CAT Beamed Stageloader Superbolt Pretensioning System Operation & Maintenance Manual

BI620938

OPERATING MANUAL Eickhoff Antriebstechnik GmbH Hunscheidtstr.176 D-44789 Bochum

TRANSLATION OF THE GERMAN ORIGINAL VERSION

Telephone (0234) 975 – 0 Telefax

(0234) 975 – 2579

BEVEL HELICAL PLANETARY GEARBOX EKP-15

Article Code:

G 028225 XA

Gearbox Model:

three stage Bevel Helical Planetary Gearbox / EKP-15

Year of Manufacture:

see rating plate

Revision No.:

00

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CONTENTS

Contents 1

INTRODUCTION......................................................................................................1-1

1.1 Legal Provisions

1-1

1.2 The Operating Manual

1-3

2

SAFETY INSTRUCTIONS .......................................................................................2-1

2.1 General Safety Instructions

2-1

2.2 Safety Instructions for Transport and Storage

2-4

2.3 Safety Instructions for Assembly

2-6

2.4 Safety Instructions for Commissioning/Start-up

2-7

2.5 Safety Instructions for Servicing and Maintenance

2-8

2.6 Safety Instructions for Waste Disposal 3

2-10

TECHNICAL DESCRIPTION ...................................................................................3-1

3.1 Scope of Supply

3-1

3.2 State as Supplied

3-1

3.3 Rating Plate

3-2

3.4 Designated Use

3-2

3.5 Design and Principle of Operation

3-3

3.6 Limits of Application

3-5

3.7 Quality Assurance

3-5

3.8 Technical Details

3-6

4

TRANSPORT AND STORAGE ...............................................................................4-1

4.1 Transport of the Gearbox

4-1

4.2 Storage of the Gearbox

4-3

5

ASSEMBLY AND COMMISSIONING/START-UP...................................................5-1

5.1 Assembly

5-1

5.2 Commissioning/Start-up

5-6

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CONTENTS 6

SERVICING AND MAINTENANCE .........................................................................6-1

6.1 Maintenance / Inspection Schedule Table

6-4

6.2 Oil Analysis and Oil Changes

6-5

6.3 Application of Loctite

6-10

6.4 Changing the Rolling Bearing Grease

6-11

6.5 Table of Malfunctions

6-12

7

DRAWINGS AND TABLES .....................................................................................7-1

7.1 Dimensioned Drawing

7-1

7.2 Spare Parts Drawings

7-3

7.3 Spare Parts Lists and Spare Parts Sublists

7-6

7.4 Table of Lubricants

7-14

7.5 Assembly of the Bevel Gears

7-15

8

ANNEX ....................................................................................................................8-1

8.1 Service

8-1

8.2 Company Address

8-1

8.3 Agencies

8-2

8.4 Declaration of incorporation

8-3

8.5 Supplement

8-4

9

ACCESSORIES .......................................................................................................9-1

9.1 CORTEC Corrosion Inhibitor

9-1

9.2 Anticorrosion Grease

9-3

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1

Introduction Revision Table Revision

Date

00

10.05.2010

Revision first edition completely revised

1.1 Legal Provisions Identification Article Code:

G 028225 XA

Year of Manufacture:

see rating plate

Gearbox Type:

three stage Bevel Helical Planetary Gearbox / EKP-15

Manufacturer Eickhoff Antriebstechnik GmbH Hunscheidtstr. 176 D-44789 Bochum

Proper Use This gearbox is designed exclusively for proper use as defined in this operating manual (see chapter 3.4 Designated Use).

Improper Use The gearbox must not be used for applications other than as provided for in chapter 1.1 Legal Provisions "Proper Use".

Any other use is classified as improper use and can lead to: • Injury to persons or death • Damage to the system • Damage to other material property

Liability The information, details and notes contained in the operating manual reflect the latest state on the day of issue. Technical modifications are reserved within the bounds of the further development of the gearbox. No claims shall therefore be raised for already delivered gearboxes on the grounds of specifications, illustrations or descriptions contained in this manual.

No liability is assumed for damage or functional disorders caused by: • Disregard of the operating manual • Operator's mistakes • Improper work on or with the gearbox • Use of other than genuine OEM spares or accessories from EICKHOFF ANTRIEBSTECHNIK GMBH

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• Unauthorized conversions or modifications of the gearbox by the user or its personnel.

EICKHOFF ANTRIEBSTECHNIK GMBH accepts liability for faults and omissions within the bounds of the warranty obligations entered into according to the main contract. Claims for damages, from whatever legal grounds they may be deduced, are excluded therefrom.

Warranty The warranty period and the warranty conditions are laid down in the general terms and conditions, the basic contracts and/or comparable agreements.

Warranty claims must be brought to the notice of EICKHOFF ANTRIEBSTECHNIK GMBH immediately after the fault or defect has been detected, by indicating the article code, the gearbox type and the serial number.

Within the warranty period, the gearbox must be opened exclusively in the presence of an EICKHOFF representative, with EICKHOFF's prior consent, or by qualified personnel authorized by EICKHOFF. Wear parts are expected from the warranty.

Warranty is forfeited in the case of: • Improper use of the gearbox • Improper work on and with the gearbox • Failure to observe the maintenance and inspection intervals (see chapter 6 Servicing and Maintenance) • Persons other than the personnel trained by EICKHOFF working on the gearbox • Use of non-permissible operating fluid • Use of other than genuine OEM spares and consumables from EICKHOFF ANTRIEBSTECHNIK GMBH • Opening the gearbox during the warranty period without the prior consent of EICKHOFF ANTRIEBSTECHNIK GMBH • Draining the oil in the event of damage

Copyright This operating manual and all information contained therein are protected by copyright.

Duplication (including extracts) or conveying to third parties, disclosure or exploitation of its contents are not permissible without the explicit consent of EICKHOFF ANTRIEBSTECHNIK GMBH © Copyright 2010 by EICKHOFF ANTRIEBSTECHNIK GMBH

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1.2 The Operating Manual The details and notes contained in the present operating manual shall enable the active personnel to work safely, properly and efficiently on and with the gearbox. It is only when the contents of the operating manual is fully understood and observed that: • Hazards are avoided • Repair cost and downtimes are kept to a minimum • Reliability and service life of the gearbox are increased.

For easy reference, the following paragraphs explain the systematics and rules as well as the textual and pictorial definitions applied in this manual.

Definition of Terms This operating manual includes a number of important terms which are defined below.

Gearbox The term "gearbox" as used in this operating manual shall mean the complete gearbox (see chapter 3.1 Scope of Supply).

Eickhoff EICKHOFF ANTRIEBSTECHNIK GMBH is the manufacturer of the gearbox and shall be called EICKHOFF hereinafter.

User The user shall be every natural or legal person who operates the gearbox or gives instructions to operate the gearbox on its behalf.

Operating Personnel Operating personnel shall be persons who have been appointed for and instructed in the operation of the gearbox. The operating personnel is authorized to carry out simple maintenance operations (such as cleaning the gearbox on the outside).

Opening of the inspection hole cover is prohibited.

Persons shall be deemed instructed after they have been • informed of the tasks assigned to them and have received corresponding training as necessary • warned of the potential hazards arising from improper handling and • made familiar with the necessary safety devices, safety precautions, accident prevention regulations, pertinent rules and service conditions.

For the required instruction duties and authority, see chapter 2.1 General Safety Instructions.

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INTRODUCTION Qualified Personnel Qualified personnel shall be persons

• with qualifications as machine fitters (recognized occupation: industrial mechanic) or equivalent qualifications and • with the ability to assess and perform, in a professional way, the tasks assigned to them owing to their professional training, knowledge and experience and • who have been trained by EICKHOFF The qualified personnel shall be familiar with the accident prevention regulations, the pertinent rules and the service conditions.

Skilled Electrical Engineers Skilled electrical engineers shall be persons • with qualifications as energy electronics engineers in the field of systems engineering or as electronics installers in the field of industrial engineering or with equivalent qualifications • with the ability to assess and perform, in a professional way, the tasks assigned to them owing to their professional training, knowledge and experience and • who have been trained by the manufacturer of the system control system.

Eickhoff Antriebstechnik GmbH Personnel EICKHOFF personnel shall be qualified personnel employed by EICKHOFF.

Residual Hazards Residual hazards shall be defined as latent risks arising from the use of the gearbox.

Example: Hazard of burns from hot components after the gearbox has been switched off.

Protective Clothing Protective clothing shall be the personal protective equipment that protects the human body against hazards arising at work. The personal protective equipment must comply with the requirements of the Equipment Safety Act. The circumstances under which protective clothing must and shall be worn are defined in the applicable local accident prevention regulations.

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INTRODUCTION Pictorial Representations and Textual Displays

The following pictograms and symbols are used to give salience to important information.

General Hazard Makes reference to safety instructions which must by all means be observed to avoid injury to persons and to which no specific pictograms (e.g. one of the following) can be assigned.

High Electric Voltage Warns of the hazard of electric shock.

Hot Components Warns of the hazard of burns from hot system components.

Ecologically Harmful Substances Warns of the hazards arising from chemical substances unless the said substances are disposed of in accordance with the applicable environmental rules and regulations.

Safety-Related Note Makes reference to statements on how to work safely on and with the gearbox.

Supplementary Information Makes reference to practical tips and hints and useful information.

Two different symbols are used in this operating manual: ► This symbol refers to individual work instructions which must be executed precisely in the given order.

• This symbol refers to enumerations, the contents of which is of equal priority. −

This symbol refers to enumerations of subsidiary points which are subordinate to the enumerations and the contents of which is also of equal priority.

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Structure and Contents of the Safety Instructions All safety instructions contained in this operating manual are of uniform structure.

Essential Elements of a Safety Instruction Each safety instruction contains several essential elements: • A pictogram • A signal word referring to the level of the hazard • A statement on the type of the hazard • A statement on how to avert the hazard The following signal words refer to the level of the hazard: Danger warns of a direct hazard to life and health of human beings Possible consequences: • Death or serious injuries Warning warns of a potential hazard to life and health of human beings Possible consequences: • Death or serious injuries Caution warns of a potential hazard to persons or material property Possible consequences: • Slight injuries to persons or damage to material property Note warns of a potentially hazardous situation for material property or the environment.

Possible consequences: • Damage to the gearbox itself • Damage to material property within the surrounding of the gearbox • Pollution of the environment Hint refers to supplementary information on how to make work easier and more efficient (practical hints).

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2

Safety Instructions

2.1 General Safety Instructions The gearbox has been built according to the state-of-the-art standards applicable at the time of ordering and is basically deemed operationally safe.

Hazards may neverthless arise from the gearbox in the event that • unauthorized or non-instructed personnel is working on and with the gearbox or • the gearbox is subject to improper use.

In such a case the following are at risk: • persons • the gearbox and • other material property of the user

Safety of the Gearbox The following must be observed when working on and with the gearbox: • The applicable rules and regulations (for example the VDE standards) • The applicable accident prevention regulations (UVV) • The pertinent directives • The applicable environmental protection laws The gearbox must be operated exclusively in a satisfactory and faultless state. This includes the prerequisite that all safety devices of the gearbox are in place and fully functional. In the event of functional disorders or defects, the gearbox must be immediately withdrawn from service and the said malfunction must be reported to the user's authorized supervisor.

The gearbox must not be restarted until proper functioning of the gearbox is reestablished.

Safety devices must not be disassembled or taken out of service in general. When safety devices need to be disassembled or taken out of service for maintenance, they must be refitted immediately upon completion of the work. All safety devices must be checked for proper functioning before the gearbox is restarted.

