safety Instructions

II) Technical Data, Group Description

III) Transport, Set Up, Connection

IV) Operating Elements, Commissioning, Operating, Troubleshooting

V) Maintenance, Repair, Storage, Spare Parts service

VI) Fixtures and Fittings

VII) Overview of CD, Declaration of Conformity

VIII) Drawings, Parts Lists

IX) Diagrams, Parts Lists

X) Electric Diagrams

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 Version: A

M-1437CIntroduction, Safety Instructions

I) Introduction, Safety Instructions

1 Introduction................................................................................. 1 - 11.1 General Information .................................................................................... 1 - 11.2 Information about Tunnelling Machine/Equipment.................................. 1 - 21.2.1 Definitions...................................................................................................... 1 - 31.2.2 Structure of the Operating Instructions.......................................................... 1 - 31.2.3 Abbreviations................................................................................................. 1 - 41.3 Guaranty and Exclusion of Liability ......................................................... 1 - 51.4 Environmental Compatibility...................................................................... 1 - 61.5 Copyright Protection................................................................................... 1 - 6

2 General Safety Instructions....................................................... 2 - 12.1 Intended Use ................................................................................................ 2 - 12.2 Use and Application .................................................................................... 2 - 12.3 Explanation of Symbols.............................................................................. 2 - 22.3.1 Explanation of Symbols ................................................................................. 2 - 22.3.2 General Symbols ........................................................................................... 2 - 32.4 Directions for Use Safety Outfit ................................................................. 2 - 42.5 Special Symbols .......................................................................................... 2 - 52.5.1 Caution and Danger Sings ............................................................................ 2 - 52.5.2 prohibitory sign .............................................................................................. 2 - 52.6 Emergency Stop and Safety Checks ......................................................... 2 - 62.7 Requirements to Operating Personnel...................................................... 2 - 62.8 Operators Engagement............................................................................... 2 - 82.9 Safety for the Operating Personnel ........................................................... 2 - 92.10 Safety Instruction ........................................................................................ 2 -102.10.1 Tunnel............................................................................................................ 2 -102.10.2 Launch and Reception Shaft ......................................................................... 2 -102.10.3 Tunnelling equipment .................................................................................... 2 -102.10.4 Operation....................................................................................................... 2 -112.10.4.1 Container Heating ..................................................................................................... 2 - 122.10.4.2 Door between Power Pack and Control Room.......................................................... 2 - 122.10.5 Maintenance .................................................................................................. 2 -132.11 Electrical Energy ......................................................................................... 2 -152.11.1 Electric and Steering Cables ......................................................................... 2 -162.11.2 Wireless transmitting stations........................................................................ 2 -16

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 I - 0 - 1

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M-1437CIntroduction, Safety Instructions

2.12 Hydraulics, Pneumatics............................................................................... 2 -172.12.1 Verifying of hydraulic hoses ........................................................................... 2 -172.13 Oil, Grease and other Chemical Substances............................................. 2 -182.13.1 Personal Protection Equipment...................................................................... 2 -182.13.2 Informations about Safety Use....................................................................... 2 -192.13.3 Informations about fire- and explosion-protection .......................................... 2 -192.13.4 Requirements of the Storage Rooms and Recervoirs.................................... 2 -192.13.5 Environmental Conservations ........................................................................ 2 -192.13.6 Disposal Considerations ................................................................................ 2 -202.14 Gas, Dust, Steam, Smog.............................................................................. 2 -202.15 Safety Equipment......................................................................................... 2 -212.15.1 First aid equipment......................................................................................... 2 -212.15.2 Fire protection ................................................................................................ 2 -212.16 Reaction when recognize a Danger............................................................ 2 -212.16.1 Rescue of People, First Aid............................................................................ 2 -212.16.2 Fight against Fire ........................................................................................... 2 -21

3 Additional Safety Instructions.................................................. 3 - 13.1 Security and Safety Equipment at the VTM/VTA....................................... 3 - 13.1.1 Symbols located at the VTM/VTA .................................................................. 3 - 13.1.2 Warning signals During Operation of VTM/VTA............................................. 3 - 13.1.3 Further information......................................................................................... 3 - 23.2 Safety Installations ...................................................................................... 3 - 23.2.1 Following Safety Installations are located at the VTM/VTA ........................... 3 - 23.2.1.1 Control Container ...................................................................................................... 3 - 33.2.1.2 Shaft .......................................................................................................................... 3 - 3

3.3 Operation at Temperatures below Zero ..................................................... 3 - 43.3.1 Machine Start-up at Temperatures below Zero.............................................. 3 - 43.3.2 Water Circuit and Armoured Pumps .............................................................. 3 - 4

Edition: April 2009 © Herrenknecht AG, Schlehenweg 2 I - 0 - 2 77963 Schwanau 2, Tel. 07824 / 3020Version: 0

M-1437CIntroduction

1 Introduction

1.1 General Information Before the first putting into operation of the tunneling equipment, read this

operating manual thoroughly to become acquainted with the tunneling equipment and to use it as directed. Observing them helps to avoid risks, reduce repair costs, downtime and increase reliability and working life of tunneling equipment.

The operating manual contains important references for a safe and proper operation and maintenance of the tunneling equipment.

This operating manual is a part of the complete technical documentation. Ensure that all safety conditions are fulfilled before putting the tunneling

equipment into operation.Any work on and with the tunneling equipment, shall be executed by

qualified and trained personnel. Statutory minimum age shall be observed. It is not possible to fulfill guaranty in accordance with our delivery contract

if maintenance work is neglect or improper.Only original spare parts of Herrenknecht AG ensure quality and

replacement.All technical information, data and references included in this operating

manual have been updated at the time of going to press and result from our present and previous experiences and realizations to the best of our knowledge.

CAUTIONWe are not liable for damages and malfunction resulting from operating faults, non-observance of this operating manual or improper maintenance. We explicitly point out that only original spare parts and original accessory parts released by us shall be used.

This operating manual complies with the demand of The European Union, in particular EG directive 98/37/ EG.


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M-1437CIntroduction

1.2 Information about Tunnelling Machine/Equipment

WARNINGPay attention to the following chapters „General Safety Instructions and Additional Safety Instructions“ to ensure health of machine operators and maintenance personnel and the function of the tunneling machine/equipment.Non observance of these instructions may endanger manufacturer’s guarantee and liability.

Project: M-1437CYear of

constructionType: Control Container

Manufacturer: Herrenknecht AG

Control container Part no 30138898 2009

Operating manual edition: April 2009

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M-1437CIntroduction

1.2.1 DefinitionsInformation concerning location ”left” and ”right” as well as direction

”forward” and ”backward” shall always be seen in direction of drive.The tunneling equipment consists of • tunneling machine• jacking station and interjack stations (optional)• conveying system• power pack for interjack stations (optional)• control container• cutting wheel, shield and machine can,• machine can 2 or trailing tube• air lock (optional)• and telescopic station (optional)• is called tunneling machine

1.2.2 Structure of the Operating InstructionsMain PartsThese operating instructions consist of 8 main parts.ChaptersEach main part is preceded by a table of contents for the individual

chapters.PagesThe pages of each chapter are numbered consecutively.Example:

In main part I chapter 2 "General Safety Instructions" the main points for accident prevention and environmental protection are summed up.

Main part I chapter 2 is a general part. It contains no information about special machines.

I - 4 -2

I = Main part

- 4 = Chapter

- 2 = Page


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M-1437CIntroduction

IllustrationsThe illustrations in these operating instructions are intended to clarify the

text passages.They may differ from the actual execution of the machine without

fundamentally altering the factual information.ModificationsImportant modifications to the standard specification of the machine will

be incorporated in each new edition of the operating instructions.

1.2.3 Abbreviations

VTR Direction of tunneling

VTM Tunnelling machine

VTA Tunnelling equipment

FCE Fuzzy control expansion

SLS-RV Control and guiding system for pipe jacking

ELS Electronic laser system

FU Frequency Converter


M-1437CIntroduction

1.3 Guaranty and Exclusion of LiabilityThis operating manual contains all required references and shall be

carefully read prior to commissioning of the tunnel-boring machine. We are not liable for damages and malfunction resulting from non-observance of operating instructions.

The guaranty expires e.g. in case of:• non-observance of the operating manual• damages in case of operaring faults or force damages• inproper Maintance• improper use• non-use of original spare parts and original accessory parts• conversions unless co-ordinated with Herrenknecht AG.

All technical information, data and references included in this operating manual have been updated at the time of going to press and result from our present and previous experiences and realizations to the best of our knowledge.

We reserve the right to all technical changes which may emerge within the range of the further development of the assemblies mentioned in this operating manual. Therefore no claims may be derived from the information, illustrations and descriptions given in this operating manual.

We are not liable for damages and malfunction resulting from operating faults, non-observance of this operating manual or improper maintenance. We explicitly point out that only original spare parts and original accessories released by us shall be used.

CAUTIONOriginal parts and system components are especially designed for AVN tunneling equipments:We explicitly remind you, that a faultless function of the tunneling equipment can only be guaranteed, if the equipment is used with original parts and system components of Herrenknecht AG.Herrenknecht AG can not be held liable for any damages and/or malfunctions resulting of the use of non-original parts and system components.


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M-1437CIntroduction

For safety reasons, assembly or use of unreleased spares or accessories and all arbitrary conversions and changes are not permitted and exclude any liability of Herrenknecht AG for resulting damages.

Translations are carried out to the best of our knowledge. We are not liable for any occuring translation faults, not even if the translation was carried out by us or by our order. Obligatory with only the original text.

1.4 Environmental CompatibilityThe national and communal legal instructions for environmental protection

shall be observed.Internal regulations shall take into account producer instructions.As a rule, never remove any operating and auxiliary material into

canalization, soil or waters.To prevent any pollution of the ground water, only biologically degradable

oil shall be used.Discarded exchange parts shall be appropriately disposed of.

1.5 Copyright ProtectionThis operating manual shall be treated confidentially. It is to be used by

authorized personnel only. They may only be passed on by written approval of Herrenknecht AG. All documents are protected within the meaning of the copyright law. A passing on as well as copying of documents, even partially, use and information as to contents is not permitted unless explicitly admitted. Violations are illicit and liable for damages. We reserve all rights to exercise industrial patent rights.

Company address:Herrenknecht AG Schlehenweg 2 D-77963 SchwanauGermanyTel. (0049) 7824/302-0 Fax (0049) 7824/4355


M-1437CGeneral Safety Instructions

2 General Safety Instructions

2.1 Intended UseOnly intended use ensures safety in operation of VTM/VTA.Intended use exits only employing the VTM/VTA as described in section

„Use and Application“. A different or exceeding use is considered contrary to this designation. The producer can not be held liable for any resulting damage. The operating company alone bears the risk.

Intended use includes also observing the operating instructions as well as observing inspection and maintenance instructions.

2.2 Use and ApplicationThe entire tunnelling equipment consists of the control container, the

slurry circuit, the jacking frame, interjack stations (optional) and the tunnelling machine.

• The control container has been designated for controlling the tunnelling equipment (tunnelling machine, jacking frame slurry circuit e.t.c.).

• The slurry circuit is used to support the material outside of the tunnel. Using an AVN machine it is a water circuit using a sedimentation tank, feed and slurry pumps and feed and slurry lines.

• Feed- and slurry pumps are exclusive designed to excavate a sand-water-mixture. It is not allowed to exceed the limit values of grain size and density of the mixture, given on the data sheet of the armoured pump

• The jacking frame serves as jacking unit for the tunnelling machine and the concrete pipes.

• The tunnelling machine is designed for tunnel advance according to the outside diameter of the selected machine. The extension also belongs to the tunnelling machine.

A different or exceeding use is considered contrary to this designation. The producer can not be held liable for any resulting damage. The operating company alone bears the risk.The tunnelling equipment has been constructed in accordance with state-of-the-art technique and the acknowledged safety requirements. Its use may yet be a danger to life and limb of operating personnel or any third party or may result in impairment of the tunnelling machine and other material assetsTherefore the tunnelling equipment shall only be used in technically faultless condition and only in accordance with its designated use. The personnel must be aware of safety regulations and risk prevention and must observe all operating instructions. Any malfunctions or faults, especially those affecting the safety of the machine, shall be immediately repaired.


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The use of VTM/VTA is not allowed:• in faulty condition,• without mounted safety devices,• with defective or for the working pressure not permissible hydraulic

hoses• unauthorized changes and conversions of the tunnelling

machine/equipment.

2.3 Explanation of Symbols2.3.1 Explanation of Symbols

Safety notices in the operating manual and warning notices at the dangerous spots on the TBM warn of residual risks of the different operating modes during operation of the TBM.

The operating manual uses the following safety notices which mean:.



2.3.2 General SymbolsIn this operating manual the following symbols and notes warn against

possible damage of persons or property or refer to working aids:

Instructions attached directly to the machine must always be complied with and be kept in perfectly legible condition at all times.

DANGERIndicates death, severe personal injury in case of non-observance of instructions.

WARNINGWarning in case of non-observance of instructions may be a risk of personal injury or substantial damage to the equipment or damage of particular assemblies

CAUTIONWarning in case non-observance of instructions may lead to damage of the equipment or damage of particular assemblies.

DANGERWarning of dangerous electrical voltage.

NOTEImportant or additional information concerning machine or documentation.


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2.4 Directions for Use Safety OutfitIn this manual occuppations which require the wearing of safety outfits are

marked with the signs shown below.

Wear safety goggles Wear safety helmet

Wear ear protection Wear safety gloves

Wear safety shoes Wear safety clothing



2.5 Special Symbols2.5.1 Caution and Danger Sings

In this manual occuppations which expose particualr risks are marked with the signs shown below.

2.5.2 prohibitory sign

Falling loads Danger of slippery

Hot surface Laser

Hot fluids Danger of crush

No smoking Do not use open fire


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2.6 Emergency Stop and Safety ChecksCheck daily all• Emergency Stop buttons• safety equipmentsee also chapter special safety instructions.

2.7 Requirements to Operating Personnel• Any work on and with the tunnelling equipment shall be executed by

reliable and qualified persons only. Statutory minimum age limits shall be observed.

• Each person in charge with transport, assembly, commissioning, operation, maintenance, and repair work shall have thoroughly read and understood• the operating manual,• the safety instructions and• the safety regulations of particular chapters and paragraphs.

• Individual responsibilities of personnel for operation, set-up, maintenance and repair shall be clearly determined.

• Make sure that only authorized personnel work on the tunnelling equipment.

• Define the responsibility of the machine operator. He shall be given the authority to refuse instructions by any third party which are contrary to safety.

• Persons to be trained shall only work on the tunnelling equipment while being permanently supervised by an experienced person.

• Any work on the electrical system of the tunnelling equipment shall only be carried out by a skilled electrician. It is required that the electrical plant is commissioned, maintained and repaired by qualified personnel and that these activities are supervised and controlled by responsible specialists. Qualified personnel are persons who have been authorized by the person responsible for the safety of the plant because of their education, experience and training as well as their knowledge of standards, regulations, conditions at work and accident prevention regulations, to carry out all required activities and to recognise and avoid all possible risks.

• The prohibition of employment of non-qualified persons working on highvoltage installations has been settled by standard IEC 364.

• Only persons with a special knowledge and experience in hydraulics may carry out works on hydraulic installations.



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Machine operator

Skilled mechanics

Skilled electrician

Personal which is special trained to hydraulic

Personal which is special trained to compressed air

Superiors with corresponding competence


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2.8 Operators Engagement• The complete operating manual must always be at hand in the control

container of the tunnelling equipment.• In addition to the operating instructions the operating company of the

tunnelling equipment shall observe all statutory or otherwise obligatory regulations for accident prevention and environmental protection .

• The operating instructions shall be supplemented by instructions including supervising and reporting duties, working procedures and information about operating personnel employed.

• The operating personnel must have read the operating manual, in particular the chapter dealing with health, safety and welfare requirements, prior to work starting.

• Make known all security installations, their function and operation.• Regularly check whether operating personnel are carrying out the work

in accordance with operating instructions and are observing risk and safety factors.

ATTENTIONPay attention to all the local regulations of tunnelling, prevention of accidents, electric and environmental regulations and other necessary regulations.



2.9 Safety for the Operating PersonnelThe following personal safety outfit must be worn when working:

On principle in all areas of the tunnelling equipment• Wear only close-fitting safety clothing. Put neckerchief or scarfs inside

clothing.• Long hair shall be secured in a hair-net. • Wear no jewellery, including rings.• When carrying out activities which require further safety outfit in

accordance with accident prevention regulations, e.g. glasses, respiratory protection mask etc. must be worn.

• All signs, attached to the tunnelling equipment, orders or prohibitions must be observed by all means.

• It shall be guaranteed that all requirements to operating personnel settled in this operating manual and in the operating instructions of the producers of particular units and machine parts (see appendix) are fulfilled.

Safety helmet with miner’s lamp

• In the Machine• In the tunnel• In the shaft

Safety gloves

• In the Machine• In the tunnel• In the shaft

Ear protection

• In the control container• In the Machine• In the tunnel• In the shaft

Safety shoes


Safety clothing



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2.10 Safety Instruction2.10.1 Tunnel

2.10.2 Launch and Reception Shaft• The starting shaft (reception shaft) should be accessible by a

permanently mounted ladder according to DIN 4420. • If simple ladders are used, these must be attached to the side guard of

the shaft such that slipping is prevented and the ladders project at least 1m above ground surface.

• If electrical protective arrangement "fault current connection" is used for the electrical equipment in the shaft, an FI safety switch for a fault current strength of 0,3 A must be used.

2.10.3 Tunnelling equipment• All safety instruction subdivided in the chapters ”Operation”,

”Maintenance” and ”Warning of particular kinds of risks” apply to the operation of the tunnelling equipment.

DANGERIt is not allowed to step into the tunnelling machine, if the nominal diameter of the concrete pipe is smaller than 800 mm.



2.10.4 Operation• Never make any modifications, attachments or conversions which might

affect the safety without the approval of the producer. This applies also to installation and adjustment of safety devices and safety valves as well as to the welding on carrying parts.

• During operation, the electrical working machines show dangerous active parts and rotating parts. These may cause serious hygienic and material damage in case of disallowed removal of necessary covers, inadequate use, wrong commissioning or insufficient maintenance.

• Never make any changes in the program of the programmable control system.

• Never manipulate, override or remove any safety installations.• All safety instructions and warning signs attached to the tunnelling

machine must always be complete and perfectly legible.• Keep all handles, steps, handrails, platforms, landings and ladders free

of dirt.• Escape routes must always kept free.• Operate tunnelling equipment only if all safety installations function

properly.• Omit all modes of working which may be critical to safety.• Observe all procedures for starting and stopping as well as indicators in

accordance with operating instructions.• Prior to commissioning of tunnelling equipment make sure no person is

endangered by starting tunnelling machine.• In case of malfunction, immediately stop tunnelling equipment. Have any

faults repaired at once.• Using diesel driven generating sets with the VTM/VTA they may only be

employed with diesel fuel which have a proven flash point higher then 55°C.


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2.10.4.1 Container HeatingIf there are intense temperature differences between day and night (15° C

and more) condensation can become evident in the switchgear cabinet and the control cabinet.

As a result of this, electronic parts of the system can fall in trouble.Switch on the container heating overnight.By using an generator, switch on the heating for minimum 30 minutes

before starting the tunnelling equipment.

2.10.4.2 Door between Power Pack and Control RoomThe door between the power pack room and the control room should be

closed during operation.



2.10.5 Maintenance• The maintenance works may only be executed by instructed persons

with the corresponding special knowledge (see „Requirements to Operating Personnel“) .

• Observe terms for inspection and maintenance activities including information about exchange of subassemblies or components in accordance with operating instructions.

• Before starting special and maintenance works nominate a supervisor and give information to the operating personnel.

• Use producer-released original spare parts and original accessory parts only.

• Use appropriate equipment and material only (grease, oil, detergents).• Secure maintenance area spacious if necessary.• In case the tunnelling equipment has been completely stopped for

maintenance and repair works, it must be secured against unexpected restart.

• In case a motor has been stopped for maintenance and repair work, it must be secured against restart.

• Use appropriate ladders or lifting platforms when carrying out maintenance works on places which are higher than your body.

• Working in high areas use appropriate safety equipment such as safety belts or stages.

• Clean machine parts, especially connections and screw fittings, prior to maintenance activity. Never use any aggressive detergents. Use lint-free cleaning rags.

• Before cleaning the machine with water, high-pressure cleaner or other detergents, cover or tape up all openings which - for safety or functional reasons - must be protected against penetration of liquids and detergents. Special care must be taken with electrical motors and switchgear cabinets.

• After cleaning, completely remove all covers and tapes.


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• Always tighten bolted connections loosened during maintenance work using the appropriate torque setting.

• Clean all handles, steps, handrails, platforms, landings and ladders after maintenance work.

• Any safety installations removed for set-up, maintenance or repair work must be reassembled and checked immediately, having completed all works.

• Before starting work on lines which may be under pressure (e.g. feed- and slurry lines, hydraulic lines, compressed air lines or oxygen lines) ensure that the lines are depressurized. Stop pumps or compressor and secure against unexpected restart.

• Pressure in a line may be the cause of a hydraulic cylinder, a pressure accumulator or other components under load. Secure hydraulic cylinder and other components under load against move and depressurize the pressure accumulator.

• Secure heavy machine parts against tip over and fall down before remove screws and bolts.

• Keep switch gear cabinets closed. Open only the necessary door for maintenance works. Close open doors at once when leaving working place or when maintenance work is finished.

• Ensure that all operating and auxiliary material as well as exchanged replacement parts are disposed of safely and with minimum environmental impact.



2.11 Electrical Energy

• Work on the electrical system or equipment may only be carried out by a professional electrician.

• Secure working area with a red-white safety chain and a warning sign. Use insulated tools only.

• Observe valid accident prevention measures when carrying out works on live appliances (e.g. VBG4).

• Necessary works on live parts shall only be carried out in the presence of a second party to cut off power supply by operating the emergency stop switch or main switch in case of emergency. The second party must be familiar with resuscitation measures.

• The electrical equipment shall be inspected and checked in regular intervals. Defects such as loose connections or scorched cables must be immediately repaired.

• Handle appliances in a way that no construction elements are deformed and/or insulation clearances changed.

• Avoid any contact with electronic construction elements (static discharge!).

