CAT Beamed Stageloader Gearbox KP-15 & KP-15.1 Operating and Maintenance Manual

Media-ID: EM028748-02 Doc.-No.: 1949 016 000 BA 00-05 Jun. 2021

Operating and Maintenance Manual Gearbox KP-15 & KP-15.1

Part-No.:

777594 to 777601 & 4921926, 606-1035

SAFETY.CAT.COM

AMENDMENTS AND ALTERATIONS TO THIS PUBLICATION ARE NOT SUBJECT TO NOTIFICATION. CATERPILLAR RESERVES ALL RIGHTS TO THIS PUBLICATION. ITS CONTENT IS PROTECTED BY COPYRIGHT LAWS. NO PART OF THIS PUBLICATION MAY BE REPRODUCED OR TRANSFERRED IN ANY WAY OR FORM WITHOUT THE PRIOR WRITTEN APPROVAL OF CATERPILLAR. CATERPILLAR DECLINES ANY LIABILITY FOR DIRECT OR INDIRECT CONSEQUENCES OF PRINTING ERRORS. WE RESERVE THE RIGHT TO INTRDUCE MODIFICATIONS AS A RESULT OF TECHNICAL DEVELOPMENTS WITHOUT PREVIOUS NOTICE. © 2021 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of contents

Table of contents 1 About this manual ....................................................................................... 5 1.1 How to use this manual ........................................................................ 5 1.2 Signs and symbols used....................................................................... 5 2 Safety............................................................................................................ 7 2.1 Operating conditions............................................................................. 7 2.1.1 Intended use .............................................................................. 7 2.1.2 Unauthorized use....................................................................... 7 2.1.3 Ambient conditions..................................................................... 7 2.1.4 Prerequisites for operation......................................................... 8 2.2 Personnel.............................................................................................. 8 2.3 Operator requirements.......................................................................... 9 Media-ID: EM028748-02 / Caterpillar Global Mining Europe GmbH 2021 ©

2.4 Using the machine and working on the machine .................................. 9 3 Storage and transport ............................................................................... 11 3.1 Storage ............................................................................................... 11 3.1.1 Gearbox preservation .............................................................. 12 3.2 Transport ............................................................................................ 13 3.2.1 Transport sheet........................................................................ 17 4 Assembly.................................................................................................... 18 4.1 Gearbox installation ............................................................................ 18 4.1.1 Before installation .................................................................... 18 4.1.2 Installation instructions............................................................. 21 4.2 Cooling water supply .......................................................................... 22 4.3 Drive connection ................................................................................. 22 4.3.1 Drive coupling assembly .......................................................... 23 4.3.2 Mounting and pulling device .................................................... 25 4.3.3 Flexible coupling for operation ................................................. 27 4.4 Gearbox commissioning ..................................................................... 30 4.4.1 Commissioning ........................................................................ 31 4.5 Test run............................................................................................... 32 4.6 Dismantle gearbox.............................................................................. 32 4.6.1 Important instructions for dismantling ...................................... 32 5 Operation.................................................................................................... 33 5.1 Maintaining the gearbox ..................................................................... 33 5.1.1 Gearbox maintenance.............................................................. 33 5.1.2 Changing the oil ....................................................................... 34 5.1.3 Maintaining the filter................................................................. 40 5.1.4 Checking the breather plug...................................................... 41 5.1.5 Maintaining the hydraulic system............................................. 41 5.1.6 Checking gearbox bearings ..................................................... 41 5.1.7 Cleaning the gearbox casing ................................................... 42 5.2 Replacing defective components........................................................ 42 5.2.1 Replacing the heat exchanger ................................................. 42 5.3 Troubleshooting .................................................................................. 45 5.3.1 Gearbox troubleshooting.......................................................... 45

Gearbox KP-15 & KP-15.1

Table of contents

6 Technical data............................................................................................ 47 6.1 Technical data sheet........................................................................... 47 6.2 Main dimensions and connections...................................................... 48 6.3 Performance data ............................................................................... 50 6.4 Technical description .......................................................................... 50 6.5 Accessories ........................................................................................ 51 6.5.1 Hose connection for oil drainage ............................................. 51 6.5.2 Mounting and pulling-off device ............................................... 52 6.6 Oil levels and oil quantities ................................................................. 52 6.6.1 Gearbox tilt............................................................................... 53 6.7 Permissible media .............................................................................. 54 6.7.1 Requirements for the cooling water quality.............................. 56 6.7.2 Greases and lubricating pastes ............................................... 56

6.9 Identification of the gearbox................................................................ 59

Gearbox KP-15 & KP-15.1

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6.8 Tightening torques .............................................................................. 58 6.8.1 Screws and bolts with ISO metric thread ................................. 58

About this manual How to use this manual

1

1 About this manual This chapter contains important information that makes it easier for you to use this manual. You will also get information about the structure of the manual and the symbols, characters and abbreviations used and frequently used terms.