Note Constructional (non-specification-compliant) additions to and/or modifications and conversions of the gearbox which may affect safety are strictly prohibited unless EICKHOFF's written consent has been obtained. The same applies to the installation and calibration of safety devices and to welding load-bearing components.

Use only genuine OEM spares for gearbox component changes. Only OEM spares keep the gearbox fully functional and safe.

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SAFETY INSTRUCTIONS Caution Risk of damage to the drive unit and/or injury hazard Forfeiture of warranty

Under no circumstance must attachment parts, hoses, oil pipes and the like be used as a climbing aid, tread surface or load attachment means during transport, assembly, commissioning, start-up, servicing and/or maintenance. Incorrect use of attachment parts, hoses, oil pipes, etc. can cause considerable damage to persons and property.

Damage caused by incorrect use is exempt from warranty. Climbing aids, tread surfaces or load attachment means are marked as such (see chapter 7.1 Dimensioned Drawing and chapter 7.2 Spare Parts Drawings).

The Operating Manual The present operating manual primarily aims at safety-conscious working on and with the gearbox. It contains safety instructions which must by all means be obeyed.

The operating manual must • be read and understood by all persons working on and with the gearbox before starting work • always be taken along by the qualified personnel (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“) for easy reference when working on the gearbox, • always be complete and kept in a legible condition.

Should this operating manual or parts thereof not be fully understood, work shall not be started until qualified personnel of • the user • the system manufacturer or • EICKHOFF has been consulted accordingly. Failure to do so can generate potentially hazardous situations.

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SAFETY INSTRUCTIONS Duties of the User

The user is bound to fulfil a number of duties towards its personnel with all diligence.

To this end the user undertakes • to supplement the operating manual with instructions containing the national accident prevention regulations and the applicable environmental protection laws • to familiarize its personnel with all relevant regulations, directives and laws, as necessary • to verify that all relevant regulations, directives and laws are observed • to have the personnel instructed in the proper way of working on and with the gearbox • to clearly define the responsibilities for assembly, commissioning, start-up and maintenance of the gearbox • to verify that the defined responsibilities are actually respected • to verify at regular intervals that its personnel operates the gearbox in a safetyconscious and hazard-conscious manner in accordance with the operating manual • to make sure that the personnel has read and understood the operating manual, and chapter 2 Safety Instructions in particular. The user of the gearbox should seek a written confirmation to this effect from its personnel.

Active Personnel Only authorized and instructed personnel shall be allowed to work on and with the gearbox. Unauthorized personnel must be prohibited from operating the gearbox.

The following work must be performed exclusively by qualified personnel: • Assembly • Commissioning and start-up • Maintenance The responsible superior shall instruct the operating personnel in health and safety at work matters at regular intervals not exceeding one year. The successfully completed instruction course shall be placed on record and signed by the instructed personnel.

The operating personnel is bound to report any anomalies in the operating behaviour of the gearbox to its responsible superior. Compliance with this requirement is absolutely imperative in cases where the safety of the gearbox is no longer ensured.

The personnel is not allowed to wear open long hair, loose-fitting clothes or jewellery such as necklaces, bracelets, rings and the like. The personnel shall wear personal protective equipment as necessary and as prescribed in the applicable rules.

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2.2 Safety Instructions for Transport and Storage Warning Injury hazard by falling objects Standing or working under suspended loads is strictly prohibited.

Warning Hazard by falling transport objects • The gearbox must be transported by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“).

• Use only transport equipment and transport aids which comply with the safety requirements and are designed for the respective loads.

• The gearbox must be lifted and transported exclusively at the marked attachment points provided for this purpose (see chapter 7.1 Dimensioned Drawing and chapter 7.2 Spare Parts Drawings).

• Load lifting appliances, where used, must be attached as prescribed. Incorrect use of load lifting appliances can cause serious damage to persons and equipment.

• Secure the gearbox against toppling and slipping using adequate transport aids.

• All transport routes must be clear of obstacles before initiating transport of the gearbox to the customer's site.

Caution Injury hazard or risk of gearbox damage Under no circumstance must the gearbox be lifted and transported on its shafts.

For lifting the gearbox, the designated lifting eyes, lifting cams, 3-D load rings or ropes slung around the gearcase, must be used. Eyebolts, for example complying with DIN 580, must not be used. See the spare parts drawings and the dimensioned drawing for the permissible attachment points (see chapter 7.1 Dimensioned Drawing and chapter 7.2 Spare Parts Drawings).

Caution Pollution of the environment by leaking oil The gearbox shall be transported exclusively without oil filling to exclude the risk of leaking oil.

Note Risk of gearbox damage by temperature variations Do not expose the gearbox to excessive temperature variations during transport to avoid condensing. Protect the gearbox against humidity during storage and transport to avoid corrosion damage.

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SAFETY INSTRUCTIONS Note Risk of damage by improper storage

• The state of the gearbox as supplied must be taken due note of for storage (see chapter 3.2 State as Supplied).

• Store the gearbox in a vibration-free place to avoid damage to the bearings.

• Stacking up the gearboxes is not permissible.

Warning Health hazard by nitrite-containing VCIs The use of nitrite-free products is absolutely imperative. Nitrite-containing VCIs can cause serious damage to health such as cancer and breathing problems.

Caution Risk of gearbox damage by nitrite-containing VCIs Nitrite-containing corrosion inhibitors attack non-ferrous metals. They can deteriorate rolling bearing cages and other components made of brass or bearing bronze, and therefore lead to premature failure of the gearbox or its components.

Caution Risk of gearbox damage by contamination Corrosion inhibitors are not suited for cleaning by filter systems due to their constituents. The cleanliness of the filled-in corrosion inhibitor is not countable but will be distinctly above the required cleanliness of 19/17/14 as defined in ISO 4406.

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2.3 Safety Instructions for Assembly Danger Fire and explosion hazard Beware of the fire and explosion hazard when using solvents.

• Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Do not smoke during assembly and commissioning/start-up.

Caution Hazard by improper work on the gearbox Assembly, installation and test run (commissioning) of the gearbox must be carried out by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“).

Danger Hazard by high electric voltages Assembly, installation and testing of the electrical components must be carried out by skilled electrical engineers (see chapter 1.2 The Operating Manual "Skilled Electrical Engineers") only.

Caution Leak Hazard When using solvents and detergents, contact with any shaft seals must by all means be avoided.

Caution Hazard to the gearbox by improper cleaning Under no circumstance must corrosion inhibitor be sanded down from the shaft extensions, the centre holes or other machined surfaces.

Note Visually inspect all lines and bolted connections for leaks and externally discernible damage before putting the gearbox into operation.

Note Mount the connecting elements exclusively using the front side threaded holes (acc. to DIN 332) in the shaft ends.

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2.4 Safety Instructions for Commissioning/Start-up Warning Hazard by improper work on and with the gearbox Hazard by improper use of the gearbox • Only authorized and instructed qualified personnel (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“) shall be allowed to put the gearbox into operation.

• The gearbox must be operated exclusively in a satisfactory and faultless state.

All safety devices of the gearbox must be in place and fully functional.

In the event of defects or functional disorders, the gearbox (or system in which the gearbox is incorporated) must be immediately withdrawn from service and secured against restarting.

• The gearbox (or system) must not be put into operation until all defects or functional disorders are rectified and the gearbox is fully functional.

Warning Injury hazard by rotating parts Secure rotating parts to prevent the risk of contact.

Caution Risk of gearbox damage by scattered tools or other objects Make sure that no tools or other objects which are foreign to the system, are within the functional reach of the safety devices of the gearbox.

Warning Hazard by the starting gearbox Make sure before commissioning or starting up the gearbox that no persons are exposed to danger from the starting gearbox.

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2.5 Safety Instructions for Servicing and Maintenance Warning Hazard by improper maintenance of the gearbox • Servicing and maintenance of the gearbox must be carried out by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms„Qualified Personnel“).

• The maintenance operations and the maintenance intervals specified in this operating manual must be strictly observed so that the gearbox is maintained in its operationally safe condition and provides a long service life.

• Switch off the system in which the gearbox is incorporated, as prescribed and secure it against restarting (for example by locking the key-operated switch or by removing the fuses from the power supply).

• Affix a warning label to the switch-on location to the effect that work is being performed on the gearbox.

• Do not remove any safety devices from the gearbox. When safety devices need to be disassembled or taken out of service for maintenance, they must be refitted immediately upon completion of the work and checked for proper functioning.

• Bolted connections separated for maintenance must always be firmly retightened and secured with Loctite (see chapter 6.3 Application of Loctite).

Screws of inspection openings which must not be secured with Loctite are expressly excepted therefrom.

• Avoid breathing in oil mist when opening the gearbox or changing the oil. Health hazard!

Danger Fire and explosion hazard When using solvents or other flammable liquids such as cleaning agents, flushing oil, diesel fuel, etc., beware of the fire and explosion hazard arising from finest droplets impinging on hot components.

• Let the gearbox cool down before carrying out inspection and/or maintenance.

• Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Do not smoke during inspection and/or maintenance.

Caution Hazard of burns from hot components or hot operating fluids The oil bath can attain temperatures as high as 90 °C with the result that also the gearbox components may be subject to a high temperature rise. Wear safety gloves where necessary when performing the oil change.

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SAFETY INSTRUCTIONS Caution Risk of gearbox damage by scattered tools or other objects

After servicing and maintenance of the gearbox make sure that no tools or other objects which are foreign to the system, are within the functional reach of the safety devices of the gearbox.

Caution Risk of gearbox damage by oil contaminants The gearbox must not be filled with fresh, unfiltered oil directly from the barrel as otherwise the required level of cleanliness of 19/17/14 as defined in ISO 4406 would not be ensured.

Caution Risk of gearbox damage by contamination Proper operation and the service life of the gearbox are affected when contaminants penetrate into the oil circuit. Therefore pay attention during maintenance of the gearbox that no fibres of cleaning rags, sand or other foreign material enter the oil circuit.

Note Risk of gearbox damage by improper cleaning • Do not use any aggressive detergents.

• Use only non-fraying cleaning rags.

• Clean the gearbox from oil and contamination before starting maintenance.

• Do not clean the oil filling area or the elastomeric shaft seals by means of a highpressure cleaner.

Caution Forfeiture of warranty • Exclusively use genuine O.E.M. spares as itemized in the pertinent spare parts lists (see chapter 7.3 Spare Parts Lists and Spare Parts Sublists) for replacement purposes.

• Within the warranty period, the gearbox must be opened exclusively in the presence of an EICKHOFF representative, with EICKHOFF's prior consent, or by qualified personnel authorized by EICKHOFF (see chapter 1.2 The Operating Manual Definition of Terms- „Qualified Personnel“). Unauthorized repairs which are carried out within the warranty period invalidate the warranty.

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2.6 Safety Instructions for Waste Disposal Note Pollution of the environment by improper waste disposal • Keep suitable collecting trays and receptacles ready for collecting leaking or spilled operating fluids (such as gear oil).

• All operating fluids, consumables and replacement parts must be disposed of in a secure and environmentally friendly manner in accordance with the applicable environmental rules and regulations.

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TECHNICAL DESCRIPTION

3 Technical Description 3.1 Scope of Supply According to the relevant order specifications, the gearbox is either a single unit or comprises a number of components which may not yet be mounted to the gearbox upon delivery. The following enumeration identifies the components which the complete gearbox is composed of: • three stage Bevel Helical Planetary Gearbox / EKP-15 The supplied gearbox shall be checked for completeness upon receipt. Any transport damage and/or missing components shall be reported immediately in writing.

3.2 State as Supplied The gearbox is supplied in the following state: • The gearbox is supplied ready for operation but without oil filling. Fill the gearbox with the specified oil (see chapter 6.2 Oil Analysis and Oil Changes "Acceptable Oil Types") before starting up.

