CAT Armored Face conveyor TECHNICAL INFORMATION Operation & Maintenance Manual - PDF DOWNLOAD

EM015721-0 (EN-US)

BI019981 June 2013

Operation and Maintenance Manual TECHNICAL INFORMATION F/CST OIL SAMPLING

SAFETY.CAT.COM

EM015721-0 (EN-US)

EM015721-0 (EN-US)

Report-0007 Technical information Add-on kit – oil sampling device Gearboxes 45 / 65 CST 2009-02-13 Engineering Gears – Longwall Division

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

Content Page 1 2

Introduction........................................................................................................................... 3 Technical description............................................................................................................ 3 2.1 Operating mode ............................................................................................................ 3 2.2 Hydraulic layout ............................................................................................................ 3 2.3 Configuration ................................................................................................................ 4 2.4 Assembly drawing ........................................................................................................ 4 3 Installation ............................................................................................................................ 5 3.1 Retrofitting .................................................................................................................... 5 3.2 Primary installation ....................................................................................................... 6 4 Operating instructions........................................................................................................... 7 4.1 Auxiliary material .......................................................................................................... 8

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 2 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

1

Introduction

To observe the condition of an operating gearbox, it is necessary to take oil samples from the unit frequently. Therefore an assembly group was created to provide two oil sampling points at the outside of the supply housing. When used as an add-on kit, this group of parts can also be implemented into consisting supply units of sizes 45 and 65. The currently delivered gearboxes already include this feature.

This oil sampling device achieves getting authentic oil from the running gearbox. It has not to be stopped and no parts have to be disassembled.

2

Technical description

2.1

Operating mode

The cooling oil system, powered by a centrifugal pump in the oil sump, has a branch connection to a sensor and a gauge to measure the oil pressure. This line will be extended by connecting two hose lines that end at the input-side housing wall. At these positions two measurement connections act as sampling valves at the outside of the housing.

When connecting a hose to one of the two valves, this one will be opened and a part of the cooling oil flow will be delivered up to this sampling point – assumed the gearbox is operating.

The measurement connections must be protected against mechanical damages. Therefore one is located below the existing protection plate at the right-top of the housing. Opposite to this an additional protection plate is recommended to be installed for the sampling point at the left side.

2.2

Hydraulic layout Figure 2.1 shows an extract of the hydraulic circuit, concerning the cooling oil section.

The area built by the assembly group “oil sampling pipe” is marked with a dash line.

Fig. 2.1: Hydraulic circuit of cooling oil

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 3 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

2.3

Configuration

The assembly group “OIL SAMPLING PIPE” (SAP-No. 777442) consists of these components: Item

Component

Description

Quantity

01 02 03 04 05 06 07 08

369756 843896 128383 369697 390618 128068 127770 268347

Fitting DN 10 Plug-In (L-Socket) Hose Line EWN 8114-2ST-K 6x1200 ST/ST Fitting (Adapter) 3/8” BSPPMxDN10 STF Swivel Notch – Clamp DN 10 Reducer Sealing Ring DIN 7603-A 18x22-PA-A Pressure Gauge Connector EMA 3/R 3/8 Hose Line EWN 8114-2ST-K 6x800 ST/ST

2 1 2 2 2 2 2 1

The current revision No. 01 refers to last change done 30 Oct. 2008.

2.4

Assembly drawing

Fig. 2.2: Drawing No. 1946 036 150 00 00 / 777442 (Rev. 01)

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 4 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

3

Installation

The connection of the assembly kit is done by locking the fitting (L-socket) into the assembly group “cooling oil pressure sensor” (see Fig. 2.2). Therefore the pressure gauge will be located on a higher level.

3.1

Retrofitting

In case of installing in a completely assembled supply unit the connections between pressure sensor and gauge have to be interrupted.

When opening the hydraulic circuit the gearbox must been stopped!

Make sure that the system is not pressurized any more.

From the inserted turnout both hose lines must be laid to the housing front wall, at top-right and top-left side. The reducers can be placed after removing two plug screws.

Figures 3.1 and 3.2 show installed sampling connections at both sides (see arrows).

Fig. 3.1: Supply unit left side with sampling connection

Fig. 3.2: Supply unit right side with sampling connection

The connection on the right side will afterwards be protected by a protection plate, that is fixed when completing the supply unit. Newly a protection plate is also available for the left side, that requires additional threaded holes in the housing (see 3.2).

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 5 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

3.2

Primary installation

When building a supply unit using a new housing, the left side sampling connection will be located different to the retrofit situation described in 3.1.

Fig. 3.3 shows a current supply unit including the latest positioning of sampling points.

The protection plate for the sampling connection on the left side is registered by SAP No. 661691. This group contains two cylindrical head screws M16 x 120 (SAP No. 126906).

The inside connection of the two hose lines using a turnout does not differ from the retrofit version (see 3.1).

protection plate for oil sampling

sampling point LH sampling point RH

Fig. 3.3: Supply unit 45 CST

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 6 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

4

Operating instructions

While the gearbox is running an oil sample can be taken from the sampling connections.

You can choose LH or RH sampling point depending on which one is accessible more easily.

1.

Remove cap from connector.

2.

Connect drain hose line and collect oil.

First amount of oil does not represent the quality of the circulating oil in the gearbox.

Do not use first 0.2 liters of draining oil in order to analysis!

Collect all the excessive oil and don’t let it drain away in the ground.

For collecting the oil sample to be analyzed use a suitable and clean reservoir (small bottle).

3.

To complete sampling disconnect hose line and screw on cap again.

The sampling connector automatically closes the outlet when no hose line is connected.

Always reuse the cap to protect the connection against dirt!

Make sure that the sampling device will not be mechanically damaged.

In case of destruction oil could be pumped out of the gearbox in an uncontrolled way.

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

©

Page 7 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US) Technical information – Add-on kit – oil sampling device – 45/65 CST Report_0007_E_01_CAT.docx

4.1

Auxiliary material

For draining the oil these hose lines with thread are available: Ident-No.

L [mm]

type of ends

acc. to Fig. No.

862801

400

M16x2 / plug with cap

4.1

768238

400

M16x2 / M16x2

4.2

768241

630

M16x2 / M16x2

4.2

Fig. 4.1: Drain hose line with plug end

Caterpillar Global Mining Europe GmbH, Luenen 2008 Engineering Gears

Fig. 4.2: Drain hose line with cap nuts

©

Page 8 / 8

2012-05-31 Author: Michael Nafe Reviewed by Thomas Uvermann, Head of Engineering Gears

EM015721-0 (EN-US)

EM015721-0 (EN-US)

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