1.1 How to use this manual applicable operating manual

Category according to Atex directive

Using an operating manual that was not specifically written for the product concerned can result in a safety hazard for yourself and others. Make sure the information on the product complies with that given in the operating manual.

The machine is a device of Group I, Category M2 according to the European Directive 2014/34/EU. The operating manual must be accessible at all times to all persons working on or with the machine. It should always be available at the place of operation.

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new operating manual

service partner

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

Please contact your service partner for spare part requests or for the clarification of technical questions.

Persons for whom the operating manual is intended The operating manual is intended for persons working with or on the gearbox.

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

Purpose of this operating manual efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all activities relating to the product.

Take the time to read this operating manual in its entirety. Pay particular attention to the respective safety instructions. Familiarize yourself well with the appearance and meaning of the safety and information symbols.

safety

Carefully read through the chapter "Safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

1.2 Signs and symbols used DANGER The combination of the signal word DANGER and a corresponding symbol warns you of an immediate danger with a high personal risk.

If not observed, you or your coworkers will be seriously injured or killed.

1. Follow the described instructions.

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1

About this manual Signs and symbols used

WARNING The combination of the signal word WARNING and a corresponding symbol warns you of a potential danger with a moderate personal risk.

If not observed, you or your co-workers might be seriously injured or killed.

1. Follow the described instructions.

CAUTION The combination of the signal word CAUTION and a corresponding symbol indicates a potential personal risk.

If not observed, you or your co-workers could suffer minor to moderate injuries.

NOTICE The combination of the signal word NOTICE and the adjacent symbol indicates a potential risk of damage to the machine.

If not observed, material damage might occur on the machine.

1. Follow the described instructions.

Tip The signal word TIP indicates useful tips and information.

This information will help you become more familiar with the machine and allow you to prepare your work more exactly.

1. Observe the provided tips and information.

Important information The combination of the signal words IMPORTANT INFORMATION and the adjacent symbol indicates important information or other operating manuals which must be observed at this place.

1. Observe the information and read the specified operating manuals.

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1. Follow the described instructions.

Safety

2

Operating conditions

2 Safety This chapter provides you with important information about your safety. Pay special attention to this chapter. The safety instructions and rules of conduct are intended to help you avoid hazardous situations and perform the necessary work as safely as possible.

2.1 Operating conditions 2.1.1 Intended use The gearbox is exclusively designed and manufactured to be used as part of a drive unit. Use the gearbox only as intended.

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Intended use includes: Reducing speed and transmitting the torque of electric motor to the drive shaft.

Do not make any modifications or carry out changes which could impair safety.

All modifications and changes must be approved by Caterpillar.

Only use original spare parts from Caterpillar. Note that using parts from other manufacturers will void the guarantee.

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

Caterpillar assumes no liability for damage caused by unauthorized use.

2.1.3 Ambient conditions Suitable measures must be taken by the operator to combat explosion hazards due to firedamp and the ignition of dust which might occur in a mine (see DIN EN 1710).

These include: adequate and consistent ventilation, water spraying systems.

The M2 equipment must be switched off if the firedamp concentration in the free cross-section of the parts of the face which are continuously ventilated reaches the lower explosion limit (LEL) defined by relevant national legislation.

It may only be restarted by an authorized person.

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

The M2 equipment must be stopped immediately and secured against restarting if the firedamp protection systems are found to be damaged.

Wherever it is necessary to support ventilation, the face must be equipped with means to dilute flammable gases in areas where cutting tools are used.

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2

Safety Personnel

2.1.4 Prerequisites for operation It is prohibited to start up the machine before it has been confirmed that the overall system in which the machine is installed complies with national regulations.

Since the equipment is only part of an overall system, the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. This must be labeled according to the legal provisions applicable at the time of its placement on the market.

The machine may be operated only if the safety requirements specified in national regulations are met. These include: equipment for preventing unauthorized startup, startup warning systems,

safe shutdown command systems, emergency-stop systems, dust extraction systems, noise protection, warnings etc.

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

2.2 Personnel The machine may only be operated by skilled or instructed personnel.

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

The following parts may only be installed or repaired by service technicians authorized by Caterpillar or mining professionals as defined below: safety components (pressure relief valves, etc.), the electrical system (controls, signaling devices, etc.), hydraulic system qualification

A skilled worker is someone who, based on his special training and experience, has sufficient knowledge and is familiar with the relevant regulations.

