CAT Armored Face Conveyor FACE CONVEYOR DRIVESFLEXBOW (MUFF) COUPLINGS Operation & Maintenance

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Operation Manual DBT-

FACE CONVEYOR DRIVES FLEXBOW (MUFF) COUPLINGS

Doc. No.:

5322 135 170 BA 11 5322 135 170 BA 12

BUCYRUS __________________________________________________ 2045 WEST PIKE STREET HOUSTON, PA 15342-1010

Internet: www.BUCYRUS.com

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Table of contents ABOUT THIS MANUAL.................................................................................................... 1.0 Preface........................................................................................................................ 1.3 General introduction .................................................................................................... 1.4 Copyright and patient rights......................................................................................... 1.4 What is the purpose of this operating manual.............................................................. 1.5 Efficiency..................................................................................................................... 1.5 Service ........................................................................................................................ 1.5 Safety.......................................................................................................................... 1.5 Characters and symbols.............................................................................................. 1.5 YOUR SAFETY ................................................................................................................ 2.0 Important notes for the user ........................................................................................ 2.3 Instruction / training ..................................................................................................... 2.4 Safety.......................................................................................................................... 2.4 Intended application .................................................................................................... 2.4 Remaining risk ............................................................................................................ 2.5 Safety instructions ....................................................................................................... 2.5 Operating the coupling ................................................................................................ 2.6 Servicing / remedy of faults ......................................................................................... 2.6 Technical description................................................................................................... 2.7 STORAGE AND TRANSPORT......................................................................................... 3.0 Storage and transport.................................................................................................. 3.3 Scope of delivery......................................................................................................... 3.3 Transport..................................................................................................................... 3.3 Storage ....................................................................................................................... 3.3 INSTALLATION................................................................................................................ 4.0 Preparatory work ......................................................................................................... 4.3 Component marking .................................................................................................... 4.3 Assembly .................................................................................................................... 4.4 Mounting hubs............................................................................................................. 4.4 Operating conditions ................................................................................................... 4.5 Installing the sleeve..................................................................................................... 4.5 Alignment .................................................................................................................... 4.5 Final assembly ............................................................................................................ 4.6 Grease lubrication ....................................................................................................... 4.7 Dismounting the coupling ............................................................................................ 4.7 Removal of coupling hubs ........................................................................................... 4.7 Maintenance and repair............................................................................................... 4.8 Disposal / recycling ..................................................................................................... 4.9 Troubleshooting .......................................................................................................... 4.9

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TABLE OF CONTENTS TECHNICAL DATA .......................................................................................................... 6.0 Drawing 1 .................................................................................................................... 6.3 Drawing 2 .................................................................................................................... 6.4

© BUCYRUS 2009

FOR YOUR INFORMATION ............................................................................................. 7.0 For your information .................................................................................................... 7.3 Our service.................................................................................................................. 7.3

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About this manual

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_______________________________________ Before starting to work preface

This manual is intended to provide basic operating information on Flexbow Coupling systems. Additional information can be obtained by referring to the Parts Book supplied with your equipment, or by contacting your local BUCYRUS representative. The illustrations, descriptions and procedures contained in this manual pertain to the equipment as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. BUCYRUS reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.

The equipment was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of manufacturing, this equipment was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this equipment, without the consent of BUCYRUS and these agencies, may void these approvals and render the equipment illegal or dangerous for use.

© BUCYRUS 2009

Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.

While this manual attempts to anticipate the most important operations and maintenance needs for this equipment, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your BUCYRUS Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable.

Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

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Before starting to work ________________________________________ General Introduction

General Introduction This operation manual accompanies every Curved Tooth Coupling supplied by RENK AG, Rheine Works. The abbreviated term Coupling is used throughout the following text.

The operation manual is an essential guide to ensure the successful and reliable operation of the coupling. It contains important instructions how to operate the coupling in a safe, appropriate and economic manner. Observing the manual helps avoiding hazards, reduces repair costs and downtimes and increases the reliability and lifetime of the coupling.

It is of utmost importance to always have the operation manual available in the direct vicinity of the coupling. The manual has to be read and followed by all persons being charged to work at or on the coupling, e.g. − Operation, including remedy of faults during service, as well as disposal of greases and other products required for the operation, and/or

NOTICE

Copyright and patent rights

NOTICE! The corresponding dimensional drawing is attached to the operation manual. The dimensional drawing includes all the important details specific to the coupling.

