CAT Armored Face Conveyor Gearbox K-20 B Operation & Maintenance Manual

BI623412

Operating manual

Translation of the original operating manual

Gearbox K-20 B Doc. no.: 1952 020 000 BA 00

Bucyrus Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

BI623412

Translation of the original operating manual.

Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus does not accept any liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications as a result of technical developments without previous notice.

Bucyrus Europe GmbH, Lünen 2011 E

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Contens

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

2.4

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

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

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 2.4 2.4 2.5

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

2.6

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.4

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Load units; dimensions and weights . . . . . . . . . . . . . . . . . .

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport plan for gearbox K-20 B . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.6

4. Installation Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.6 4.7

How to put the gearbox into service . . . . . . . . . . . . . . .

4.8

Before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 4.9 4.9

Dismantling and removing equipment . . . . . . . . . . . . . 4.10 Important instructions for dismantling . . . . . . . . . . . . . . . . .

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4.10

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Contens 5. Operation Maintenance of the gearbox . . . . . . . . . . . . . . . . . . . . . .

5.3

Tightening the bolted connections . . . . . . . . . . . . . . . . . . . .

Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking breather filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking gearbox bearings . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the gearbox casing . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3 5.4 5.5 5.5 5.5

Replacing defective components . . . . . . . . . . . . . . . . .

5.6

Replacing the heat exchanger . . . . . . . . . . . . . . . . . . . . . . .

5.6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

Gearbox troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

6.3

Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Oil levels and oil quantities . . . . . . . . . . . . . . . . . . . . . . .

6.7

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9

Screws with coarse metric thread DIN 13 . . . . . . . . . . . . . .

6.9

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 Recommended oil for gearboxes . . . . . . . . . . . . . . . . . . . . .

Requirements for gear oil for gearboxes . . . . . . . . . . . . . . .

Lubricating greases and pastes . . . . . . . . . . . . . . . . . . . . . .

Cooling water quality requirements . . . . . . . . . . . . . . . . . . .

6.10 6.11 6.12 6.13

Marking of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14

7. For your information Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Referenced standards and guidelines . . . . . . . . . . . . . . . . .

7.3

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

Technical data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6. Technical data

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1

About this manual

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Before starting work

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

Before starting work applicable operating manual

gearbox type

Using an operating manual that is not written for the gearbox type at hand can result in a safety hazard for yourself and others.

Ensure that the data on the gearbox agrees with the data given in the operating manual.

This operating manual is designed for: Gearbox K-20 B ID No.:

1952 020 000 00 00

It is only permitted to be used for gearboxes of this type. category acc. to Atex directive

The operating manual must be accessible at all times to all persons working on or with the gearbox.

An operating manual for the gearbox should always be available at the place of operation.

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According to European Directive 94/9/EC, the gearbox belongs to equipment group I, category M2.

new operating manual

Send for a new operating manual immediately if the present operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the gearbox.

All persons working on the face, at the edge of the face, or at the entry must read this operating manual.

This includes persons who: J are in charge of transport, J prepare the rise heading, J perform assembly/disassembly work, J operate the conveyor/crusher, J correct malfunctions, J perform daily routine work on the face, J perform maintenance work, J perform repair work.

Supervisory personnel who: J initiate and/or supervise the above activities

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1.3

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Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work economically and safely with our product. It provides you with important information on all the activities related to the gearbox.

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

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

service

safety

Should you have any questions, please contact our Service Department. Our service address is given in the chapter “For your information”.

Read the chapter “Your safety” closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

Characters and symbols used

Warning!

These points contain information on dangerous situations.

Possible consequences are death or very serious injuries.

Caution!

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

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

. Points in the text marked in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

Danger!

Points in the text marked with this symbol alert you to an imminent danger. Possible consequences are: very serious injury or even death.

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

Try to memorize the symbols and their meanings.

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2

Your safety

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Personnel

Your safety This chapter provides important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state-of-the-art technology

The gearbox has been manufactured using state-of-the-art technology and in accordance with the generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations, e.g., as a result of environmental influences, machine damage or operator errors.

Do not make any modifications or carry out conversions which could impair the safety of the gearbox. All modifications and changes must be approved by Bucyrus.

Use only original spare parts from Bucyrus. Note that use of parts from other manufacturers will void the guarantee.

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The European Directives and Standards referred to in this operating manual must be applied when using the gearbox within the member states of the European Union (EU).

If the device is used outside the EU, the directives and standards which apply in those countries must be observed.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations of the following parties: J of the mine, J of the mines inspectorate, and J of mining supervisory authorities. additional operating manuals

Please also read the operating manuals of the components required for operation, e.g. of conveyors, crushers, electric motors etc., carefully and thoroughly. Clarify any questions before starting work.

Personnel Installation and repairs As a fundamental rule, installation and repair work may be carried out only by personnel who have been adequately trained for these particular requirements.

Installation and repair work on the following may only be carried out

by Bucyrus service engineers or by specially trained mine personnel: J safety components (pressure relief valves, extinguishers, etc.), J the electrical systems (controls, signaling devices, etc.), J the hydraulic system.

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2.3

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Operating conditions Operating conditions Intended use The gearbox is exclusively designed and manufactured to be used as part of a drive unit for driving a crusher.

J It reduces the speed and transmits the torque of an electric mo-

tor bolted onto the drive shaft of the crusher.

Use the gearbox only as intended.

Unauthorized use Uses not listed explicitly as intended uses are unauthorized and must not be carried out with the gearbox.

Bucyrus does not accept any liability for damage resulting from any such unauthorized use.

Ambient conditions Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust (see DIN EN1710).

J sufficient and consistent ventilation, J plow water curtain / water spraying system.

The M2 equipment must be switched off if the firedamp concentration in the free cross section of the consistently ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL), defined by national legislation.

It may only be restarted by authorized persons.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except those which are relevant for safety and suitable for use in explosive atmospheres.

The M2 equipment has to be stopped at once and secured to prevent a restart (locked out) if firedamp protection facilities are found to be damaged.

2.4

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These include:

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Operating conditions Prerequisites for operation Putting the gearbox into service is prohibited until the machine into which this gearbox is installed has been found to comply with the European Directive 94/9/EC and the standard DIN EN1710.

As the equipment supplied is only part of an overall system, the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. These shall be marked according to the legal provisions applicable at the time they are placed on the market.

The M2 equipment/gearbox is only allowed to be operated when the safety requirements according to DIN EN 1552 have been met.