• The gearbox has been preserved with an operating oil/corrosion (1:1) inhibitor mixture (see chapter 9.1 CORTEC Corrosion Inhibitor) before delivery. This type of preservation is adequate for a storage period of max. 12 months from the date of readiness for dispatch and subject to dry indoor storage (rel. air humidity <60%) (see chapter 4 Transport and Storage).

• Shaft seals are already packed with grease ex works.

• Gearboxes intended for airfreight or seafreight may have the attachment parts (such as coolers, filters, etc.) dismantled. All ports, hoses and other openings are closed by adequate means for transport.

• The gearcase and the gearcase components are provided with an external and internal coat of paint.

• External shaft extensions, hollow shaft bores and/or other machined parts are coated with a corrosion protection paint coating (see chapter 9.2 Anticorrosion Grease) which is saltwaterproof and tropicalized for a period of 12 months.

• Vent holes, oil filling holes, oil drain holes, the oil level indicator and any lubricating points have a colour identification.

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3.3 Rating Plate The gearbox type and the serial number indicated on the rating plate and the article code stated in this operating manual (see chapter 1 Introduction) should always be quoted in the case of enquiries. The rating plate is securely affixed to the gearbox and contains the following details: • Gearbox type / article code • Year of manufacture • Power • Serial number • Operating torque • Transmission ratio • Input speed / Output speed • Weight • Oil quantity • Oil type

3.4 Designated Use The gearbox is designed for power transmission between the electric motor and the chain conveyor.

The rotational speed of the motor is reduced to the required speed of the chain conveyor.

Any other use or any use beyond the above limits is classified as improper use, in which case EICKHOFF shall not be held liable for resultant damage of any kind whatsoever.

Proper use also takes it for granted that all instructions and details of the present operating manual are observed.

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TECHNICAL DESCRIPTION

3.5 Design and Principle of Operation General The design of the three stage Bevel Helical Planetary Gearbox / EKP-15 and the individual article codes are shown on the spare parts drawing (see chapter 7.2 Spare Parts Drawings).

The gearbox EKP-15 is designed as a three-stage bevel helical planetary gearbox.

It is equipped with an attachment flange for the coupling housing and, on the machine side, with an attachment flange with bores for torque support.

The design of the planetary stage ensures an even load distribution by the freely adjustable central wheel.

The input shaft has a cylindrical extension with parallel key.

The output shaft is designed as a coupling shaft with spline according to DIN 5480.

The gearbox can be mounted in either a left or a right-hand version (see chapter 5.1 Assembly “Converting the Gearbox to the Clockwise or Counterclockwise Direction of Rotation”).

Casing The housing consists of several components which are: • the gearcase which is of two-piece cast design and made of cast steel or high-grade nodular graphite cast iron • the ring gear and • the flange-mounted housing which is made of cast steel or high-grade nodular graphite cast iron.

The housing is provided with an inspection hole cover for inspection purposes.

Toothing Transmission is via one bevel gear stage, one helical gear stage and one planetary gear stage.

Bevel pinion shaft and bevel wheel are made of case-hardening steel and are hardened; the tooth flanks are HPGS cut. Bevel pinion and bevel wheel are fabricated as a pair and have to exchanged together. The bevel wheel stage is assembled based on the installation instructions (see chapter 7.5 Assembly of Bevel Gears).

The central wheel and the planetary gear wheels of the planetary stage as well as Pinions and gearwheels of the helical gear stage are made of case-hardening steel, and the tooth flanks are ground.

The ring gear is made from high grade quenched and tempered steel.

Bearings All shafts, the planetary gearwheels and the output planetary carrier are supported in amply dimensioned roller bearings.

The central wheel of the planetary stage is unsupported.

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TECHNICAL DESCRIPTION Lubrication

All roller bearings and the toothings have a splash lubrication system.

Cooling The gearbox is cooled by ribbed coolers incorporated in the housing. They withstand a test pressure of 40 bar. At least 15 liters of cooling water are required per minute. See the dimensioned drawing (see chapter 7.1 Dimensioned Drawing) for the connection points.

Monitoring The oil temperature must be monitored by an oil temperature switch.

To this end temperature sensors must be mounted under the oil level. The corresponding points are shown in the dimensioned drawings (see chapter 7.1 Dimensioned Drawings).

The cooling water quantity must be monitored by a flow controller.

Temperature switch and flow controller are not in scope of supply.

Sealing The input shaft is sealed by a shaft seal ring and a grease-filled grooved seal on a hardened bush.

The output shaft is sealed by a sliding ring seal.

This groove seals must be filled with grease every time the gearbox has been cleaned and disassembled. Use only lithium saponified grease having a worked penetration of approx. 220 to 250.

The parting faces of the housing and the fitting surfaces of the cover are sealed with LOCTITE 128068 sealing compound against escaping oil.

All sealing surfaces shall be cleaned and resealed with LOCTITE 128068 or an equivalent sealing compound after every disassembly and reassembly.

When remounting the inspection hole cover take care that it is aligned in the same position as it was before disassembly.

Bolted and Screwed Connections All screws and nuts are tightened to the specified tightening torques. For the tightening torques see 7.2. Spare Parts Drawings.

Internal bolts and screws are secured acc. to GEN 6 00812.06 "SV". External bolts and screws are secured acc. to GEN 6 00812.06 "LV". The bolts and screws must be cleaned and re-inserted with Loctite after every disassembly (see chapter 6.3 Application of Loctite).

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TECHNICAL DESCRIPTION

3.6 Limits of Application The temperature rise of the gearbox varies as a function of the operating conditions. At an ambient temperature range between 0 °C and 30 °C, the normal continuous temperatures of the oil bath will lie between 50 °C and 90 °C. For rolling bearing gearboxes with mineral oil lubrication, the continuous temperature of the oil bath may be 100 °C as a maximum. If higher temperatures are encountered which are, for example, due to elevated ambient temperatures or heat generated by external sources, special precautions must be taken. In such cases synthetic lubricants may be used but consult EICKHOFF first to have their compatibility with the provided sealings and paintings confirmed.

Ambient temperatures of less than - 10 °C require the use of controlled heaters and / or proper lubricants.

The thermal capacity and the operating range of the gearbox are based on the operating details specified in chapter 3.8 Technical Details.

We recommend that you should consult EICKHOFF before using the gearbox outside its contractual limits of application or under different operating conditions.

Operating the gearbox at higher loads than the nominal load will reduce the service life of the gearbox components and that of the bearings in particular. In addition, permanent oil contamination with a level of contamination of worse than 19/17/14 as defined in ISO 4406 will lead to premature bearing failure.

3.7 Quality Assurance The EICKHOFF Quality Assurance System is audited in accordance with DIN ISO 9001 – Design / development, production, installation and servicing – and in accordance with the European Standard EN 29001 and the British Standards BS 5750.1.

The Certificate (Registration No. 002298 QM) has been awarded to EICKHOFF by Deutsche Gesellschaft zur Zertifizierung von Qualitätssicherungssystemen mbH – DQS – (German Association for the Certification of Quality Systems).

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TECHNICAL DESCRIPTION

3.8 Technical Details Use

Drive of a chain conveyor gearbox model:

Identification

three stage Bevel Helical Planetary Gearbox

gearbox type:

EKP-15

article code gearbox: Size

G 028225 XA

dimensions:

(see chapter 7.1 Dimensioned Drawing)

and packing dimensions:

G 028225 XA (see chapter 7.2 Spare Parts Drawing)

weight Drive Torques

Rotational speeds

1 785 kg

type of drive

electric motor (three-phase)

nominal power

250 kW

input torque

1 624 Nm

max. output torque (3 sec./hour)

150 kNm

max. input speed

1 470 r.p.m.

max. output speed

52.22 r.p.m.

direction of rotation (when looking onto the face of the input shaft)

anti-clockwise clockwise

Transmission Ratio Lubrication

28.147 : 1 Type of lubrication: Oil quantity

splash lubrication approx.

ISO viscosity class Oil type

45 l ISO VG 220

Designation acc. to DIN 51517

CLP 220

Designation acc. to ISO 3496

CC - 220

The DIN designation is indicated on the type plate of the gearbox. place of installation Location/ Operating Conditions

underground (midland)

Ambient temperature:

+10°C up to +40 °C

Period of operation:

20 h/day

duty cycle

75 %

starts per hour Oil Cooling System Paint

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cooling water pressure

max. 25 bar

Water quantity required

min. 15 l/min.

external

acc. to specification

internal

acc. to specification

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TRANSPORT AND STORAGE

4 Transport and Storage The safety instructions contained in chapter 2 Safety Instructions must also be observed for transport.

4.1 Transport of the Gearbox Transport Conditions It is essential that the gearbox is transported in a shock-free manner. If shocks cannot be safely excluded, for example during railway transport, additional precautionary measures must be taken after consultation with EICKHOFF. EICKHOFF should also be consulted for proper measures when components are to be dismantled from the gearbox for air or sea transport.

Where storage, transport and handling times exceed the periods provided for in chapter 3.2 State as Supplied specific corrosion protection measures must be taken. Consult EICKHOFF in this respect.

Where transport by sea lasts longer than provided for in chapter 3.2 State as Supplied the consignor and/or packer is responsible for providing seaworthy and state-of-the-art packaging according to the "closed system" principle. The corrosion protection must be adequate for a period of at least "maximum transport time plus 6 months“. Consultation with EICKHOFF is required.

Warning Injury hazard by falling objects Standing or working under suspended loads is strictly prohibited.

Warning Hazard by falling transport objects • The gearbox must be transported by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“).

• Use only transport equipment and transport aids which comply with the safety requirements and are designed for the respective loads.

• The gearbox must be lifted and transported exclusively at the marked attachment points (see chapter 7.1 Dimensioned Drawing and chapter 7.2 Spare Parts Drawings).

• Load lifting appliances, where used, must be attached as prescribed. Incorrect use of load lifting appliances can cause serious damage to persons and equipment.

• Secure the gearbox against toppling and slipping using adequate transport aids.

• All transport routes must be clear of obstacles before initiating transport of the gearbox to the customer's site.

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TRANSPORT AND STORAGE Caution Injury hazard or risk of gearbox damage

Under no circumstance must the gearbox be lifted or transported on its shafts.

For lifting the gearbox, the designated lifting eyes, lifting cams, 3-D load rings or ropes slung around the gearcase, shall be used. Eyebolts, for example complying with DIN 580, must not be used. See the spare parts drawings and the dimensioned drawing for the permissible attachment points (see chapter 7.1 Dimensioned Drawing and chapter 7.2 Spare Parts Drawings).

Caution Pollution of the environment by leaking oil The gearbox shall be transported exclusively without oil filling to exclude the risk of leaking oil.

Note Risk of gearbox damage by temperature variations Do not expose the gearbox to excessive temperature variations during transport to avoid condensing. Protect the gearbox against humidity during storage and transport to avoid corrosion damage.

Tip How to avoid condensation during transport • Enwrapping with a tearproof foil which should enclose the gearbox as airtight as possible • Addition of humidity-absorbing granulates outside the gearbox and inside the packing

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4.2 Storage of the Gearbox Storage Conditions The gearbox must be stored indoors in general. If the actual storage period exceeds the period stated in chapter 3.2 State as Supplied, long-term preservation must be applied (see chapter 4.2 Storage of the Gearbox "Long-Term Preservation").

If storage extends over several years, further preservations may become necessary depending on the state of the gearbox (see chapter 4.2 Storage of the Gearbox "LongTerm Preservation").

In the case of extremely long storage periods, but after five years at the latest, the gearbox must be subjected to a general inspection before commissioning or start up.

The gearbox must be protected against the effects of aggressive or corrosive media such as gases, mists or aerosols of acids, alkalis or salts, throughout the storage period.