Copyright and Patent Rights This operation manual shall be treated confidentially. It shall only be made available to authorized persons.

It is not allowed to transfer this operation manual to any third party without having received the written permission from RENK AG beforehand.

All the documents are protected according to the copyright law. It is not permitted to copy or reproduce any documents as a whole or in part, or to use them or make them available to others, unless explicitly approved in writing.

Contravention is punishable and subject to claims for compensation.

We reserve all rights to exercise commercial trademarks.

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© BUCYRUS 2009

− Maintenance (servicing, repair)

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_______________________________________ Before starting to work What is the purpose of this operating manual? efficiency This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the FLEX BOW COUPLING. Read this operating manual completely and carefully. In particular, pay attention to the safety instructions.

Note the appearance and meaning of the safety and warning symbols. service If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For your information”. safety Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. characters and symbols Observe the information and follow the instructions contained in this operating manual.

© BUCYRUS 2009

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

These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

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

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

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

Items in lists are marked with bullets. Points in sub-lists are marked with an arrow at the start of the line.  Points in the text marked in this way describe individual work steps.

Follow these instructions step-by-step.

They will help you carry out your work faster and, more importantly, safer.

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Your safety

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________________________________________________ Your safety Instruction / Training

Instruction / Training As the operator of the equipment you are obliged to advise and instruct the operating staff of valid legal provisions and regulations regarding the prevention of accidents and on existing safety equipment at or around the coupling. The different qualifications of the employees have to be taken into account.

The operating personnel must have understood the instructions and it has to be safeguarded that the instructions are strictly observed. This way only will promote the personnel’s awareness of hazards and safety at work. This should be verified at regular intervals. It is strongly recommended that the operator of the plant requests the operating staff to confirm in writing the participation in such training/ instruction courses.

Safety

© BUCYRUS 2009

The coupling has been designed and constructed according to the latest state of technology and in compliance with recognized safety regulations. Nevertheless, the use of the coupling may cause risks for the operator or other persons, or may deteriorate the function of the coupling or other equipment, if it is: − operated by unskilled and non-instructed personnel, − not used for the purpose and application as intended, − improperly serviced and maintained.

Intended Application This coupling exclusively serves for the transmission of torque between two machines. The coupling compensates misalignments and displacements.

The technical coupling data have to be observed and adhered to.

These can be found on the dimensional drawing Any other use or operation of the coupling beyond the above mentioned application purpose is not regarded as the intended application.

The operator / user of the coupling is solely responsible for all damages resulting there from. This also applies to unauthorized modifications which are carried out on the coupling.

The intended application also includes the observance of instructions relating to: − safety and security, − operation, − maintenance/ repair, as described in this operation manual.

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Storage and transport _________________________________________ Remaining risk

Remaining Risk Even if all the safety regulations and instructions are strictly observed, there remains a risk when operating the coupling.

DANGER! Injuries due to touching the rotating coupling.

DANGER

The coupling has to be secured with suitable protective devices against unintentional physical contact (finger-safe).

Safety instructions

Safety Instructions The coupling must only be used in a technically unobjectionable state and in accordance with the intended purpose as agreed while carefully complying with this manual. In particular, circumstances or disturbances which affect the safety have to be eliminated immediately.

The operation manual shall always be kept ready to hand in the direct vicinity of the coupling.

No responsibility will be assumed for any damages and accidents which result from the non-observance of this operation manual.

The relevant regulations and provisions regarding the prevention of accidents and other generally recognized rules on safety at work and occupational medicine and health care have to be strictly observed.

The instructions with respect to maintenance work have to be observed when inspecting, servicing or repairing the coupling!

The responsibilities and competencies as regards the various activities to be carried out in conjunction with the operation, maintenance and \ repair of the coupling have to be clearly defined. Only in this way, mistakes or false handling can be avoided, in particular in danger situations.

If safety affecting changes in the operational behavior or irregularities are observed, the coupling has to be put out of operation immediately. The responsible post/ person has to be notified without delay.

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Every person being involved or charged with the assembly or maintenance of the coupling is obliged to have read and understood this operation manual.

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________________________________________________ Your safety Operating the coupling

Operating the Coupling The coupling must only be put into service in assembled state, ready for use.

The coupling shall only be operated after all the protecting equipment and safety devices, e.g. detachable protective devices, have been mounted and are ready to operate.