These include, among other things: J systems preventing unauthorized startup, J startup warning systems, J water-sprinkling systems, J safe lockout command systems,

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J EMERGENCY STOP systems, Bucyrus Europe GmbH, Lünen 2011

J dust extraction systems, J noise protection, J warning statements, etc.

All electrical equipment required to operate the gearbox must be marked according to the legal provisions applicable at the time when it is placed on the market.

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2.5

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Safety instructions Safety instructions Basic principles Always work with utmost concentration.

Familiarize yourself with your working environment. protective clothing and equipment

Always wear personal protective equipment. This also includes wearing ear protectors as the noise emitted by the crusher may exceed 85 dB(A).

Inform your colleagues of: J your exact location, J the work you are carrying out, J the amount of time you will probably require.

safety equipment

Start the crusher only when it is in a good and safe condition and all safety equipment, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

symbol plates EMERGENCY STOP

Observe the symbol plates on the gearbox and crusher.

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, so that necessary action can be taken immediately.

Also press the EMERGENCY STOP switch when safety equipment such as firedamp protection systems break down.

lock out

Lock-out the crusher during the following: J maintenance work, J inspection work, J repair work, J failure of safety equipment, e.g.:

– firedamp protection. cordon off working area

moving parts

2.6

Secure your working area over a wide range for monorail and floor conveying devices.

Never allow parts of your body to come between crusher/gearbox components which could move.

danger of explosion

Be sure to adhere to the maintenance and inspection intervals for the gearbox. Be sure that the gearbox is adequately cooled, since hot surfaces might cause potentially explosive atmospheres (air) and dust to ignite.

hot surfaces

The gearbox casing can heat up to 85 _C during normal operation.

If you have to work on the gearbox, the temperature should be no higher than 60 _C. If it is hotter, wait until it has cooled down enough.

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

Pay special attention to the system's acoustic and optical start-up warnings.

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Maintain the signaling and lighting systems in a functional order.

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Safety instructions Storage and transport Observe the specified storage periods and the storage instructions.

Do not store any materials or components in the travel way or in your working area.

Inform the persons concerned about the intended transport route and the probable duration of the transport. transport safety devices

Ensure that the transport safety devices have been correctly installed.

Secure all moving parts so that they are stationary.

Never stand under unsecured components or suspended loads.

means of attachment

Connect the lifting gear only to the lifting points provided for that purpose. Observe the different load limits of the lifting points. Also observe the instructions on the transport sheets.

Only use means of attachment which are in a good condition and have been designed for the loads concerned.

Only use transport straps to attach round parts that do not have any lifting points. Never use chains or steel cables for this purpose.

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Do not damage the finished or polished surfaces of shafts, sealing surfaces, etc. floor conveying devices

When using floor conveying devices for transport, make sure that the center of gravity is as low as possible.

Installation and commissioning

inclined faces

environmental acceptability

Use chains or straps to secure all individual parts on inclined faces, e.g. on the extensions.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and other person concerned about maintenance and repair work. Provide them with information on the intended work and its probable duration.

securing

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

Secure the crusher before all work on the gearbox against unauthorized and unintentional restarting.

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2.7

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Safety instructions replacing components

Stop and lock-out the crusher and prevent from restarting before replacing any defective components.

Defective components should immediately be transported away from the working area, in order to avoid hindering other persons.

Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

original parts

Only use spare parts which satisfy the specified technical requirements. This is only ensured with original Bucyrus replacement parts. Please refer to the replacement parts catalog for the order numbers.

For raising the gearbox, use only: J the lifting points provided for the purpose J lifting gear with adequate load-carrying capacity.

Only use only the points of attachment intended for that purpose.

On no account should cylinder lifting points be used as they are not designed to withstand tensile loads.

Refit any safety equipment removed immediately after completion of work and check that they function properly.

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protective devices

2.8

Gearbox K-20 B

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3

Storage and transport

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Storage

Storage and transport This chapter contains important information on the correct storage and safe transport of the gearbox.

Following this information and the instructions in it will extend the service life of the gearbox. You will be able to carry out transport work more safely and quickly.

Paying careful attention to the points in this chapter will also help you to simplify your day-to-day work.

Storage Storage of the equipment corrosion protection

avoid direct exposure to sunlight

Protect the equipment from direct exposure to sunlight.

Always store all electrical equipment, electronic components, spare parts made from rubber or plastic - such as seals and hoses - and hydraulic fluids in closed rooms at 15 C to 25 C.

moisture and dirt

Protect all parts of the equipment stored outdoors against moisture and dirt, e.g., using tarpaulins.

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Components with a temporary anticorrosion coating are protected for about six months.

You need to protect the connecting faces of hydraulic components from corrosion and seal them with blind plates. Protect the hydraulic plug-type connections and the connectors of the electrical cables with the caps and plugs supplied. short-term storage

long-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

The stored components must be checked before use after a storage period of approximately two years to find out whether the measures taken and the type of storage have prevented damage.

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. Do not use these components if they have been stored for more than two years.

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

frost protection for oil cooler

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Before storing gearboxes with an oil cooler, when ambient temperatures are below freezing, the oil cooler must be flushed with an antifreeze agent.

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3.3

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Storage Gearbox preservation When the gearbox is to be stored for a long period, its interior must be specially preserved. Preserving only especially corrosion-sensitive, bright exterior surfaces such as shaft extensions, flanges, etc. is insufficient.

We recommend the following preservative: J TECTYL 511-M by VALVOLINE

The following steps must be carried out to preserve the interior of the gearbox: J The gear oil must be completely drained and bubbles must be

avoided because they hinder anticorrosives. The gearbox may need to be swiveled or turned to the side.

J Next, fill the gearbox up with preservative until full (about 320 to

340 l). The quantity required is determined by the volume of the interior of the gearbox. The coverage capacity of the preservative is 35 to 45 m2/l.

the preservative.

J Allow the gearbox to run for at least 15 min without load so that

it becomes thoroughly coated.

J Drain the preservative as thoroughly as possible. Do not allow

small pools of liquid to form in the process.

J Vent the gearbox thoroughly for at least 24 hours with open in-

spection hole cover because the preservative contains a solvent (petroleum spirit) that must be discharged.

Danger!

Solvent flashpoint (petroleum spirit) 40 C according to DIN 51 755. Hazard class A II according to VbF (Ordinance for flammable liquids) The volatile solvent is heavier than air. For this reason, the opening should be at the bottom or the lower side so that the solvent can discharge downward. The gearbox may need to be swiveled or turned to the side.

After anticorrosion treatment the gearbox can be stored undercover without additional packaging for nine months.

It should be stored so that vents and other openings are covered to prevent water from penetrating the interior of the gearbox. The measures to prevent the water from penetrating should not adversely affect the inner ventilation of the gearbox.