The gearbox must furthermore be protected against direct solar radiation to avoid condensing by excessive temperature variations and the detrimental effects of ultraviolet radiation.

The following conditions must be fulfilled to avoid condensing: • Storage temperature between +6°C and +25°C; short-term temperatures up to 30 °C are acceptable • Storage temperature differences between day and night: ≤ 8 K • Relative air humidity: ≤ 60 % Note Risk of damage by improper storage • The state of the gearbox as supplied must be taken due note of for storage (see chapter 3.2 State as Supplied).

• Store the gearbox in a vibration-free place to avoid damage to the bearings.

• Stacking up the gearboxes is not permissible.

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TRANSPORT AND STORAGE Long-Term Preservation

Long-term preservation beyond the period specified in the chapter 3.2 State as Supplied must be carried out exclusively by qualified personnel (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“).

A nitrite-free, vapour-phase depositing corrosion inhibitor (VCI, Vapor Corrosion Inhibitor or Volatile Corrosion Inhibitor), such as CORTEC VCI 329, is suited for long-term preservation of the gearbox.

For achieving a storage period of 2 years, completely fill the gearbox with undiluted corrosion inhibitor. Then turn the gearbox through at least one full rotation, measured on the output shaft. Drain the corrosion inhibitor thereafter. Please observe the manufacturer's product instructions and safety data sheet for handling the corrosion inhibitor.

Warning Health hazard by nitrite-containing VCIs The use of nitrite-free products is absolulely imperative. Nitrite-containing VCIs can cause serious damage to health such as cancer and breathing problems.

Caution Risk of gearbox damage by nitrite-containing VCIs Nitrite-containing corrosion inhibitors attack non-ferrous metals. They can deteriorate rolling bearing cages and other components made of brass or bearing bronze, and therefore lead to premature failure of the gearbox or its components.

Caution Risk of gearbox damage by contamination Corrosion inhibitors are not suited for cleaning by filter systems due to their constituents. The cleanliness of the filled-in corrosion inhibitor is not countable but will be distinctly above the required cleanliness of 19/17/14 as defined in ISO 4406.

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TRANSPORT AND STORAGE Interim Storage / Withdrawal from Service

If the gearbox or system is subject to interim storage or temporary withdrawal from service for a period of more than 3 months, a preservation treatment as specified in chapter 3.2 State as Supplied must be provided.

If the gearbox is subject to interim storage or temporary withdrawal from service for a longer period than stated in chapter 3.2 State as Supplied, a long-term preservation treatment as specified in chapter 4.2 Storage of the Gearbox, "Long-Term Preservation" must be provided with the resultant consequences or

Only for gearboxes with complete sealing by shaft seal rings ► Completely fill the gearbox with the specified oil (pay attention to leak tightness) ► Check the oil level at regular intervals not exceeding one 1 month. ► Turn the gearbox through at least 1 rotation viewed from the output shaft at regular intervals not exceeding one month. Make sure that the position of the shafts after turning is not identical with the previous position. ► Change the gear oil before commissioning/start up if interim storage or temporary withdrawal from service exceeds a period of more than 1 year from readiness for despatch and transport.

Inspection A general inspection can be conducted by EICKHOFF upon request, either at their works or at the user's site.

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5 Assembly and Commissioning/Start-up The safety instructions contained in chapter 2 Safety Instructions must be observed for assembly and commissioning/start-up.

5.1 Assembly Prerequisites for Assembly The following prerequisites must be fulfilled for the assembly of the gearbox: • Adequate transport equipment and transport aids must be available for transporting the gearbox. All transport routes to the place of installation of the gearbox must be clear of obstacles. Observe the instructions contained in chapter 4 Transport and Storage.

• Gearboxes other than shaft-mounted gearboxes must be mounted on foundations.

The foundation must be plane, nonyielding and torsionally rigid. Any surface faults of the foundation must be rectified.

• The place of assembly of the gearbox must be clean and dry.

Mounting the Gearbox Caution Hazard by improper work on the gearbox Assembly, installation and test run (commissioning) of the gearbox must be carried out by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“).

Danger Hazard by high electric voltages Assembly, installation and testing of the electrical components must be carried out by skilled eletrical engineers (see chapter 1.2 The Operating Manual -Definition of Terms"Skilled Electrical Engineers") only.

Danger Fire and explosion hazard Beware of the fire and explosion hazard when using solvents.

• Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Do not smoke during assembly and commissioning/start-up.

Caution Leak Hazard When using solvents and detergents, contact with any shaft seals must by all means be avoided.

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Caution Hazard to the gearbox by improper cleaning Under no circumstance must corrosion inhibitor be sanded down from the shaft extensions, the centre holes or other machined surfaces (see chapter 9.2 Anticorrosion Grease).

Note Leak Hazard Visually inspect all lines and bolted connections for leaks and externally discernible damage before putting the gearbox into operation.

Note Mount the connecting elements exclusively using the front side threaded holes (acc. to DIN 332) in the shaft ends. ► Remove the corrosion inhibitor from the shaft extensions, the centre holes and/or the other connecting surfaces with a solvent before mounting the connecting elements and/or other connections. ► Check the seats and the edges of all connections for damage. Inform EICKHOFF in the case of damage.

Hint When mounting the gearbox be careful • to keep the holes for venting, oil filling and draining, and the oil level indicator easily accessible.

• not to impede the air flow on the suction and pressure sides for fan-cooled gearboxes. ► Mount the gearbox to the conveyor frame using adequate screws. For the diameters of the holes provided for this purpose see the dimensioned drawing contained in chapter 7.1 Dimensioned Drawing.

Note A rigid attachment of the gearbox is not permissible as this could cause damage to the gearbox bearings or the machine shaft. Use the torque arm to compensate for the reaction torque.

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Converting the Gearbox to the Clockwise or Counterclockwise Direction of Rotation The following measures must be taken for the conversion from the left to the right version and vice versa: • The gear oil must be drained for all conversion measures.

• The breather must be exchanged against the corresponding closing screws, the oil level sight glass against the corresponding closing screws and the lifting rings against the corresponding screws. The Breather must always be positioned on top of the gearbox.

• If the gearbox is equipped with a monitoring system the oil temperature switch must always be positioned under the oil level.

• Fill the gearbox with oil.

Aligning the Gearbox Note Additional loads by misalignment reduce the service life and may lead to premature failure of the gearbox. Oblique gearbox positions are only permissible with the explicit consent of EICKHOFF. ► Align the gearbox without angular offset to ensure smooth and low-vibration operation.

Hint For the permissible angular and axial offset tolerances of the ancillary units included in the scope of supply such as couplings, see the details of the respective manufacturer (see chapter 9 Accessories).

Environmental Conditions In the case of adverse environmental conditions such as effects of dust, dirt, water, heat or other unfavourable influencing factors, the gearbox must be protected against such effects by protective cladding or other appropriate means.

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Mounting the Shaft Connections The torque is transmitted via a coupling, a shrink disk, one or more parallel keys, a flange or other connecting elements in accordance with the order specifications and the gearbox type.

For parallel key connections: ► Grease the shaft and the bore before establishing the connection where parallel key connections are provided.

For flange connections: ► Firmly tighten the bolts where flange connections are provided. For the size and tightening torque of the bolts see the spare parts drawing in chapter 7.2 Spare Parts Drawing.

For frictional connections (such as shrink disks): ► Observe the corresponding assembly instructions of the manufacturer where frictional connections are provided.

Mounting the Ancillary Units Hint For the assembly of ancillary units, observe the assembly and operating instructions of the manufacturers (see chapter 9 Accessories). ► Mount the loosely supplied components to the gearbox in accordance with the available drawings. ► Clean the loosely supplied components prior to assembly.

For Couplings, Hubs, Flanges ... : Caution Hazard to the gearbox by improper cleaning Under no circumstance must corrosion inhibitor be sanded down from the shaft extensions, the centre holes or other machined surfaces (see chapter 9.2 Anticorrosion Grease). ► Remove the corrosion inhibitor from the shaft extensions, the centre holes and/or the other connecting surfaces with a solvent before mounting the connecting elements and/or other connections. ► Check the seats and the edges of all connections for damage. Inform EICKHOFF in the case of damage. ► Mount the connecting elements exclusively using the front side threaded holes (acc. to DIN 332) in the shaft ends.

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For Backstops: For gearboxes with mounted backstops attention must be paid to ensure that the motor and the gearbox have the same direction of rotation.

For Forced Lubricating Systems: Gearboxes with forced lubricating systems have the oil pump directly flanged to the gearbox. Oil pumps with electric motors of their own are used in specific cases (see chapter 7.2 Spare Parts Drawing).

For Oil Heaters: If the order specifies an oil heater for the gearbox, the required connections must be established according to the manufacturer's instructions.

Electrical heating elements with cartridge-type heating insets below the oil level are used as oil heaters. The heating temperature is regulated and/or monitored by means of thermostats which are integrated in the heating element or positioned separately in the oil sump.

For Oil Coolers: If the order specifies built-in coolers or separate coolers for the gearbox make sure in the case of oil/water coolers that the water connections (fresh water with a low lime content) are connected according to the manufacturer's instructions.

After Assembly ► Check the corrosion inhibitor film and the paint of the gearbox for damage, and retouch where necessary. ► Labels affixed to the gearbox such as the rating plate or the arrows indicating the direction of rotation, must be duly observed. They must be free of paint and dirt.

Missing labels must be replaced. ► Mount a proper guard to the gearbox when it is exposed to heavy contamination, dust, water, thermal effects or other adverse environmental effects.

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5.2 Commissioning/Start-up Warning Hazard by improper work on and with the gearbox Hazard by improper use of the gearbox • Only authorized and instructed qualified personnel (see chapter 1.2 The Operating Manual -Definition of Terms- „Qualified Personnel“) shall be allowed to put the gearbox into operation.

• The gearbox must be operated exclusively in a satisfactory and faultless state.

All safety devices of the gearbox must be in place and fully functional.

In the event of defects or functional disorders, the gearbox (or system in which the gearbox is incorporated) must be immediately withdrawn from service and secured against restarting.

• The gearbox (or system in which the gearbox is incorporated) must not be put into operation until all defects or functional disorders are rectified and the gearbox is fully functional.

Warning Injury hazard by rotating parts Secure rotating parts to prevent the risk of contact.

Caution Risk of gearbox damage by scattered tools or other objects Make sure that no tools or other objects which are foreign to the system, are within the functional reach of the safety devices of the gearbox.

Warning Hazard by the starting gearbox Make sure before commissioning or starting up the gearbox that no persons are exposed to danger from the starting gearbox.

Preservation The gearbox is supplied without oil filling but has been treated with a preservative before delivery.

This type of preservation is adequate for a storage period of max. 12 months from the date of readiness for dispatch and subject to dry indoor storage (rel. air humidity <60%).

(See also chapter 4 Transport and Storage).

The preservative need not be removed prior to commissioning as it dissolves when the oil is at operating temperature.

If the gearbox is provided with long-term preservation acc. to chapter 4.2 Storage of the Gearbox “Long-Term Preservation”, the gearbox must be cleaned by flushing as described in chapter 6.2 Oil Analysis and Oil Changes “Flushing Procedure”.

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Prior to Commissioning Procedure ► Fill the gearbox with the specified oil (see chapter 6.2 Oil Analysis and Oil Changes "Acceptable Oil Types"). ► The greasing points of the gearbox are already packed with the specified grease quantity and quality ex works. ► Make sure that the gearbox is only run in the permissible direction of rotation. ► Check the gearbox and all ancillary units for proper assembly. ► Secure rotating parts (such as couplings, shafts, brakes) ► Make sure that the system is fully functional

For Hydraulic Motors Before pressurizing the hydraulic motor make sure that the multiple disk holding brake, if any, is vented hydraulically.