DANGERBefore starting the tunnelling equipment the control container must be grounded appropriately DIN 100 / VDE 0100 PART 410 and DIN 100 / VDE 0100 PART 540!

CAUTIONCheck that contact screws are firmly fixed before putting the equipment into operation.


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• Use an appropriate measuring instrument with an internal resistance of at least 10 kW for measurements of signal voltages.

• Components on which inspection, maintenance and repair work is to be carried out must be stopped if appropriate. Before starting any work, check whether de-energized parts are voltage-free.

• Use only original fuses with the specified current rating, to immediately stop the tunnel-boring machine in case of any problems with the electrical energy supply.

• Before starting works on high-voltage assemblies and after cutting off the power supply, the feeder must be grounded and components, such as condensers, must be short-circuited by a grounding rod.

• Never modify the electrical plant without consultation of Herrenknecht AG and the written approval of Herrenknecht AG.

2.11.1 Electric and Steering Cables

2.11.2 Wireless transmitting stationsHandies, radio sets and other wireless transmitting stations should not be

used in the tunnel

DANGEREnsure there are no current flowing through the cables before you disconnect them.Danger: Electrical voltage!



2.12 Hydraulics, PneumaticsWork on hydraulic installations may only be carried out by persons having

a special knowledge and experience in hydraulics.Regularly check all lines, hoses and bolted joints for leakage and obvious

damage. Repair damage immediately. Splashed oil may cause injury and fire.

Before starting maintenance work, the corresponding hydraulic system must be relieved of pressure.

2.12.1 Verifying of hydraulic hoses

Examples of possible deficiencies of hydraulic hoses• Deffectives of the outer layer down to the insert

(e.g. scouring spots, cuttings or cracks).• Embrittling of the outer layer

(formation of cracks of the hose material).• Deformations which are not according to the natural form of the

hydraulic hose in depressurised or pressurised condition or during bending of the hydraulic hose e. g. disconnection of coatings, bubbles, squeezing areas and breaking areas.

• Are the requirements of the assembling observed?• Peregrination of the hose out of the fitting.• Deffectives or defamations of the fitting which are reducing the function

and resistance of the fitting or the connection hose and fitting.• Corrosion of the fitting which is reducing the function and resistance of

the fitting.• Are the storage time and usage time of the hydraulic hose exceeded?

NOTEVerify and record hydraulic hoses minimum once a year for secure working conditions by an technical expert,Remove defective hose lines immediately.


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2.13 Oil, Grease and other Chemical SubstancesWhen handling oil, grease and other chemical substances, observe the• usual precautions• product-related safety instructions• and the informations about using the personal safety outfit.• Be careful when handling hot operating and auxiliary material (risk of

burning or scalding).• Due to increased danger from fire and slippery surfaces, clean oil and

grease from surfaces immediately.

2.13.1 Personal Protection Equipment

Respiratory protection• Not required under normal circumstances.• In case of aerosol formation wear approved respirator with a filter.

Hand protection• Wear approved protective gloves or use protectiv skin oitment.

Eye protection• In case of danger of squirt wear safety goggles.

Skin and body protection• Prevent skin contact• Wear overalls,

in case of danger of squirt wear oil resistant overall.• Wear oil resisted shoes.

General safety and hygiene measurements• Remove and wash contaminated clothing.• Do not put contaminated cleaning cloth into your clothing.• Take care for skin cleaning and skin appearance after work.• Do not eat, drink, smoke or snuff during work.• Oil, grease and other chemical substances keep away from food.



2.13.2 Informations about Safety Use• Prevent spill of the products.• Prevent aerosol formation.• Use appropriate tools and safety shoes when handling heavy

containers.• Wear personal safety outfit.• Prolonged or fetched skin contact may cause skin irritation.• Do not allow uncontrolled achieve into the environment to the products.

2.13.3 Informations about fire- and explosion-protection• Take products away from fire.

2.13.4 Requirements of the Storage Rooms and Recervoirs• Ensure a sufficient room ventilation.• Use only containers witch are permitted to store the substance.• Keep locked-up. • Prevent penetration of the substances into the earth.

2.13.5 Environmental Conservations• Advise water authority if spillage has entered water course, sewage

system or earth.• Do not allow the substances to get into the sewage systems.• Cover sewage systems.


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2.13.6 Disposal Considerations• Dispose of as special waste in compliance with local and national

regulations.

2.14 Gas, Dust, Steam, Smog • There is unrestricted ban on smoking.• During welding, grinding and torch works there is fire and explosion

hazard. Because of that it is essential to provide the accorsing fire fight mediums during such works and to nominate a supervisory person, who initiate the required measures if required.

• Before welding, grinding and torch works clean the parts that have to be machined and their surrounding of dust and other combustble mediums and provide for sufficient ventilation.

• During weldingworks electrode holder and earth have to fit on the same component part in distance as short as possible.

• By operation in crowded rooms consider the national rules.

NOTEFor special informations about handling and safety of the used oils and greases see safety data sheet of the producer.



2.15 Safety Equipment2.15.1 First aid equipment

It is customers responsibility to provide safety and first aid equipment such as safety helmet, first aid box and stretcher etc. This equipment has to be available in the job site office or control container.

2.15.2 Fire protectionTwo types of fire extinguishers may be used at the tunnelling equipment:

Powder or CO2 fire extinguishers.• Fire extinguishers have to be installed by the customer and their location

have to be signed.• Ensure maintenance and inspection of the fire extinguishers within the

prescribed time limit.

2.16 Reaction when recognize a DangerWhen recognize any danger stop the tunnelling machine/equipment using

the next emergency stop button.

2.16.1 Rescue of People, First Aid Pay attention to your self protection when carrying out first aid. Call a

doctor at once.

2.16.2 Fight against FireExtinguishing fire at the hydraulic system use only fire extinguishers which

are permissible to hydraulic fire.Extinguishing fire at the electrical system use only fire extinguishers which

are permissible to electrical fire.

WARNINGSafety and first aid equipment have to be checked weekly for orderly function and completeness.Safety and first aid equipment have to be readyon hand every time.


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M-1437CAdditional Safety Instructions

3 Additional Safety Instructions

3.1 Security and Safety Equipment at the VTM/VTA3.1.1 Symbols located at the VTM/VTA

3.1.2 Warning signals During Operation of VTM/VTA

Electrical VoltageLocated at all electrical cabinets.

First AidLocated at all places where are first aid equip-ment is installed. This sign must be posi-tioned from the customer.

Fire extinguisherLocated at all places where are fire extinguish-er is installed. This sign must be posi-tioned from the customer.

Faults of the tunnelling machine/-equipment are shown by an acoustically signal and illuminating of the „RESET“ button on the control panel.

At the same time a general fault indication is shown on the monitor of the visualisation. F5 - ERROR


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3.1.3 Further information• The hydraulic system is equipped with pressure relieve valves. Never

change the adjusted values. Exceptions: The values of the jacking frame and interjack stations must be adjusted in accordance to the jacking pipe. The values of the pump „cutting wheel drive“ has to be adjusted in ac-cordance to the data sheet of the use tunnelling machine.

• All electric motors are secured against overload an short circuit.• The customer has to ensure the power supply and the supply of cooling

water (if necessary) for the tunnelling equipment.

3.2 Safety InstallationsNever Manipulate • EMERGENCY STOP installations• Other safety installations as

pressure relieve valves, overload protection of electric motors etc.

3.2.1 Following Safety Installations are located at the VTM/VTAThe equipment will be stopped by an „EMERGENCY CUT-OUT“

• on the control panel• in the power pack room near the door,• in the starting shaft •



3.2.1.1 Control Container

3.2.1.2 Shaft

In the control container one „EMERGENCY CUT-OUT“ is located on the op-erators control panel.

The second „EMERGEN-CY CUT-OUTS“ is located in the power pack room di-rectly at the door between control- and power pack room.

In the starting shaft you have to use two „EMER-GENCY CUT-OUTS“. One is on the remote control for the jacking frame, the other one is connected with the remote control by an exten-sion cord.

Both „EMERGENCY CUT-OUTS“ should be mounted in the shaft near the jacking frame, so that you can use them without crossing the jacking frame.

The „EMERGENCY CUT-OUTS“t will stop all equip-ment, except for lighting and the hoist unit (if installed) which will stay in operation.

Sketch: Installing Emergency Stope.g. in a round shaft


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3.3 Operation at Temperatures below ZeroOperation at temperatures below zero or if temperature will fall below

zero.

3.3.1 Machine Start-up at Temperatures below Zero• Inside temperature of switch gear cabinet has to average +10° C.• Check the oil temperature in the hydraulic package. It has to average be-

tween +5° C and +10° C to prevent cavitation due to viscous oil during cold starting of the hydraulic pumps. Heat oil if its necessary.

3.3.2 Water Circuit and Armoured Pumps• Completely drain, thoroughly insulate, or heat the feed and slurry line

and the armoured pumps in the evening after ending the jacking operations.

• After jacking operations have ended and after the machine has been re-moved, connect the machine directly to the control container, lifting the front end slightly while opening and closing the bypass 3 or 4 times to al-low water to drain from clearance space of the globe valves and from the feed and slurry lines.

• After this open all ball valves partly. Only so it is possible that freezing water can expand without damaging sealings or valve boxes. or if the machine is equipped with slide valves you have to open it completely.

• Avoid formation of ice in the settling basin.


M-1437CTechnical Data, Group Description

II) Technical Data, Group Description

1 Technical Data ............................................................................ 1 - 11.1 Control Container ........................................................................................ 1 - 11.1.1 Cutting wheel drive ........................................................................................ 1 - 11.1.2 Main jack, Jacking Frame............................................................................ 1 - 11.1.2.1 Geared Pump PGP517B0700CD1H3VE8B1 ............................................................ 1 - 21.1.3 Tank Capacity................................................................................................ 1 - 21.1.4 Transport Dimensions Container................................................................... 1 - 21.1.5 Compressor ................................................................................................... 1 - 31.1.6 Installed Power .............................................................................................. 1 - 31.2 Feed Pump ................................................................................................... 1 - 41.2.0.1 Transport Dimensions ............................................................................................... 1 - 4

1.3 Slurry Pump ................................................................................................. 1 - 51.3.0.1 Transport Dimensions ............................................................................................... 1 - 5

2 Technical Description ................................................................ 2 - 12.1 Control Container ........................................................................................ 2 - 12.1.1 Control Components...................................................................................... 2 - 12.1.2 Overview Control Panel................................................................................. 2 - 12.1.3 Overview Screen ........................................................................................... 2 - 22.1.4 Machine Controls........................................................................................... 2 - 22.1.5 Feed and Slurry Pumps................................................................................. 2 - 32.2 Conveyance circuit...................................................................................... 2 - 3


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M-1437CTechnical Data, Group Description


M-1437CTechnical Data

1 Technical Data

1.1 Control Container1.1.1 Cutting wheel drive

1.1.2 Main jack, Jacking Frame

Electric motor Part. Nr. 23000599

Drive power 75 kW

Voltage 400 V

Frequency 50 Hz

Revolutions 1500 RPM

Weight 647 kg

Variable displacement pump Part. Nr. 23501867

Nominal flow 181 l/min

Maximum pressure possible 420 bar

Weight approx. 80 kg

Gear pump Part. Nr. 23502045

Nominal flow at 1450 RPM 101 l/min

Pressure cut off adjusted at 15 bar


Weight approx. 10,5 kg

Electric motor Part. Nr. 23000519

Drive power 37 kW

Voltage 400 V

Frequency 50 Hz

Revolutions 1500 RPM

Weight 310 kg

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 II - 1 - 1

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1.1.2.1 Geared Pump PGP517B0700CD1H3VE8B1Part. no.: 23502039

1.1.3 Tank Capacity

1.1.4 Transport Dimensions Container

High pressure regulation pump Part. Nr. 23502037

Nominal flow at 1450 RPM 0 - 80 l/min

Nominal pressure 420 bar

Weight approx. 39 kg

Gear pump Part. Nr. 23502045

Nominal flow at 1450 RPM 101 l/min

Pressure cut off adjusted at 15 bar


Weight approx. 10,5 kg

Flow range at 1450pm 101,5 l/min

Maximum pressure briefly possibly 215 bar

Maximum pressure 200 bar

Weight approx. 20 Kg

Hydraulic tank 1500 litre

Length L 5500 mm

Width B 2450 mm

High H 3200 mm

Weight 8500 kg

Edition: April 2009 © Herrenknecht AG, Schlehenweg 2 II - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020Version: 0


1.1.5 CompressorKC350-40D, Part No.: 21000826

1.1.6 Installed Power

Compressor blockInlet capacity 350 l/minDelivery range at 6 bar operating pressure 230 l/minMaximum operating pressure 10 barNumber of cylinders 1 no.Revolution 1500 rpmOil capacity 0,2 LiterOil top-up quantity 0,1 Liter

Drive motorRated power 1,7 kWRevolution 1500 rpm

Compressed-air reservoirCapacity 40 LiterMaximum permissible operating pressure 11 bar

Factory settingsCut-in pressure pmin 7 barCut-off pressure pmax 9 barPressure difference Δp 2 bar

Weight approx.Total weight compressor unit 56 kg

Cutting wheel drive 110 / 400V 50Hz

Jacking cylinders 37kW / 400V 50Hz

Compressor 1,7KW / 400V 50hZ

Feed pump 75kW / 400V 50Hz

Frequency converter feed pump 75 kW

Slurry pump shaft 30kW / 400V 50Hz

Frequency converter slurry pump shaft 30 kW

Slurry pump machine 45kW / 400V 50Hz

Frequency converter slurry pump machine 45 kW

Slurry pump tunnel 45kW / 400V 50Hz

Frequency converter slurry pump tunne 45 kW


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1.2 Feed Pump Art. Nr.23500760

1.2.0.1 Transport Dimensions

Infinitely speed variable 0 - 2900 rpm

Drive power 30kW/400V 50Hz

Power frequency converter 30 kW

Nominal flow 0-170 m3/h

High of delivery 47,1 m

Density 0,9981 kg/dm3

Length L 1250 mm

Width 400 mm

Heigh H 750 mm

Number of lifting points 1 number

Weight approx. 350 kb



1.3 Slurry PumpArt. Nr.: 25101702

Lubricant indicator

1.3.0.1 Transport Dimensions

Infinitely speed variable 0 - 1500 rpm

Drive power 30kW/400V 50Hz

Power frequency converter 30 kW

Pumping medium Water-sand mixture

Nominal flow 0-100 m3/h

High of delivery 30 m

Density 1,17 kg/dm3

Maximum grain size 50 mm

Vane-width of the impeller 70 mm

Grease cartridge capacity 120 cm3

Time of delivery in months at 25°C 3 Months

Daily delivery at 25°C approx. 1,2 cm3

Length L 2200 mm

Width 700 mm

Heigh H 600 mm

Number of lifting points 4 number

Weight approx. 800 kb


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M-1437CTechnical Description

2 Technical Description

2.1 Control ContainerThe control panel and the hydraulic power pack are mounted in the control

container, which will be placed behind the starting shaft. Tunneling machines type „C“, e.g. AVN1200TC or AVN800XC are

controlled by SPS via 37 pin electrical cable.If there is a PBA-box installed in the tunneling machine, it can be

controlled via external SPS cable connected to the SPS socket of the control container.

2.1.1 Control Components• AVN• Jacking frame / interjack stations• Feed pump / slurry pump / bentonite pump• Compressed air system (if installed)

2.1.2 Overview Control PanelThe readings for the several measuring values are shown on screen on

the right side and analogue displays on top of the control panel.Pressure gauges show:

On the right side of the upper section of the control panel a screen used with video control for the pressure gauges in the tunnelling machine is installed. Below this monitor the screen and the computer are installed. Between Screen and computer the keyboard to operate the measuring system and the visualisation is installed.

Cutting wheel drive (0-400 bar) Pressure hydraulic pump

Jacking cylinders (0-600 bar) Pressure hydraulic pump

Interjack cylinders 1 (0-600 bar) Pressure hydraulic pump


Pipe Brake (0-400 bar) Pressure hydraulic pump

Steering oil (0-600 bar) Pressure hydraulic pump

locking cylinders Jacking frame

(0-250 bar) Pressure hydraulic pump


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2.1.3 Overview Screen On the lower section of the control panel, the start and stop buttons for the

hydraulic pumps, feed and slurry pumps, laser and bentonite pump are located. Also buttons for steering and bypass cylinders, push cylinders, cutting wheel and warning lamps, for different functions, are placed in this part of the control panel.

2.1.4 Machine ControlsThe following functions of the tunnelling machine are influenced from the

control panel.• Steering cylinders• Cutting wheel drive• Bypass • All valves of feed and slurry lines • Hydraulic power pack for interjack stations (optional)Steering CylindersThe steering cylinders are extended / retracted by pressing the specific

push buttons.Cutting Wheel DriveThe cutting head is able to rotate clockwise and anti-clockwise. The pre-

selection will be done by pressing the specific push button on the control panel. Afterwards the rotational speed of the cutting head can be increased by turning a rotary switch. The torque of the cutting head is shown as cutting head pressure on the screen . The revolution of the cutting head is also shown on the screen.



2.1.5 Feed and Slurry PumpsThe feed pump and the slurry pump will be started, stopped and controlled

from the control panel.Push buttons to start and stop the pumps and rotary switches for speed

control are located on the lower section of the control panel. Revolution, flowrate and water pressure are shown in the lower section of the screen on display „ADVANCE“.

2.2 Conveyance circuitThe Conveyance circuit consists of feed and slurry pumps, settlement

tank and the necessary hoses and pipelines. Two flowmeters, one in the feed and one in the slurry line, are installed for controlling the flowrate. Both flowmeters have to show the same flowrate while feed and slurry pumps are running.When running the feed pump clean water will be flow into the excavating chamber via the feed line. In the excavating chamber the water will be mixed with the excavated material. The running slurry pump’s, pumps the mixed water via the slurry line into the settlement tank or a separation plant. Excavated material will be separated from the water and the water flows back into the water circuit.


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M-1437CTransport, Set Up, Connection

III) Transport, Set Up, Connection

1 Transport..................................................................................... 1 - 11.1 Safety Instructions ...................................................................................... 1 - 11.1.1 Lifting Points .................................................................................................. 1 - 21.1.2 Table of Load Carrying Capacity in kg .......................................................... 1 - 31.2 Use and Assembly Instruction for Swivels ............................................... 1 - 41.3 Particular Risks ........................................................................................... 1 - 71.3.1 Remove Package .......................................................................................... 1 - 71.3.2 Cleaning bright Steel Surfaces ...................................................................... 1 - 71.3.3 Oil Soiling ...................................................................................................... 1 - 71.4 Alignment of the Control Container........................................................... 1 - 81.5 Slurry Pump Transport ............................................................................... 1 - 9

2 Installation................................................................................... 2 - 12.1 Site Set Up.................................................................................................... 2 - 12.1.1 Jacking Shafts and Reception Shafts............................................................ 2 - 12.2 Construction Site Set Up ............................................................................ 2 - 22.2.1 Survey for shaft direction and depth.............................................................. 2 - 22.2.2 Position jacking frame in the shaft ................................................................. 2 - 32.2.3 Place control container behind the shaft ....................................................... 2 - 3

3 Connecting Control Container .................................................. 3 - 13.1 Electrical Connection.................................................................................. 3 - 13.1.1 Control Container .......................................................................................... 3 - 13.1.1.1 Explanation Connection sheets 1 and 2................................................................... 3 - 23.1.1.2 Additional Text Connection sheet 2;.......................................................................... 3 - 2

3.2 Hydraulic Connection ................................................................................. 3 - 43.2.1 Installation ..................................................................................................... 3 - 43.2.1.1 Preparation................................................................................................................ 3 - 43.2.1.2 Mounting Hydraulic Hoses ........................................................................................ 3 - 43.2.1.3 Installing Hydraulic Hoses ......................................................................................... 3 - 6

3.3 Connecting Feed and Slurry lines (optional) ............................................ 3 - 73.3.1 Connecting to the Bypass.............................................................................. 3 - 73.3.2 Quick Couplings for Feed- and Slurry Lines (optional) .................................. 3 - 8


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M-1437CTransport, Set Up, Connection


M-1437CTransport

1 Transport

1.1 Safety Instructions

Principally observe safety warnings of the producer prior to commissioning of lifts and hoist plants.

When exchanging heavy machine parts, see to it that they are carefully fastened to lifts and secured.

Use only appropriate and technically faultless hoists as well as load carrying devices with a sufficient capacity.

Reliably secure loads.

Order only experienced personnel to deal with the slinging of the loads.

DANGERPrior to lifting any section of the machine, the site operator must ensure the lifting equipment used is safely installed on firm ground, with adequate capacity to lift the required load and all site safety precautions are observed.

NOTEDimensions and Weights see technical data tunnelling equipment.

DANGERNever work or stand under suspended loads.

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 III - 1 - 1

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M-1437CTransport

1.1.1 Lifting Points

Use only suitable lifting points for transport of the equipment. All lifting points are marked red.

DANGERImproper slinging of loads, damaged ropes, chains and slings may cause serious accidents.

CAUTIONWear your personal safety equipment during all transportation work.

DANGERFix lifting equipment only to the designated lifting points (red-marked).

Using other lifting points may result in parts falling off the equipment. Not using the designated lifting points may also result in exclusion of liability.

Edition: April 2009 © Herrenknecht AG, Schlehenweg 2 III - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020Version: 0

M-1437CTransport

1.1.2 Table of Load Carrying Capacity in kg multi-rope slinging chain DIN 5688 - 8 grade 8 (Grade 80)

*chains - nominal diameter, not standard

2- cords tunnelling machine with 2

suspension brackets

4- cords e.g. Container, settlement

tank, jacking frame tunnelling machine with 4

suspension brackets

angle of inclination β 0 - 45° 45 - 60° 0 - 45° 45 - 60°

capacity factor 1,4 1 2,1 1,5

chain - nominal diameter in mm The specified values obtain to symmetrical load

6 1400 1000 2100 1500

7* 2200 1600 3300 2400

8 2800 2000 4250 3000

10 4500 3200 6700 4750

13 7100 5000 10000 7500

16 11200 8000 17000 11800

18 14000 10000 21200 15000

19* 16000 11300 24000 17000

20 18000 12500 26500 18000

22 21200 15000 32000 22400

26 28000 20000 40000 30000

32 45000 32000 63000 47000

NOTEThe length of the chains must be selected to reach an angle of inclination "β" between 0 and 45 degrees.The best security will be reached using an angle of inclination "b" between 0 and 45 degrees.