Preserved gearboxes must be marked with information on the anticorrosive, date of preservation and storage period.

Bright exterior flanges such as shaft extensions, flanges, etc. should be coated with a non-slippery wax film or wax tape.

When the gearbox is put into operation, the preservative dissolves in the gear oil. It can remain in the gearbox until the next oil change without adversely affecting the ability of the oil to lubricate.

3.4

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

J Remove the breather filter so that it is not adversely affected by

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Caution!

The operating temperature of the preservative must be at least 18 C to 20 C. Observe VALVOLINE's instructions.

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Transport Any preservative in the breather filter must be removed before start up. You can use gasoline, kerosene, diesel oil, wax solvents, or alkaline agents to do this.

Filters that are part of the gear oil circuit must be monitored regularly for the first months after commissioning.

Transport Load units; dimensions and weights It is imperative that you observe the transport sheets. They include information on: J dimensions, J weight, J points of attachment and J centers of gravity.

Where technically possible, the load units have suitable lifting pointsfor transport and installation.

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Warning!

Use only load handling devices which comply with the technical and legal regulations for transporting loads.

Falling components can cause serious injury and death.

Use only suitable load handling devices.

Before transport temperatures below freezing

The transport of equipment at temperatures of -21 C to -40 C is only safe if certain requirements for these conditions have been taken into account in the design and production of the equipment.

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to max. 25 km/h for truck transport.

frost protection for oil cooler

Before transporting gearboxes with an oil cooler, when ambient temperatures are below freezing, the oil cooler must be flushed with an antifreeze agent.

electrical and electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the complete equipment is protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and the connections protected against dirt.

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Transport Transport plan for gearbox K-20 B Fig. 1:

Transport plan gearbox K-20 B S1 S1

S1 S1

B

a

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L

B1

a

L = 1882

a shaft protection S1 load ring, capacity: 5000 kg

B = 1020 B1 = 960

Weight: 3350 kg (without oil)

Important!

Always use all four lifting points for lifting the gearbox.

3.6

Gearbox K-20 B

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4

Installation

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Installing the gearbox

Installation Installing the gearbox Caution!

Incorrect installation can cause major damage to the gearbox and drive.

Install the gearbox only according to the instructions of Bucyrus technicians.

Before installation installation parts

The dipsticks, breather filters and the magnetic rods are supplied as separate parts.

They must be installed according to the following instructions before the gearbox is attached.

The gearbox can be attached in a right-handed or left-handed version. Observe the position of use when installing.

Both dipsticks must always be installed at the top. One dipstick is screwed into the main gearbox chamber and one is screwed into the gearbox chamber of the drive shaft bearings.

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Both breather filters are always installed at the top.

One magnetic rod is mounted at the top and one at the bottom in the gearbox.

Fig. 2:

Gearbox K-20 B - installing dipsticks and breather filters 11 11 23

23

12, 23, 16, 25

12, 23

8 13 8 11 12 13

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shaft protection dipstick 685 lg breather filter magnetic rod

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16 guide piece 23 sealing ring 30x36 25 sealing ring 42x49

4.3

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Installing the gearbox flange plate

The spacer box must be installed on the crusher before the gearbox can be attached.

Notice!

The couplings must be fitted on the gearbox before installing the gearbox. Always observe the instructions in the crusher's separate operating manual.

Check whether all bolted connections between the crusher and the spacer box are in place and check the tightening torque.

Make sure that all screws for fastening the gearbox to the drive connection assembly and the parallel key for the spacer box have been inserted.

heat exchanger

The heat exchangers are labeled with a “cooling water inlet” or “cooling water outlet” plate.

Depending on the operating conditions on-site, the “cooling water inlet” or “cooling water outlet” heat exchangers can be installed either at the top or the bottom. The cooling water inlet is installed on top in Fig. 3.

Fig. 3:

Cooling water ports

a

< 25 ºC !

b

3 3 pressure relief valve, 30 bar a cooling water inlet DN 12

4.4

b cooling water outlet DN 12

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

The heat exchanger system is equipped with a pressure relief valve (3) for protecting the entire cooling system.

The pressure relief valve must always be installed on the “water inlet” cooler.

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To replace the heat exchanger, see chapter 5, “Replacing the heat exchanger” section.

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Installing the gearbox Fig. 4:

Heat exchanger 10, 15

10, 15 X

X

15, 20, 21, 26 15, 20, 21

23 Y

Z

Y

Z

23, 24 1

cooling water inlet

11, 16 2, 3, 16, 17 27

2, 4, 16, 17

11, 16

23, 24

23

Bucyrus Europe GmbH, Lünen 2011

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25 Z

Y

Z

Y

cooling water outlet 15, 20, 21

X

X 15, 20, 21, 26 10, 15

10, 15 1 2 3 10 11 15 16 17 20

heat exchanger reducing piece M 42x1.5 pressure relief valve, 30 bar screw plug G 3/4 screw plug M 42x1.5-5.8 sealing ring 27x32 sealing ring 42x49 sealing ring 33x39 screw-in socket G 3/4“ - DN 12

21 recess clamp DN 12 23 fitting connection R 3/4” 24 plug DN 12 25 hose line 12x1200 26 plug-in elbow socket DN 12 27 hose line 12x400 X, Y, Z ports DN 12

The cooling water ports are identified with the letters X, Y and Z. Install the cooling water inlet at port Y of the heat exchanger and the cooling water outlet at port Z. The port combination X - Y must not be used because the cooling water would not flow through the heat exchanger, but would immediately flow out again.

Caution!

Insufficient cooling can lead to serious gearbox damage. Adequate heat exchange is only guaranteed when the water supply has been connected correctly. Under no circumstances should the water supply be connected using the combination of ports X and Y as that would “short circuit” the cooling circuit and heat exchange could not take place via the heat exchanger.

Connect the cooling water supply via the port combinations Y and Z or X and Z only.

Doc. no.: 1952 020 000 BA 00

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4.5

BI623412

Installing the gearbox Important information on installing the gearbox J Remove the transport protectors from the drive input shaft and

the output shaft.

J All flange surfaces, centering bores, parallel keys and grooves

must be clean and free from burr.

J The gearbox must be aligned to slide over the centering bores

and the parallel keys without tilting.

J For torque support mount the gearbox with the coupling casing

against the crusher.

J Observe the tightening torque of the connection screws.

Important!

Instructions on installation can be found in the crusher operating manual.