For Forced Lubricating Systems: ► For oil pumps with electrical motors of their own: Start the pump motor prior to starting the main motor to ensure an adequate lubrication of the gearbox. ► Take care that an adequate oil pressure (approx. 0,5 to 4 bar) is applied at operating temperature. A pressure gauge, a contact making pressure gauge, a pressure monitor or a flow switch is provided for monitoring in accordance with the order specifications.

Hint For adjusting the monitoring and control devices, see the operating instructions of the manufacturers (see chapter 9 Accessories).

For Oil Coolers: ► Take care that − for oil/water coolers the water pressure does not exceed the pressure specified by the cooler manufacturer. − for oil/air coolers the environmental conditions specified by the cooler manufacturer are taken into account.

For Oil Heaters: ► Heat the gear oil to at least + 5 °C if the ambient temperature is lower than that. The same applies to existing additional oil reservoirs.

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Oil Filling The gearbox is supplied without oil filling.

First fill the gearbox with the specified oil (see chapter 6.2 Oil Analysis and Oil Changes "Acceptable Oil Types"). The oil quantity, the oil type and the viscosity class are specified in chapter 3.8 Technical Details. Decisive is the oil level existing in the mounting position.

The gearbox has been treated with a preservative before delivery. The preservative need not be removed prior to commissioning as it dissolves when the oil is at operating temperature.

The oil shall be filled in with the aid of a filling device ensuring an oil filter mesh of ≤ 25µ abs. through the threaded hole of the breather (see chapter 7.1 Dimensioned Drawings).

Caution Risk of gearbox damage by oil contaminants The gearbox must not be filled with fresh, unfiltered oil directly from the barrel as otherwise the required level of cleanliness of 19/17/14 as defined in ISO 4406 would not be ensured.

Beyond an overflow screw, an oil lever indicator or an oil dipstick the oil level can be checked.

For filling through the Oil Filling Hole or the Threaded Hole of the Breather Attention Pollution of the environment by leaking oil • To prevent oil from leaking out, the filling device should be fitted with a ball cock in the filling area.

• Remove any oil spillage immediately with an oil binding agent.

Hint When filling through the oil filling hole take care that the filling device is fitted with a venting facility.

Close the ball valve before removing the filling device, then remove the filling device and close the free thread of the ball valve with the sealing plug.

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Oil Level Check The oil level is checked beyond an overflow screw, an oil level sight glass or an oil dipstick.

The oil level for the gearbox G 028225 XA EKP-15 is checked through an oil level sight glass.

Attention!

The oil level check must be conducted when the gearbox and the pump (if any) are at standstill and after the oil foam has settled. Settling of the oil foam can take as long as 10 minutes.

Note The oil level must be correctly adjusted in the mounting position.

Overfilling leads to additional heating and foaming of the oil. It should be noted that the cooling circuit absorbs some oil so that oil needs to be replenished after commissioning or start-up.

For Gearboxes with Oil Level Sight Glass The oil level shall be in the middle of the oil level indicator in the mounting position.

Caution Environmental hazard by spilled oil Remove any spillage immediately with an oil binding agent.

During the Running-in Period ► Let the gearbox run at 30 % of the nominal load for 2.5 hours, thereafter at 60% of the nominal load for 2.5 hours and finally at 80% for another 2.5 hours. ► Check the oil and bearing temperatures during the running-in period.

Caution The machine must be immediately switched off when anomalies in the operating behaviour of the gearbox are found such as unusual gearbox noise or elevated bearing temperature. Contact our Service Department when the cause of such anomalies cannot be found (see chapter 8.1 Service).

Commissioning / Start up ► Check the gearbox for proper mounting ► Check the oil level. ► Replenish oil, if required. ► Start the machine.

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SERVICING AND MAINTENANCE

6 Servicing and Maintenance The safety instructions contained in chapter 2 Safety Instructions must be observed for servicing and maintenance.

The servicing and/or maintenance intervals specified in the present EICKHOFF operating manual must be verifiably observed within the warranty period.

A comprehensive documentation evidencing the performed servicing and/or maintenance operations and stating the date and type of all operations must be maintained throughout the warranty period. The location of the machine must also be stated therein.

Warning Hazard by improper servicing and maintenance of the gearbox • Servicing and maintenance of the gearbox must be carried out by qualified personnel only (see chapter 1.2 The Operating Manual -Definition of Terms„Qualified Personnel“).

• The maintenance operations and the maintenance intervals specified in this operating manual must be strictly observed so that the gearbox is maintained in its operationally safe condition and provides a long service life.

• Switch off the system in which the gearbox is incorporated, as prescribed and secure it against restarting (for example by locking the key-operated switch, by removing the fuses from the power supply or for example by affixing a warning label in the entrance area of the system in which the gearbox is incorporated) • Do not remove any safety devices from the gearbox. When safety devices need to be disassembled or taken out of service for maintenance, they must be refitted immediately upon completion of the work and checked for proper functioning.

• Bolted connections separated for maintenance must always be firmly retightened and secured with Loctite.

• Avoid breathing in oil mist when opening the gearbox or changing the oil. Health hazard!

Danger Fire and explosion hazard When using solvents or other flammable liquids such as cleaning agents, flushing oil, diesel fuel, etc., beware of the fire and explosion hazard arising from finest droplets impinging on hot components.

• Let the gearbox cool down before carrying out inspection and/or maintenance.

• Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Do not smoke during inspection and/or maintenance.

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SERVICING AND MAINTENANCE Caution Risk of gearbox damage by improper cleaning • Do not use aggressive detergents.

• Use only non-fraying cleaning rags.

• Clean the gearbox from oil and contamination before starting maintenance.

• Do not clean the oil filling area or the elastomeric shaft seals by means of a highpressure cleaner.

Caution Risk of gearbox damage by scattered tools or other objects After servicing and maintenance of the gearbox make sure that no tools or other objects which are foreign to the system, are within the functional reach of the safety devices of the gearbox.

Caution Risk of gearbox damage by contamination Proper operation and the service life of the gearbox are affected when contaminants penetrate into the oil circuit. Therefore pay attention during maintenance of the gearbox that no fibres of cleaning rags, sand or other foreign material enter the oil circuit.

Caution Forfeiture of warranty • Exclusively use genuine O.E.M. spares as itemized in the pertinent spare parts lists (see chapter 7.3 Spare Parts Lists and Spare Parts Sublists) for replacement purposes.

• Within the warranty period, the gearbox must be opened exclusively in the presence of an EICKHOFF representative, with EICKHOFF's prior consent, or by qualified personnel authorized by EICKHOFF (see chapter 1.2 The Operating Manual Definition of Terms- „Qualified Personnel“). Unauthorized repairs which are carried out within the warranty period invalidate the warranty.

Caution Pollution of the environment by improper waste disposal All operating fluids, consumables and replacement parts must be disposed of in a secure and environmentally friendly manner in accordance with the applicable environmental rules and regulations.

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SERVICING AND MAINTENANCE Note Make sure throughout maintenance that

• all bolts, screws and nuts are tightened to the specified tightening torques and secured with Loctite "LV" and • all internal bolts and screws are secured with Loctite "SV".

After every disassembly • the bolts and screws must be cleaned, reinserted with Loctite (see chapter 6.3 Application of Loctite), and tightened to the specified tightening torques.

• the groove-type seals and the labyrinth seals of the shaft exits on the gearbox must be cleaned and repacked with grease. Use only lithium-saponified grease with a worked penetration of 220 to 250.

• the parting faces of the housing and the fitting surfaces of the cover must be cleaned and resealed with the specified sealing compound (see chapter 7.2 Spare Parts Drawings).

Hoses (if any) Note Hoses must be checked for cracking, pinch points and other types of damage at halfyearly intervals and replaced, if required. To this end the testing and inspection criteria specified in DIN 20066 Part 5 must be observed.

Replace the hoses by new ones after 6 years at the latest!

Ball Cocks (if any) Note Close the ball cocks fitted to the hoses before detaching the hoses. Open them after reconnection and remove the levers. Open the upstream ball valve before taking the readings from the pressure gauge, and close it again after having taken the readings.

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SERVICING AND MAINTENANCE

6.1 Maintenance / Inspection Schedule Table Interval Maintenance

Replace the oil filter insert

weekly

monthly

yearly

(2)

during the oil change z

Oil sampling and analysis See chapter 6.2 Oil Analysis and Oil Changes

Change the gear oil Re-grease the grease-packed rolling bearings

(2)

See chapter 6.4 Changing the Rolling Bearing Grease

Clean the screw plug magnets

z

Clean the interior of the gearbox Clean the oil circulating system

(3)

z

(3)

Check the condition monitoring system

(2)

z

z

z

z

z

Interval

Lubrication system (2) incl. hoses

Inspection

weekly Oil temperature

z

Oil level

z

Oil pressure

z

Oil filter

z

monthly

Internal condition and proper operation

z

Bearing temperatures

z

Tightness / leaks

z

Noise

z

Vibrations (structure-borne sound (4) analysis) Bearings (videoscopy)

yearly

(1), (4)

z

z z

Breather

z

Condition of the tooth flanks Gearbox

oil change

z

Mounting of the gearbox and of the attachment units

z

Check the internal condition and for proper operation External condition

during the

z z

z

z

z

(1) not possible for all bearing types (2) if any (3) if necessary (4) optionally recommended

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6.2 Oil Analysis and Oil Changes Acceptable Oil Types The table of lubricants contained in chapter 7.4 Table of Lubricants specifies various gear oils in accordance with the recommendations of the respective producers. Equivalent premium oils of other producers may be used as well.

Specified oil quality: • ISO VG 220 Regular oil sample analyses and/or the use of synthetic lubricants may extend the intervals for the oil change but consult EICKHOFF first before using synthetic lubricants.

Oil Sampling General Notes: • Take a fresh-oil sample after every oil change to determine the reference value.

• Always take the oil sample from the same sampling point and under the same conditions.

• The sampling point must not lie within an oil quiescent area.

• Take the sample when the gearbox is at operating temperature.

• Always use new sample reservoirs.

• Affix labels indicating the following details to the reservoirs: −

Location of the machine

−

Gearbox serial number

−

Sampling date and time

−

Period of operation since the last oil change

−

Period of operation since the last oil filling

−

Period of operation since the last oil sampling

−

Oil type and producer / Name of the person having taken the sample

Oil sampling should be conducted using appropriate sampling devices. The following procedure applies to all sampling points on the gearbox: ► Thoroughly clean the sampling point. ► Put an oil collecting receptacle under the sampling point. ► Connect the sampling device to the sampling reservoir. ► Take the sample. ► Carefully close the sampling point.

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SERVICING AND MAINTENANCE Oil Analysis The analysis should cover the following parameters: Parameters Outer appearance Viscosity Density Neutralization number Neutralization number increase over the fresh-oil sample Water content

Element analysis

Limit Values Visually clear Typical odour Product-specific colour 200 – 240 cSt at 40 °C Ageing-induced changes along with viscosity increase 2.3 – 5.0 mg KOH/g < 0.8 mg KOH/g ≤ 0.15 % Iron

< 180

ppm max.

Chromium

< 20

ppm max.

Tin

< 15

ppm max.

Aluminium

< 20

ppm max.

Nickel

< 20

ppm max.

Copper

< 75

ppm max.

Lead

< 20

ppm max.

Manganese

< 20

ppm max.

Molybdenum

depending on the oil used

Silicon

< 50

ppm max.

Potassium

< 15

ppm max.

Sodium

< 50

ppm max.