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M-1437CTransport

1.2 Use and Assembly Instruction for SwivelsFor attachment swivels and attachment points, bolt-on and weld-on For the selected attachment points the general rules forprevention of acci-dents are valid.

• Demages of attachment pionts due to sharp edged loading have to be excluded.

• The position of the lifting point has to be provided in that case, that the plane surface is able to absorb the expected load transmission.

For attachment point TAWGK/EAWK it is necessary • The contact surfaces must be plane.• The flat bearing surface must at least correspond to the diameter meas-

ure “b” of the applied attachment swivel.• tighten to stopping face with spanner as per DIN 895 or 894.• secure if required with Loctite™material. min. thread depth:

NOTE

NOTE• All attachment swivels and attachment points have to be in-

spected by an authorized person at least once a year.• The used links for lifting have to be inspected on wear and

elongation in accordance to the general rules for pre-ven-tion of accidents.

CAUTIONAn inspection of ability of utilization and function has to be effected before every use. For example: strong corro-sion, wear, cracks in the welding zone, deformings, tight screws etc.

in steel 1 x d

in cast steel 1,25 x d

in aluminium 2 x d

in aluminium - magnesium alloy 2,5 x d


M-1437CTransport

* contact the manufacturer before application The corresponding SWL are in tabular and graphical form per correspond-

ing nominal size are printed in our catalogue.They must not exceed.

It is valid for all attachment swivels:In case that the maximum clearances >S<, which are shown in the follow-

ing table are exceeded, the swivels must not be used anymore.

Temperature range for attachment swivels

> -40¡C <=200¡C = 100% WLL

>200¡C <=300¡C = 90% WLL

>300¡C <=400¡C = 75% WLL*

CAUTION

Before attaching put link in the right position

right application wrong application


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M-1437CTransport

Max. clearance be-tween upper and low-er part >S<

Nominal size Max. >S<

0,5 - 1,4 t 1,5 mm2,0 - 2,5 t 1,5 mm3,0 - 6,7 t 2,4 mm8,0 - 10,0 t 3,2 mm15,0 t 4,0 mm20,0 - 30,0 t 4,5 mm

Temperature range for attachment pointsfor TAPS the EN-Standard is valid

>-40°C ≥ +200°C 100% WLL

>200°C ≥ 300°C 90% WLL

>300°C ≥ 400°C 75% WLL


M-1437CTransport

1.3 Particular Risks1.3.1 Remove Package

Parts of tunnelling machine are packed in wooden boxes. Remove packaging at job site. Secure producing nails.

Job site takes the responsibility for dumping or reuse the wood.

1.3.2 Cleaning bright Steel SurfacesIf bright steel surfaces are protected with preservation wax, clean them

with thinners and cloths. Pay attention to sufficient ventilation. Collect used cloths and dispose of it in accordance with the environmental

regulations.

1.3.3 Oil Soiling When connecting hydraulic lines and refilling the hydraulic system oil

leaks may occur. Collect the hydraulic oil at the expected leakage points using suitable

equipment. Clean the location carefully and dispose oil and dirty cloth in accordance

with the environmental regulations.

WARNINGHazardous gases are expected, when working with thinners.Wear safety outfit such as safety goggles, safety gloves, safety shoes, safety clothing and respirator when working with thinners.


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M-1437CTransport

1.4 Alignment of the Control Container• In principle the control container may be unloaded only by means of a

crane. Sufficiently dimensioned chains or wire ropes have to be used, which must be hang up into the ISO standard corners.

• Pay attention that the control container may not be bent during transport. (danger of running out operating fluids!)

• It is very important that the control container is optimally aligned before commissioning. Not optimally alignement can cause in malfunctions of the installed equipment.

NOTEFor dimensions an weight of the control container see techni-cal data of the respective control container


M-1437CTransport

1.5 Slurry Pump Transport4 suspension brackets are welted to the base frame of the slurry pump for

transport. Use only this suspension brackets for slinging the load carrying devices.

Other lifting points (e.g. lifting tackles on the electric motor) are only de-signed to lift the according part and must not be used for transport the whole slurry pump.

Pay attention that installed parts e.g. grease pump or terminal box will be not damaged.


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M-1437CTransport


M-1437CInstallation

2 Installation

2.1 Site Set Up2.1.1 Jacking Shafts and Reception Shafts

Note the following for preparation of the jacking pits:• Launching shaft must be perpendicular; otherwise the installation of the

jacking frame can be problematic.• Seal the launching shaft thoroughly from the outside, so that the shaft is

stable when jacking force is applied. In case of a poor soil mechanical conditions, additional measures (e.g. injection outside of the shaft) may be necessary to stabilise the shaft.

• Clearance space must be provided for the launching seal in the launch-ing shaft. (a depression in the concrete)

• Reinforce the starting shaft that concentrated jacking force can be ab-sorbed. (see technical data jacking frames dimension E).

• The bottom of the starting shaft must be deeper than the planed tunnel axis. The height between the tunnel axis and the shaft bottom is speci-fied in technical data jacking frames (dimension G).

• The entryway openings in the starting and reception shafts must be of lean concrete (max. B 15).


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M-1437CInstallation

2.2 Construction Site Set Up2.2.1 Survey for shaft direction and depth

Suggested Surveying Procedure for Shaft Location

1) Assemble the laser at the proper height and align approximately. 2) Centre the theodolite over the measuring point (M) and level. The

measuring point can also be located behind the trench. 3) Aim the station staff (point of aim). 4) Transit the theodolite telescope and sight the target. 5) Slide the sighting disk with the tripod alignment and the horizontal and

lock in position. 6) Extend the alignment into the trench by means of the theodolite an align

the laser..

11) Check step 8 again, correct errors, repeat steps 9 and 10.

I Target

II Theodolite

III Station Rod

IV Tripod

VLaser Mounting De-vice

VI Tracking Slide

VIISkate Adjustment of Height

VIII Laser

IX Laser Beam

7) Extend the alignment into the trench by means of the theodolite an align the laser

8) Exchange the theodo-lite with the target board and sight the station staff (point of aim).

9) The vertical axis of the theodolite must be aligned with the laser beam.

10) Align the laser beam by adjusting direction.


M-1437CInstallation

2.2.2 Position jacking frame in the shaftLift the mounted jacking frame at the red marked suspension brackets

(number of lifting points and location see technical data) and release the jacking frame into the shaft.

2.2.3 Place control container behind the shaft

For security it is necessary, that the operator has a good examination into the starting shaft. Therefore position the control container with the window to the shaft as near as possible.

Connect the electrical system and ground the control container (see chap-ter „Connecting Tunnelling Equipment“).

For pipe jacking us-ing a container without hoist unit the control container has to be placed behind the starting shaft. The container should not touch shaft rings. In this case use founda-tions to raise the control container.


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M-1437CInstallation


M-1437CConnecting Control Container

3 Connecting Control Container

3.1 Electrical Connection

3.1.1 Control ContainerThe electrical connection is made directly at the main switch cabinet of the

container and main sswitch cabinet of the Tunnelling machine by means of a cable (see connection sheet 1 and 2 following page). The end of the cable is connected directly (do not use a pin and socket connector) to the existing terminals. The cable must be provided by the customer.

A connecting cable appropriate TBG / VDE must be used.Pin and socket connections are only allowed in the launching shaft.

DANGERWork on the electrical system and equipment of the Tun-nelling equipment may only be carried out by a skilled electrician or by instructed personnel under the supervi-sion and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.Before starting the equipment take a measurment of insu-lation of the main switch cabinet and the lead! Pay attention to national rules.

DANGEREnsure that the container is grounded by connecting the PE (protection earth) of the terminals with an earth rod by means of an earth lead.The VDE regulations are to be observed under all circumstances.When using a generator, a stable voltage of 400 ± 10% must be provided. Minimum generator power 400 kVA.Faulty connections endanger the electrical and electronic equipment as well as increasing the risk of accident for personal.


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3.1.1.1 Explanation Connection sheets 1 and 2• Cable cross section dimensioning appropriate the regulations. (Pay at-

tention into nominal current and voltage drop)• Pay attention to the local regulations.• Additional potential correction serves to reduction of passive earth pres-

sure (RE near 0 Ohm)• Provided reaction in case of short circuit and fault current, necessary

protection against inductive and capacitative influences (EMV)• That the fault-current protective switches in the container are working ef-

fective, the additional potential correction and the passive earth pressure (RE near 0 Ohm) are necessary.

• The effectiveness of the protective switches must be checked periodical.• Pay attention to the local inveshgation regulations

3.1.1.2 Additional Text Connection sheet 2;

CAUTIONThe function of the fault-current protective switch in the feed from the supply main is not ensured.The fault-current protective switch in the container keeps its function.



Block Diagram Electrical Connection 1 and 2

Connection sheet 1

connection sheet 2


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3.2 Hydraulic ConnectionFunction and service life of hydraulic equipment depends on proper

handling.Pay attention to the following guidelines.

• Commissioning and maintenance of hydraulic equipment (VDI 3027)

• German standards for "hydraulic equipment" DIN 24346• ISO standards ISO 4413

3.2.1 Installation

3.2.1.1 Preparation

Take care of:

• A clean environment, when assembling hydraulic parts.• Contamination and moisture of the hydraulic oil. Use only clean and dry

hydraulic oil.• Cleanliness of the hydraulic tank. Ensure that no ambient dirt can enter

into the hydraulic tank.

3.2.1.2 Mounting Hydraulic HosesTo avoid tension and lateral forces on pipe lines and devices the parts ha-

ve to be assembled without force.

CAUTIONFill the tank by using a filter station that uses filters which have the minimum sensitivity of the built-in equipment filters.

Use only the fill connector (quick coupling 28L size 6) to fill up or top up hydraulic oil into the hydraulic power pack

CAUTIONDon't use putty or hemp for sealing. They can contaminate the hydraulic oil. As a result of contaminated hydraulic oil, malfunctions can follow.



In hydraulics, hoses are used to connect points which move in relation to one another. In addition, hoses help to dampen physically transmitted noi-se. Pay attention to the following notes when installing hydraulic hoses.

• Lay the hoses with the connecting passage in such way, to compensate for a possibility of shortening the hose.

• Do not twist during installation• Do not bend the hose excessively• Use elbows or angle fittings• Pay attention to minimal bending radius.The minimum bending radius refers to the rigid installation of hoses. If mo-

vement of the hose in a bending radius must be repeated often (continuous operation), it is recommended to select the largest bending radius possible.

Before putting into operation hydraulic pumps check direction of rotation.

wrong right wrong right

CAUTIONEnsure that hoses are free of buckling. If buckling should occur, use external spiral support.

CAUTIONNever use cleaning rags or other fibrous materials to cover hydraulic lines or hoses.

Cleaning rags and other fibrous materials are a hazard to hydraulics.

twisted


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3.2.1.3 Installing Hydraulic Hoses

1) Lay hydraulic hose between the hydraulic power pack and the consu-mer. Do not open the hose caps.

2) Open the cap of the hydraulic hose at the side of the hydraulic power pack. Let the other end of the hydraulic hose closed.

3) Screw off the plug at the connection port of hydraulic power pack and screw on the hydraulic hose. Collect hydraulic oil and dispose in accor-dance with environmental regulations.

4) Open the plug of the consumer or the next hydraulic hose which should be connected.

5) Open the cap of the installed hydraulic hose and screw it on to the con-sumer or the next hydraulic hose.

6) Check that all hydraulic hoses are tightened correctly and all screw joints are sealed.

7) Check the oil level of the hydraulic power pack. Top up if necessary. 8) Operate the hydraulic power pack without load, until the air has es-

caped from the hydraulic system. Carefully loosen the screw joint which is positioned up top or the vent screw if necessary (see chapter „Putting into operation“).

NOTEInstall hydraulic hoses in the way that they• run parallel• do not scour• are not twisted• do not hit• do not have a tight bend radius

CAUTIONHydraulic hoses are filled with hydraulic oil. Therefore:

• Never open hydraulic hoses at both si-des simultaneously.

• Collect waste hydraulic oil and dispose in accordance with environmental regulations.



3.3 Connecting Feed and Slurry lines Seen in the direction of tunneling the slurry line is on the left, the feed line

is on the right.

3.3.1 Connecting to the Bypass

Preperation 1) Properly clean the pipe ends on approx. ½ the coupling´s width and remove the damages (longintudinal scratches, cracks, etc.) 2) Remove sharp edges and burrs from the pipe faces.

Assembly 1) Mark the half-coupling width symmetrically on both pipe ends. 2) Slide the coupling (never turn if teeth are gripping) over the pipe ends. 3) Push the pipes, axially in line, against each other. 4) Possition the coupling centrally over junction (marks visible from both

sides). 5) Thighten the bolts alternately and uniformly by means of torque wrench.

The prescribed torque value, valid for radially riged pipes, is indicated on each coupling

Desassembling 1) Undo the screws until the end of the thread is in the cross bar. 2) Expand the casing´s opening. 3) With a srewdriver, release the gripper ring from ther anchoring at sever-

al point of the circumference. 4) Remove the coupling axially from the pipe end.

CAUTIONNever turn a coupling as long as the anchoring teeth bite the pipeThe couplings must be free of any dirt before re-use. Dirty couplings will result in leakage and broken connections.Lubricate the clamp screws after each use.


Version: 0


3.4 Quick Couplings for Feed- and Slurry Lines (optional)

When assembling quick couplings, ensure that• the surface of the pipe between pipe end and rove is not damaged, and

that the pipe end is not burred.• the sealing surface is free of loose soil and grease.• the grove is clean.Place the sealing ring on the pipe ends and lubricate the outer circumfer-

ence lightly. then place the coupling on top of this and close.

1 Feed- / slurry line

2 Snap join

3 Gasket



3.5 Connection of Feed- and Slurry Lines to Control Container3.5.1 Overview Connection

Indication Note1 Supply feed Line from feed pump to flow meter

2 Delivery Feed Line from flow meter into the tunnel

3 Delivery Slurry Line from flow meter to setting tank

4 Supply Slurry Line from slurry pump to flow meter


Version: 0


3.6 Connection Feed PumpOverview Connections

3.7 Connection Slurry Pump3.7.1 Overview Connections

Indication Note1 Suction Line Supply from sedimention tank

2 Pressure Line Connection to Flow meter

Indication Note1 Suction Line Supply from the tunnelling machine

2 Pressure LineConnection to Flow meter (in the container) or slurry pump in the shaft

3 Connecting box Electrical connection power supply


M-1437COperating Elements, Commissioning, Operating, Troubleshooting

IV) Operating Elements, Commissioning, Operating, Troubleshooting

1 Operating Elements, Alarm and Indicating Devices ............... 1 - 11.1 Overview Control Stand.............................................................................. 1 - 11.2 Operating Areas on Control Panel............................................................. 1 - 21.2.1 Control Tableau Layout ................................................................................. 1 - 31.3 Computer...................................................................................................... 1 -171.3.1 Overview Pressure gauges ........................................................................... 1 -171.4 Monitor Guidance System .......................................................................... 1 -181.5 Video Monitor............................................................................................... 1 -181.6 Loud Speaker............................................................................................... 1 -181.7 Displays on the Monitor.............................................................................. 1 -191.8 Main Distribution ........................................................................................ 1 -211.8.1 Multifunction Display ..................................................................................... 1 -221.9 Shaft Tableau ............................................................................................... 1 -23

2 Putting into Operation................................................................ 2 - 12.1 First Putting into Operation........................................................................ 2 - 12.1.1 Power supply ................................................................................................. 2 - 12.1.2 Hydraulic........................................................................................................ 2 - 12.1.3 Initiation of the Hydraulic Power Pack ........................................................... 2 - 22.1.3.1 Putting in Operation Crew ......................................................................................... 2 - 22.1.3.2 Test run ..................................................................................................................... 2 - 22.1.3.3 Tightness control ....................................................................................................... 2 - 32.1.3.4 Air Bleed.................................................................................................................... 2 - 42.1.3.5 Temperature Monitoring ............................................................................................ 2 - 42.1.3.6 Oil level...................................................................................................................... 2 - 52.1.3.7 Particular information ................................................................................................ 2 - 62.1.4 Control Container with MH-Visualisation ....................................................... 2 - 62.1.5 Pressure Adjustment Jacking Cylinders ........................................................ 2 - 72.2 Testing the Hydraulic and Electrical System of Tunnelling Machine..... 2 -102.2.1 Check Switch over Sequence for Gate Valves............................................. 2 -112.3 Instructions for Revolution Switching Stage 1 - Stage 2......................... 2 -122.4 Daily commissioning................................................................................... 2 -14

3 Operating Control Container .................................................... 3 - 13.1 Steering Control .......................................................................................... 3 - 13.1.1 Assembly ....................................................................................................... 3 - 13.1.2 Steering Movements...................................................................................... 3 - 1


Version: 0

M-1437COperating Elements, Commissioning, Operating, Troubleshooting

3.1.3 Steering Movements in normal Ground Conditions ....................................... 3 - 23.1.4 Steering Movements in hard Ground Conditions ........................................... 3 - 33.1.5 Steering Information when working with Rock Cutting Head ......................... 3 - 33.1.6 Guidelines ...................................................................................................... 3 - 43.1.7 Notes............................................................................................................. 3 - 43.2 Steering Control ........................................................................................... 3 - 53.2.1 Assembly........................................................................................................ 3 - 53.2.2 Steering Movements ...................................................................................... 3 - 53.2.2.1 Steering Movements In Normal Ground Conditions .................................................. 3 - 63.2.3 Steering Movements in Hard Ground Conditions........................................... 3 - 73.2.4 Steering Information when working with Rock Cutting Head ......................... 3 - 83.2.5 Guidelines ...................................................................................................... 3 - 83.2.6 Notes.............................................................................................................. 3 - 93.3 Operating tunnelling machine .................................................................... 3 - 93.4 Start up Pipe Jacking .................................................................................. 3 -103.5 Jacking Procedure ....................................................................................... 3 -113.6 End of Jacking Procedure........................................................................... 3 -123.7 Cutting Wheel ............................................................................................... 3 -133.7.1 Roll Correction ............................................................................................... 3 -133.7.2 Blocked Cutting Wheel................................................................................... 3 -143.8 Use of Water Circuit Whilst Pipe jacking ................................................... 3 -153.8.1 Bypass operating ........................................................................................... 3 -163.8.2 Pipe jacking.................................................................................................... 3 -163.8.3 Flow Rate Diagram ........................................................................................ 3 -173.9 Operating High pressure Water System .................................................... 3 -183.9.1 Operating Tunnelling Machine with High pressure Water Nozzles ................ 3 -183.9.2 Tunnelling starts............................................................................................. 3 -183.9.3 Tunnelling ends.............................................................................................. 3 -183.10 Emergency Ball Valve or Emergency Slide Valve..................................... 3 -193.10.1 Switch over Sequence of Emergency Ball Valve (Emergency Slide Valve)... 3 -19

4 Trouble Shooting ....................................................................... 4 - 14.1 Overview Error ............................................................................................. 4 - 14.1.1 Messages Visualization.................................................................................. 4 - 14.2 List of Possible Faults ................................................................................. 4 - 2


M-1437COperating Elements, Alarm and Indicating Devices

1 Operating Elements, Alarm and Indicating Devices

1.1 Overview Control Stand

1 Tableau

2Printer (behind the door)Computer

3 Monitor Visualisation

4 Monitor laser target

5 Monitor measurement

6 Pressure gauge

7 Main distribution gauges

8 Connections for computer (USB, keyboard...)

9 Socket-outlet

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© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 IV - 1 - 1

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1.2 Operating Areas on Control Panel

1.1 Emergency stop 1.6 Compressed air equipment 1.11 FCE automatic1.2 START-STOP push buttons 1.7 Cutting wheel 1.12 Roll correction1.3 Conveyance system 1.8 Steering cylinders 1.13 Pipe Thruster1.4 Jacking cylinders 1.9 Communicating pipe 1.14 Reserve1.5 Interjack stations 1.10 Bypass pump


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Art. Nr. 30139545

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Edition: April 2009 © Herrenknecht AG, Schlehenweg 2 IV - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020Version: 0


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Version: 0


1.2.1 Pos. 1.1: Emergency stop

1.2.2 Pos. 1.2: START - STOP push buttons

Function

By pressing the emergency stop button, all equipment will be stopped. Only the lighting, the hoist unit and the compressed air service unit will stay in operation.Twist to reset before attempting to start again.CHECK DAILY

Function

Press push button to switch on the control voltage supply of the machine. The lamp in the push button illuminates. Press push button again to switch off the control volt-age supply of the machine. The lamp in the push button goes out.

Pilot lamp Illuminates when steering pump is in operation

Press push button to switch on the jacking pump 1. The lamp in the push button illuminates. Press push button again to switch off the jacking pump 1. The lamp in the push button goes out.





Press push button to switch on the cutting head pump. The lamp in the push button illuminates. Press push button again to switch off the cutting head pump. The lamp in the push button goes out.

Press push button to switch on the bentonite pump. The lamp in the push button illuminates. Press push button again to switch off the bentonite pump. The lamp in the push button goes out.

Press push button to switch on the laser. The lamp in the push button illuminates. Press push button again to switch off the laser. The lamp in the push button goes out.

Press push button to switch on the waste water pump 1 to automatic operation. (The waste pump is started or stopped by a float switch) The lamp in the push button is blinking. Press push button again to switch off the automatic operation of the waste water pump 1. The lamp in the push button goes out.Automatic operation of the waste water pump is only possible if the key switch of the remote con-trol in the tunnelling machine is set to the „OFF“ position.

Press push button to switch on the waste water pump 2 to automatic operation. (The waste pump is started or stopped by a float switch) The lamp in the push button is blinking. Press push button again to switch off the automatic operation of the waste water pump 2. The lamp in the push button goes out.Automatic operation of the waste water pump is only possible if the key switch of the remote con-trol in the tunnelling machine is set to the „OFF“ position.

Press push button to switch on the grease pump of the tunnelling machine. The lamp in the push button illuminates.Press push button again to switch of the grease pump of the machine. The lamp in the push button goes out.