Transport protection

Bucyrus Europe GmbH, Lünen 2011

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Fig. 5:

8 3

9 3

3 hex head screw M 24x55-8.8 8 shaft protection 9 shaft protection

Drive connection The drive connection includes all the parts between the gearbox and the electric motor.

The following factors determine which drive connection is required: the motor and gearbox connection dimensions, motor output, motor speed and additional equipment if any.

Important!

Instructions on the drive connection can be found in the crusher operating manual.

4.6

Gearbox K-20 B

BI623412

Installing the gearbox Electric motor Flange position “W” For electric motors, flange position “W” describes the distance from the motor flange to the shaft collar. For the drive connection, it is the distance from the contact surface of the protection cover (motor side) to the contact surface of the elastic coupling.

Caution!

If flange position “W” on the electric motor is larger than on the drive connection, the motor shaft and gearbox drive shaft bearings can become warped, which may lead to damage to the gearbox and the electric motor.

Fig. 6:

Flange position “W” on electric motor

Bucyrus Europe GmbH, Lünen 2011

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Electric motor

Pay particular attention to the following instructions before installing the electric motor: J The motor's exact flange position “W” must be measured be-

fore installation.

J If the flange position of the electric motor is greater than that of

the drive connection, a component in the drive connection (e.g. hub of the flexible coupling) must be shortened by a corresponding amount.

J The connecting pieces must be installed using the mounting

and pulling-off device.

Installing the electric motor Clean the shaft of the electric motor and lubricate with “gleitmo 805” lubricating molybdenum or another molybdenum-disulfide-free substance of the same type and quality. Pull the motor-side coupling half of the plug-in coupling (coupling hub) onto the motor shaft.

Flange the electric motor onto the protection cover and guide the coupling hub into the rubber tappet of the coupling flange. Make sure that the flange connection fits firmly and is centered perfectly.

Caution!

Blows to the motor shaft and gearbox shaft will damage the shaft bearings. Therefore, always use a mounting and pullingoff device for installing and removing the connecting pieces.

Caution!

Only mount electric motors if their performance data (torque, rpm) are approved for the mounted gearbox and the drive frame.

If you want to mount an electric motor other than those approved by us, be sure to consult our Service Department first.

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BI623412

How to put the gearbox into service How to put the gearbox into service The gearbox must be put into operation according to the instructions of Bucyrus technicians.

Caution!

Observe the respective information on start up in the separate operating manual for the entire system. Serious damage to the machine resulting in high costs can result from errors made during start up.

Read all operating manuals for the entire system thoroughly.

Before startup The following work has to be performed before beginning with the actual start-up: J Check the oil level

Before start-up, make sure you check the oil level of the gearbox.

The gearbox contains no oil when it is delivered.

The oil is filled into the hole left by the oil filling screw after it has been removed. Make sure that the magnetic rod and the screw plug have been inserted into the oil drainage hole and tightened.

Caution!

The required oil level varies depending on the incline on which the gearbox is positioned. A plate on the gearbox specifies the oil level mark line that applies to the respective inclined position (see oil levels and oil quantities in the “Technical data” section).

Fill the respective oil chamber with oil until it reaches the correct oil mark level line on the dipstick.

Insufficient oil impairs lubrication of the gears and roller bearing.

Excessive oil results in high churning loss, oil foam and an increase in heat development.

J Check the gearbox

Check whether the gearbox is equipped with both breather filters (“main gearbox” and “drive shaft bearing” oil chambers). breather filters

4.8

The breather filters must always be installed at the top.

The position of the breather filter is displayed in the “Installing the gearbox” section.

Gearbox K-20 B

E

Gearbox K-20 B is equipped with two oil chambers. The “main gearbox” and “drive shaft bearing” oil chambers must be filled with oil separately.

Bucyrus Europe GmbH, Lünen 2011

two separate oil chambers

BI623412

How to put the gearbox into service Commissioning The gearbox must be put into operation according to the instructions of Bucyrus technicians.

Danger!

Make sure that nobody is in the danger zone of the conveyor system. Keep a safe distance from the conveyor, especially during the test run and start-up. Possible installation errors could give rise to risks that would be absent during normal operation.

. The crusher must be aligned before beginning the start up procedure.

. Remove all tools, auxiliary equipment, etc. from the crusher and your working area.

. Check that all screw connections are firmly in place, especially on the drives.

. Check the electrical connections. . Check the rotational direction of the motors.

Bucyrus Europe GmbH, Lünen 2011

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. Check the cooling water supply for the gearbox and electric motor.

. Check that the signaling devices and the intercom are working.

When the gearbox is started up, any residual preservative remaining in the gear oil dissolves. It can remain in the gearbox until the next oil change without adversely affecting the ability of the oil to lubricate.

Preservatives must be removed from the breather filter before start up if required. You can use gasoline, kerosene, diesel oil, wax solvents, or alkaline agents to do this.

Test run Check the following: J Carefully check the gearbox for leaks. Any oil residue must be

thoroughly cleaned from the gearbox before checking, otherwise it will not be possible to see if small amounts of oil escape.

J After a test run of two hours, the temperature of the gearbox

should not exceed 85 C.

J The smoothness of running of the gearbox.

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BI623412

Dismantling and removing equipment Dismantling and removing equipment Dismantling should be carried out in the most practical sequence according to the prevailing conditions, generally in reverse assembly order.

Important instructions for dismantling Dismantling and removal operations must only be carried out by persons who have adequate knowledge of the work to be performed and who have been instructed in carrying out the tasks. treatment of delicate components

J When dismantling the gear drive set, all exposed shafts, hubs,

labyrinth channels, and flanges must be protected against corrosion, contamination, and damage.

J When removing hose lines and cables, close off the disconnec-

tion points with protective caps or plugs.

J Small parts, screws etc. should be kept in suitable, well organ-

Bucyrus Europe GmbH, Lünen 2011

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ized containers and protected from contamination and damage.

4.10

Gearbox K-20 B

BI623412

5

Operation

BI623412

BI623412

Maintenance of the gearbox

Operation Warning!

The gearbox casing temperature can be 85 C. You can burn or scald yourself on hot surfaces, the components screwed into them (dipstick, breather filter, gearbox sensors, heat exchanger, etc.) or hot, leaking oil (oil change).

Check the gearbox temperature and wait until the temperature has fallen to at least 60 C. Pay attention to the signs on the gearbox itself.

Maintenance of the gearbox Maintenance at regular intervals increases operational reliability and the service life of the gearbox. danger of explosion

Be sure to observe the intervals specified for maintenance and checks of the gearbox since hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Maintenance includes: J checking the functions,

Bucyrus Europe GmbH, Lünen 2011

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J checking bolted connections, J checking the oil level, J changing the oil, J checking the gearbox bearings.