Servicing / remedy of faults

Servicing / Remedy of Faults Prescribed time periods or intervals being specified in this operation manual with respect to routine and recurring checks/ inspections have to be observed.

It is of importance that the workshop selected to perform necessary servicing and repair work is appropriately equipped.

© BUCYRUS 2009

If the machinery branch into which the coupling is mounted has to be disconnected for servicing or repair work, it has to be secured against unexpected re-engagement: − Main control devices such as switches and valves have to be locked away and the key has to be taken out, and/or − attach warning signboards to the main control devices.

Screwed connections which have been loosened for maintenance or repair works have to re-tightened. If specified, the screws have to be tightened with a torque wrench.

If safety equipment has to be removed in order to carry out installation, maintenance and repair works, these devices have to be re-mounted and checked immediately upon completion of the maintenance or repair work!

If individual components or larger assemblies have to be replaced, these have to be carefully attached and secured to the lifting appliance, so a to minimize all risks. Only use suitable and technically unobjectionable lifting appliances and load lifting elements of sufficient lifting capacity.

Take care for the safe and environment-friendly disposal of spare parts, greases, oils and other agents used for operation.

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Your safety _________________________________________________ Technical description

Technical Description The coupling consists of a coupling sleeve [9220] with internal teeth and a coupling hub [9030 or 9040] with curved teeth. The coupling sleeve is axially guided by several hexagon screws.

The coupling compensates shaft misalignments. Axial, angular and parallel misalignments are possible. The coupling is designed for grease lubrication.

The internal and curved teeth are gas-nitrided. The teeth are additionally coated with Molycote for emergency lubrication purposes.

© BUCYRUS 2009

All the coupling parts are finish-machined and prepared to be assembled/ installed.

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Storage and transport

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________________________________________ Storage and transport storage and transport Scope of delivery

Transport and Storage Scope of Delivery The coupling is supplied in completely or partially assembled state. The components shown on the drawings which are attached to this operation manual are included in the scope of delivery.

On receipt of the delivery, check whether all the parts have been supplied and that they are not damaged. Complaints regarding the delivery have to be immediately addressed to RENK AG in writing. The Standard General Terms and Conditions of RENK AG are applicable.

Transport

Transport DANGER! Injuries are possible due to coupling parts falling down!

DANGER

© BUCYRUS 2009

The appropriate lifting appliance has to be selected in dependence on weight and size of the delivery or packaging.

Packaging is provided according to the mode of transport and to the size of the coupling. During transport, the coupling has to be secured against slipping or falling down. Observe the relevant provisions for the prevention of accidents!

Storage

Storage The coupling is supplied with anti-corrosion protection. This protection is suitable for normal transport and storage conditions.

The corrosion protection is effective for six months, provided the parts are stored in a dry and protected place.

IMPORTANT! Corrosion damages on the coupling parts!

When the storage period of 6 months has been exceeded, the corrosion protection has to be regularly checked on all coupling components. If required, the coupling parts have to protected with a long-

term preservation agent (consult RENK AG beforehand!). The coupling parts have to be stored in a dry place under roof

and have to be protected against mechanical damages. Do not expose the coupling parts to a saliferous or

acidiferous environment. 

NOTICE

NOTICE! RENK AG does not assume any responsibility for damages due to improper corrosion protection!

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Storage and transport _________________________________________

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Installation

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__________________________________________________Installation Preparatory work

Preparatory Work At first, strip down the coupling completely. The final installation is only done after having cleaned all the parts and having drawn on the hubs (flanges).

IMPORTANT! The coupling or the machines to be connected can be damaged due to the use of false tools!

IMPORTANT

The coupling must only be disassembled by instructed and skilled personnel.

Suitable tools/ devices have to be used to strip down the coupling.

Never use striking tools and/or sharp tools for the installation/ assembly!

The puller threads are used to separate the cover.

Component marking

Component Marking

© BUCYRUS 2009

The main parts of the coupling (i.e. the sleeves, and the hubs) are marked with the RENK order number (Com. No.).

Care has to be taken that the correct coupling and the appertaining parts are used for the specified application.

Cleaning

NOTICE

Cleaning NOTICE! All the coupling parts have to be cleaned of anti-corrosion agents. Use wax solvents, cleaning gasoline (no petroleum!) or an

alkali industrial cleaner to clean the coupling parts.

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Assembly

Assembly IMPORTANT! Damages on the coupling or coupled machines can result from incorrect assembly of the coupling!