Version: 0


1.2.3 Pos. 1.3: Conveyance system

Press push button to switch on the automatic control of the steering cylinders (FCE) The lamp in the push button illuminates.Press push button again to switch of the automatic control of the steering cylinders (FCE) The lamp in the push button goes out

1 shaft slide valve feed line 8 centre slide valve

2 slide valve feed line 9 slurry slide valve suction port

3 medium pressure valve 2 10slide valve slurry line in the pressure chamber

4 medium pressure valve 11 slurry slide valve

5 annulus slide valve 12 bypass

6 invert slide valve 13 tunnel slide valve

7slide valve feed line in the pressure chamber 14 shaft slide valve slurry line

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Function

Press push button to open the according valve. The lamp in the push button is illuminating.The lamp in the push button „valve close“ goes out.

Press push button to close the according valve. The lamp in the push button is illuminating.The lamp in the push button „valve open“ goes out.

Press the push button to switch the slurry circuit to au-tomatic operation. The slurry circuit is controlled via the limit values of cutting wheel and thrust cylinders. The lamp in the push button lights up. Press the push button again to switch automatic opea-tion off. The lamp in the push button goes out.

Selection switch to preselect the cutting head nozzles or the annulus nozzles for the automatic operation of the bypass.

Rotary switch control for varying the rotational speed of the feed pump P1.1.Turn the rotary switch clockwise (direction of 100%) to start the pump.Turn the rotary switch back over the switching resist-ance to the stop sign ( )=„STOP“ to switch off the pump.



Version: 0


Function


Rotary switch control for varying the rotational speed of the slurry pump 2.1.Turn the rotary switch clockwise (direction of 100%) to start the pump.Turn the rotary switch back over the switching resist-ance to the stop sign ( )=„STOP“ to switch off the pump.

P1.1Rotary switch control for varying the rotational speed of the slurry pump 2.2.Turn the rotary switch clockwise (direction of 100%) to start the pump.Turn the rotary switch back over the switching resist-ance to the stop sign ( )=„STOP“ to switch off the pump.

P2.2




Function

P2.3


Jogging operationThe flushing of the level points. will stay in operation as long as the push button is pressed.

Press push button to start the automatic flushing of the level points. The lamp in the push button illuminates.Press push button again to stop the automatic flush-ing of the level points. The lamp in the push button goes out


Version: 0


1.2.4 Pos. 1.4: Jacking Cylinders

Function

Jacking cylinders extend The lamp in the push button is illuminating.The lamp in the push button preselection retract goes out.Preselection jacking cylinder extend is only possi-ble if the jacking cylinders are stopped..

Preselection Jacking cylinders retract. The lamp in the push button is illuminating.The lamp in the push button preselection extend goes out.Preselection jacking cylinder retract is only possi-ble if the jacking cylinders are stopped.

Press push button for fast retract of the jacking cylin-ders.

After preselection forward or return, the speed of jack-ing cylinders will be adjusted by turning the rotary switch.Turn the rotary switch back over the switching resist-ance to the stop sign ( )=„STOP“ to stop the jack-ing cylinders.The total sum of both adjustments is shown on the monitor in display advance as a red beam. (0 - 100%).



1.2.5 Pos. 1.5: Interjack Stations

Function

Rotary switch to infinitely adjust the revolution of the jacking pump 2. Turn the rotary switch back over the switching resist-ance to the stop sign ( )=„STOP“ to stop the jack-ing pump 1.

Pressing the push button start the automatic opera-tion of the interjack stations. The lamp in the push button is illuminating.

Pressing the push button starts the operation of the preselected interjack station The lamp in the push button is illuminating.

I bis IX

Push button add the interjack stations I to IX which are connected to the jacking pump 1 in the tunnelling machine. Preselection is only possible if interjack stations and jacking cylinders are stopped.

I bis IXPush button add the interjack stations I to IX which are connected to the jacking pump 2 in the control container. Preselection is only possible if interjack stations and jacking cylinders are stopped.


Version: 0


1.2.6 Pos. 1.6: Compressed air control unit

NOTEShort pressing of a push button: Preselection interjack sta-tion extend (push button will illuminate).Pressing push button for a longer time (min. 3 seconds) change over to release the interjack station if this function is present.

Function

I Pressing the push button starts the compressed air control unit 1 and stops the compressed air control unit 2 simultaneously.The lamp in the push button is illuminating.The lamp in the push button „compressed air control II“ goes out

+ -Switches the nominal rate of the compressed air unit 1- = pressure reducing+ = pressure raising

II Pressing the push button starts the compressed air control unit 2 and stops the compressed air control unit 1 simultaneously.The lamp in the push button is illuminating.The lamp in the push button „compressed air control I“ goes out

+ -Switches the nominal rate of the compressed air unit 2- = pressure reducing+ = pressure raising



1.2.7 Pos. 1.7: Cutting Wheel

Function

Press push button: Preselection to start the cutting head in anticlockwise rotation. The lamp in the push button is illuminating.The lamp in the push button preselection „clockwise“ goes out.Preselection of direction of rotation is only possi-ble, when the cutting wheel is stopped.

Press push button: Preselection to start the cutting head in clockwise ro-tation. The lamp in the push button is illuminating.The lamp in the push button preselection „anticlock-wise“ goes out.Preselection of direction of rotation is only possi-ble, when the cutting wheel is stopped.

Rotary switch control for infinitely varying the rotation-al speed of the cutting head from 0 rpm up to max. Turn the rotary switch clockwise (direction of 100%) to start the cutting wheel rotation.Turn the rotary switch back over the switching resist-ance to the stop sign ( ) to stop cutting wheel rota-tion.

Indicates a roll over right of the tunnelling machine by illuminating.

Indicates a roll over left of the tunnelling machine by il-luminating.


Version: 0


Press push button to activate the hydraulic crusher mode (torque switching). The button only can be activated in jogging operation and is automatically deactivated after a defined time.

Press push button to switch over cutting head speed from step I to step II. The lamp in the push button is illuminating if the cutting head speed is set to step II.

Press push button agein to return to step I. The lamp in the push button goes out.

Grease bridgingBy operating the switch, the tunnelling machine can be operated without grease supply of the cutting wheel drive for a short time.NOTE:Operating the machine in grease bridging mode is shown on the machine log.

In this mode, the cutting wheel can only be moved at crawl speed (approximately 0.5 rpm). Maintenance work on the cutting wheel can be performed in this position.

CAUTIONThe key of the switch must not be inserted during opera-tion of the tunnelling machine. It has to be deposited by the site manager or any responsible person.Grease bridging may only be switched on after arrange-ment with the site manager or the Herrenknecht AG.

WARNINGIf grease bridging is active for a longer time, damages at sealing system and gearbox can occur. (e.g. water drain-age into gearbox, charring of sealings, destruction of bearing by sand drag-in).



1.2.8 1.8: Steering cylinders

Function

Extend the according steering cylinder as long as the push button is pressed. The lamp in the push button is illuminating as long as push button is pressed.

Retract the according steering cylinder as long as the push button is pressed. The lamp in the push button is illuminating as long as push button is pressed.


Version: 0


1.2.9 Pos. 1.9: Communicating Pipe

Function

Jogging operationThe flushing of the communicating pipe will stay in operation as long as the push button is pressed.

Pressing the push button opens the communicating pipe The lamp in the push button is illuminating.The lamp in the push button „communicating pipe close“ goes out.

Press the push button to close the communicating pipe The lamp in the push button is illuminating.The lamp in the push button „communicating pipe open“ goes out.

NOTEThis is a general overview of the control panel. Not every tunnelling machine uses all functions. You are only able to use the functions, which are necessary for your machine.



1.2.10 Pos. 1.10: Bypass Slurry pump

1.2.11 Pos. 1.11: FCE Steering - automatic

Function

Press the push button to open the bypass of the slurry pumps.

Press the push button to close the bypass of the slurry pumps.

Function

Press push button to switch on the automatic control of the steering cylinders (FCE) The lamp in the push button illuminates.Press push button again to switch of the automatic control of the steering cylinders (FCE) The lamp in the push button goes out

Press the push button in conjunction with the steering cylinders to align the second shield articulation. The lamp in the push button goes out.


Version: 0


1.2.12 Pos. 1.12: Roll correction

Function

Press the push button to retract the roll cylinder. The cylinder is moved as long as the button is pressed. The lamp lights up when the button is pressed.

Press the push button to advance the roll cylinder. The cylinder is moved as long as the button is pressed. The lamp lights up when the button is pressed.



1.2.13 Pos. 1.13: Pipe Thruster

Funktion

Pilot lamp Illuminates when jacking cylinders and interjack sta-tions are operated by the external shaft tableau.

This selector switch is used for selecting the advance direction.

Pressing push button:The interlock will be opened The lamp in the push button is illuminating.

Pressing push button:The interlock will be closed. The lamp in the push button is illuminating.

Pressing this push button opens or closes the jaws of the Pipe Thruster. The lamp in the button lights up.


Version: 0


1.3 Main Distribution

1 Multifunction display 7 Lamp test

2 Reset / Fault 8 Reset

3 Fault phase sequence 9 Horn

4 Reset RCD 10 Voltage OK

5 Container lighting internal / external 11 Motor OFF

6 Control voltage ON / OFF 12 Motor ON

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Art. Nr. 3013 9652

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510

DANGERThe main distribution of the control container is partly still on circuit.For this reason it is not sufficient to switch off the key-type switch.The main switch of the equipment has to be switched off and has to be secured against reconnection.



Button to invoke programming mode and to confirm the entries

In measuring mode: Scrolls to the mains variable displayed last.In programming mode: Scroll to the previous function or reduce the parameter value. In measuring mode: Scroll to the next mains variable to be displayed.In programming mode: Scroll to the next function or increase the pa-rameter value

Alphanumeric LCD display to - represent the configuration parameters- represent all measured variables

Mains variables that can be displayedNo Display 1 Display 2 Display 3 Comment

1 L1 L2 L3 Voltage of the individual phases

2 VL12 VL23 VL31 Voltage between the individual phases

3 AL1 AL2 AL3 Current of the individual phases

4 An AL.n Alarm messages without utilization

5 WL1 WL2 WL3 Effective power of the individual phases

6 PFL1 PFL2 PFL3 Power factor of the individual phases

7 VARL1 VARL2 VARL3 Apparent power of the individual phases

8 VAL1 VAL2 VAL3 Reactive power of the individual phases

9 VA system W system VAR system Reactive power, effective power, and apparent power in the system

10 VA dmd sys-tem W dmd system VAR dmd sys-

temReactive / effective power and frequency in the system

11 W dmd Max maximum effective power in the system

12 V LN dmd AL.U PF System Display 1 and 2 without utilization Display 3: Power factor in the system

13 A MAX Maximum current in the 3 phases


Version: 0


Funktion

Reset / fault Pressing this push button resets error messages.

Fault phase sequence

Reset RCD (FI)

This selector switch is used for switching the internal / external lighting on.

Voltage OK

Pressing this push button switches off the motor. The lamp in the button lights up.

M



Pressing this push button switches on the motor. The lamp in the button lights up.

Acoustic fault indication

Indicates faults by illuminatingPressing the push button resets only the fault indica-tions on the control panel.It does not remove the faults.

Press the lamp check button, this will illuminate all warning lamps and push button controls on the control panel to verify bulb function.CHECK DAILY

Turning key to position switch off control voltage

Turning key to position switch on control voltage

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1.4 Shaft Tableau

Funktion

Operating tableau intern ON

Pressing the push button I - III switches on the related thrust pump. The lamp in the button lights up. Pressing the push button again switches off the thrust pump. The lamp in the button goes out.

A U S

N O T


HERRENKNECHT

3012 1744

I - III



Pressing the push button activates the winch. The lamp in the button lights up.

Pressing the push button switches on the machine po-wer supply. The lamp in the button lights up. Pressing the button again switches off the machine po-wer supply. The lamp in the button goes out.

Maintenance switch: By turn the maintenance switch the aggregates in the control container and in the tunnelling machine stops, so maintenance works can be done.By turn back the maintenance switch the aggregates runs again.

Press the lamp check button, this will illuminate all warning lamps and push button controls on the control panel to verify bulb function.CHECK DAILY

Indicates faults by illuminatingPressing the push button resets only the fault indications on the control panel.It does not remove the faults.

Preselection Jacking cylinders retract. The lamp in the push button is illuminating.The lamp in the push button preselection extend goes out.Preselection jacking cylinder retract is only possible if the jacking cylinders are stopped.

Jacking cylinders extend The lamp in the push button is illuminating.The lamp in the push button preselection retract goes out.Preselection jacking cylinder extend is only possible if the jacking cylinders are stopped.

I


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Speed adjusting roughly

Speed adjusting finely

By pressing the emergency stop button, all equipment will be stopped. Only the lighting, the hoist unit and the compressed air serv-ice unit will stay in operation.Twist to reset before attempting to start again.CHECK DAILY

Pressing push button Pipe bracke will be opened. The lamp in the push button is illuminating.

Pressing push button Pipe bracke will be closed. The lamp in the push button is illuminating.

Pressing push button:The interlock of the jacking cylinders will be opened The lamp in the push button is illuminating.

Pressing push button:The interlock of the jacking cylinders will be closed. The lamp in the push button is illuminating.

Display in bar



Push button add the interjack stations I to IV which are con-nected to the jacking pump in the control container. Preselection is only possible if interjack stations and jacking cylinders are stopped.

I - IV


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1.5 Computer

1.6 Pressure gaugesPosition 3: Pressure gaugeThe analogue pressure gauge is showing the actual pressure

of the hydraulic pump.

1) Touchscreen with visuali-sation

2) Buttons on the touchscreen

3) Buttons to adjust the monitor

4) Monitor for laser target representation

5) Buttons to adjust the monitor

Cutting wheel drive (0-400 bar) Pressure hydraulic pump

Jacking cylinders (0-600 bar) Pressure hydraulic pump



Pipe Brake (0-400 bar) Pressure hydraulic pump

Steering oil (0-600 bar) Pressure hydraulic pump

locking cylinders Jacking frame

(0-250 bar) Pressure hydraulic pump



Monitor Guidance System

1.7 Video Monitor

1.8 Loud Speaker

The measured data from guidance system are displayed at this monitor.

The video cameras are installed in the tunnelling machine and in the shaft.

The tunnel boring machine contains a microphone that transfers the sounds in the machine (switching of the solenoid valves, etc.). This enables the machine operator to detect faults. The volume can be adjusted at the control button.


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1 Display of laser target 2 Display of angles and roll3 Touchscreen function buttons

2

1

3


M-1437CPutting into Operation

2 Putting into Operation

2.1 First Putting into Operation

2.1.1 Power supply• Take care that the necessary power supply for the tunneling equipment

is secured.• Check for correct voltage.• Take care that the necessary cable dimension are kept.• Check all signal and supply cables for correct connection and damages.

Change damaged cables.• Check all fuses and Emergency stops for a correct function.

2.1.2 Hydraulic• Check direction of rotation of electric motors. • Check level and qallity of hydraulic oil in the tanks.• Check direction of rotation of the electric motors after connecting an

elongation cable during pipe changing.• Check screw joints and hydraulic lines for tightness.

NOTESee every new job site using this tunneling equipment as first putting into operation. Therefore at every new job site pay attention to this chapter.


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2.1.3 Initiation of the Hydraulic Power Pack

2.1.3.1 Putting in Operation Crew• For safety there should only people stay in that area who are directly

concerned with putting the equipment into operation.

2.1.3.2 Test runBefore starting a test run, the following things should once again be

inspected:• All parts cleaned and neatly assembled?• All connections firmly tightened and all devices correctly connected ac-

cording to the hydraulic diagram.• All shut off valves open?• Driving motor and pump correctly connected? (Observe the direction of

rotation of the pump.)• Open suction valves of the hydraulic pump, fill the pump housing with

hydraulic oil, if necessary.• Prescribed hydraulic filters correctly installed in the direction of flow.• Sufficiently fill with the prescribed oil (upper edge of the oil-level

indicator)During test running pay attention to the following:• Operation of the system without loading• Run under loaded condition only, after reaching the working temperature

of the system• Monitor control and measuring instruments.• Listen for noises• Monitor oil level and refill as needed.• Check the position of the pressure control valve during loading of the

system.

CAUTIONIt has to be ensured that all people are teached about pos-sible risks, when they are present in the area of putting the equipment into operation.



After finishing test run• Top up oil if necessary• Bleed the system• Check all screw joints for tightness, tighten leaking screw joints.

2.1.3.3 Tightness control• Switch off the driving mechanism.• Depressurise the system.• Tighten all screw joints..

CAUTIONRefill the hydraulic oil only through a fine filter 1-3 µm.Refill the hydraulic oil only through the refill joining (Quick coupling 28L Size 6).

DANGEROnly tighten screw joints when the system is depressurised.


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2.1.3.4 Air BleedIf the hydraulic circuit has been opened at any point (e.g. due to defective

cylinder), operate the system parts for approx. 10 to 15 minutes without load.

Symptoms of air in the hydraulic circuit• formation of foam in the tank• abnormal noises• jerks and joltsCarefully loosen the screw joint which is positioned up top or the vent

screw. After the emergence of dense hydraulic oil, secure the screw joint once

again

2.1.3.5 Temperature MonitoringThe tunneling equipment includes a permanent oil temperature control

system.Temperature Monitoring in the ContainerTemperature is measured on the hydraulic power pack and displayed at

the control system (Display TUNNELLING).The oil cooler is automatically switched on at approx. 30° C. If the oil tem-

perature increases to approx. 60° C, the entire system is automatically shut down.

The values are factoryset .Cold StartingWhen cold starting in the morning, the differential pressure display may re-

spond due to the high viscosity.This will be shown as a malfunction (red beam on display TUNNELLING) .

CAUTIONBefore the system is put into operation after air bleed, check all flanges and screwed connections for tightness



Pressing the RESET push button, the acoustical fault indication will be switched off and the blinking push button will change to illuminating.After the operating temperature has been reached, the differen-tial pressure indication will reset to normal range and the lamp in the RESET push button stops burning

2.1.3.6 Oil level

• Switch the water circuit to bypass control and stop it.• Check all hydraulic components for leakage and repair the defective

parts.• Top up hydraulic oil and bleed the equipment.

NOTEError messages of filters are shown with a delay of about 30sec.Error messages of filters will not be saved. Error messages of filters will be deleted automatically if the malfunction is no longer present.

CAUTIONAfter the operating temperature has been reached and there is still a fault indication, it is necessary to change the filter element of the filter; which is shown by a red beam behind on display "ERROR1".

RESET

NOTE If oil level reaches the minimum level, a red bar will illuminate abov the F5 ERROR key on display „advance“. Switch over to ERROR1 display to locate the error.All hydraulic pumps are automatically shut down.


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2.1.3.7 Particular informationWhen the hydraulic power pack is started in cold weather, the hydraulic oil

must be warmed up to a temperature between +5° and 10° C by a suitable heating system in the generator room of the container; otherwise the hy-draulic pumps may be damaged.

Operate the hydraulic system for approx. 10 to 15 minutes without load in cold temperatures.

2.1.4 Control Container with MH-VisualisationUsing control container equipped with MH-Visualisation check the para-

meters and options which are necessary for your machine to get correct indications and values.

See parameterlist point in this chapter for parameters and options for your machine.

Machines using the PBA (profi bus control) are equipped with the auto-matic function for option identification. So the options are automatically identified and displayed in screen TUNNELLING.

In this case you only have to check the machine parameters.



2.1.5 Pressure Adjustment Jacking CylindersThe pressure of the jacking cylinders must be adjusted accordingly

to the concrete pipes.

Pressure adjustment jacking cylinders

1) Connection block jacking cylinders

2) Relief valve extend jacking cylinders (black)

3) Relief valve extend interjack cylinders (blue)

4) Relief valve extend jacking cylinders (red)

1) Start push pump on the hydraulic power pack

2a) If jacking frame is connected extend push cylinders

completely

2b) If jacking frame is not connected

hydraulic must work against quick coupling system for pressure build-up.

3) Relief valve item 4 (extend jacking cylinders RED)

for pressure build up turn clockwisefor pressure reducing turn anti clock wise

4) If you adjusted pressure specified at point 2b)

connect jacking frame after pressure drop.


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Pressure adjustment Interjack cylinders

1) Start push pump on the hydraulic power pack

2a) If interjack station is connected extend interjack cylinders

completely

2b)

If interjack station is not connected

hydraulic must work against quick coupling system for pressure build-up.

3) Relief valve item 3 (extend interjack cylinders BLUE)

for pressure build up turn clockwisefor pressure reducing turn anticlockwise

4) If you adjusted pressure specified at point 2b)

connect interjack station after pressure drop.

CAUTIONIt is advisable to adjust only 70% to 80% of the maximum permissible jacking force of the jacking pipes. Relief valve for retract push cylinders item: 4 (GREEN) is factory set. (safety function)Control pressure, relief valve for the complete connection block item: 1 is also factory set. It may not be adjusted!

NOTEThere are four hydraulic blocks (item 3) for interjack stations shown on the sketch. The number of hydraulic blocks depends on the number of interjack stations.



Example: Labelling on the hose line

WARNINGTo high pressure in the hydraulic hose line.Can leading to bursting of the hydraulic hose lines.Do not adjust the hydraulic pressure higher than the hydraulic pressure labelled on the hose fitting. (see example below)

• Stop the hydraulic unit at once.• Rescue the injured people, carry out the first aid and

notify the emergency physician.• Change the hydraulic hose line.• Adjust the hydraulic pressure according to the max.

permissible working pressure labelled on the hose line.

Producerproducing date

max. working pressure in barmonth year

JAE 06 05 PN430


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2.2 Testing the Hydraulic and Electrical System of Control Container

Microphone• Check operation.

Push Pressure• Check maximum pressure and set in accordance with pipeline

capabilities.

Guidance System• Check editor values,• date and time,• plausibility of measured values

2.3 Daily commissioning

Before tunnelling operating begin, carry out the following checks.Power supply• Check all signal and supply cables for correct connection and damages.

Replace damaged cables.• Check all fuses and Emergency stops for a proper operation. Hydraulics• Check direction of rotation of the electric motors after connecting exten-

sion cables during pipe changing.• Check screw fittings and hydraulic lines for tightness.

NOTEStarting the equipment after pipe change is also part of the daily commissioning.


M-1437COperating Control Container

3 Operating Control Container

3.1 Steering Control3.1.1 Assembly

The cylindrical body of the cutting head is of articulated design, linked by three hydraulic cylinders. The front part or steering head is connected to the rear part or machine can by these cylinders.