J cleaning the gearbox casing.

Use only suitable tools for maintenance work.

Important!

You should keep a container in the vicinity of the operating location with the required tools and the most frequently used spare parts. Protect the contents of this container from dirt and moisture.

Tightening the bolted connections retightening screws

The screw connections listed below must be retightened 60 hours after putting into operation for the first time and every 500 hours after that: J Drive connection (motor side and gearbox side)

tightening torque

See chapter 6 “Technical data” for the required tightening torques.

Checking the oil level The oil level must be checked weekly when the gearbox is stopped.

Foreign bodies must be prevented from penetrating the gearbox (see chapter 6, “Oil levels and oil quantities”).

Too little oil jeopardizes the lubrication of the gearwheels and roller bearings. Too much oil results in large churning losses, foaming, and increased heat generation.

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VPSS / 03

5.3

BI623412

Maintenance of the gearbox Changing the oil The first oil change on a new or overhauled gearbox must be done after 300 hours of operation. After that the gearbox should be filled with fresh oil after every 2000 hours of operation and at least once every six months, after thorough cleaning.

Important!

The oil must be changed when the gearbox is at operating temperature, as the warm, viscous oil is better able to wash away the oil sludge.

The oil is drained through the oil drain plug for the respective oil chamber.

Screw the oil drain plugs back in tightly before filling with fresh oil.

Draining oil

a a oil drain plug (at the bottom)

a

Remove both angles before filling with oil so that you can reach the oil filling screws. The angles are protective devices for the oil filling screws.

Fig. 8:

Filling with oil c b

d

a

a

a oil filling screw (at the top) b hex head screw M 16x40-8.8

5.4

c hex head screw M 16x130-8.8 d angle

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

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Fig. 7:

BI623412

Maintenance of the gearbox An early oil change is required if: J the level of contamination has reached the value of 0.1%

foreign particles, J the water content has exceeded the value of 0.5%, J the ageing resistance of mineral oil has diminished to the level

that the increase in neutralization NNUsed oil - NNFresh oil =  NN has exceeded the value  NN = 2.0 mg KOH/g of oil.

Determine the J acid number according to DIN 51 558, J water content according to DIN 51 582, J proportion of foreign particles according to DIN 51 592, J sulfate residue according to DIN 51 575.

Checking breather filters Check that breather filters are functioning properly and replace if necessary on a weekly basis.

E

Remove the breather filter at operating temperature. If air escapes, the breather filter is defective and has to be replaced.

Bucyrus Europe GmbH, Lünen 2011

Notice!

Replace a defective breather filter with a new filter only. Do not try to clean the old filter.

Used breather filters may not be reused. Please dispose of them in an environmentally acceptable manner.

Checking gearbox bearings Take note of unusual noises in the gearbox, as these often indicate bearing damage. Defective bearings can lead to serious damage to the gearbox and to overheating of the gearbox.

The bearings must be replaced as soon as they have reached their maximum service life. Forward the gearbox to servicing.

Important!

You should have the bearings replaced as a precautionary measure if they reach their maximum service life while a panel section is being worked. Bearing service life data is listed in chapter 6 “Technical data”. acoustic emission monitoring

To detect bearing damage at an early stage, continuous acoustic emission monitoring can be used.

Cleaning the gearbox casing Excessive dust deposits cause heat accumulation, which can cause the gearbox casing to heat up significantly.

In extreme cases, this can lead to spontaneous combustion of the coal dust.

Remove dust deposits, etc. from the casing on a daily basis.

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5.5

BI623412

Replacing defective components Replacing defective components Replacing the heat exchanger The cooling system consists of four heat exchangers: two in the main gearbox chamber and two in the drive shaft bearing. The heat exchangers are connected by an exterior hose pipe.

Fig. 9:

Positions of the heat exchangers

1

1

1 heat exchanger

The heat exchangers can be replaced in the event of damage to the cooling system.

Observe the following instructions.

. Drain the gear oil. . Depressurize the water circuit. . Remove the water feed lines. . Remove the recess clamps (item 21 - Fig. 10) of the connection line (item 25 - Fig. 10) between the heat exchangers.

. Then pull out the connection line. . Remove the mounting bolts (item 10 - Fig. 10) of the heat exchanger and pull it out of the housing.

The heat exchanger is delivered with a protective tube on the cooling coils and plugs in the holes. The protective tube and the plugs must be removed before installation.

The cooling water ports are identified with letters X, Y and Z. The heat exchangers must be installed so that the cooling water port Z on the lower heat exchangers points to the right, and cooling water port Y on the upper heat exchangers also points to the right (see Fig. 4).

5.6

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

1

E

1

BI623412

Replacing defective components . Insert the new heat exchanger.

Fig. 10: Cooling water ports 25 15, 20, 21 15, 20, 21 17

17 1

18

18

10

10

23 1 3

Bucyrus Europe GmbH, Lünen 2011

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1 23 1

25 1 3 10 15 17

heat exchanger pressure relief valve, 30 bar cyl. head screw M 16x80-8.8 sealing ring 27x32 o-ring 49.2x3

18 20 21 23 25

o-ring 100x3 screw-in socket DN 12 recess clamp DN 12 fitting connection R 3/4” hose line

Caution!

Make sure the heat exchanger pegs with the o-ring, item 17, have been inserted correctly in the bearing location in the housing. The o-ring, item 18, must be positioned in the groove on the connecting socket.

. Fasten the connecting socket tightly using screw M16x80 (10). . Reconnect the connection line between the heat exchangers and install all required fittings.

. The “cooling water inlet” or “cooling water outlet” heat exchangers can be installed in the gearbox either at the top or at the bottom. Install the cooling water inlet at port Y of the heat exchanger and the cooling water outlet at port Z.

. The pressure relief valve (3) must always be installed at the cooling water inlet.

. Seal all open holes with screw plugs. . Fill gear oil. . Check the cooling system for leakage.

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VPSS / 03

5.7

BI623412

Replacing defective components Fig. 11: Cooling water ports Possible connections for the cooling water supply wrong right Y

Y

X

Z

Z

X

The cooling water ports are identified with letters X, Y and Z. The port combination X - Y must not be used because the cooling water would not flow through the heat exchanger, but would immediately flow out again.

Bucyrus Europe GmbH, Lünen 2011

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Caution!

Insufficient cooling can lead to serious gearbox damage. Adequate heat exchange is only guaranteed when the water supply has been connected correctly. Under no circumstances should the water supply be connected using the combination of ports X and Y as that would “short circuit” the cooling circuit and heat exchange could not take place via the heat exchanger.