The coupling must only be assembled by skilled and qualified personnel.

It is of utmost importance to acquaint oneself with all the markings on the coupling and to assemble the coupling in accordance with these markings.

Only use appropriate tools/ devices to assemble and install the coupling.

Never use striking tools and/or sharp tools!

Mounting the Hubs IMPORTANT! If the sequence of mounting the hubs is not followed exactly, the procedure to remove them will become more complicated.

Before fitting the hub on the sprocket wheel side, it is of utmost importance to first slide the coupling cover and the O-ring [9180] over the shaft journal. Observe the installation location of the cover.

Fit the O-ring into the groove of the cover.

NOTICE

NOTICE! The O-rings easily drop out of the grooves. This can be prevented by applying a small quantity of grease at three or four locations in the groove before inserting the O-rings.

IMPORTANT!

Heat destroys the O-rings.

When heating the hub and/or the shaft, the O-rings have to be protected against heat, until the parts have cooled again.

DANGER! Extreme care must be exercised when heating the hubs to DANGER avoid burns on arms and hands.

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Mounting hubs

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It is of utmost importance to wear heat-resistant gloves. To facilitate mounting, the hub can be heated to a

temperature of 80°C. Locate the coupling hub axially. Locking disks are not

included in the scope of delivery of RENK. Fasten cover [9060] to the gearbox-side hub by using the

screws [9151]. See dimension drawing for tightening torque. Mount hub into gearbox shaft and lock it axially. If necessary,

heat up the gearbox shaft.

Installing the sleeve Installing the Sleeve

Prior to mounting the sleeve, remove the screws and the washers.

© BUCYRUS 2009

Apply a thin coat of the intended lubricant to the internal

sleeve teeth and to the curved teeth of the sprocket wheel side hub. Engage sleeve with the hub teeth. Assemble the sleeve with the cover and bolt these parts with the screws. Please see dimension drawing for the correct tightening torque. Insert O-ring into the groove of the sleeve. Push on the sleeve until it is flush with the hub.

Alignment

Alignment It is appropriate to align the two shafts to each other after having assembled the coupling.

In order to ensure trouble-free operation and a long lifetime of the machines and of the coupling, the shafts to be connected have to be aligned as accurately as possible.

If known, the thermal expansions of the machines to be coupled have to be considered for the alignment. The details given by the machine suppliers have to be observed on principle.

The maximum values for parallel and angular misalignment as stated on the dimension drawing must not be exceeded while aligning the parts. It is recommended to utilize max. 50 % of the permissible values.

Use appropriate devices for the alignment, such as dial gauges or optical instruments if larger spans have to be bridged.

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NOTICE

NOTICE! Observe the instructions given by the suppliers of the machines to be connected!

1 Axial Displacement Align the machine shafts to be connected to the shaft distance with a tolerance of ± 1 mm.

Final Assembly Check first, whether the O-ring is firmly fitted in the groove of

the sleeve (if not, insert it properly). with a bit of lubricant. Engage the coupling sleeve with the teeth of the hub. Check the coupling sleeve for axial displaceability. It must be possible to easily displace the sleeve axially. Apply lubricant to the threaded bore and to the screw support face at the sleeve with sealing compound (e.g. Hylomar M). Mount the screw and washer . Insert the strap of the washer into the groove of the sleeve. Please refer to the dimension drawing for the tightening torque. Bend up the washer at the side which is opposed to the strap. (see fig. 1).

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Slightly grease the coupling hub teeth on the gearbox side

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IMPORTANT

IMPORTANT! Greases and grease-containing waste represent a high danger potential to the environment.

Extreme care has to be exercised to avoid lubricants from falling to the ground, from penetrating the soil or reaching sewerage systems or ground water. The disposal of lubricants has to be accomplished in compliance with valid regulations and provisions.

IMPORTANT! Damages to the gear teeth are possible due to insufficient IMPORTANT lubrication.

Never put the coupling into operation without lubricant. The specified lubricant quantity must be filled in beforehand.

© BUCYRUS 2009

NOTICE

NOTICE! The lubricants recommended by RENK AG are listed on the attached Table of Lubricants.

Grease lubrication Grease Lubrication The coupling is supplied without grease filling.