3.1.2 Steering MovementsThe three steering cylinders are have the following strokes

The steering cylinder stroke is dependant upon the machine type (see technical data) and is indicated on the monitor at the operators control panel in mm.

Experience shows that extreme steering movements with maximum stroke are not necessary.

Tunnelling machine Control panel

Monitor: Display steering cylinders

View in direction of tunnelling Section steering cylinders

I

III II


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3.1.3 Steering Movements in normal Ground ConditionsNormal operationFor normal operation, start with all three cylinders at mid stroke.

Straight ahead movement

If the tunnelling operation is to be conducted with-out control movements, all steering cylinders have to be set to the same stroke.

Upward movement

Retract cylinder „1“ by the desired steering stroke.Extend cylinders „2“ and „3“ by the same amount.

Downward move-ment

Retract cylinders „2“ and „3“ by the desired steering stroke.Extend cylinder „1“ by the same amount.

Movement left / right

Starting from normal operating position.Extend cylinder „2“.Retract cylinder „3“ by the same amount to give steering to the left.Opposite movements give steering to the right.

Combined move-ments

Starting from normal operating position. Extend cylinder „2“: steers left / up.Retract cylinder „2“: steers left / down.The same movements executed with cylinder „3“ give steering to the right / up or down.



3.1.4 Steering Movements in hard Ground Conditions• A more time consuming procedure must be used.• A higher steering force is needed.• The steering movement is in partial assistance from the jacking frame.The following steering methods are not started from the normal position.

3.1.5 Steering Information when working with Rock Cutting HeadWhen working with the rock cutting head, in principal the same steering

procedures are maintained as when working with the cutting wheel. Steering movements proceeding also by pipe jacking.

Straight ahead movement All steering cylinders are completely extended

Upward movement Retract cylinder „1“ while the cutting wheel is in rotation and the pipe jacking is still in operation.

Downward move-ment

Retract cylinder „2“ and „3“ while the cutting wheel is in rotation and the pipe jacking is still in operation.


Retract cylinder „2“ by the desired steering stroke and retract cylinder „1“ by half of this val-ue while the cutting wheel is in rotation and the pipe jacking is still in operation. This results in a control movement to the right.Opposite movements using cylinders „1“ and „2“ give steering to the left.

Combined move-ments

Retract cylinder „3“ while the cutting wheel is in rotation and the pipe jacking is still in operation.This results in a control movement to the left.The same movements executed with cylinder „2“ give steering to the right.

CAUTIONWhile extending steering cylinders, ensure that cutting wheel is in rotation


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3.1.6 GuidelinesIn longer sections, even larger deviations from the determined course

must be returned to the nominal axis. To return to the nominal axis gradual curves should be used. Do not use sharp changes of the direction which may brake the jacking pipe.

If driving through intermediate concrete shafts, do not attempt to drive a curve through the shaft. The first steering movement should be done, when the cutting head and at least one pipe are in the ground.

3.1.7 NotesThe laser target is mounted in the machine can. With every steering

movement the machine can and target will move.When steering, regardless of whether the machine is moving forward or

not, the measured values displayed by the guidance system will change in the opposite direction to that which the machine is being steered because of the articulation of the machine.

In reverse case, surveying data will change to the previously controlled di-rection when a controlled movement is negated.

CAUTIONExtreme steering movements are avoided in all cases



3.2 Steering Control3.2.1 Assembly

The cylindrical body of the cutting head is of articulated design, linked by four hydraulic cylinders. The front part or steering head is connected to the rear part or machine can by these cylinders.

3.2.2 Steering Movements

• The four steering cylinders have all the same stroke (see technical data of tunnelling machine).

• Experience shows that extreme steering movements with maximum stroke are not necessary.

• Steering cylinder stroke indicated on the monitor at the operators control panel in mm.

Tunneling machine Control panel

Detail control monitor: Display stroke/pressure steering cylinders

View in VTR control panel: section steering cylinders

II

II

II

II


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3.2.2.1 Steering Movements In Normal Ground ConditionsFor normal operation, start with all three cylinders at mid stroke.

Straight ahead movement

If the tunnelling operation is to be conducted with-out control movements, all steering cylinders have to be set to the same stroke.

Upward movement

Retract cylinders „1“ and „4“ by the desired steering stroke.Extend cylinders „2“ and „3“ by the same amount.

Downward movement

Retract cylinders „2“ and „3“ by the desired steering stroke.Extend cylinders „1“ and „4“ by the same amount.


Starting from normal operating position.Extend cylinders „1“ and „2“. Retract cylinders „3“ and „4“ by the same amount to give steering to the left.Opposite movements give steering to the right.

Combined move-ments

Starting from normal operating position.Extend cylinder „2“ and „3“ by the desired steer-ing stroke gives steering upward. Extend cylinder „3“ and „4“ by the desired steer-ing stroke gives steering to the right. At the end of this movements cylinder „3“ will have done the double steering stroke than cylin-ders „2“ and „4“. This will result in steering right up.Steering movement right down, left up and left down will be done as described above using the according steering cylinders.



3.2.3 Steering Movements in Hard Ground Conditions• A more time consuming procedure must be used.• A higher steering force is needed.• The steering movement is in partial assistance from the jacking frame.The following steering methods are not started from the normal position.

Straight ahead movementt All steering cylinders are completely extended.

Upward movementRetract cylinders „1“ and „4“ (top right and left) while the cutting wheel is in rotation and the pipe jacking is still in operation.

Downward movement

Retract cylinder „2“ and „3“ (bottom right and left) while the cutting wheel is in rotation and the pipe jacking is still in operation.


Retract cylinder „3“ and „4“ while the cutting wheel is in rotation and the pipe jacking is still in operation. This results in a control movement to left.Opposite movements using cylinders „1“ and „2“ give steering to the right.

Combined movements

Starting from normal operating position.Retract cylinder „2“ and „3“ by the desired steer-ing stroke gives steering downward. Retract cylinder „3“ and „4“ by the desired steer-ing stroke gives steering to the left. At the end of this movements cylinder „3“ will have done the double steering stroke than cylin-ders „2“ and „4“. This will result in steering left down.Steering movement right down, right up and left up will be done as described above using the ac-cording steering cylinders.


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3.2.4 Steering Information when working with Rock Cutting HeadWhen working with the rock cutting head, in principal the same steering

procedures are maintain as when working with the cutting wheel. Steering movements proceeding also by pipe jacking

3.2.5 GuidelinesIn longer sections, even larger deviations from the determinate course

must be returned to the nominal axis. To return to the nominal axis gradual curves should be used. Do not use sharp changes of the direction which may brake the jacking pipe.

If driving through intermediate concrete shafts, do not attempt to drive a curve through the shaft. The firs steering movement should be done, when the cutting head and at least one pipe are in the ground.

CAUTIONPress push buttons to extend or retract stee-ring cylinders always two by two.

push button push button

ore.g.:

CAUTIONWhile extending steering cylinders, ensure that cutting wheel is in rotation.

CAUTIONExtreme steering movements are avoided in all cases.



3.2.6 NotesThe laser target is mounted in the machine can. With every steering

movement the machine can and target will move.When steering, regardless of whether the machine is moving forward or

not, the measured values displayed by the guidance system will change in the opposite direction to that which the machine is being steered because of the articulation of the machine.

In reverse case, surveying data will change to the previously controlled di-rection when a controlled movement is negated.

3.3 Operating tunnelling machine

CAUTIONStart pipe jacking only if the cutting wheel is in operation.Pipe jacking with blocked cutting wheel can damage the bearing, the steering cylinders etc.

CAUTIONTo prevent incorrect data from the laser target switch off the tunnel light before pipe jacking starts.

CAUTIONParticle limitationBefore water circuit start up, ensure that there is a suc-tion strainer installed in the separation plant, which allows a maximum particle diameter of 5mm.


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3.4 Start up Pipe Jacking

Select speed of jacking frame, slow to start with in order to determine ground conditions.

Start up the water circuit.Turn rotary switch for feed and slurry pump clock-wise to start the pumps.Ensure that the bypass is in the open position and set the feed pump and slurry pump to the de-sired flow rate.

Switch on:

the cutting wheel pump

the push pump

and the pilot pump

Select maximum speed for the cutting wheel (re-duce the speed if required by the ground condi-tions)

Close the bypass. Hold "bypass closed" push button until the required characteristic curve se-quence at the pressure gauge as described earli-er is finished. (duration circa 15 - 20 seconds). The feed and slurry ball valves are opened auto-matically.



3.5 Jacking ProcedureThe pump speeds must be continuously monitored and adjusted if neces-

sary to maintain a balanced flow rate of feed water and slurry (see table flow...).

Generally, operate the equipment with as low a water flow as possible to convey the excavated material.

Select the jacking frame speed so that the cutting wheel pressure is at least 90 - 100bar. Over excavation may occur at lower pressures if the cut-ting wheel is not always maintaining pressure against the face.

If high cutting wheel rotation speeds are being used and cutting wheel pressure is 80 bar or less, the water flow should be regulated to the lowest permissible level in order to prevent over excavation.


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3.6 End of Jacking Procedure

As soon as the pipejacking is finished (e.g. reset push ring on next ratchets, install new pipe etc.), switch to "bypass open" observing the character-istic curve of the pressure gauge (see checklist).

Stop cutting wheel rotation.

When the bypass is fully open, allow the water circulation to continue to ensure that all excavat-ed material is flushed out of the slurry line.

If watercircuit is to be stopped directly after by-pass operation, set the rotary switches for feed and slurry pump to 0 at the same time.

CAUTIONSwitch off the pumps only when the speed controlling de-vices are set to zero and water circulation has stopped.



3.7 Cutting WheelThe cutting wheel operates in both directions of rotation.At the operators control panel:

If the machine is operated at max. torque and the jacking force is to be in-creased further, the cutting wheel will block.

3.7.1 Roll Correction If the cutting wheel is running clockwise, the cutting head will tend to roll

anti - clockwise. The amount of roll is indicated on the guidance system monitor in degrees.

• Roll to the left can be compensated by excavating with the cutting wheel operating in left rotation.

• Roll to the right can be compensated by excavating with the cutting wheel operating in right rotation.

In general, it is good practice to continually change the direction of rotation of the cutting wheel on a regular basis, to maintain even wear to the cutting wheel.

switch on the cutting wheel pump. Press push button START/STOP

select direction of rotation pressing push buttons Cutting wheel left or right (is only possible if the cutting wheel rotation is set to zero ).

use the rotary switch to increase the speed of the wheel to the desired rpm.

CAUTIONChanging the direction of rotation of the cutting wheel is only possible if the speed control (rotary switch) is set to zero !


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3.7.2 Blocked Cutting WheelIndication: Revolution display is "0"Cutting wheel speed display reads zeroCutting wheel pressure at maximum (relief setting) indicates that the cut-

ting wheel has stalled. Release the jacking frame i.e. stop pipejacking and loosen the cutting wheel by rotating it in the opposite direction of rotation.

If the cutting wheel still cannot be released, try the following: a Unload push cylinders (Push cylinders STOP) b Switch the water circuit to bypass control. c Extend the steering cylinders to maximum stroke. d Retract the steering cylinders completely. e Loosen cutting wheel by rotating one direction and then the opposite. Do

not hold at relief pressure for more than 10 seconds at a time.

CAUTIONThe steps b-e, described above, may only be done if the push cylinder valve is set to circulation (Push cylinder STOP).

Ausschnitt Steuerstand Tableau: Bereich Vortriebspressen



3.8 Use of Water Circuit Whilst Pipe jackingIf pipe jacking is interrupted for a period of time longer than 10 - 15 sec-

onds, always switch the water circuit to bypass mode by pressing the "Bypass open" push button (see sketch below).This is normally necessary for following reasons:

• Blocked cutting wheel.• Retraction of the jacking frame.• Setting a new pipe into the jacking frame.When opening and closing the bypass, always check, that the bypass

pressure gauge shows the correct characteristic. This guarantees that the ball valves in the machine are operating correctly.

With light sandy soils, circa 40 cu me/hr, in order to avoid flushing out too much material from the face and thus avoid over excavation.

With gravels or sandy gravels, circa 50 cu me/hr.With clay, ca 80 cu me/hr.In general: Always reduce the flow rate with sands and gravels to avoid

blockages in the slurry line.See table flow rates.

Characteristics Flow Rate is to LowIf the flow rate in the slurry line is falling without having made any Adjust-

ment to the pump speed at the operators control panel whilst the feed remains constant (or almost constant), then a blockage within the slurry line will occur within a short time

Characteristics Flow Rate is to HighThe pressure of cutting wheel is to low (below 80 - 100 bar) whilst pipe

jacking, than to much material is being flushed out from the excavated face area thus creating Voids. The cutting wheel pressure falls, because the wheel is not in full contact with the excavated face.

This is also indicated by having more material in the settling tank than would normally correspond to the volume relating to the number of pipes installed.

CAUTIONThe water circuit flow rate must always be adapted to the ground conditions


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Water Pressure at Face (Suction Inlet)The water circuit pressure is measured at the slurry line suction inlet and

displayed at the operators control panel.

3.8.1 Bypass operatingWhen the bypass is opened and the feed and slurry lines are closed, the

groundwater pressure can be read directly from the gauge (e.g. 0,6 bar cor-responds to 6 me of ground water above the machine). When the bypass is open, the groundwater pressure reading should be constant and indicates that the ball valves in the feed and slurry lines are closed correctly.

3.8.2 Pipe jackingWhen bypass is closed i.e. during pipe jacking, the water circuit pressure

should exceed the groundwater pressure by 0,05 to 0.2 bar. Adjust this val-ue by use of the pump speed controls. With the flow rate set correctly to suit ground conditions and pressure balancing the groundwater conditions, the level of water in the settling tank will remain constant i.e. groundwater is nei-ther increasing the volume within the system nor is the system water being lost to ground.

NOTEDuring pipe jacking, the water pressure at the face will oscil-late by circa 0.1 to 0,2 bar.



3.8.3 Flow Rate Diagram


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3.9 Operating High pressure Water System

3.9.1 Operating Tunnelling Machine with High pressure Water NozzlesInstallation of the high pressure water nozzles is necessary for Tunnelling

in cohesive soils or when the development of such soils is expected.When Tunnelling with the built in high pressure water nozzles, water must

flow through these nozzles so that they do not become closed. When near gravelly and sandy soils, the water pressure should be higher than the pres-sure of the feed pump. In cohesive soils, the maximum pressure should be used.

3.9.2 Tunnelling startsAfter the bypass is closed and the slurry and feed lines are open, the high

pressure pump should be turned on.

3.9.3 Tunnelling endsBefore closing the slurry and feed lines, the high pressure pump must be

turned off.

CAUTIONTo avoid major damage to the sealing of the gear box and crusher room, make sure that:before starting the high pressure pump (high pressure nozzles) make sure that the slurry and feed lines are open.before closing the slurry and feed lines, the high pres-sure pump (high pressure nozzles) must have no pressure and is turned off.

CAUTIONHigh pressure water lines which supply water for the high pressure nozzles should not be next to or on electri-cal lines.



3.10 Emergency Ball Valve or Emergency Slide ValveTunnelling machines AVN 800 and bigger are equipped with an

emergency ball valve or an emergency slide valve. This would help you to change bypass, feed or slurry line if it is damaged.

3.10.1 Switch over Sequence of Emergency Ball Valve (Emergency Slide Valve)

1) Slurry line nozzle closes Pressure gauge increases to 150 bar, afterwards pressure drops down to 0 bar. (Valids only if slurry line nozzles are open)

2) Cutting wheel nozzles closes Pressure gauge increases to 150 bar, afterwards pressure drops down to 0 bar. (Valids only if cutting head nozzles are open)

3) Emergency valve closes Pressure gauge increases to 150 bar.

After the third pressure increasing, the pressure gauge has to hold 150bar for 10 to 15 sec.

Now the emergency ball valve is closedTo open the emergency ball valve, press the push button suction valve

1"OPEN" on the control panel.The switch over sequence during opening the emergency ball valve will

be the same as the switch over sequence during closing the emergency ball valve.

CAUTIONThe high pressure water lines should not be separated after standing still for some time (over night or on the weekends) this is because the back flow of ground water through the high pressure nozzles must be avoided.

To close the emergency ball valve, press the push button suction valve 1 "CLOSE"on the control panel.


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CAUTIONThe emergency ball valve must be open during tunnelling operations.The emergency valve should be closed for maintenance only.The ball valve is provided to allow emergency maintenance to be carried out on the bypass assembly / flexible pipe forward of the front bulkhead.


M-1437CTrouble Shooting

4 Trouble Shooting

4.1 Overview Error 4.1.1 Messages Visualization


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4.2 List of Possible FaultsThe following list does not claim completeness. The cause for malfunction

occurring most commonly in practice are included in this list.

Fault Cause

1 Control cylinders cannot be extend or retracted

Check via microphone whether the magnetic valves closeIf not, the electrical system is at fault:If the magnetic valves do close, the hydraulic system is at fault:

exchange electric control cables. the valve magnet may be defectivecontrol hose couplings defective (hydraulic hoses 8S and 18L) a hose has burst cylinder defective (packing) valve soiled pump does not supply pressure

2 Bypass and feed/slurry slide do not switch

Check via microphone whether the magnetic valves switch; open and close bypass valve individually in manual mode at the same time.If the magnetic valves do not switch, the electrical system is at fault:If the magnetic valves do close, the hydraulic system is at fault:

A stone is jammed in the system:

exchange electric control cables. the valve magnet may be defectivecontrol hose couplings defective (hydraulic hoses 8S and 18L) a hose has burst cylinder defective (packing) valve soiled pump does not supply pressureFlush the lines out by switching back an forth several times with the slurry pump running.

3 Slurry line clogged or material is not transported:

Flow velocity is to low.Bypass valve does not switch cor-rectly.Rinse the line as described in sec-tion "Possibilities to Remove Stop-pers in the Slurry Lines"



Fault Cause

4 Path measurement display for con-trol cylinders shows false values or no values:

Electric control cables defective or not connected correctly.Path measuring system in the cylin-der is defective, or the mounted electronics housing is defective.

5 Thrust jacks do not work properly: Check the magnetic valves in the hydraulic system.Check the hydraulic hoses.Pump does not supply pressure.

6 Hydraulic pumps do not function: Check the oil level in the tank.Check the electrical supply.Check contactors and fuses.Check oil temperature.

7 Control voltage at the control panel cannot be switched on:

Release emergency stop.The main switch is switched on.If the >voltage monitoring< control lamp lights up, overvoltage or undervoltage has been measured, or nor right hand field is generated.Control transformer is defective.

8 Main switch cannot be switched on: If the >voltage monitoring< control lamp lights up, the following is pos-sible: over or undervoltageno right hand field is generated in voltage supply:If neither applies, the main switch is defective.

9 Feed and slurry pumps do not ope-rate:

Check for malfunction of frequency converter according to the instruc-tions for troubleshooting in the fre-quency converter manual.Check armoured pumps for clog-ging or blockages.Check the temperature of the elec-tric motor.


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Fault Cause

10 Oil temperature too high: Check oil cooler to determine whe-ther motor is switched on, or in run-ning order.Check the switch points on the ther-mometer for correct setting. 30° C > Ventilator switches on 60° C > Equipment stops

11 Cutting wheel does not rotate cor-rectly:

Pump does not rotate correctly.Control pressure of the pump must be approx. 25 bar when the pump is not swung out.The control pressure decreases as the pump is swung out. Check at the gauge connection at connec-tionpoint of the pump.Hydraulic lines are not correctly coupled or the couplings are defec-tive.Electric pump trigger is defective.Amplifier card for electric trigger is defective.Speed indicator is defective.Flow sensor is defective.

12 Malfunction of cutting wheel pump: The power switch has responded, indicating motor overload.Motor defective.Pump is blocked, leading to over-current in motor.Motor is overloaded; operate cutting wheel at lower rotational speed.