Connect the cooling water supply via the port combinations Y and Z or X and Z only.

5.8

Gearbox K-20 B

BI623412

Troubleshooting Troubleshooting Gearbox troubleshooting If the gearbox temperature is too high, you should ... ... check the oil cooling Check the cooling water feed; required quantity of water: approx. 25 - 30 liter/min.

Important!

The cooling water must not be hotter than 25 C when it enters the system. ... enable adequate heat dissipation Fine coal on the gearbox casing acts as an insulating layer that prevents heat dissipation.

Remove fine coal - also from the sides and underneath. ... check the oil level If the oil level is too low, the lubrication of the roller bearing and gears can be adversely affected, which contributes to increased heat buildup (see chapter 6 “Oil levels and oil quantities”).

Bucyrus Europe GmbH, Lünen 2011

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If the oil level is too high, it will result in heat-generating churning losses and to foaming of the gear oil. Foam hinders heat dissipation. ... check for possible overloading Continual overloading of the gears leads to higher gearbox temperatures. Check for overloading using an ammeter.

If the gearbox is losing oil, you should ... ... look for leaking connections and covers Tighten casing screws, cover bolts, magnetic rod and oil drain plugs.

Important!

Remove oil that has already escaped, to help you to see whether or not there is a leak at the port. ... make sure oil is not leaking from the breather filters Check the installation position of the breather filters.

Breather filters must always be installed at the top. ... check the oil level See chapter 6 “Oil levels and oil quantities". ... check the breather filters Remove the breather filters at operating temperature. If air escapes, the breather filters are defective.

Wet breather filters can also be blocked by dust because the moisture makes it adhere to the filters.

Notice!

When in doubt, always insert a new breather filter. Do not try to clean the breather filter.

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BI623412

Bucyrus Europe GmbH, Lünen 2011

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Troubleshooting

5.10

Gearbox K-20 B

BI623412

6

Technical data

BI623412

BI623412

Technical data sheet

Technical data This chapter contains the most important technical specifications for the gearbox. At the end of this chapter, you will find additional information on tightening torques, oil types, greases, etc. Read the chapter very thoroughly. Pay special attention to any safety instructions.

Technical data sheet Tab. 1: Technical data sheet

Permissible continuous input power 1) max. at n1 = 1500 rpm . . . . . . . . . . . . . . . . . . . . PAN Permissible continuous input power 1) max. at n1 = 1800 rpm-1 . . . . . . . . . . . . . . . . . . . PAN

E

= 900 kW

Max. permissible torque at output . . . . . . . . . . T1 Max. rated input speed . . . . . . . . . . . . . . . . . . . n1 max

= 24000 Nm = 1800 rpm

Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Itotal

= 5:1

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucyrus Europe GmbH, Lünen 2011

= 750 kW

L = 1882 mm B = 960 mm H = 1020 mm Shaft Ø120 with parallel key

Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Ø240 h6 smooth Weight (without oil) . . . . . . . . . . . . . . . . . . . . . . . M

= 3350 kg

Oil temperature at rated power . . . . . . . . . . . . . t Service life of bearings (continuous operation at rated power) . . . . . . . . . . . . . . . . . . . . . . . . . . Q

= 80 - 85 _C

Heat exchangers, plug-in version, to be screwed in from outside: Heat exchangers - main chamber . . . . . . . . . .

Heat exchangers - drive shaft bearing . . . . . . .

Ports for water, inlet and outlet . . . . . . . . . . . . .

Required cooling water quantity . . . . . . . . . . . .

Pressure relief valve set to . . . . . . . . . . . . . . . .

Cooling water pressure . . . . . . . . . . . . . . . . . . .

Maximum cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum cooling water dirt particle size . . . .

Required pH value of cooling water . . . . . . . . .

1)

Doc. no.: 1952 020 000 BA 00

2x 2x

= 25000 h 1)

Q Pgauge Pmax

535 mm long 535 mm long DN 12 ~ 25 - 30 l/min = 30 bar = 25 bar

tmax

= 25 _C

max pH

= 0.25 mm ~ 7

Corresponds to 90% of the calculated nominal bearing service life.

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BI623412

Main dimensions Main dimensions Fig. 12: Fitting dimensions 1 1882 230 7

Bucyrus Europe GmbH, Lünen 2011

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Ø 1020

Ø 900 h6

Ø 120 m6

210

1185

85

30

285

960

763

Ø 240 h6 Ø 650 h6

6.4

Gearbox K-20 B

BI623412

Main dimensions Fig. 13: Fitting dimensions 2 15º 15º 15º

15º 15º Ø 30 H7

Ø 26

35 deep

20x

15º 15º

15º

Ø 960 10º

10º

10º

10º 15º

15º E

Ø 30 H7 Bucyrus Europe GmbH, Lünen 2011

15º

15º 15º

15º 15º

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VPSS / 03

15º

6.5

BI623412

Technical description Technical description construction

The K-20 B bevel helical gearbox is suitable for attaching to crushers with separate shafts and for use underground and above ground.

The following ratio can be delivered: Itotal 5:1.

The gearbox can be used in a right-handed or left-handed version simply by relocating the dipstick and the breather filter. Torque support to the crusher is created by the drive connection assembly with parallel key.

Maintenance-free axial face seals are integrated into the output stage.

The gears, roller bearing and seals are lubricated using splash lubrication.

There is a second separate oil chamber in the area of the drive shaft bearings. This allows the drive shaft bearings to be lubricated perfectly when the gearbox is positioned on an incline.

Each oil chamber has a dipstick and a breather filter. Defined oil levels must be complied with depending on the inclination of the gearbox.

The gearbox contains no oil when it is delivered.

The oil coolers are secured against overpressure with a pressure relief valve set to 30 bar. The required quantity of cooling water is 25 - 30 l/min.

The cooling water must be filtered before it enters the gearbox (max. dirt particle size 0.25 mm).

The cooling water inlet temperature must not exceed 25 C. The inlet and outlet ports on the cooler have the dimension DN 12.

The oil coolers are pushed into the gearbox from the outside and fastened (plug-in version) and can be replaced underground.

6.6

Gearbox K-20 B

E

lubrication

The permissible continuous input power is 750 kW for an input speed of 1480 rpm (50 Hz motor) and 900 kW for an input speed of 1780 rpm (60 Hz motor).

Bucyrus Europe GmbH, Lünen 2011

power and torque

BI623412

Oil levels and oil quantities Oil levels and oil quantities Different oil levels must be complied with depending on the inclination of the gearbox. A sign on the gearbox or the following “Oil level mark lines” table specifies the oil level mark line that applies to the respective inclined position.