Fill in grease after completion of the coupling assembly. Use a grease gun to press in the specified grease quantity (see dimension drawing) through the lubrication nipples. Grease Monthly Dismounting the coupling

Dismounting the Coupling Loosen the screw and remove it together with the washer. Push sleeve toward the sprocket wheel until the sleeve is flush with the hub. Move apart the machines. Loosen the cover screws and remove them. Dismount the sleeves. Further operations can now be performed, such as e.g. inspection, cleaning, etc..

Removal of coupling hubs Removal of Coupling Hubs Use a suitable mechanical puller device for removal. Dismount axial locking disks. Mount and operate the puller device in accordance with the relevant operation manual.

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DANGER

DANGER! Carelessness while heating the hub can lead to burns on arms and hands.

It is absolutely necessary to wear heat-resistant gloves. Should the hub not detach directly, uniformly apply heat up to a max. temperature of 80°C around the hub. Then try it again. Heat up the gearbox shaft on the gearbox side.

Maintenance and Repair DANGER! Critical injuries due to flying around coupling pieces or tools in case of unexpected rotational movement of the shaft.

DANGER

If the coupled machinery train has been switched off for repair or maintenance operations, the same has to be secured against unexpected re-engagement: Main control devices such as switches and valves have to be

IMPORTANT! Severe injuries are possible due to flying around coupling pieces if the coupling has not been assembled correctly.

IMPORTANT Once the coupling has been disassembled, it must only be

taken into operation again after having re-assembled it completely and when it is ready to operate.

Every 8.000 operation hours, or after 2 years - whichever comes first: − Check coupling sleeve for axial displaceability. − Continue to dismount coupling − Clean all coupling parts. − Inspect coupling teeth and O-ring. − Replace damaged O-rings. − Check sealing surfaces for damages. − Check alignment of the machines, and if need be, re-align them. − After re-installation of the coupling, fill in new grease.

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locked, and the key has to be taken out, and/or attach warning signboards to the main control devices.

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NOTICE

Disposal / recycling

NOTICE! The maintenance interval can be prolonged by the use of selected lubricants: − If synthetic greases are used for the lubrication, the maintenance interval is 3-months.

Disposal / Recycling The operation of the coupling does not require any substances or liquids which are subject of particular disposal regulations.

Any cleaning products or greases which are used for the maintenance of the coupling have to be disposed of in accordance with valid laws and provisions.

IMPORTANT! Greases or grease-containing waste represent a high danger potential to the environment. For this reason, specialized IMPORTANT companies have to be charged with the waste disposal

© BUCYRUS 2009

Waste has to be stored in the company-own disposal area. From this area they are handed over to specialized disposal companies.

If the coupling is replaced by a new one, the laws and provisions concerning waste disposal being in force at the point of time have to be carefully observed.

Troubleshooting

Troubleshooting It is essential to also consider the coupled machines when determining the causes for any problems or troubles with the coupling.

During all the operation modes, the coupling has to run at low noise and low vibrations. Any deviation from the above must be considered as an operation fault which has to be corrected immediately.

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Technical data

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_______________________________________________ Technical data

1 FLEXBOW COUPLING 6 RETAINING DISK 7 BOLT [HH] 8 WASHER [LOCK] 9 RING [SNAP] 10 BOLT [HH] 11 PLUG [SEALING] 12 ADAPTOR 20 GREASE

PLEASE REFER TO THE SPARE PARTS BOOK FOR FURTHER DETAILS

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1 FLEXBOW COUPLING 4 SHAFT [STUB] 6 FLEXBOW COUPLING RETAINING DISK 7 BOLT [HH] 8 WASHER [LOCK] 9 RING [SNAP] 10 BOLT [HH] 11 SEALING PLUG 20 GREASE

PLEASE REFER TO THE SPARE PARTS BOOK FOR FURTHER DETAILS

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For your information

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_________________________________________________ Our service for your information If you need to order spare parts, or if technical problems occur, please contact our after-sales service personnel or contact us directly. our service Service address BUCYRUS (Manufacturing & Design Facility) 2045 West Pike Street Houston, PA 15342-1010 Telephone (724) 743-1200 Fax: (724) 743-1201

© BUCYRUS 2009

BUCYRUS (Rebuild and Service Facility) 255 Berry Road Washington, PA 15301 Telephone (724) 743-1200 Fax: (724) 743-1201 BUCYRUS (Service Center) 2301 West Pike Street Houston, PA 15342 Telephone: (724) 743-1200 Fax: (724) 743-1521

Internet: http://www.BUCYRUS.com

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Our service __________________________________________________

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