≤ 35 mg/ml

Metal particles

≤ 60

Particle quantity (PQ) index Typical additives

Unit

Fresh oil

Used oil

Zinc Phosphorus Molybdenum Calcium Magnesium

ppm ppm ppm ppm ppm

2000 1725 1490 23 not quantifiable

> 1000 > 863 > 745 -

The above limit values specified for the oil are for guidance and shall enable a differentiated assessment on whether the one or other value may be exceeded.

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SERVICING AND MAINTENANCE Oil Changes Recommended Intervals for Mineral Oil Changes First oil change

300 - 500 hours of operation or after one month at the latest

All further changes

according to the condition of the oil, at the latest after 12 months

Coefficient data for further oil changes depending on the service temperature

up to 70 ° C 80 ° C 90 ° C 100 ° C

-

8000 service hours 5000 service hours 3000 service hours 2000 service hours

Caution Forfeiture of warranty Deviating oil change intervals must be determined in a separate inspection agreement with the Service Department of EICKHOFF ANTRIEBSTECHNIK GMBH (see chapter 8.1 Service).

The gear oil must be drained completely and replaced by fresh oil upon expiration of the oil change interval or depending on the result of the oil analysis. If severe contamination is found, the gearbox must be flushed out with diesel fuel or flushing oil. If the level of oil contamination has permanently increased to a level of worse than 19/17/14 as defined in ISO 4406, premature failure of the rolling bearings is to be expected.

Caution Pollution of the environment by improper waste disposal All operating fluids, consumables and replacement parts must be disposed of in a secure and environmentally friendly manner in accordance with the applicable environmental rules and regulations.

Caution Injury hazard by accidental starting of the machine Secure the machine against accidental starting before performing the oil change. Affix a corresponding warning label to the switch-on facility.

Caution Hazard of burns from hot components or hot operating fluids The oil bath can attain temperatures as high as 90 °C with the result that also the gearbox components may be subject to a high temperature rise. Wear safety gloves where necessary when performing the oil change.

Caution Risk of gearbox damage by contamination Proper operation and the service life of the gearbox are affected when contaminants penetrate into the oil circuit. Therefore pay attention during maintenance of the gearbox that no fibres of cleaning rags, sand or other foreign material enter the oil circuit.

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SERVICING AND MAINTENANCE Note Drain the oil at operating temperature.

Oil Changing Procedure ► Switch off and secure the system in which the gearbox is incorporated ► Keep an amply dimensioned oil collecting receptacle ready for use (for the oil volume see chapter 3.8 Technical Details). ► Carefully open the oil drain plug (see chapter 7.1 Dimensioned Drawing). ► Completely drain the oil. ► Open the inspection hole cover (Attention! See chapter 1.1 Legal Provisions ”Warranty”). ► Inspect the interior of the gearbox. ► Flush out the interior with flushing oil or diesel fuel (see also "Flushing Procedure") if the gear oil is severely contaminated. ► Suck off the residual flushing oil, if any. ► Close the inspection hole cover. ► Reinsert the oil screw plugs with new sealing rings. ► Fill the gearbox with the specified oil type (see chapter 6.2 Oil Analysis and Oil Changes "Acceptable Oil Types") (see chapter 5.2 Commissioning/Start-up "Oil Filling”) ► Check the oil level. ► Replenish oil, if required. ► Remove the line of the filling device. ► Screw in the breather or the screw plug using a new copper sealing ring (if the threaded hole of the breather is used for oil filling). ► Carry out a leak test run (check all openings which were opened for the oil change). ► Put the system in which the gearbox is incorporated into operation.

Caution Pollution of the environment by splash oil The interior of the gearbox may be pressurized. Provide for an appropriate splash protection to avoid damage to the environment.

Caution Risk of gearbox damage by oil contaminants The gearbox must not be filled with fresh, unfiltered oil directly from the barrel as otherwise the required level of cleanliness of 19/17/14 as defined in ISO 4406 would not be ensured.

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SERVICING AND MAINTENANCE Note

The oil level must be correctly adjusted in the mounting position.

Observe chapter 5.2 Commissioning/Start-up “Oil Level Check" when checking the oil level.

Flushing Procedure The safety instructions contained in chapter 2 Safety Instructions shall be observed for flushing the gearbox.

Caution Fire and explosion hazard When using flushing agents beware of the fire and explosion hazard arising from finest flushing oil droplets impinging on hot components.

• Let the gearbox cool down before carrying out inspection and/or maintenance.

• Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Smoking is prohibited during inspection and/or maintenance.

State of the gearbox before flushing (see 6.2 Oil Analysis and Oil Changes "Oil Changing Procedure") • The system in which the gearbox is incorporated is switched off.

• The gearbox was allowed to cool down.

• The hose for the oil change is connected.

• The operating oil is drained.

Flushing with Flushing Oil The instructions of the flushing oil manufacturer must be followed when flushing oil is used. Make sure that the flushing oil does not contain any additives deteriorating the hose lines, the rubber seals, the internal coats of paint or the like.

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6.3 Application of Loctite The Loctite products referred to in this operating manual are used when bolted or screwed connections must be secured against unintentional loosening (for example due to vibration or shock loads).

Applying the Adhesive Apply the adhesive to one contact surface only (preferably to that of the bolt thread).

Take care that the product is completely distributed when turning in the bolt or screw over several thread turns. This is ensured by circular application of the adhesive.

When screwing a bolt into a threaded blind hole, screw it back by several turns so that the entrapped compressed air can escape.

For Bolted or Screwed Connections Type of Bond

Nominal Thread Size [mm]

Loctite product 243 Colour: blue Breakloose torque DIN 54454, M10 bolts/screws: 14-34 Nm

Detachable mediumstrength bond (bonds are detachable with the aid of standard tools) Non-detachable highstrength bond (for bonds which need not be detached later on)

G 028225 XA Rev. No.: 00

Product Information

≤ 36

Service temperature range: - 55 °C up to +150 °C Loctite product 262 Colour: red Breakloose torque DIN 54454, M10 bolts/screws: 15-50 Nm Service temperature range: - 55 °C up to +150 °C

10.05.2010

Notes on the Drawings

Identification of the secured bolts or screws: * Secured as per GEN 6 0 00812.06 "LV“ adjacent to the drawing title block Identification of the secured bolts or screws: * Secured as per GEN 6 0 00812.06 "SV“ adjacent to the drawing title block

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6.4 Changing the Rolling Bearing Grease If grease lubricated rolling bearings are used in the gearbox, the grease type and the required quantity of the grease packing are stated on the spare parts drawing (see chapter 7.2 Spare Parts Drawing).

The rolling bearings in question are already packed with grease upon delivery. The grease packing is sufficient for the entire life of the bearings so that regreasing is not necessary. The grease, however, must be renewed in the case of disassembly or overhaul. For this purpose the gearbox and the bearings must be thoroughly cleaned with petroleum ether beforehand.

Caution Fire and explosion hazard Beware of the fire and explosion hazard when using petroleum ether or other flammable liquids such as cleaning agents.

• Avoid getting into contact with hot components.

• Let the gearbox cool down before carrying out inspection and/or maintenance • Provide for adequate ventilation when using such liquids.

• Observe the safety instructions of the respective product manufacturer.

• Do not smoke during inspection and/or maintenance.

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6.5 Table of Malfunctions Malfunction

Possible Cause

Remedy

Gear oil level too low

Elevated rolling bearing temperature

Oil pump* defective Overaged oil Rolling bearing defective Cooler* defective

Gear teeth damaged

Unusual gearbox noise

Excessive bearing clearance Bearing defective

Louder noise in the area of the attachment parts

Coupling defective Gear motor defective Gear oil level too high

Elevated oil sump temperature

Overaged oil Heavily contaminated oil Oil pump* defective Cooler* defective

Pressure monitor (when retrofitted) outputs an alarm

*

Oil pressure < 0.5 bar

Check the oil level when the system is at standstill. Replenish oil, if required.

Check and, if required, replace the pump.

Change the oil.

Contact the Service Department.

Check the bearings.

Withdraw the system from service, if required.

Contact the Service Department.

Withdraw the system from service, if required.

Contact the Service Department.

Check the gear teeth.

Withdraw the system from service, if required.

Contact the Service Department.

Check and, if necessary, adjust the bearing clearance.

Contact the Service Department.

Check the bearings.

Withdraw the system from service, if required.

Contact the Service Department.

Contact the Service Department.

Check the oil level when the system is at standstill. Correct the oil level, if required.

Change the oil.

Change the oil.

Check and, if required, replace the pump.

Contact the Service Department.

Withdraw the system from service, if required.

Check the oil level. Replenish oil, if required.

Check and, if required, replace the oil pump.

Check and, if required, replace the oil filter.

Check the pressure monitor.

Measure the oil pressure on the miniature measuring port using a pressure gauge.

if any

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DRAWINGS AND TABLES

7

Drawings and Tables

7.1 Dimensioned Drawing ARTICLE CODE

DESIGNATION

TYPE

006923G2C

BEVEL HELICAL PLANETARY GEABOX

EKP-15

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1

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DRAWINGS AND TABLES

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DRAWINGS AND TABLES

7.2 Spare Parts Drawings ARTICLE CODE

DESIGNATION

TYPE

G028225XA

BEVEL HELICAL PLANETARY GEABOX

EKP-15

G 028225 XA Rev. No.: 00

10.05.2010

SHEET

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1, 2

7-4 – 7-5

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DRAWINGS AND TABLES

G 028225 XA Rev. No.: 00

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DRAWINGS AND TABLES

G 028225 XA Rev. No.: 00

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DRAWINGS AND TABLES

7.3 Spare Parts Lists and Spare Parts Sublists Spare Parts Lists ARTICLE CODE

DESIGNATION

TYPE

G028225XA

BEVEL HELICAL PLANETARY GEABOX

EKP-15

G 028225 XA Rev. No.: 00

10.05.2010

PAGE 7-7 – 7-10

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DRAWINGS AND TABLES G028225X SPARE PARTS LIST G 028225XA BEVEL SPUR PLANETARY GEARBOX ARTICLE CODE

QTY

UNIT

DESIGNATION

G 019120Z

1

SZ

TAPER ROLLER BEARING

G 021116

1

ST

COVER

G 021705

1

ST

BUSH

G 024441

1

ST

RING

G 027657

1

ST

RETAINING PLATE

G 028544

1

ST

PINION SHAFT

G 028570

1

ST

BUSH

G 028579Y

1

ST

ASSEMBLY

G 028580

1

ST

THROUGH-COVER

G 028581

1

ST

INTERMEDIATE SHAFT

G 028584Y

1

ST

UNIT BEVEL GEAR

G 028585

1

ST

FLANGE-TYPE HOUSING

G 028587

1

ST

GEAR RING

G 028588

3

ST

PLANETARY WHEEL

G 028589

3

ST

PIN

G 028591

6

ST

RING

G 028689

1

ST

BUSH

G 028765Y

1

ST

GEARBOX

G 028766

1

ST

RING

G 028767

1

ST

RING

G 028823

9

ST

CYLINDRICAL ROLLER BEARING

G 028824

6

ST

STOP DISC

G 028831

3

ST

RETAINING RING

G 028225 XA Rev. No.: 00

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DRAWINGS AND TABLES SPARE PARTS LIST G 028225XA BEVEL SPUR PLANETARY GEARBOX ARTICLE CODE