A skilled worker can carry out the work assigned to him. He can recognize potential hazards and take the necessary measures to eliminate them. He also has the required repair and installation knowledge.

An instructed person is someone who has been instructed with regard to the tasks assigned to him and the potential hazards which arise due to improper behavior, and, if applicable, has been trained/instructed concerning the necessary safety equipment and protective measures. The instructed person is able to work while looking ahead, recognize hazards and act accordingly.

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water spraying systems in areas where there is a danger of explosion

Safety

2

Operator requirements

2.3 Operator requirements Operators are responsible for ensuring that the machine is always in a technically serviceable condition. This includes for example: Regularly maintenance and checking the machine in accordance with the provided schedule Ensuring sufficient supplies for operation such as electricity, water or hydraulic fluid Regularly checking all safety equipment (document the test results).

If any irregularities are noticed during operation, investigate them immediately and shut down the machine until any problems have been rectified Make sure that all of the signage on the machine is legible, and immediately replace any lost signs

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2.4 Using the machine and working on the machine Each time before you turn on the machine, check that all protective devices are on the machine and functional.

Keep the signaling and lighting systems in proper working order.

Clean the operating plate at regular intervals. Make sure that the operating symbols are clearly recognizable.

Never reach into or enter areas between machine components which can move.

Immediately replace damaged components relevant for safety. Shut down the relevant section immediately if component damage creates a hazard and immediate repair is not possible. If there is a safety hazard, secure this area and notify the entire face crew and responsible superiors without delay.

Secure the conveyor against being switched back on again while carrying out: Maintenance work Inspection work Repair work Notify the responsible personnel of the following prior to working on the longwall: your exact location, the work you are carrying out how much time you will probably need You may only carry out work in the mining area if: the roof has been secured against falling rock, the coal face has been secured against collapsing and the mining equipment and conveyor have been shut down and secured against being switched back on.

Refit any protective devices removed immediately after completing work, and check that they are working properly.

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

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2

Safety Using the machine and working on the machine

emergency stop

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

Actuate the EMERGENCY STOP SWITCH also if safety equipment.

danger of ignition

Make sure to comply with the intervals specified for maintenance and inspections of the conveyor, as hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Observe the separate operating manuals for the components used.

Storage and transport

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

Only use means of attachment that are in perfect condition and have been designed for the loads that occur.

For round components use transport straps only. Never use chains or steel cables for this purpose.

Do not damage any finished or polished surfaces, such as shaft surfaces, sealing surfaces, etc.

Make sure that the transport safety devices have been correctly fitted.

Secure all moving parts so that they are stationary.

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

Never walk or stay under unsecured components or suspended loads. lubricants and chemicals

When working with oils, greases and other chemicals, pay attention to the safety regulations applicable to the product (manufacturer's safety data sheet).

Dispose of oil, grease and other chemicals as well as contaminated fluids in accordance with national environmental laws.

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Only hook the lifting tackle into the lifting points provided for this purpose. Pay attention to the different load limits of the lifting points. Also observe the instructions on the transport sheets. Never attach lifting tackle to brackets and cylinder connections.

Storage and transport Storage

3

3 Storage and transport Important information Please note further information in our technical information guide "Equipment for use underground, Transport and storage conditions", Media no. EM027870.

3.1 Storage

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General This chapter contains important information on correct storage and transport.

Following the instructions and notes will increase the life cycle and service life.

You will be able to carry out transport work more safely and quickly. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storing the equipment corrosion protection

avoid direct exposure to sunlight

dirt and moisture

Components coated with temporary corrosion protection are protected for about six months.

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15oC to 25oC. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. by using tarpaulins.

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic plug-type connections and the connections of the electrical cables with the caps and plugs supplied.

short-term storage

long-term storage

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

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

After a storage period of approximately two years, an inspection must be performed to determine whether the measures taken and the method of storage have prevented damage. This inspection can be carried out by our service technicians upon request.

natural aging

Frost protection for water-conducting components

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

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

Tip When storing and removing machines and machine parts from storage with a limited service life, make sure to use old deliveries first.

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Storage and transport

3

Storage

Storing used equipment The above points, with the exception of the one concerning corrosion protection, similarly apply to the storage of equipment parts that have already been used. corrosion protection of hydraulic components

corrosion protection of waterconducting components

If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor, e.g. MinetechTM Protection Fluid (Quaker). If this is not done, then the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

Equipment parts for conveying water, such as the parts for the water spraying system or motor cooling circuit, must be completely drained, or also filled with antifreeze if required.