13 Surveying system: See malfunction messages sur-veying system.


M-1437CMaintenance, Repair, Storage, Spare Part Service

V) Maintenance, Repair, Storage, Spare Part Service

1 Maintenance................................................................................ 1 - 11.1 Safety Instructions ...................................................................................... 1 - 11.2 General information .................................................................................... 1 - 21.3 Removal........................................................................................................ 1 - 31.4 Consumption Materials............................................................................... 1 - 31.5 Structure of Maintenance Plan................................................................... 1 - 42 Maintenance Plan Tunnelling Equipment ................................ 2 - 12.1 Daily Maintenance Works ........................................................................... 2 - 12.2 Weekly Maintenance Works every 50 Operating Hours........................... 2 - 12.3 After the first 100 Operating Hours .......................................................... 2 - 12.4 Maintenance Works every 500 Operating Hours/

minimum once a Year ................................................................................. 2 - 22.5 Alarm is Shown on the Display, or after long Stop Periods................... 2 - 32.6 Lubricant list ................................................................................................ 2 - 33 Maintenance Works.................................................................... 3 - 13.1 Safety Instructions ...................................................................................... 3 - 13.1.1 Requirements of Operating Personnel .......................................................... 3 - 23.2 Maintenance Switch .................................................................................... 3 - 33.2.1 The Shaft Tableau ......................................................................................... 3 - 33.2.2 The control container..................................................................................... 3 - 33.3 Cleaning Works ........................................................................................... 3 - 43.3.1 Requirements of Operating Personnel .......................................................... 3 - 43.4 Maintenance Works at the Hydraulic Installations................................... 3 - 53.4.1 Before starting maintenance works ............................................................... 3 - 53.4.2 After finishing Maintenance Works ................................................................ 3 - 73.4.3 Tightness Control .......................................................................................... 3 - 73.4.4 Hydraulic oil ................................................................................................... 3 - 83.4.4.1 Specified Degree of Cleanliness ............................................................................... 3 - 83.4.5 Oil Change..................................................................................................... 3 - 93.4.6 Replace Hydraulic Hoses .............................................................................. 3 -103.4.7 Suction Basket............................................................................................... 3 -113.4.8 Filter Element Change................................................................................... 3 -123.4.9 Changing filter element of high pressure filter ............................................... 3 -133.4.10 Filter Element Change at the Return-line - Suction Filter .............................. 3 -143.4.11 Filter element service High pressure filter ..................................................... 3 -15


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3.5 Cleaning the Air Filter of the Computer ..................................................... 3 -163.5.1 Cleaning the Filter Mat ................................................................................... 3 -163.6 Switch Cabinet and Control Panel Filters.................................................. 3 -173.6.1 Part Numbers for Filter Mats .......................................................................... 3 -173.7 Maintenance of Air Compressor................................................................. 3 -183.7.1 Checking Oil Level & Refilling ........................................................................ 3 -183.7.2 Accumulator Tank .......................................................................................... 3 -193.7.3 Compressor Oil Change................................................................................. 3 -203.7.4 Cleaning & Replacing the Air Filter ................................................................ 3 -213.8 Compressed air Service Unit ...................................................................... 3 -223.8.1 Filter ............................................................................................................... 3 -223.8.2 Pressure Reducing Valve............................................................................... 3 -223.8.3 Pressure Adjustment...................................................................................... 3 -233.8.4 Cleaning of plastic bowls................................................................................ 3 -233.9 Cleaning the Oil-Air-Cooling Equipment ................................................... 3 -243.9.1 Cleaning the Air-Side ..................................................................................... 3 -243.9.2 Cleaning the Oil-Side ..................................................................................... 3 -243.9.3 Disposal ......................................................................................................... 3 -243.10 Maintenance of the Bladder Accumulator ................................................. 3 -253.10.1 Preparations for Working with the Filling and Testing Unit ............................ 3 -253.10.2 Checking the Gas Pressure in the Bladder Accumulator ............................... 3 -263.10.2.1 Intervals between Checking ...................................................................................... 3 - 263.10.3 Reducing the Gas Pressure in the Bladder Accumulator............................... 3 -263.10.4 Pressure Increase (FILLING) of the Bladder Accumulator............................. 3 -27

4 Re-Inspections ........................................................................... 4 - 14.1 Hydraulic Equipment ................................................................................... 4 - 14.1.1 Qualified Persons........................................................................................... 4 - 14.1.2 Duty of Documentation................................................................................... 4 - 24.1.3 Inspection Deadlines for Hydraulic Hose Lines.............................................. 4 - 24.2 Electrical Equipment.................................................................................... 4 - 44.2.1 Qualified Electrician ....................................................................................... 4 - 44.2.2 Pre-requisites for the Implementation of the Inspection................................. 4 - 44.2.3 Duty of Documentation................................................................................... 4 - 44.2.4 Stationary Electrical Equipment ..................................................................... 4 - 54.2.5 Non-Stationary Electrical Equipment ............................................................. 4 - 54.2.6 Re-Inspections of Electrical Systems............................................................. 4 - 64.2.7 Re-inspection Procedure for Electrical Devices ............................................. 4 - 84.2.8 Measuring Tasks and Measuring Procedures for Re-Inspections on

Electrical Devices........................................................................................... 4 - 94.2.9 Wireless Transmission Systems .................................................................... 4 -104.3 Hoisting Devices and Lifting Accessories................................................. 4 -104.3.1 Persons with Inspection Authorisation ........................................................... 4 -104.3.2 Inspections ..................................................................................................... 4 -10



4.3.3 Implementation Instructions........................................................................... 4 -11

5 Bolt Tightening Torques ............................................................ 5 - 15.1 Tightening by applying clamping force..................................................... 5 - 25.1.1 Installing - Preload......................................................................................... 5 - 25.1.2 Bolt Tensioning Cylinder................................................................................ 5 - 2

6 Storage ........................................................................................ 6 - 16.1 Storage of Control Container ..................................................................... 6 - 16.2 Storage of Feed and Discharge Lines ....................................................... 6 - 16.2.1 Feed and Discharge Lines System MH ......................................................... 6 - 16.2.2 Feed and Discharge Lines System Victaulic ................................................. 6 - 16.3 Storage of Slurry Pumps ............................................................................ 6 - 16.4 Storage of Hydraulic Power Packs ............................................................ 6 - 26.4.1 Hydraulic........................................................................................................ 6 - 26.4.1.1 Cylinders ................................................................................................................... 6 - 26.4.1.2 Pumps und Motors .................................................................................................... 6 - 26.4.1.3 Storage of Hydraulic Hoses....................................................................................... 6 - 36.5 Storage of Electrical Parts.......................................................................... 6 - 46.5.1 Switch Gear Cabinets.................................................................................... 6 - 46.5.2 Electrical Cables............................................................................................ 6 - 4

7 Spare Parts.................................................................................. 7 - 17.1 Stocking Spare Parts .................................................................................. 7 - 18 Branchadress Herrenknecht AG ............................................... 8 - 18.1 Europe .......................................................................................................... 8 - 18.2 Middle East................................................................................................... 8 - 18.3 Amerika ....................................................................................................... 8 - 28.4 Asia ............................................................................................................... 8 - 28.5 Australia ....................................................................................................... 8 - 2


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M-1437CMaintenance

1 Maintenance

1.1 Safety Instructions

WARNINGMaintenance works may only be done, if tunneling ma-chine is at stand still and if it is out of operation. Repair works may only be executed by instructed persons with the corre-sponding knowledge.Necessary repair works on live equip-ment, put up a signe to the main switch of control panel that “START“ or “STOP“ of any function of the equipment is forbidden.

WARNINGCatch production facilities in suitable containers.Remove production facilities which where run out at once.

Danger of slipping!

WARNINGObserve all safety instructions of the operating manual.

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 V - 1 - 1

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M-1437CMaintenance

1.2 General informationOperational safety and readiness are the demands that a tunnelling ma-

chine must fulfil in order to contribute in the most extensive rational economical manner.

Your tunnelling machine will fulfil these demands if it is properly handled and taken care of.

Malfunctions can be prevented by correct handling, ample lubrication and maintenance with suitable lubricants as well as close observation of the ma-chine in operation.

These maintenance instructions contain all the explanations and state-ments necessary for the correct handling of the machine.

The listed maintenance work in these instructions should be carried out in order to guarantee safe and reliable operation of the tunnelling machine and reduce breakdown times.

NOTEAll maintenance-, cleaning- and repair work may only be car-ried out by authorised and suitably qualified persons. (see chapter 2: General Safety Instructions)These persons must have read and understood this operating manual.

CAUTIONObserve all terms for inspections and maintenance work including the information about exchange of subassem-blies and components.

CAUTIONUse only producer-released original spare parts and orig-inal accessory parts as well as appropriate operating means and operating material.

Edition: April 2009 © Herrenknecht AG, Schlehenweg 2 V - 1 - 2 77963 Schwanau 2, Tel. 07824 / 3020Version: 0

M-1437CMaintenance

1.3 RemovalMake sure that all operating and auxiliary material as well as exchange

parts are removed securely and with minimal environmental impact.As a rule, never remove any operating and auxiliary material into canaliza-

tion, soil or waters. Collect and remove all oils.

See to it that reusable exchange parts are being recycled.

1.4 Consumption MaterialsThe following lubricants are recommended for lubrication purposes. This

information does not represent a value judgement. The order of producers is not meant to be a quality order.

As can be proved, equivalent operating material of other producers may also be used, provided it fulfils the requirements of the DIN standards, e.g. DIN 51825

When using other lubricants it is recommended to rinse the respective bearing or housing prior to refilling it with new grease.

NOTECollect production facility eg. transmission oil, hy-draulic oil and grease and dispose it in accordance with the environmental regulations.

CAUTIONMixing of different types of grease decrease the lubricat-ing qualities and is therefore not permitted.


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M-1437CMaintenance

1.5 Structure of Maintenance PlanThe maintenance works described in the maintenance plan must be car-

ried out to guarantee the reliable and secure operation of the tunneling equipment and to reduce downtime.

Periodically maintenance works are described in the maintenance plan.The maintenance works are arranged by intervalsMost of the maintenance works are described in the maintenance plan, for

a detailed description see operating instructions of individual assemblies and components. The operating instructions enclosed in chap. 8 must al-ways be consulted and all maintenance works must be carried out in accordance with described procedures.

NOTEIf the operating hours designated in the maintenance plan are reached before the according time intervals (daily, week-ly..) maintenance work has to be carried out without reaching the time interval.


M-1437CMaintenance Plan Tunnelling Equipment

2 Maintenance Plan Tunnelling Equipment

2.1 Daily Maintenance Works

2.2 Weekly Maintenance Works every 50 Operating Hours

2.3 After the first 100 Operating Hours

Assembly Location Maintenance works Consumption material

Hydraulic power pack

Control container

Check the oil level tank andtop up as necessary.

Hydraulic oil according to the tank sticker.

Compressor

Check the oil level in the compressor block.top up as necessary.

Motor oil according to the operating manual

Drain the condensate from the air receiver

Compressed air service unit

Check condensation water drain as necessary

Check the oil level of the air line lubricator top up as necessary.

Motor oil according to the operating manual


Hydraulic power pack Control container Check tank ventilation filter Hydraulic oil according to the

tank sticker.

Assembly Locality Maintenance works Consumption material

Hydraulic power pack Control container Check tank ventilation filter Hydraulic oil according to the

tank sticker.


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2.4 Maintenance Works every 500 Operating Hours/ minimum once a Year


Hydraulic power pack Control container

Check oil qualityOil renewal depends on oil quality

hydraulic oil according to the tank sticker

at every oil renewal:

change all filter elementsclean filter housing

Filter element according to hydraulic diagram

Clean all the suction filter change if necessary

Filter according to hydraulic diagram

Compressor Control container

Oil change motor oil according to the tank sticker

Check and clean the air filter

Check and clean the non-return valve

Check and clean the safety valve

NOTE

Oil quality check oil:Examination of the oil sample in a suitable laboratory to: • Lubricating oil quality:• Soiling of the lubricating oil caused by outside influences

(Water, Sand etc.)• Wear particles, produced during operation (Metals etc.)Oil change is necessary when soiling is max. 19/17/14 per 100 ml in accordance with ISO 4406.



2.5 Alarm is Shown on the Display, or after long Stop Periods

2.6 Lubricant list


Return line filter container

Hydraulic power pack control con-tainer

Change filter element Filter element according to hydraulic diagram

High pressure filter A container Change filter element Filter element according to

hydraulic diagram

High pressure filter B container Change filter element Filter element according to

hydraulic diagram

Assembly Component Type Capacity Part no.

Control container

Hydraulic tankMain jacking power

pack1500

Compressor Motor oilARAL API CF-4 / SG 0,2 29700044

Compressed air service unit

Pneumatic oilARAL VITAM GF 22 29700737

WARNINGFor the hydraulic power packs, use only one type of oil.When changing the hydraulic oil types the complete hydraulic equipment must be cleaned. This must also be carried out with the hydraulic hoses and hydraulic lines.


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M-1437CMaintenance Works

3 Maintenance Works

3.1 Safety InstructionsBefore starting repair works put the tunnelling machine out of operation. It

must be secured against unexpected restart.

WARNINGMaintenance works may only be carried out, if tunnelling machine is at stand still and if it is out of operation.Maintenance works may only be exe-cuted by instructed persons with the corresponding knowledge.Necessary repair works on live equip-ment, put up a sign at the main switch of control panel that “START“ or “STOP“ of any function of the equip-ment is forbidden.

WARNINGExchanging heavy machine parts, ensure they are careful-ly fastened and secure.Use only appropriate and technically faultless hoists as well as load-carrying devices with a sufficient capacity.


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• When exchanging heavy machine parts, ensure that they are carefully fastened to lifts and are secure.

• Do not store heavy machine parts in unstable places.• Secure heavy parts reliable also for a short time of storage.• Reliably secure loads.• Use only appropriate and technically faultless hoists as well as load-car-

rying devices with a sufficient capacity.• Principally observe safety warnings of the producer prior to commissio-

ning of lifts and hoist plants.• Never work or stand under suspended loads.• Always pay attention to the sequence of the working steps during disas-

sembling or assembling machine parts.

Inspect all works to ensure that repairs will be carried out correctly, after they are finished.

Before the machine will be put into operation again, check all adjustments by a test run.

3.1.1 Requirements of Operating PersonnelRepair works may only be executed by instructed persons with the corres-

ponding special knowledge (see Chapter “General safety instructions“).

CAUTIONNever start disassembly / assembly with a part before the disassembly / assembly of the previous part is finished.



3.2 Maintenance SwitchBy activating the maintenance switch the aggregates in the control

container and in the tunnelling machine stops, so maintenance works can be done.

After the maintenance works the maintenance switch must be turned back again, so the aggregates in the control container and in the tunnelling machine are again in operation.

3.2.1 The Shaft Tableau

At the Shaft Tableau is a maintenance switch applied. This must be activated when maintenance works must be done.

3.2.2 The control container

In the control container is a maintenance-box with a emergency-stop button and a maintenance switch applied.

Maintenance switch

Maintenance switch

Emergency-stop button


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3.3 Cleaning WorksSafety InstructionsBefore starting cleaning works put the tunnelling machine out of operation.

It must be secured against unexpected restart.

• Before cleaning the machine with water, high-pressure cleaner or other detergents, cover or tape up all openings which - for safety or functional reasons - must be protected against penetration of liquids and deter-gents. Special care must be taken with electrical motors and switchgear cabinets.

• After cleaning, completely remove all covers and tapes.• Always tighten bolted connections loosened during cleaning work using

the appropriate torque moment.• Any safety installations removed for cleaning work must be reassembled

and checked immediately, having completed all works.

3.3.1 Requirements of Operating PersonnelCleaning works may only be executed by instructed persons with the cor-

responding special knowledge (see Chapter “General safety instructions“).

WARNiNGCleaning works may only be done, when tunnelling machine is at stand-still and carried out by instructed persinnel with the corresponding knowledge.For necessary cleaning works on live equipment, put up a sign to the main switch of control panel that “START“ or “STOP“ of any function of the equipment is forbidden



3.4 Maintenance Works at the Hydraulic InstallationsPay attention to:• a clean environment where the maintenance works will be done.• If it is necessary to disconnect hydraulic lines to do maintenance works,

close the ends of the lines with plastic plugs. This will prevent the flow out of hydraulic oil and the encroaching of dirt.

3.4.1 Before starting maintenance works

• Stop and depressurize the equipment.• Hydraulic equipments with preloading. • Relieve the preloading of the hydraulic tank turn the tank breather coun-

ter clockwise approx. two times. • Let the hydraulic oil cool down to approx. 30 - 40°C.• Inspect if the system is depressurized by the pressure gauges. • Pressure gauges (oil and air) must show 0 bar.

CAUTIONNever use cotton waste or other fibrous materials to close hydraulic lines or hoses.Fibre can enter into the hydraulic oil and stop filters and/or hydraulic valves.

CAUTIONHydraulic equipments with preloading.Relieve the preloading of the hydraulic tank before start-ing any maintenance work!


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Do not refill collected hydraulic oil into the tank.

DANGERFailure to depressurize the system before opening could result in an explosive loss of fluid, damage to equipment and possible per-sonal injury. Wear safety gloves and safety gogglesBe careful when handling hot hydraulic oil (risk of burning or scalding).

NOTECollect flowing out hydraulic oil and dump it in ac-cordance with the environmental regulations.

CAUTIONFailure to replace damaged parts in filter can cause com-ponents in the hydraulic.Failure to replace damaged parts in filter can cause com-ponents in the hydraulic system to fail or degrade in their performance. Do not use pipe wrench, hammer or any similar tool to tighten the bowl.



3.4.2 After finishing Maintenance Works• Replace lost oil volume.• Use hydraulic oil according to the tank sticker.• Bleeding the system.For that purpose:• Stop the hydraulic system.• Adjust a preload of 0,3 bar by additioning compressed air when using hy-

draulic equipments with preloading.• Carefully loosen the screw joint which is positioned up top or the vent

screw. • After the emergence of dense hydraulic oil, secure the screw joint once

again.

3.4.3 Tightness Control• Switch off the driving mechanism and depressurize the system.• Inspect if the system is depressurized by the pressure gauges. • Pressure gauges must show 0 bar.• Tighten all screw joints.

CAUTIONBefore the system is put into operation after air bleed, check all flanges and screw joints for tightness.

DANGERTighten the screw joints only, when the system is depressurized.


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3.4.4 Hydraulic oil

3.4.4.1 Specified Degree of CleanlinessTo increase the working-life of components, a certain degree of cleanli-

ness of the oil to ISO 4406 is necessary. On the basis of the system pressure, and the sensitivity of system components, a minimum oil cleanli-ness requirement can be laid down. For example, with 200 bar system pressure, and normal hydraulic components, the required degree of cleanli-ness is at least 19/17/14 to ISO 4406.

Contamination class to ISO 4406Besides particle size, the number of particles present is responsible for the

wear characteristics of a system. The more particles there are in circulation, the higher the wear.

There are several methods in use for classifying the cleanliness of a sys-tem, those most commonly used are ISO 4406 and NAS 1638 - of the two, ISO 4406 is currently recognised worldwide. In 100 ml of fluid, the number of particles >4µm, >6µm and the number >14µm are determined. Counting can be carried out under a microscope, or with the help of an automatic par-ticle counter. The fluid is given a code number grading for the number of particles found. In this case oil cleanliness 19/17/14 according to ISO 4406 means:

The oil is continuously filtered in the bypass flow by a fine filter (10µm).

Particle concentration per 100 ml

Particle size particleconcentration Counting sector Cleanliness

classification

> 4 µm 354.800 250.000 - 500.000 19

> 6 µm 89.200 64.000 - 130.000 17

> 14 µm 15.400 8.000 - 16.000 14

mikroskopic photgraphy 100 hundredfold enlargment1 graduation mark: 10 µm



Proceed as follows after longer downtime:• Drain the water which has collected on the bottom of the oil tank.• Replace the lost volume.• Operate the system for approx. 1 hour and run through all functions.• Flush out the hydraulic lines.• Exchange soiled filters (electrical display).• Exchange filter in the machine.• Bleed the system.

Use the oil which is named on the tank sticker. Dry oil must always be used; otherwise, the pumps / valves and measuring equipment may be damaged.

3.4.5 Oil Change• Preparing the system for oil change

(Siehe “Before starting maintenance works” auf Seite 5.)• Drain oil from the drain cock (at the bottom of the tank).• Open the round tank cover and clean the tank.• Fill in new oil into the tank, using the filler connection.• Bleeding the system.

NOTEThe oil quality must be checked every 500 working hours. Change hydraulic oil if necessary.

CAUTIONTop up hydraulic oil or filling the tank only by using a fil-ter station 1 - 3 µm.For refilling or renewal hydraulic oil use filler connection (Quick coupling 28L size 6).


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3.4.6 Replace Hydraulic Hoses

• Preparing the system for replacing hoses (Siehe “Before starting maintenance works” auf Seite 5.)

• Screw off the hydraulic hoses. Collect flowing out hydraulic oil and dump it in accordance with the environmental regulations.

• Screw on the new hydraulic hose.

CAUTIONThe time of use of hydraulic hose lines should not exceed a time of six years including 2 years of storage.

CAUTIONClose all ball cocks of the hydraulic system before screw-ing of any hydraulic hose.

CAUTIONBefore restart the hydraulic pumps check that all ball cocks of the hydraulic system are openOpen all closed ball cocks. Don not open the drain cock of the hydraulic tank. Dry running hydraulic pumps may damage.



3.4.7 Suction BasketAt every oil renewal clean also the suction filters in the tank.

Procedure:

NOTENever use hard objects (wire brush etc.) for cleaning suction filters.

• Screw off the suction filter from the suction pipe in the tank.

• Put the filter into a cleaning bath for about 15 minutes (cleaning materials see chap-ter „Operating materials and Aids“).

• Take the filter out of the cleaning bath.• Blow out the filter from the inside to the out

using compressed air.• Screw on the suction filter to the according

suction pipe into the hydraulic tank.


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3.4.8 Filter Element ChangeControl Container using MH Visualization• If a alarm is shown on the display (visualisation), strike the "F5" key to

change to the display "ERROR MESSAGES". If an error message is present, shown by a red back-lighting, replace oil filter element

• Replace filter elements after a longer period of disuse.

CAUTIONFilter elements of the following described filters are not cleanable. Used filter elements must be disposed in accordance with the environmental regulations. Clean filter housing also each time a filter element is replaced.



3.4.9 Changing filter element of high pressure filterVorgehensweise:

1) Turn off and depressurize the system. 2) Unscrew and removethe filter bowl by turning

the it counter clockwise. Clean the filter bowl with an adequate medium.

3) Remove the filter element by lightly sway it downward.

4) Check the o-ring in the filter bowl and the filter element retainer for damages. Replace dam-aged parts.

5) Open the plastic covering and push the filter el-ement over the retainer of the filterhead

6) Remove the plastic covering completely. 7) Screw the filter bowl into the filter head. Screw

in the filter bowl until the stop position is reached and turn it counter clockwise for 1/8 to 1/2 turn.


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3.4.10 Filter Element Change at the Return-line - Suction Filter Procedure:

4) Pull the filter parting plat with the filter element and the filter casing out of the filter head. A lightly lever movement will be necessary for this work because the filter parting plate is located in an O-ring seal-seat.

5) Remove the complete filter unit. 6) After lifting out the filter unit, wait for a short time to allow the oil level fal-

ling down. Oil is running out through a 4mm whole in the preload valve or the suction valve of the filter clean side.

7) Place the complete filter unit into a suitable oil tank. Remove the parting plate from the filter element in rotary motion. The filter element remains into the filter casing.

8) Remove filter element (4) out of the filter casing in rotary motion. (In-spect the surface for significant visible contamination. Visible dirt or particles can be an early warning of system component breakdown and can indicate potential failure).

9) Pour the rest of oil out of the filter casing 10) Installing an new filter element and installing the complete filter unit will

be done in reverse mode.

1) Stop system and relieve filter from pressure (see chapter: „Before starting maintenance works“).

2) Open the plug (5) about three turns. In case of the clearance of the thread it is possible to breath the filter casing for oil level balance.

3) Wait for 1 minute. Then open the co-ver screws (2) and remove the cover (1). During this work no oil will coming out over the casing edge.



3.4.11 Filter element service High pressure filter Element replacement

7) Discard both the element and its O-ring. 8) Inspect filter housing and its bypass/reverse flow valve for possible

damage or malfunction. Determine whether replacement of any compo-nent is necessary. Remove any accumulated dirt from filter, being careful to prevent contamination from entering the and washing downstream.