QTY

UNIT

DESIGNATION

G 028891

1

ST

CLOSING COVER

G 029288

1

ST

O-RING

G 029506

1

ST

SLIDING RING COVER

G 029507

1

ST

SLIDING RING COVER

G 029508

1

ST

RING

G 030902

2

ST

CYLINDRICAL ROLLER BEARING

G 031767

1

ST

BUSH

G 031768

2

ST

RING

G 031769

1

ST

PLANETARY SUPPORT

G 038063Y

1

ST

TRANSPORT COVER

L 000469

24

ST

HEXAGON NUT

L 001573

4

ST

CLOSING SCREW

L 001600

1

ST

CLOSING SCREW

L 001708 A

8

ST

GROOVED DRIVE STUD

L 001747 C

1

ST

GROOVED NUT

L 002989

3

ST

DISC

L 003052

2

ST

HEXAGON SCREW

L 003052

3

ST

HEXAGON SCREW

L 005371

8

ST

HEXAGON SCREW

L 005373

12

ST

HEXAGON SCREW

L 005393

8

ST

HEXAGON SCREW

L 005393

8

ST

HEXAGON SCREW

L 005393

8

ST

HEXAGON SCREW

L 005514

3

ST

HEXAGON SCREW

L 005969

24

ST

STUD SCREW

G 028225 XA Rev. No.: 00

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DRAWINGS AND TABLES SPARE PARTS LIST G 028225XA BEVEL SPUR PLANETARY GEARBOX ARTICLE CODE

QTY

UNIT

DESIGNATION

L 008858

2

ST

SCREW JOINT

L 009146

8

ST

DOWEL PIN

L 051622

1

ST

SELF-ALIGNING ROLLER BEARING

L 051639

1

ST

SELF-ALIGNING ROLLER BEARING

L 051642

1

ST

SELF-ALIGNING ROLLER BEARING

L 052297

2

ST

TAPER ROLLER BEARING

N 002577

2

ST

ADJUSTING RING

N 002578

4

ST

ADJUSTING RING

N 002579

6

ST

ADJUSTING RING

N 002580

2

ST

ADJUSTING RING

N 002585

3

ST

ADJUSTING RING

N 002586

1

ST

ADJUSTING RING

N 002587

1

ST

ADJUSTING RING

N 002588

1

ST

ADJUSTING RING

N 002945 B

2

ST

RATING PLATE

N 003240

1

ST

PARALLEL KEY INSERT

N 003287

1

ST

PARALLEL KEY INSERT

N 004833

2

ST

ADJUSTING RING

N 004834

4

ST

ADJUSTING RING

N 004835

6

ST

ADJUSTING RING

N 004836

2

ST

ADJUSTING RING

N 004845

1

ST

ADJUSTING RING

N 004846

2

ST

ADJUSTING RING

N 004847

2

ST

ADJUSTING RING

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DRAWINGS AND TABLES SPARE PARTS LIST G 028225XA BEVEL SPUR PLANETARY GEARBOX ARTICLE CODE

QTY

UNIT

DESIGNATION

N 004848

2

ST

ADJUSTING RING

N 006335

1

ST

SEAL RING

N 006378

4

ST

SEAL RING

N 007886

1

ST

O-RING

N 007890

1

ST

O-RING

N 007965ZB 1

ST

OIL LEVEL GLASS

N 009816

1

ST

SHAFT SEAL RING

S 059544U

1

ST

PIPE

S 163719WA 3

ST

3-D LOAD RING

S 207975

ST

SLIDING RING SEAL

110302202502 100

MM

PIPE

G 013321

2

ST

INSPECTION HOLE COVER

G 020899

2

ST

SEAL

G 028577

1

ST

GEARWHEEL

G 028578

1

ST

PINION SHAFT

G 029475ZA 1

ST

GEARBOX CASING

G 044642

1

ST

BREATHER FILTER

L 005372

12

ST

HEXAGON SCREW

N 003907

5

ST

CLOSING SCREW

N 004996

2

ST

CLOSING SCREW

N 006378

8

ST

SEAL RING

G 028225 XA Rev. No.: 00

2

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DRAWINGS AND TABLES Spare Parts Sublists ARTICLE CODE

DESIGNATION

TYPE

PAGE

G029475ZA GEARBOX CASING

EKP-15

7-12

G038063Y

EKP-15

7-13

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DRAWINGS AND TABLES G029475ZA SPARE PARTS LIST G 029475ZA GEARBOX CASING

EKP-15

ARTICLE CODE

QTY

UNIT

DESIGNATION

L 001600

2

ST

CLOSING SCREW

L 001601

4

ST

CLOSING SCREW

L 001603

2

ST

CLOSING SCREW

L 001605

2

ST

CLOSING SCREW

L 001610

16

ST

CLOSING SCREW

L 005061

3

ST

HEXAGON NUT

L 005089

17

ST

HEXAGON NUT

L 005433

6

ST

HEXAGON SCREW

L 005449 A

9

ST

HEXAGON SCREW

L 005484 A

3

ST

HEXAGON SCREW

L 005490 A

2

ST

HEXAGON SCREW

L 006034 A

2

ST

FIT SCREW

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DRAWINGS AND TABLES G038063Y SPARE PARTS LIST G 038063Y

TRANSPORT COVER

ARTICLE CODE

QTY

UNIT

DESIGNATION

L 005375

2

ST

HEXAGON SCREW

L 005579

1

ST

HEXAGON SCREW

V 810139

1

ST

TRANSPORT COVER

V 810139

1

ST

TRANSPORT COVER

G 028225 XA Rev. No.: 00

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DRAWINGS AND TABLES

7.4 Table of Lubricants The respective technical details of the gearbox as stated in this operating manual are decisive for the selection of a lubricant.

Gear Oils based on Mineral Oil Viscosity

Manufacturer *

ISO-VG **

ARAL

BP

DEA

ESSO

VG 680

Degol BG 680

Energol GR-XF 680

Falcon CLP680

SPARTAN EP 680

Klüberoil GEM 1-680

Mobilgear XMP 680

Omala Oil F 680

Tribol 1100/680

Optigear BM 680

Renolin 680 Plus

VG 460

Degol BG 460

Energol GR-XF 460

Falcon CLP460

SPARTAN EP 460

Klüberoil GEM 1-460

Mobilgear XMP 460

Omala Oil F 460

Tribol 1100/460

Optigear BM 460

Renolin 460 Plus

VG 320

Degol BG 320

Energol GR-XF 320

Falcon CLP320

SPARTAN EP 320

Klüberoil GEM 1-320

Mobilgear XMP 320

Omala Oil F 320

Tribol 1100/320

Alpha MW 320

Optigear BM 320

Renolin 320 Plus

VG 220

Degol BG 220

Energol GR-XF 220

Falcon CLP220

SPARTAN EP 220

Klüberoil GEM 1-220

Mobilgear XMP 220

Omala Oil F 220

Tribol 1100/220

Alpha MW 220

Optigear BM 220

Renolin 220 Plus

VG 150

Degol BG 150

Energol GR-XF

Falcon CLP-

SPARTAN EP

Klüberoil GEM

Mobilgear XMP

Omala Oil

Tribol 1100/150

Alpha MW

Optigear BM

Renolin 150

VG 100

Degol BG 100

150

Klüber MOBIL SHELL Tribol Castrol Optimol FUCHS

150

150

1-150

150

F 150

150

150

Plus

Falcon CLP100

SPARTAN EP 100

Klüberoil GEM 1-100

Mobilgear XMP 100

Omala Oil F 100

Tribol 1100/100

Alpha MW 100

Optigear BM 100

Renolin 100 Plus

Orona 00 Orona FG EP 0

Fibrax EP 370

Alvania GL 00

MolubAlloy 00

CLSGrease Grease

Longtime PD 00

Calypsol SF7-047 00

Spheerol AP2 LZV-EP

Longtime PD 2

Greases for Gearboxes Aralub FD00 FDP 00

Enegrease HTO HT 00 EP

Aralub HL 2

Enegrease LS 2

Microlube GB 00

Mobilplex 44

Lithium Saponified Greases for Rolling Bearings Glissando 30 Glissando

Beacon 3

Centoplex GLP 402

Mobilux 2 Mobilux 3

Alvania R2

MolubAlloy BRB 572

20

(*designation acc. to DIN 51 502

** designation acc. to DIN 51 519 at 40 °C)

The above gear oils on CLP mineral oil base comply with the minimum requirements as specified in DIN 51517 Part 3. They contain additives for improving the oxidation, corrosion, foaming and wear protection properties and are suited for operating temperatures ranging from -10°C to +100°C. Synthetic lubricants are used when different operating temperatures are encountered.

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7.5 Assembly of the Bevel Gears Klingelnberg Cyclo-Palloid-Bevel Gears Note Always ensure during assembly that the gears have the correct flank contact, irrespective whether the tooth ends are flush or not.

Correct flank contact: Under no-load conditions: The contact zone on both sides should be in the tooth centre.

The teeth should never make contact at their ends (small and large diameters).

Displacement of the flank contact: The higher the load, the greater the axial offset and, consequently, the greater the flank contact displacement.

Therefore: Weak bearing assemblies require short contact zones under no-load conditions.

Note Too short contact zones are detrimental to the load bearing capacity and promote noise generation. As a consequence, the contact zones should not be less than 50% of the total tooth length. Alternatively, the bearing assembly needs to be upgraded.

Checking the flank contact: Coat the tooth flanks on one gear with light colour oil paint. Rotate the gearbox for a couple of turns into the operating direction.

The contact zones then appear as bright spots. Normally, the torsional backlash (tooth play) should not exceed 0.05-0.3 mm or 0.002 – 0.012 in. (at mn 0.5-13 or 13-2 D.P.).

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Contact Zone of Klingelnberg Cyclo-Palloid Bevel Gears No-load Condition

Under Load

The Klingelnberg cyclo-palloid tooth system can be applied to all bevel gear designs, irrespective of the circular path radius of the cutter head and the mean spiral angle.

The contact zone displacement is related to the design and thus subject to a number of different parameters. The amount of displacement depends on the diameter of the plane gear and on the cutter head used in gear cutting, and also on the mean spiral angle of the bevel gear set.

The following interrelations apply: Height displacement of the contact zone: is caused if the spiral angle at the tooth centre is too small or if the circular path radius is too large in relation to the plane gear diameter.

Lateral displacement of the contact zone: is caused if the spiral angle at the tooth centre is too large or if the circular path radius is too small in relation to the plane gear diameter.

In addition to the above described two extreme reactions, combinations of contact zone displacements in different directions are possible depending on the actual gear design.

Which of the reactions occurs on a specific gearbox, can be easily established by checking a master set on a tester. It is advisable that the assembly engineer should study the contact zone displacement on the tester with the aid of a master set.

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DRAWINGS AND TABLES Options for Correcting the Contact Zone Height Displacement of the Contact Zone Existing Contact Zone

Adjustment

Result

Lateral Displacement of the Contact Zone Existing Contact Zone

Ajustment

Result

All of the corrections specified above apply to the driving bevel gear, whereby (v) represents the forward flank and (r) the reverse flank.

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Guides for the Torsional Backlash Relative to the Normal Module Module mm Backlash Module mm Backlash Module mm Backlash

0.3 – 1.0

1.0

2.0

3.0

4.0

0.03 – 0.06

0.06 – 0.08

0.08 – 0.11

0.10 – 0.13

0.12 – 0.14

5

6

7

8

8 – 10

0.14 – 0.17

0.15 – 0.18

0.16 – 0.19

0.18 – 0.20

0.20 – 0.25

10 – 12

12 – 14

14 – 16

16 – 18

18 – 21

0.25 – 0.30

0.30 – 0.35

0.35 – 0.40

0.40 – 0.45

0.45 – 0.50

Note Care should be taken that the backlash is always checked and set at different places at the circumference of the bevel gears.

If the backlash is set too small, there is the risk that the oil film could be choked off.

If the backlash is set too large, a load change shock could occur and the contact zone would deteriorate.