Dipstick Gearbox K-20 B has a second oil chamber located near the drive shaft bearings. This enables the drive shaft bearings to be perfectly lubricated when the gearbox is inclined.

Each oil chamber is equipped with a dipstick.

J Dipstick, 685 mm long - gearbox main chamber J Dipstick, 685 mm long - gearbox chamber for drive shaft bear-

ings Fig. 14: Dipstick

The standard dipstick can be replaced with a flexible dipstick when the gearbox is used in low seams.

Oil level mark lines 1cm

Bucyrus Europe GmbH, Lünen 2011

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Reference edge 100

The dipstick has markings every 1 cm working from the 100 reference edge (the sealing face of the dipstick), which are marked with numbers from 100 to 0 (see Fig.14).

The dipstick is inserted into the dipstick hole vertically and screwed in. The minimum oil level must not be more than one mark line below the required oil level mark line (see “Installing the gearbox” for the position of the dipsticks).

Fig. 15: Oil level mark lines K-20 B (values in cm) Inclination in conveying Drive shaft direction 25° - 54 Output shaft 20° - 55 high 15° - 56 10° - 57 5° - 57 0° - 59 Output shaft 5° - 61 low 10° - 64 15° - 67 20° - 69 25° - 72

Main gearbox 25° - 59 20° - 58 15° - 57 10° - 56 5° - 53 0° - 55 5° - 57 10° - 61 15° - 65 20° - 70 25° - 75

Caution!

Make sure that the gearbox is not operated over the specified angle of inclination. Exceeding the angle of inclination can cause great damage to the gearbox. The oil level mark lines must always be adhered to.

Important!

The values apply to the dipstick that is screwed in.

The permissible deviation is ±1 mark line.

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Oil levels and oil quantities Oil quantities Fig. 16: Oil quantities K-20 B (values in liters) Inclination inconveying direction

Output high

Output low

Drive shaft

Main gearbox

25º - 42 l

25º - 112 l

20º - 44 l 15º - 45 l

20º - 111 l 15º - 111 l

10º - 46 l

10º - 110 l

5º - 46 l

5º - 116 l

0º - 49 l

0º - 110 l

5º - 50 l 10º - 53 l

5º - 114 l 10º - 122 l

15º - 55 l

15º - 130 l

20º - 57 l

20º - 141 l

25º - 59 l

25º - 154 l

Bucyrus Europe GmbH, Lünen 2011

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Important!

The oil quantities are indicative values. The oil level mark lines must be observed.

6.8

Gearbox K-20 B

BI623412

Tightening torques Tightening torques Screws with coarse metric thread DIN 13 Tightening torques at total = 0.14

Tab. 2:

Thread 1)

Pitch P

Torque 4)

(mm)

(mm)

MA (Nm)

d

Coarse thread

M8

8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

3

535

-

-

3

965

1360

1630

24 m Bucyrus Europe GmbH, Lünen 2011

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DM 24

Fine thread

2 2)

(M 27)

-

1600

-

(DM 27 2))

(M 27) 3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

2

3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists must be observed during installation and maintenance work.

1) 2) 3) 4)

Doc. no.: 1952 020 000 BA 00

The dimensions listed in brackets are used in exceptional cases only.

As per Bucyrus works standard (EWN 6110, edition February 1985).

Only for expansion bolts having a reduced shaft cross-section of 24.2 mm.

Tightening torques as per Bucyrus works standard (EWN 6003).

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6.9

BI623412

Permissible media Permissible media Recommended oil for gearboxes Use only the recommended gear oils or proven equivalents. gear oils on mineral oil basis gear oils on synthetic basis

When using other manufacturers, gear oils based on mineral oil with corresponding active components can be used.

If synthetic oils other than those listed in the right column are used, the durability of the gearbox interior coating cannot be guaranteed.

Only synthetic oils with EP characteristics may be used. In GRC special test A/16.6/140 there must be no escalation to the upper wear profile in any of the 12 load stages.

changing the type of oil

concerning the gear oil table

Before changing from one gear oil to another, we recommend that you clean the gearbox - or have the suppliers confirm that the two types of oil are compatible.

The different types of gear oil listed in the two columns of the table are equivalent. The order in which the suppliers are listed does not indicate the oil quality. However, do not mix the brands of different oil companies.

ARAL

BP

ESSO

KLÜBER

MOBIL

SHELL

TEXACO

WINTERSHALL

6.10

Gear oils on mineral oil basis

Kinematic viscosity mm2/s (cST)

Flashpoint

At 40 _C

_C

Aral Degol BG 220

220

265

Aral Degol TU 220

220

255

BP Energol GR-XP 220

218

240

BP Energol GR-XP 320

315

245

SPARTAN EP 220

210

236

SPARTAN EP 320

300

237

Klüberoil GEM 1-220

220

> 200

Klüberoil GEM 1-320

320

> 200

Mobilgear 630

206

>232

Mobilgear 632

302

>232

Shell Omala 220

220

240

Shell Omala 320

320

245

Universal gear lubricant EP SAE 85 W/90

195

225

Meropa 220

220

245

Ersolan 220 Ersolan 320

220 320

240 245

Gear oils on synthetic basis

Kinematic viscosity mm2/s (cST)

Flashpoint

At 40 _C

_C

Aral Degol GS 220

230

215

BP Energol SG-XP 220

240

250

Klübersynth GH 6-220

220

>300

MOBIL SHC 632

300

250

Shell Tivela Oil WB

234

320

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

Manufacturer

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Tab. 3: Oil types for gearboxes

BI623412

Permissible media Requirements for gear oil for gearboxes The correct choice of gear oils and diligent monitoring of lubrication are important prerequisites for fault-free operation. They also help to lengthen the service life of the gearbox.

Load-bearing capacity In the mechanical testing of gear oils in accordance with DIN 51354, there must be no escalation to the upper wear profile in any of the 12 load stages in GRC normal test A/8, 3/90 and in GRC special test A/16,6/120; in other words the failure load stage should be over 12.

In addition, the “specific change in weight” of the test gears ms (specific wear) may not exceed 0.27 mg/kWh. Ageing resistance The gear oils must have excellent “thermostability” and “ageing resistance” at the prescribed oil change times after 2000 hours of operation.

Fig. 17: Acid number curve

Bucyrus Europe GmbH, Lünen 2011

E

Oil change

NN

NN

Used oil Turning point

Fresh oil

1000 NN = acid number

2000

Operating period in hours

The acid number (NN) curve of mineral oils at actual operation of 2000 hours and the permissible continuous temperatures must be prevented from reaching the point of inflection (see Fig.).