9) Check that bowl seal (3) and backup ring (4) in head are not damaged. 10) Wet sealing surfaces on bowl (5) and the O-Ring in element with clean

system fluid. 11) Push open end of filter element straight onto nipple in head. 12) Screw bowl to head until bottomed. O-ring sealing is not improved by

over-tightening; do not exeed 15 lb ft (20 Nm) torque. 13) Bleed system. 14) Pressurise system fully and check for external leaks.

1) Turn off and depressurise system. 2) Open bleed plug at top of filter, if fitted,

one and one half turns. 3) Remove plug if fitted at the base of fil-

ter and drain fluid into a suitable container. Drained fluid should not be returned to the system but should be retained for subsequent reclamation.

4) Reinstall drain plug and tighten both plugs.

5) Remove bowl (5). 6) Remove element (6.) and carefully in-

spect the surface for significant visible contamination which can be an early warning for system component break-down and may indicate potential failure.


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3.5 Cleaning the Air Filter of the ComputerA dirty filter mat may cause the system to overheat. In this case , the tem-

perature LED at the front of the system will flash. Naturally the filter mat will have to be replaced more frequently in rough environment the in a clean environment.

The filter mat is located behind a panel on the system front that can easily be pulled out towards the front to take out the filter mat.

3.5.1 Cleaning the Filter Mat

• Soak in water (up to 40 °C; add some mild detergent, if necessary)• You may also remove dirt by beating it off, using a vacuum cleaner, or

compressed air.• Greasy dirt may be removed by soaking the mat in warm water and fat-

soluble detergent. Avoid strong water jets and do not wring out the mat.• After cleaning or replacing the filter mat, simply replace the panel on the

front of the system.

1 Control panel

2 Monitor

3 Computer

4 Cover filter mat

Using tunnelling equipments with standard ELS, the computer is behind the door on the left side of the control panel

Upper Right Control Panel

CAUTIONPlease wait until the filter mat is completely dry before replacing.Make sure the compact side of the filter mat faces to-wards the inside of the system when installing it. Otherwise the filter maybe clogged up quickly.



3.6 Switch Cabinet and Control Panel FiltersFor cooling of the electronic parts of the equipment ventilators are mount-

ed in control panel and switch cabinet.It is recommended to exchange the filter mat of the ventilators every 50

hours.For that:• Pull out protective grating (item: 3)• Pull out the dirty filter mat and replace a new filter mat (item: 2)• Replace the protective grating. (item: 3)

3.6.1 Part Numbers for Filter Mats

1 Ventilator housing

2 Filter mat

3 Protective grating

Filter ventilator Outlet filter Part No.

SK 3150 SK 3160 26601400

SK 3151 SK 3161 26601401

SK 3152 SK 3162 26601402

SK 3153 SK 3163 26600314


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3.7 Maintenance of Air Compressor

3.7.1 Checking Oil Level & Refilling

Procedure:• Disconnect main switch of air compressor and pull power cable.• Open vent (1) of oil refill opening.• Refill with oil up to the upper mark of the sight gauge (2).

DANGERDisconnect power for any kind of service or maintenance at the air compressor by turning off the main switch. Ad-ditionally, pull the plug of the air compressor power cable to be safe of reconnection (lock-out feature).When working on compressed air hoses or lines, depres-surize them first. Relief pressure from accumulator tank.Before reconnecting power to the air compressor, make sure that nobody is working on it any more and that all covers and safety devices are installed.

The oil level must be checked daily at the sight gauge, and each time before operation of the unit.

If the oil level dropped down to the lower mark, refill with oil according to the recommended list. Refill only to the upper mark of the sight gauge. Do not over-fill.

Use a screen when refilling with oil, unless the oil is filled directly from its original container.



• Close refill opening (1).

3.7.2 Accumulator Tank

NOTEThe maximum oil quantity when refilling is reached only after a few minutes since the oil needs to penetrate into the crank-case first.

The accumulator tank collects moisture during operation. This water must be drained daily by opening drain valve (4).

Collect the drained water in a suitable contain-er and dispose according to environmental protection regulations.


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3.7.3 Compressor Oil ChangeChange oil only when compressor reached operation temperature.

The first oil change should be performed after approx. 50 hours of operation.

Thereafter, the oil must be changed every 500 hours of operation or at least once a year, which ever happens first.

In certain operating conditions, moisture from the air and water may col-lect in the oil. In those cases, the oil must be changed immediately. With water contaminated oil can be detected by the milky color of the oil (visible at sight gauge).

Procedure:• Disconnect main switch of air compressor and pull power cable.• Open vent (1) of oil refill opening.• Place oil pan or other suitable container underneath oil drain plug (3).• Remove oil drain plug (3) and let oil drain into oil pan.• Flush crankcase with a small amount of (new) oil.• Close oil drain (3) and refill with new oil up to the upper mark of sight

gauge (2).

WARNINGHot oil can cause burning of limbs and other body parts.

Some parts and components of the air com-pressor may be hot also.

CAUTIONUse a screen when refilling with oil, unless the oil is filled in directly from its original container.

NOTEThe waste oil must be drained into a suitable container and disposed off according to environmental protection regulations.The maximum oil quantity when refilling is reached only after a few minutes since the oil needs to penetrate into the crank-case first.



3.7.4 Cleaning & Replacing the Air Filter

Procedure:• Disconnect main switch of air compressor and pull power cable.• Remove air filter (1) from cylinder head.• Push open snap bar (2) and open filter enclosure.• Clean filter enclosure and seal areas (3) in particular.• Wash filter element with diesel fuel.• Once the filter is dry, apply moderate amount of oil to the filter element.• Assemble air filter, and apply all covers and safety devices to air com-

pressor again.

The air filter must be cleaned every 500 hours of operation, at least. When heavy contamina-tion occurred or the air filter was cleaned very often, it must be replaced completely.

WARNINGClean the filter with diesel fuel only outside the control container in a well ventilated area.Follow the correct regulations and safety guidelines when operating with flammable liquids.

CAUTIONWhen assembling the air filter, make sure that the air in-take opening (2) points downwards.


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3.8 Compressed air Service Unit

3.8.1 FilterDrain condensation water periodical. Clean filter if it is dirty.Demounting the FilterUnscrew the filter bowl and take it off. Unscrew the fixing nut from the sin-

tered filter. Take out the sintered filter, clean it by using benzene or per and dry it. Rebuild the sintered filter. Take care to a flawless sealing of the filter.

3.8.2 Pressure Reducing ValveGrease O-ring at the density cone and pin periodical. Streaming dry air

dries up the O-ringGreasing the O-RingsSwitch off compressed air and relieve the equipment. Unscrew the screw-

cap (hand nut). Remove the density cone. Grease O-ring and pin lightly.

1 Pressure reducing valve2 Water seperator3 Fog Lubricator4 Pressure adjusting screw5 Pressure gauge6 Water bowl7 Oil drain plug 8 Filter9 Oil bowl

10 Oil filler plug



3.8.3 Pressure AdjustmentBefore the compressed-air line is put into operation, relieve the pressure

reducing valve by unscrew the control screw. Screw in the control screw clockwise, until the required pressure is shown on the pressure gauge.

3.8.4 Cleaning of plastic bowlsThe plastic bowls may only be cleaned with water or paraffin.

Under no circumstances must petrol, acetone solutions containing trichlor-ethylens or similar solutions be used.

Fluids containing plasticizers e. g. alcohol, glysantine etc. Should not be poured into plastic bowls.

There is no liability for any damage, which are resulting on nonattention of this maintenance.

CAUTIONPetrol is no pure benzene


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3.9 Cleaning the Oil-Air-Cooling EquipmentThe oil-air cooling equipments require no special maintenance. But by op-

eration with heavy soilings clean it regularly.

3.9.1 Cleaning the Air-SideThe cleaning takes place with pressured air in arrow direction. The direc-

tion of the cleaning stream has to be parallel to the ribs to prevent damages. Oil and fatty soilings can be cleaned by a steam or hot-water stream. Pay

attention to the stream direction. The drive motor has to be covered during cleaning procedure.

3.9.2 Cleaning the Oil-SideThe oil parts are cleaned with sufficient cleaning mediums. The washing

time has to be adapted to grade of soiling. After washing the cleaning medi-um has to be blowed out completely.

3.9.3 DisposalUse reception tanks by opening the cooling equipment. Pay attention to

the statutory regulations by selection and disposal of all operation and cleaning mediums.

CAUTIONBefore putting into operation again the cooling equip-ment has to dry completely.Cooling ribs may not be damaged.



3.10 Maintenance of the Bladder Accumulator3.10.1 Preparations for Working with the Filling and Testing Unit

Prior to each check or prior to filling and re-filling nitrogen, the hydraulic accumulator must be disconnected from the pressurised system by a shut-off valve and relieved at the liquid side.

The following steps must be carried out before all checking and filling works:

1) Screw off the protection cap (S) and the cap nut (H) from the bladder accumulator.

2) Remove the O ring (O) from the bladder accumulator. 3) Assemble the filling and checking unit. 4) Manually screw the filling and checking unit as well as the cap nut (A3)

onto the storage gas valve. It must be observed that the relief valve (B) of the filling unit is closed.

5) Turn the filling unit in a way which ensures that the manometer can be optimally read.

CAUTIONWhen the bladder is either damaged or leaky, nitrogen and operating fluid escapes when filling or checking the accumulator.

- Health hazard due to aggressive media. > It is not permissible to disassemble the check valve. The valve has

a safety function for the complete filling and checking unit. > Prior to recommissioning the system after bleeding, check all

flanges and screw connections for tightness.

S

H

O

A

CB

A3


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3.10.2 Checking the Gas Pressure in the Bladder Accumulator 1) Open the valve of the bladder accumulator, by rotating the spindle (A) in

clockwise direction. 2) When the manometer pointer starts to respond, turn the spindle another

full rotation. >The manometer now indicates the pre-filling pressure in the

accumulator.The check valve (C) prevents the nitrogen from escaping.

3.10.2.1 Intervals between CheckingOn the whole, nitrogen losses on hydraulic accumulators are very low. However, a regular check of the gas pre-charge pressure is recommended to prevent the piston from hitting the cover plate or the bladder or diaphragm from becoming too deformed if there is a drop in the pressure p0. The pre-charge pressure p0 as shown on the label or the accumulator body must be reset after every new installation or repair and then checked at least once in following week. If no nitrogen loss is detected, a further check should be made after approx. 4 months. If after this period no change in the pressure is found, a yearly check should be sufficient.

3.10.3 Reducing the Gas Pressure in the Bladder AccumulatorExecute steps 1 and 2 under "Checking the gas pressure in the bladder accumulator".• Carefully open the relief valve (B). The nitrogen escapes.



3.10.4 Pressure Increase (FILLING) of the Bladder Accumulator• For filling the hydraulic accumulator, only 99.995% nitrogen must be

used.• If the gas pressure in the nitrogen bottle is higher than the max.

operating pressure of the hydraulic accumulator, a gas pressure reduction valve must be connected upstream.

1) Connect the cap nut (G 1) of the filling hose to the pressure reduction valve of the nitrogen tank. With many international containers, a corresponding adapter will be required. The adapter must fit a W24.32x1/14" thread.

2) Connect the cap nut (M) of the filling hose to the check valve (C) of the filling and checking unit.

3) Open the shut-off valve of the nitrogen tank and let the nitrogen slowly flow into the accumulator. Only after a pressure of approx. 1 bar has been reached, the shut-off valve can be opened for a faster filling process.

WARNINGRisk of explosion

- Severe injuries caused by flying parts > Never fill in oxygen or compressed air

manifold Gpressure reducing

G1

filling and test control unit FPU-1

inflating hose

M

nitrogene gas cylinder

adapterA

hydrostorage

valve


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4) Every now and then, the filling process must be interrupted and the reached pre-filling pressure read. Repeat this process until the desired gas pre-filling pressure has been reached.

5) After a temperature compensation with the environment, the pre-filling pressure must be checked again and, if required, corrected. If the pre-filling pressure should be too high, pressure can be released via the relief valve of the checking and filling unit.

6) After the desired gas pre-filling pressure has been reached, the spindle at the bladder accumulator must be rotated in anticlockwise direction to close the gas valve.

7) Relief the filling unit via the relief valve and remove it by loosening the cap nut.

8) Screw off the adapter and remount the O ring (O). 9) Use a leak detector spray or a similar tool to check the tightness of the

gas valve at the accumulator. 10) Screw the cap nut (H) and the protection cap (S) onto the gas valve of

the accumulator and fasten it.


M-1437CRe-Inspections

4 Re-Inspections

4.1 Hydraulic EquipmentThe inspections must only be carried out by qualified persons authorised by the employer.

4.1.1 Qualified PersonsWith regard to the special inspection tasks in connection with hydraulic hose lines, "qualified persons" must at least meet the following requirements.

• Professional qualification: The qualified person must have successfully completed a professional training which allows for a comprehensible determination of his/her pro-fessional skills. Proof of such professional training is to be provided in the form of a training qualification certificate or similar documents.

• Professional experience: Professional experience implies that the qualified person dealt with op-erating equipment [i.e. hydraulic hoses] for a proven time period during his/her professional career. A qualified person has therefore learned about sufficient occasions which require an implementation of inspec-tions, e.g. based on the results of the risk assessment or everyday monitoring.

• Recent professional occupation: A recent professional occupation in the environment of the object to be inspected [i.e. the hydraulic hoses] and appropriate advanced training measures are imperative. The qualified person must have gained expe-rience in the implementation of the respective inspections or comparable inspections. The qualified person must be familiar with the state-of-the-art of the operating equipment to be inspected and the hazards to be ob-served. Experts who have inspected the hydraulic hose lines so far and meet the three above-mentioned requirements and are familiar with the contents of the German Occupational Safety and Health Act and the cor-responding modifications are qualified persons who can be further commissioned with the implementation of inspections.

NOTEThe qualified person is not bound by any instructions when performing the inspection and must not be adversely affected due to this provision.


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4.1.2 Duty of DocumentationThe inspection deadlines as well as the replacement intervals have to be documented in writing together with all other protective measures. The same applies to the results of these inspections.Furthermore, the inspection results have to be recorded (e.g. by means of the inspection protocol of the operating equipment) and stored on site at least until the next inspection is carried out.

4.1.3 Inspection Deadlines for Hydraulic Hose Lines

Inspection criteria for hydraulic hose lines:• Damaged external layer down to the insert (abrasion spots, cuts,

fissures),• Embrittled external layer (fissures in the hose material),• Deformations which are not in accordance with the natural shape of the

hydraulic hose line, in depressurised or pressurised state or when bent, e.g. separation of layers, bubbles, crushing and bending spots,

• Leaking hose, hose line or fitting• Hose leaving the fitting• Damaged or deformed fitting, which results in an impaired function and

stiffness of the fitting or the hose-fitting connection,• Fitting corrosion impairing function and stiffness,• Can the hydraulic hose lines be freely moved or has the installation of

new system components or units resulted in crushing, shearing or abra-sion spots?

• Has it been ensured that the hydraulic hose lines do not protrude into transport routes even when the units connected to the hydraulic hose lines are in their end position?

• Were hydraulic hose lines varnished over (explanation: fissures and marks are not visible!)?

• Were storge and utilisation periods exceeded?• Have all covers been re-installed and are they functioning (after inspec-

Requirements to be met by the hydraulic hose lines Inspection intervals Inspector

Standard requirements 12 months

Qualified personIncreased operating times (e.g. multi-shift opera-tion)

6 monthsMajor external influences

Scheduled extension of utilisation period



tion, relocation, conversion)?• Are additional anti-tear-off devices available or required?

NOTEThese inspections must be logged.Faulty hose lines and hose lines whose storage and utilisation periods were exceeded must be immediately replaced.

Requirements to be met by the hydraulic hose lines Replacement intervals

Standard requirements 6 years

Increased operating times (e.g. multi-shift operation) 2 years

Major external influences


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4.2 Electrical EquipmentRe-inspections on electrical systems and equipment must be carried out by qualified electricians only.

4.2.1 Qualified ElectricianThe qualification as electrician has to be proven by the successful comple-tion of a vocational training, e.g. as electrical engineer, electrician, electrical engineering master technician, electrical assistant.It can also be proven through several years of work including theoretical and practical training to be verified by a qualified electrician. Proof has to be documented.

4.2.2 Pre-requisites for the Implementation of the InspectionA pre-requisite for the implementation of the inspection is that the responsi-ble electrician is familiar with and knows how to implement the applicable national electrical regulations concerning the "operation of electrical installa-tions" and the "re-inspection of electrical equipment".

• Measuring devices used for inspection have to comply with DIN VDE 0413 or EN 61557 DIN 0404.

• During inspection, the electrical regulations referring to measuring de-vices must be complied with.

4.2.3 Duty of DocumentationElectrical systems and equipment must only be commissioned in a flawless condition and have to be maintained in a proper state.The inspection deadlines as well as the replacement intervals have to be documented in writing together with all other protective measures. The same applies to the results of these inspections.Furthermore, the inspection results have to be recorded (e.g. by means of the inspection protocol of the systems, operating equipment) and stored on site at least until the next inspection is carried out.



4.2.4 Stationary Electrical Equipment

4.2.5 Non-Stationary Electrical Equipment

Installations/operating equipment Inspection intervals Type of inspection Inspector

Electrical systems and stationary operating equipment

4 years

For proper condition Qualified electricianElectrical systems and stationary electrical equipment "on special type of industrial premises and in spe-cial type of rooms and plants"

1 year

Protective measures with RCCBs in non-sta-tionary systems

1 month

For effectiveness (measurement of fault voltage and tripping current, earthing resist-ance measurement)

Qualified electrician or electrotechnically in-structed person using suitable measuring and testing devices

Fault current, differen-tial current and fault-voltage circuit breaker- in stationary systems

6 months For proper functioning through operation of the test equipment

Operator

- in non-stationary sys-tems Every work day

Systems/operating equipment Inspection intervals Type of inspection Inspector

Non-stationaryelectrical equipment

3 monthsIf the inspections re-veal an error rate < 2%, the inspection intervals can be longer.

For propercondition(visual check – inspection for me-chanical damage–,inspection of the imple-mented protective measuresfor protection against indirect contact and in-sulation resistance measurement, in detail like DIN VDE 0702)

Qualified electrician or electrotechnically in-structed person using suitable measuring and testing devices

Extension cables anddevice connectinglines with plugs

Connecting lineswith plug

Movable lineswith plugand permanent connec-tions

at least once a year.


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4.2.6 Re-Inspections of Electrical SystemsMeasurements, measuring procedures and values / reference values for measurements in systems with protective measures in the TN/TT system

2) Practical value, not specified by the standard, depending on cross-section, length, material.

Measuring tasks Measuring procedures Values

Main potential equalisation and ad-ditional potential equalisation

Low-impedance resistance measurement < 1 Ω 2)

Insulation resistance of the PE conductor measured to N and phase conductors

Insulation resistance measure-ment

= 300 Ω/V with load= 1000 Ω/V without load and witha line voltage of up to 500 V and ameasuring voltage of 500 V

Confusion of PE and phase con-ductor

Phase check or voltage meas-urement towards ground Line voltage

Confusion of PE and N conductor Low-impedance resistance measurement < 1 Ω 2)

With more than one RCCB for the entire system: < 1 Ω 2)

• Correct allocation of N conduc-tors to the respective current cir-cuits detected by the RCCB.

Low-impedance resistance measurement

• Short-circuit between N conduc-tors of different RCCBs.

Insulation resistance measure-ment

See insulation resistance meas-urement



Additionally, the protection devices such as overcurrent protection device and RCCB must be assessed. Here, the inspection of protection devices in a TN system is presented to provide an example.

The values for the assessment of the overcurrent protection devices and RCCBs are speci-fied in DIN VDE 0100 Part 610.

Protection device Measuring tasks Measuring procedures

Overcurrent protection device

Measurement of the loop im-pedance (short-circuit current measurement) or calculation / proof on the basis of the line model

between the phase and PE or PEN conductor (U0 = line volt-age measured to grounded conductor, Ia = breaking current of the overcurrent protection device)

RCCB

1. UB ≤ UL and U ≤ Un

(UL < 50 V, max. permissible touch voltage)

2. Connection of all other bodies with the central protective bar (PE)

Measurement of the tripping current (I) and the touch voltage (UB) by generating a fault cur-rent and verification that the RCCB trips with nominal fault current (In) at the latest. Low-impedance inspection of the PE conductor

Schleifenimpedanz Zs U0Ia------=


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4.2.7 Re-inspection Procedure for Electrical DevicesThe inspections have to be carried out in the specified sequence and every inspection must have been successful before the next inspection is started.

* with connecting lines up to max. 5m, plus Inspection of the protection devices

0.1 Ohm for every additional 7.5 m, maxi-mally 10 Ohm

** Spare measurement after successfully passed measurement of the insulation re-sistance. If it is technically not feasible or if it cannot be ensured that all parts subjected to the line voltage are detected by the insula-tion measurement. (e.g electr. star relays). The measuring method can be freely select-ed. The measurement only has to be carried out on touchable conductive parts which are not connected to the PE conductor.

Check of device functions

Evaluation (assessment)

Log, if required device label for next inspection date

PE conductorresistance< 3 Ohm

Insulationmeasurement

> 0.25 Ohm


> 2 MOhm


> 1 MOhm

PE conductor ordifferential current

< 3.5 mA

Spare leakage currentup to 3.5 kW < 3.5 mA

< 3.5 mA

Spare leakage current< 3.5 mA

Touch ordifferential current

< 0.5 mA

Touchcurrent

< 0.5 mA



4.2.8 Measuring Tasks and Measuring Procedures for Re-Inspections on Electrical Devices

Measuring taskMeasuring procedures

Protective class I Protective class II Protective class III

PE conductor re-sistance

Low-impedance measure-ment of the PE conductor

≤ 0.3 Ω for devices with connecting line up to a length of 5 m plus 0.1 Ω for every additional 7.5 m

n/a n/a

Insulation resist-ance

≤ 0.3 MΩ(devices with activated

heaters)≤ 1 MΩ

(other devices)

≤ 2 MΩ(switch, temperature con-trollers etc. of the devices must be closed)

≤ 250 kΩ(switch, temperature controllers etc. of the devices must be closed)

Spare leakage current

Heating capacity≤ 3.5 kW≤ 3.5 mA

Heating capacity> 3.5 kW

≤ 1 mA / kW(only with devices featuring protection class I which do not reach the required in-sulation resistance)

n/a n/a

PE conductor current

≤ 3.5 mA(only with devices featuring protection class I with heaters which do not reach the required insulation re-sistance)

n/a n/a

Touch current

≤ 0.5 mA(only with devices featuring protection class I whose touchable conductive parts are not connected with the PE conductor)

≤ 0.5 mA(only with devices featuring protection class II, where a measurement of the insu-lation resistance would be critical)

n/a


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4.2.9 Wireless Transmission SystemsUnits serving the wireless transmission of control commands must be regu-larly, at least annually, inspected by a qualified person.A qualified person is a person who has sufficient know-how in the field of the wireless transmission of control commands due to his/her professional qualification and experience and is familiar with the relevant national indus-trial safety regulations, accident prevention regulations, guidelines and generally recognised codes of practice (amongst others DIN standards, VDE regulations, technical regulations of other EU member states or other contracting states of the Agreement on the European Economic Area) in a way which ensures that he/she can assess the safe condition of equipment for the wireless transmission of control commands.