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ANNEX

8

Annex

8.1 Service EICKHOFF ANTRIEBSTECHNIK GMBH „Service“ offers their customers a 24–hours hotline service at the following telephone number: Within the office hours (+49) 2 34 / 9 75 – 25 02 Outside the office hours Hotline (+49) 2 34 / 9 75 – 27 00 Telefax service (+49) 2 34 / 9 75 – 22 72

8.2 Company Address Eickhoff Antriebstechnik GmbH Postfach 10 06 29 44706 Bochum Hunscheidtstrasse 176 44789 Bochum Telephone: Telefax EAT: E-Mail: Internet

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(02 34) 9 75 – 0 (02 34) 9 75 – 25 79 getriebe@eickhoff-bochum.de www.eickhoff-bochum.de

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8.3 Agencies Deutschland • Germany Nord- u. Ostdeutschland • North and East Germany Dipl.-Ing. Reiner Müller Eickhoff Antriebstechnik GmbH Hunscheidtstrasse 176 D-44789 Bochum Tel. (+ 49) 0234 975-2677 Mobil (+ 49) 0172 2 88 90 28 Fax (+ 49) 0234 975-2579 E-Mail: r.mueller@eickhoff-bochum.de

Süd- u. Südostdeutschland und Österreich • South and South Eastern Germany and Austria Dipl.-Ing. Sabine Hörling-Eckhard Eickhoff Antriebstechnik GmbH Hunscheidtstrasse 176 D-44789 Bochum Phone (+ 49) 02 34 / 9 75-22 54 Mobile (+ 49) 0172 / 2 84 30 82 Fax (+ 49) 02 34 / 9 75-25 79 E-Mail shoerling-eckhard@eickhoff-bochum.de

West- u. Südwestdeutschland • Western and South-Western Germany Dipl.-Ing. Hans Bäcker Eickhoff Antriebstechnik GmbH Hunscheidtstrasse 176 D-44789 Bochum Phone (+ 49) 02 34 / 9 75-25 01 Mobile (+ 49) 0172 / 2 82 85 93 Fax (+ 49) 02 34 / 9 75-25 79 E-Mail hbaecker@eickhoff-bochum.de

Export • Exports Dipl.-Ing. Klaus-Dieter Meyer Eickhoff Antriebstechnik GmbH Hunscheidtstrasse 176 D-44789 Bochum Phone (+ 49) 02 34 / 9 75-23 62 Mobile (+ 49) 0172 / 2 84 30 81 Fax (+ 49) 02 34 / 9 75-25 79

E-Mail

kdmeyer@eickhoff-bochum.de

Schweden/Finnland • Sweden and Finland Injab Transmission AB Ringvägen 99 SE-118 60 Stockholm Phone (+ 46) 08 55697660 Fax (+ 46) 08 55697661 E-Mail injab@injab.se

Amerika • America USA und Mexiko • USA and Mexico Eickhoff Corporation 200 Park West Drive Pittsburgh PA 15275, USA Phone (+ 1) 04 12 / 7 88 - 14 00 Fax (+ 1) 04 12 / 7 88 - 41 00 E-Mail eickhoff@bellatlantic.net

Asien • Asia V. R. China • P. R. China Eickhoff Office Beijing Room A0708, Huixin Plaza No. 8 Beichen East Road Chaoyang District Beijing 100101 Tel. (+ 86) 10 51662022 Fax (+ 86) 10 84982560 E-Mail: eickhoff@vip.sina.com Tianjin Eickhoff Precision Machinery Co., Ltd. No. 9 Xiangrui Road Tianxiang Industrial Park Xiqing Economic Development Area Tianjin 300385 Mobil (+ 86) 0136 22 09 35 29 E-Mail: b.fluegel@eickhoff-bochum.de

Taiwan (R.O.C.) KCW Eternal Enterprise Co., Ltd. No. 666, Yung-An St., Tainan 702, Taiwan, R.O.C. Phone (+ 886) 06 / 2 96 53 96 Fax (+ 886) 06 / 2 96 57 00 E-Mail kcw0323@seed.net.tw

Europa • Europe

Australien • Australia

Großbritannien • Great Britain

Australien • Australia

Eickhoff (G.B.) Ltd. Darnall Works, Prince of Wales Road Sheffield S9 4EX Tel. (+ 44) 870 122 1164 Fax (+ 44) 870 122 1165 E-Mail: contact@eickhoffgb.idps.co.uk

Eickhoff Australia Pty. Ltd. P.O. Box 4 06, 41 Prince William Drive Seven Hills, N.S.W. 21 47 Phone (+ 61) 02 / 96 74 67 33 Fax (+ 61) 02 / 96 74 65 81 E-Mail eickhoffaust@optusnet.com.au

Polen • Poland

Afrika • Africa

Eickhoff Polonia Ltd. Ul. Podleska 72 43-190 Mikolow Tel. (+ 48) 032 2066010 Fax (+ 48) 032 2028744 E-Mail: eickhoff_sekretariat@onet.pl

Spanien • Spain Alfred Klöpp c/ Dr. Robert, 7, 2°, 2a E-08915 Badalona (Barcelona) Tel. (+ 34) 093 3993562 Mobil (+34) 0618 316090 Fax (+ 34) 093 4601419 E-Mail: alfred.kloepp@cityweb.de

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Südafrika • South Africa Eickhoff Pty. Ltd. Mining Machinery and Gearboxes 12 Strauss Crescent, Wadeville Ext. 6 P.O. Box 1 46 74, Wadeville 1422 Phone (+ 27) 0 11 / 9 02-56 30 Fax (+ 27) 0 11 / 9 02-58 30 E-Mail md@eickhoff.co.za

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ANNEX

8.4 Declaration of incorporation Declaration of incorporation for included partly completed machinery covered by EC Directive 2006/42/EC, Annex II, No. 1 B

Eickhoff Antriebstechnik GmbH, Hunscheidtstr. 176, 44789 Bochum, declares that the product: description function type / article code trade name

Bevel Helical Planetary Gearbox drive of a Chain Conveyor EKP-15 / G 028225 XA three stage Bevel Helical Planetary Gearbox

is partly completed machinery in accordance with Article 2g and exclusively intended for incorporation in or assembly with other machinery or equipment.

Putting into service is prohibited until it is found after incorporation that the final machinery is in conformity with the EC Directive 2006/42/EC. The following essential health and safety requirements according to 2006 / 42 / EC, Annex I are applied and fulfilled: 1.1.2, 1.1.3, 1.1.5, 1.3.1 – 1.3.4, 1.3.7, 1.3.8.1, 1.4.1, 1.5.4 – 1.5.9, 1.5.13, 1.5.15, 1.6.1, 1.6.4, 1.7.2, 1.7.3, 1.7.4.1, 1.7.4.2 The relevant technical documentation has been compiled in accordance with Annex VII, Part B of EC Machine Directive 2006 / 42 / EC. We undertake, in response to a reasoned request, to supply it in electronic form to the responsible national authorities.

The following harmonised standards (or parts of these standards) have been applied: DIN EN ISO 12100-1: 2003 / prA1: 2008 DIN EN ISO 13732-1: 2008 DIN EN ISO 14121-1: 2007 The following persons are authorized to compile the relevant technical documentation defined in 2006/42/EG, Annex VII B: Date / Place :

Particulars to the signees:

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Dr.-Ing. Dipl.-Oec. Ralf G. Wittor Rainer Lohmann Management Eickhoff Antriebstechnik GmbH

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8.5 Supplement Supplement to the Operating Manual Governing the Use of Gearboxes according to 94/9/EC 1.

Safety Instructions Governing the Use in Potentially Explosive Atmospheres

Explosive gas mixtures or dust concentrations in combination with hot and moving parts of gearboxes can cause severe or fatal injuries.

Assembly, commissioning/start-up, maintenance and repairs on the gearbox shall thus be carried out by qualified and authorized persons only whilst taking into account • these instructions • the plant-specific provisions and requirements • the applicable national rules and regulations.

The gearboxes are intended for industrial applications and shall be used exclusively in conformity with the details contained in the operating manual and the data specified on the rating plate. They comply with the applicable rules and standards and conform to the requirements of the Directive 94/9/EC.

2.

Assembly and Commissioning/Start-up of the Gearboxes

Prerequisites for operation: • The gearbox is provided with cooling chambers (EP) or installed oil/water coolers.

A flow switch (mounted by EICKHOFF or provided by the mining company) monitors the minimum water flow rate.

• The gearbox is fitted with a temperature switch located in the oil sump. The temperature switch (mounted by EICKHOFF or provided by the mining company) monitors the oil sump for the maximum temperature of 100 °C. Actions to be carried out before commissioning/start-up: ► Check the components for transport damage ► Remove the transit clamp, if any, before commissioning/start-up ►

Check that the data on the rating plate corresponds to the equipment group category that is approved for the Ex area at site.

► Make sure that the gearboxes are exclusively assembled in an area that is free of a potentially explosive atmosphere. ► Check that the ambient temperature is within the permissible ambient temperature range between –20 °C and +40 °C. ► Provide for adequate ventilation of the gearboxes ► Make sure that no external heat is introduced into the gearbox ► Verify that the type of construction and the assembly arrangement correspond to the operating manual ► Check that the oil level corresponds to the details contained in the operating manual G 028225 XA Rev. No.: 00

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► Make sure that all breathers, oil fill ports and oil drain ports are easily accessible ► Observe the required clearances from rotating parts when mounting covers ► Make sure that the signals of both the temperature switch and the flow switch lead to a warning or shutdown of the plant.

Actions to be carried out during commissioning/start-up: ► Measure the surface temperature after about 3 hours of operation. A temperature of 110 °C shall not be exeeded. If exceeded, shut down the plant and consult EICKHOFF. ► Measure the oil temperature after 3 hours of operation. Add 10K to the measured value and use the resultant temperature value to determine the oil change interval as described in the manual. ► Make sure that the flow switch and the temperature switch are properly connected electrically. ► Check the flow switch for proper functioning.

3.

Inspection and Maintenance

Inspection work on the gearboxes to be carried out at weekly intervals: ► Check the oil level ► Visually inspect the seals for leaks ► Check the surface temperature in the area of the oil sump ► Check the surface temperature in the area of the bearings ► Check the gearbox and the attachment parts, if any, for proper mounting ► Check the gearbox for noise and vibrations ► Check the breathers Inspection work on the geaboxes to be carried out during overhauls on the surface: ► Open the gearbox and clean it thoroughly ► Inspect the rolling bearings and the gear teeth

Recommended Overhaul Intervals In case of operation at maximum ratings as defined in the data sheet "Standard max. motor rating"

after 10 000 hours of operation, or after eighteen (18) months at the latest replace the rolling bearings at the latest after every second overhaul

In case of operation at lower ratings

after consultation with Eickhoff but at the latest after 20 000 hours of operation or after 30 month of operation replace the rolling bearings at the latest after every second overhaul

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ANNEX Maintenance on the gearboxes

• - Change the oil at the determined oil change intervals whilst taking note of the safety instructions contained in the operating manual.

Recommended Mineral Oil Change Intervals First oil change

300 - 500 hours of operation or after one month of operation at the latest

Further oil changes depending on the operating temperature

up to

4.

80 °C

every

5.000

hours of operation

90 °C

every

3 000

hours of operation

100 °C

every

2 000

hours of operation

Functional Disorders

Functional disorders of the gearbox such as: Unusual noise and vibrations, temperature rises, oil leaks are serious incidents on gearboxes used in potentially explosive atmospheres and could endanger the operational safety of the plant. Such incidents shall be reported immediately to the supervisor in charge. The plant may continue operation only on the condition that utmost care be exercised under strict observance of the temperature limits before it is shut down for repair at the soonest possible point of time.

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ACCESSORIES

9

Accessories

9.1 CORTEC Corrosion Inhibitor

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9.2 Anticorrosion Grease

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