Kinematic viscosity The gear oils should lie within the viscosity range 210 to 320 mm2/s at 40 C, with a high viscosity index.

Additives J anti-wear EP protection, J anticorrosion protection, J antifoaming protection.

Suitability J Compatibility with commercial sealing elements.

Doc. no.: 1952 020 000 BA 00

VPSS / 03

6.11

BI623412

Permissible media Lubricating greases and pastes Only the recommended lubricants or products certified as equivalent may be used.

Important!

The lubricants to be used are specified in the respective chapters.

Greases grease A1

Greases for general application, e.g. for roller bearings subject to normal load, for labyrinths, and for installation.

Tab. 4: Greases A1 Supplier

Type

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . practically insoluble in water

Greases containing additives for high pressure applications, e.g. for roller bearings and other bearing points exposed to extreme load.

Tab. 5: Grease A2 Supplier

Type

Base

Shell

Alvania E.P. grease 2

Lithium soap

NLGI class

Flashpoint in °C

2

205

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . practically insoluble in water Temperature range of application: . . . -15 to +120C grease A8

High-load grease for high loads and low speeds, e.g. for roller bearings in drive frame and crusher, for installation and corrosion protection purposes, suitable for central lubrication.

Tab. 6: Grease A8 Supplier

Type

Base

Castrol

Molub-Alloy 3036/680-1

Lithium soap

NLGI class

Flashpoint in °C

1

210

Worked penetration: . . . . . . . . . . . . . . . 310 to 340 (0.1 mm) Behavior in the presence of water: . . . insoluble in water at 90C Temperature range of application: . . . -20 to +120C

6.12

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

grease A2

E

Temperature range of application: . . . -40 to +120C

BI623412

Permissible media Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation.

Tab. 7: Lubricating paste B3 Supplier

Type

Base

gleitmolybdän

gleitmo 805

Lithium soap

NLGI class

Flashpoint in °C

2

220

Worked penetration: . . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . . insoluble in water Temperature range of application: . . . -20 to +120C Lubricants lubricant B6

Parting agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support.

Bucyrus Europe GmbH, Lünen 2011

E

Tab. 8: Lubricant B6 Supplier

Type

Base

Chesterton

parting and lubricating material 785

Petroleum

Flashpoint in °C 132

Behavior in the presence of water: . insoluble in water Application temperature range: . . . . -34 to +120°C

Doc. no.: 1952 020 000 BA 00

VPSS / 03

6.13

BI623412

Permissible media Cooling water quality requirements To prevent damage to the heat exchangers, the cooling water must not contain any aggressive ingredients or dirt particles. Furthermore it must not contain any components that could precipitate out when the temperature rises in the heat exchanger, forming deposits and thus impairing cooling function or, in extreme cases, even leading to the complete breakdown of the system.

Therefore to ensure reliable operation, the requirements defined in the following table should be met.

Tab. 9: Requirements of the cooling water Requirement

Appearance, color, smell

Clear, no sediment, no odor

pH value

7 – 8.5

Total water hardness

≤ 60 °dH (≤ 1070 mg/l CaCO3 equivalent or ≤ 10.7 mmol/l alkaline earths Ca2+/Mg2+)

Carbonate hardness

≤ 20 °dH (≤×142 mg/l Ca2+)

Input temperature

≤ 25 °C

Max. dirt particle size

≤ 0.25 mm

Bacteriological requirement

≤ 105 kol/ml (dip slide)

If the input temperature of the cooling water is over 25 C, deposits and the consequent effects described above are to be expected even with low values of carbonate hardness.

If the limit values specified in the table are not complied with, proper operation must be ensured through suitable water preparation or treatment (hardness stabilizers).

We will be happy to assist you if you require more detailed information.

6.14

Gearbox K-20 B

Bucyrus Europe GmbH, Lünen 2011

E

Criterion

BI623412

Marking of the gearbox Marking of the gearbox Manufacturer:

Bucyrus Europe GmbH

Type:

K-20 B

Year of manufacturing:

MM/YY (e.g.: 01/11 ≙ January 2011)

ID No.:

1952 020 000 XX *)

Weight:

3350 kg (without oil)

The gearbox is identified with the following information.

Fig. 18: Markings on gearbox Gearbox data

K-20 B 1952 020 000 00 XX No xxx / xx I = xx G = 3350 KG

1 2

Bucyrus Europe GmbH, Lünen 2011

E

3 4 5

1 type 2 ID number 3 serial No. / year of manufacturing

4 reduction ratio 5 weight

CE marking

The design of the gearbox meets the requirements of the European Directive 94/9/EC and DIN EN1710 and is suitable for use in potentially explosive atmospheres.

*) X = Placeholder for variant ID number

Doc. no.: 1952 020 000 BA 00

VPSS / 03

6.15

BI623412

Bucyrus Europe GmbH, Lünen 2011

E

Marking of the gearbox

6.16

Gearbox K-20 B

BI623412

7

For your information

BI623412

BI623412

Standards and guidelines

For your information If you should require spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Standards and guidelines Referenced standards and guidelines Tab. 10: Standards and guidelines, extract

Bucyrus Europe GmbH, Lünen 2011

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Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 2006/42/EC the approximation of the laws of the Member States relat2006-05-17 ing to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and Directive 94/9/EC 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 2004-04 Safety of machinery 12100-1/A1 2009-07 DIN EN ISO 12100-2 Safety of machinery 2004-04 Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water - Distillation method Non-electrical equipment for potentially explosive atmoDIN EN 13463-1 2009-07 spheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079-0 2010-03 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface 2007-11 Underground mining machinery - Specification for the DIN EN 12321 2009-07 safety requirements for armoured face conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shear loaders and plough systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic powered roof supports 2010-05 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation DIN 2000 Quality of drinking water 2000-10 DIN 6789 Documentation System 1990-09 DIN 20043 Plug connectors for hydraulics 2003-09 DIN 24320 Fire-resistant hydraulic fluids 2006-12 DIN 24343 Maintenance and inspection list for hydraulic systems 1982-02 DIN 51558-1 Determination of the acid number 1979-07 DIN 51575 Determination of sulfated ash 2011-01

Doc. no.: 1952 020 000 BA 00

VPSS / 03

7.3

BI623412

Standards and guidelines Date of issue

Designation

Title

EWN 6003 1)

Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

1985-02 1992-06 1985-02 2008-01

Bucyrus Europe GmbH, Lünen 2011

E

EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = Bucyrus works standard

7.4

Gearbox K-20 B