4.3 Hoisting Devices and Lifting Accessories4.3.1 Persons with Inspection Authorisation

Qualified person:A person who has sufficient know-how in the field of winches, lifting and towing devices due to his/her professional qualification and experience and is familiar with the relevant national industrial safety regulations, accident prevention regulations, guidelines and generally recognised codes of prac-tice (amongst others DIN standards, VDE regulations, technical regulations of other EU member states or other contracting states of the Agreement on the European Economic Area) in a way which ensures that he/she can as-sess the safe condition of winches, lifting and towing devices.

4.3.2 Inspections• The entrepreneur has to ensure that devices, including the supporting

structure as well as winch blocks, are inspected by a qualified person prior to the first commissioning and, after major modifications, prior to re-commissioning.

• The entrepreneur has to ensure that devices, including the supporting structure as well as the winch blocks, are inspected by a qualified per-son at least once a year. Additionally, the entrepreneur has to arrange for an inspection outside the above-mentioned intervals - depending on the application and operational conditions.

• The inspection prior to the first commissioning in acc. with Section 1 re-fers to the proper erection and readiness for operation.

• Within the scope of the inspection in acc. with Section 2 Sentence 1, the entrepreneur has to determine the expired theoretical service life of pow-ered wire rope and chain hoists for load lifting and for powered crane lifting devices. If required, the entrepreneur has to commission an official expert.

• Notwithstanding Section 4, the expired theoretical service life does not



have to be determined if a) technical measurements were implemented to ensure that load cannot

drop when components fail, b) the devices are exclusively used in fenced off areas which cannot be

accessed by persons, c) damage which may cause load to fall is early detected and rectified by

means of suitable inspection procedures or 4., if, in case of powered crane lifting devices which are not series lifting gear and are regularly inspected by official experts, damage which may cause load to fall is early detected and rectified by means of a condition-dependent maintenance. A suitable form of maintenance has to be specified either by the manufacturer or an official expert. The intervals of the official expert's inspections must not exceed four years.

4.3.3 Implementation InstructionsThe inspection basically refers to completeness, suitability and functionality of the safety installations as well as to the condition of the device, the load carriers, the rollers, the equipment and the supporting structure. Safety in-stallations are, for example, non-return fingers, holdbacks, braking devices, auxiliary brakes, rope winding devices, devices for locking the load shaft, overload protection devices, final terminal stopping devices.


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M-1437CBolt Tightening Torques

5 Bolt Tightening TorquesExtract of Herrenknecht standard A-MBQ002 A-GW002 A-FS003 A-MT005: controlled preloading of screws and studs. Tightening screws involves great uncertainty in respect to the achieved

performance. Therefore it is absolutely necessary to be very thorough in the process.

The following criteria have an influense on successful bolt connections and the clamping force:

• New screws, smooth surface of the thread, thread and head supporting surfaces lightly oiled,

• Proper match of material: steel / steel,• No dirt, no paint or rost on the contact surfaces,• No contact between the shaft of the bolt and the drill hole,• Screws are tightened in a diagonal sequence for two times

have an influence on the clamping force of the screw connection.

Notice:Screw condition „lightly oiled“ means that head / nut supporting surface

and the flanks of the threads which are in operation are sprinkled with a thin oil film. Usable oils are transmission oils according to ISO VG 100 up to ISO VG220.

Creeping oils are not allowed.

Dimensions(standard

thread)

Bolt tightening torques in Nm at strength of Dimensions

(standard thread)

Bolt tightening torques in Nm at strength of

5.6 8.8 10.9 12.9 5.6 8.8 10.9 12.9

M5 2,5 5,7 8,1 9,7 M27 415 910 1300 1500

M6 4,3 9,9 14 16,5 M30 570 1250 1800 2100

M7 7,1 16,5 23 27 M33 780 1700 2400 2800

M8 10,5 24 34 40 M36 980 2150 3100 3600

M10 21 44 64 75 M39 1250 2800 3950 4650

M12 35 75 110 130 M42 1550 3450 4900 5800

M14 56 120 175 205 M45 1950 4300 6100 7100

M16 85 180 265 310 M48 2400 5200 7400 8700

M18 120 260 370 430 M52 3000 6700 9500 11100

M20 165 360 520 600 M56 3800 8300 11800 13900

M22 220 485 690 810 M60 4630 10100 14400 17000

M24 285 630 890 1050


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M-1437CBolt Tightening Torques

The specified bolt tensioning torques are not applied for HV-bolts and HV- nuts according to DIN 6914 and DIN 6915 (bolts and nuts with big width across glats). Also this table may not be applied for screws and nuts which are secured with adhesives.

5.1 Tightening by applying clamping forceBy using hydraulic bolt tensioners it is possible to use 90% of the bolt’s

yield point (0,2 limit) for clampin, because no torque component is superim-posed during the tightening process.

Influences doe to fiction don not need to be cosidered.Pay attention for cleanliness (e.g. dirt, welding nuggets, paint), and per-

pendicular support between bolts and parts, as well as flatness of bolt head or nut.

5.1.1 Installing - Preload Adjust the following tensioning forces in KN

5.1.2 Bolt Tensioning Cylinder• Bolt tensioning cylinders may only be used by specially trained

personnel.• For safety read the operating instructions of the manufacturer.• Ensure that the correct pressure / tension table is present for the bolt

tensioning cylinder used. • Positioning and use of the bolt tensioning cylinders see the operating in-

structions of the manufacturer.

Dimensions(standard thread)

Clamping force in KN at strengtht

of

10.9

M27 355

M30 430

M36 635

M42 875

M45 1020

M48 1150

M56 1600

M60 1850

M64 2100


M-1437CStorage

6 Storage

6.1 Storage of Control Container• Container has not to be stored under 0° C.

6.2 Storage of Feed and Discharge Lines6.2.1 Feed and Discharge Lines System MH

• Reassamble all sealings (O-rings) from the nipples of the pipes. Store them dark, dry and frost-free room.

• Grease the bright steel surfaces (nipples and sockets) or spray them with a preservation wax.

6.2.2 Feed and Discharge Lines System Victaulic• Reassamble all sealings out of the couplings. Store them dark, dry and

frost-free room or store the compelte couplings in a dark, dry and frost-free room.

• Grease the bright steel surfaces of the nipples or spray them with a pre-servation wax.

6.3 Storage of Slurry Pumps (optional)• In general armoured pump plants have to be stored in a frost - free room

with a constantly atmospheric humidity. If it is not possible to store ar-moured pumps in a frost - free room, doe as follows:

• Drain armoured pumps completely.• Depending on the pump size fill up approx. 1 - 2 liters of anti freeze into

the pump casing. This will prevent freezing a rest of water and conden-sation water in the pump casing.

• When storing armoured pump plant outdoors it has to be covered water-tight (e.g. using a polythene awning).


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M-1437CStorage

6.4 Storage of Hydraulic Power Packs6.4.1 Hydraulic

Fill all parts of the hydraulic equipment (pumps, motors, tanks, cylinders etc.) fully with preseravation oil, if the tunnelling equipment has to be stored for longer than 3 months.

6.4.1.1 Cylinders• Fill hydraulic cylinders with preventation oil. Pay attention to sufficient

airbolster for heat extension of the preventation oil• Close pipes and threaded connections using plastic screw joints or plas-

tic plugs. Close flanges with plugs made of soft plastic and secure it with metal plate.

• Store hydraulic cylinders standing in dry rooms at temperatures approx. 14°C to 20°C.

• Secure piston rods against damages if they are extended out of the hy-draulic cylinders. Pay attention to prevent corrosive effect to chromium layer of the piston rood.

• Spray piston rods with preservation wax before pack up.• Don’t store hydraulic cylinders near radiators.• Remove package and preservation wax from the piston rods before put

the hydraulic cylinders into operation again.

6.4.1.2 Pumps und Motors• Fill up all hydraulic pumps and motors with preservation oil which are

disconnected to the hydraulic lines. Pay attention to sufficient airbolster for heat extension of the preservation oil.

• Close thread connections with plasic screw plugs or plastic plugs. Close flange connections with plates of soft plastic and secure them with an sheet metal.

• Make the hydraulic equipment empty and refill it with new hydraulic oil according to the tank sticker before put into operation again.

CAUTIONEvery 6 months check the hydraulic equipment and com-ponents for condence of water. Drain arised condence water and refill the lost volume with new preservation oil.


M-1437CStorage

6.4.1.3 Storage of Hydraulic HosesWhen storing hydraulic hoses pay attention to the following points:• Store hydraulic hoses in a cool, dry and almost dust free place, prevent

direct sun-radiation and UV radiation, shield heatings near hydraulic hoses.

• Don’t store elastomere at temperatures below -10°C. May be there are different guidance values for thermoplastics. Don’t store near ozone for-mating lighting fixtures or electric instruments with spark fomation. Ozone formating lighting fixtures are e.g. fluorescent sources of light and quicksilver-steam-lamps.

• Wrap hydraulic hoses in a plastic awning for dust-free storage.• Temperatures between +15°C and +25°C and a relative atmospheric

humidity below 65% are convenient contions ro store hydraulic hoses.• Do not allow the hoses to come into contact with other substances and

materials which may damage them.• Store hydraulic hoses stress free, lying and closed. Pay attention to the

minimum bending radius given by the manufacturer when storing the hy-draulic hoses in rings.

• Do not store hydraulic hoses for more than 2 years.FeatureHydraulic hoses must be signed durable and continuously with the follo-

wing specifications in a distance of maximum 50 cm.• Manufacturer,• Type,• Nominal diameter,• Date of manufacture (quarter and year).

Eg. “1 Q 83“ means the first quarter in the year 1983.

Hoses have to be indicated clearly recognizable and permanent with the following points:

• License plate of the producer of the hoses• Date of production (Month and Year),• Maximum permissible dynamic operating pressure.

CAUTIONDo not store hydraulic hoses for more then 4 years and hydraulic hose lines for more then 2 years.


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M-1437CStorage

6.5 Storage of Electrical Parts6.5.1 Switch Gear Cabinets

Switch gear cabinets are to be water tight. To prevent condenced water on the base of temperature variations fill the switch gear cabinets with dry cells according to DIN55473-A+B.

6.5.2 Electrical CablesTo store electrical cables pay attention to following rules: • Store electrical cables in a cool and dry place. Prevent direct sun-radiati-

on and UV radiation to electrical cables.• Avoid temperature variations. Temperature variations may result in de-

velopment of condenced water in the cables.• Store electrical cables with plug and socket only, with plug and socket

connected together.• Do not fall short of the minimum bending radius (1,5 x d) when storing

electrical cables in rings (d = outside diameter of the cable).

CAUTIONThe quantity of dry cell has to be adjusted to the volume of the switch gear cabinets.


M-1437CSpare Parts

7 Spare PartsOrdering Spare PartsWhen ordering spare parts please write the description, order number

(part number) and the number of parts on your order list. Send your order to the following address to the attention of

"Ersatzteilservice".Herrenknecht AG Schlehenweg 2 77963 Schwanau Tel: 07824 / 3020 Fax: 07824 / 3403Example::

7.1 Stocking Spare PartsParts, marked with “E“ or "V" on the parts list, are wear parts.To ensure running of the equipment it is recommended to stock these

parts as spare parts in your store.

Pos Part- Number Bezeichnung designation quantity E/V

1 30015276 MISCHBODENKOPF CUTTING HEAD 1,00 ST

2 30015328 SCHLEISSRING WEAR RING 1,00 ST

3 25604753 WERKZEUGHALTERSATZ BUCKET 5,00 ST

. . . . .

. . . . .

. . . . .

101 29602757 SCHNEIDROLLE 3-FACH CUTTER DISC 5,00 ST V

102 29603137 SCHNEIDROLLE 3-FACH CUTTER DISC 2,00 ST V

explanantion: E=spare part, V=wearing part

Baukastenstückliste STLDISPO2227.02.03

Part Number 30015368 MISCHBODENKOPF drawing number: 973-01-012-00 CUTTING HEAD

Modular parts list


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M-1437CSpare Parts


M-1437CBranchadress Herrenknecht AG

8 Branchadress Herrenknecht AG

8.1 Europe

8.2 Middle East

Herrenknecht AGSchlehenweg 277963 SchwanauDeutschlandGesch. 1: +49 (7824) 302 0

Herrenknecht International Ltd.WearfieldSouthwick RiversideSunderlandSR 5 2 TAVereinigtes KönigreichGesch. 1: +44 (191) 54 89 191 Fax geschäftl.: +44 (191) 54 89 292

Herrenknecht France S.A.R.L.Espace Lumière Bâtiment 32, rue Emile Pathé78400 ChâtouFrankreichGesch. 1: +33 (1) 300 960 30 Fax geschäftl.: +33 (1) 300 960 35

Herrenknecht Ibérica S.A.Paseo de la Castellana 192-14 D28046 MadridSpanienGesch. 1: +34 (91) 345 26 97 Fax geschäftl.: +34 (91) 359 20 32 E-Mail: [email protected]

Herrenknecht Schweiz AGIm Grund6474 AmstegSchweizGesch. 1: +41 (41) 884 80 80 Fax geschäftl.: +41 (41) 884 80 89

Herrenknecht Nederland B.V.Meentwal 13432 GL NieuwegeinNiederlandeGesch. 1: +31 (30) 6000333 Fax geschäftl.: +31 (30) 6000955

Herrenknecht & Grindat AGMottastrasse 273005 BernSchweizGesch. 1: +41 (31) 3510 249 Fax geschäftl.: +41 (31) 35 13 791

Herrenknecht Tunneling Service RussiaBirjusinka 4107497 MoskauRusslandGesch. 1: +7 (095) 462 38 78 Fax geschäftl.: +7 (095) 462 57 44 E-Mail: [email protected]

Herrenknecht AG - IRAN6th floor#32, Ahmad Ghasir (Bokharest) St.1513755511 TehranIranGesch. 1: +98 (21) 872 77 15 Fax geschäftl.: +98 (21) 872 85 14 E-Mail: [email protected]

Herrenknecht AG Middle EastJebel Ali Free Zone LOB 4F27Po. Box 61251DubaiVereinigte Arabische EmirateGesch. 1: +971 (4) 8811200 Fax geschäftl.: +971 (4) 8871011 E-Mail: [email protected]


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M-1437CBranchadress Herrenknecht AG

8.3 Amerika

8.4 Asia

8.5 Australia

Herrenknecht Corporation201 Clay Street NW Suite# A2Auburn, WA 98001Vereinigte Staaten von AmerikaGesch. 1: +1 (253) 804 6511 Fax geschäftl.: +1 (253) 804 6507

Herrenknecht Tunnelling Systems USA Inc.P O Box 11288Tacoma, WA 98411-0288Vereinigte Staaten von AmerikaGesch. 1: +1 (253) 4 76 47 00 Fax geschäftl.: +1 (253) 4 76 47 70

Herrenknecht ArgentinaBartolomé Mitre 921 piso 2 depto. 271036 Buenos AiresArgentinienGesch. 1: +54 (11) 4394 3243 Fax geschäftl.: +54 (11) 4394 3243

Herrenknecht ASIA LtdFederal Express Building 12/621 Moo 15 Soi SornhirunBangna Trad Road, BangpleeSamut Prakarn 10540ThailandGesch. 1: +66 (2) 7450843 Fax geschäftl.: +66 (2) 7450845

Herrenknecht Asia-Pacific Pte.Appartement 602Building Chunjiang 1050Zhong Shan Nan Yi LuShanghai 200023ChinaFax geschäftl.: +86 (21) 630 31 721

Herrenknecht Asia-Pacific Pte.Room 1407, No. 3 Building,Xi Luo Yuan No. 3 Section,Feng Tai DistrictBeijing 100077ChinaFax geschäftl.: +86 (10) 8726 0301

Herrenknecht Asia-PacificXinhua RoadLane 569 Number 158Block 7 Room 503Shanghai 200052ChinaE-Mail: [email protected]

Herrenknecht Australia Pty. Ltd2 Mosaic Street WestShelley, PerthWestern, Australia 6148AustralienGesch. 1: +61 (8) 945 766 15 Fax geschäftl.: +61 (8) 945 767 15


M-1437C

VI) Accessory Equipment

Visualisation 1

Guidance system U.N.S. 2

Flow meter ABB_Copa-XL 3

Compressed Air Service Unit 4

Pneumatic Ratchet 5

Printer 6

Frequency Converter ELIN ECO 7

Electric Motor_VEM 8

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 VI - 1 - 1

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M-1437C

VII) Overview of CD, Declaration of Conformity

english

The operating manual is arranged on this CD as follows.AcrobatReader Copy of Acrobat Reader prepared for instal-

ling on your computer. Install if necessary.1_Operating Manual

Operating manual in english

2_Drawings Parts Lists

Spare parts drawingsParts lists Drawings and parts lists are arranged accor-ding to their parts number

3_Diagrams Parts Lists

Electric, hydraulic, compressed air and water diagramParts lists Diagrams and parts lists are arranged accor-ding to their parts number

4_Appendix Operanting and Maintenance manuals of the accessory equipment

Deutsch

Die Betriebsanleitung ist auf der CD wie folgt gegliedert:AcrobatReader Installationsfähige Kopie von Acrobat Rea-

der. Bei Bedarf installieren.1_Betriebsanleitung

Betriebsanleitung in deutsch

2_Zeichnungen Stücklisten

ErsatzteilzeichnungenStücklisten Die Zeichnungen und Stücklisten sind nach Artikelnummern geordnet

3_Schemen Stücklisten

Elektro-, Hydraulik-, Druckluft und Wasser-schemenStücklisten Die Schemen und Stücklisten sind nach Arti-kelnummern geordnet

4_Anhang Betriebs und Wartungsanleitungen für Zube-hör

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 VII - 0 - 1

Version: 0

Declaration of Conformity

x EC-regulation for machines (98 / 37 / EG)

x EC-regulation for low voltage (73 / 23 / EWG i.d.F. 93 / 68 / EWG)

x EMV - regulation for solenoid compatibility (93 / 97 / EWG)

EC-regulation for high pressure vessels (97 / 23 / EG)

We herewith confirm that the following described product corresponds to the above menti-oned regulations because of its conception and construction as well as the carrying out which is put into circulation by us. The maintenance schedule is to be followed.

This declaration losses its validity, if a change, repair or overhaul is performed without our agreement.

Project M-1437C

Designation of the product Control Container

Drawing number 2616-04-000-00

Part number 30138898

Year of construction 2009

Used harmonized standards:

prEN 12336, Tunnelling machines - safety requirements

DIN EN ISO 12100-T1 and T 2, safety of machinery - basic concepts, and general principles for design

EN 60 204-1, safety of machinery - electrical equipment

Used national standards and technical specifications

Telefon 07824 - 3020 Telefax 07824 - 3403 e-mail : [email protected]

Sitz der Gesellschaft : Schlehenweg 2, 77963 Schwanau Registergericht : Lahr HRB 485

Vorsitzender des Aufsichtsrates : Dr. h.c. Lothar Späth Vorstand : Dr. Ing. E.h. Martin Herrenknecht, Vorsitzender Dipl. Ing. Gebhard Lehmann, Stellvertreter Dipl. Ing. Werner Suhm Betriebswirt ( VWA ) Kurt Stiefel

G:\MM_DOKUMENTATION\02-PROJEKTE\Pro_2009\M-1437C\M-1437C\M-1437C_INTERN\Englisch\Abschnitt_07\Konf_Conta_GB.fm

PPA. Uwe BreigTechnischer Leiter BU Utility Tunneling

DatePlaceSchwanau 2. 4. 2009

M-1437C

VIII) Drawings and Part Lists

No.. Part. No. Designation Drawing No.

30138898 CONTROL CONTAINER 2616-04-000-00

30076512 HYDRAULIC POWER UNIT 809-31-010-00

30076513 OIL TANK 809-30-052-00

30080334 PIPEWORK 809-22-403-40

23500971 FEED PUMPE ETANORM 612-02-001-11

25101702 SLURRY PUMPE TUNNEL 207-02-013-04

23500487 SLURRY PUMPE 612-02-001-13

30006291 GREASE DISTRIBUTOR 207-02-004-45

30078987 WATER CIRCULATION 809-22-490-30

30054991 SLURRY HOSE 809-22-407-23

30063409 SLURRY HOSE 809-22-407-40

25200081 SLURRY HOSE 809-22-407-26

25400135 SLURRY HOSE 809-20-120-21

25400136 SLURRY HOSE 809-20-120-30


25200008 SLURRY HOSE 809-22-407-02

30047153 FITTING ADJUSTMENT 809-22-401-10

30047167 SLURRY HOSE 809-22-407-20

25200014 SLURRY HOSE 809-22-407-03

30047173 SLURRY HOSE 809-22-407-21

25200004 SLURRY HOSE 809-22-407-05


25200001 CONNECTING BOW 809-22-409-00

30072169 RETURN DISTRIBUTOR 809-72-000-07

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 VIII - 1 - 1

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M-1437C

IX) Diagrams and Part Lists

No.. Part. No. Designation Drawing No.

1 25263090 HYDRAULIC DIAGRAM CONTAINER M-1437C 2616-45-060-00

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 IX - 1 - 1

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M-1437C

X) Electric Diagrams

Nr. Part. Nr. Designation Drw. Nr.

1 25172440 ELECTRIC DIAGRAM CONTAINER 2616-562-002

© Herrenknecht AG, Schlehenweg 2 Edition: April 2009 77963 Schwanau 2, Tel. 07824 / 3020 X - 1 - 1

Version: 0

operating manual m-1437c en

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