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

Important information Observe the data sheet of the respective manufacturer. This includes specifications and specific safety instructions for safe handling of the product.

We recommend the following preservative: TECTYL 511-M by VALVOLINE The following steps must be carried out to preserve the interior of the gearbox: The gear oil must be completely drained and residue must be avoided because there is no corrosion protection at these locations. The gearbox may need to be swiveled or turned to the side.

Next, top off gearbox with preservative up to the oil level mark (see oil levels and oil quantities). Or spray the gearbox with preservative using the spray method. This method may be applied only if a sufficient supply to the bearings inside can be ensured. During the spray procedure, the gear wheels must be turned so that all tooth flanks and bearings receive a sufficient amount of preservative.

CAUTION Operating temperature The operating temperature of the preservative must be at least 18°C to 20°C. Observe VALVOLINE's instructions Remove the breather plug so that it is not adversely affected by the preservative.

Allow the gearbox to run for at least 15 min without load so that it becomes thoroughly coated.

Drain the preservative as thoroughly as possible. Do not allow small pools of liquid to form in the process.

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3.1.1 Gearbox preservation

Storage and transport

3

Transport

DANGER Flammable solvent Solvent flashpoint (petroleum spirit) is 40°C according to DIN 51 755. Hazard class A II according to VbF (Ordinance for Flammable Liquids). Ensure the solvent is discharged thoroughly.

Vent the gearbox thoroughly for at least 24 hours with open inspection hole cover because the preservative contains a solvent (petroleum spirit) that must be discharged.

The volatile solvent is heavier than air. For this reason, the opening should be at the bottom or the lower side so that the solvent can discharge downward.

The gearbox may need to be swiveled or turned to the side.

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After receiving the anticorrosion treatment mentioned above, the gearbox can be stored underneath a roof without additional packaging for nine months. It should be stored so that vents and other openings are covered to prevent water from penetrating the interior of the gearbox. The measures to prevent the water from penetrating should not adversely affect the inner ventilation of the gearbox.

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

Bright exterior flanges such as shaft extensions, flanges, etc. should be coated with a non-slippery wax film or wax tape. When the gearbox is put into operation, the preservative dissolves in the gear oil. It can remain in the gearbox until the next oil change without adversely affecting the ability of the oil to lubricate.

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

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

3.2 Transport Load Units, Dimensions and Weights Make sure to pay attention to the transport sheet. It includes information on: dimensions weight lifting points centers of gravity The load units are provided with suitable lifting points for transport and installation as far as technically possible.

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3

Storage and transport Transport

DANGER Attaching loads Insufficient technical knowledge and/or inattention can result in severe or fatal injuries when lifting and transporting loads.

1. To lift and transport loads, only use serviceable load handling devices that are sufficiently large.

2. Attach the loads only to the lifting points provided for this purpose.

3. Make sure that boltable lifting points such as lifting eyes are completely bolted in.

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4. Never stand under suspended loads.

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Storage and transport Transport

3

Fig. 1: Lifting eye and load ring example

A

B c

b

a

a

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d A

Lifting eye

B

Load ring

a

Load capacity 5000 kg

b

Eye

c

Welded onto component

d

Screwed onto component

Before transport temperatures below freezing

It is only permitted to transport equipment at temperatures of -21oC to -40oC if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on roads in bad condition, the transport vehicle's speed must therefore be limited to a maximum of 25 km/h for truck transport.

hydraulic component frost protection

frost protection for oil cooler

electrical and electronic components

Before transporting the equipment at temperatures below freezing, all hydraulic components that are operated with emulsion (HFAE or HFAS) must be completely drained and filled with a corrosion inhibitor such as MinetechTM Protection Fluid (Quaker).

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

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the entire equipment are protected against harmful environmental influences by suitable packaging. The electrical cables remain in the equipment. They must be protected carefully from transport damage and the connectors must be protected from dirt.

Transporting the components Use machine parts are equipped with lifting eyes or load rings for transportation.

In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport.

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3

Storage and transport Transport

Use suitable transport equipment such as belts, chains, etc. to transport components without load attachment points.

Transport boxes Machine parts for hydraulic components can be packed in transport boxes.

They should stay in these transport boxes until they reach their final place of operation. This protects them from external damage.

Make sure that the transport boxes are not damaged during transport.

Protect the transport boxes from moisture.

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Fig. 2: Correct transport of machine parts

Storage and transport Transport

3

3.2.1 Transport sheet Fig. 3: Transport sheet 1372

700

1

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2

890

3

1

Lifting eye TAWGK 3 (3000 Kg)

2

Shaft protection

3

Protective cover

Gearbox weight: 2220 kg (without oil)

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4

Assembly Gearbox installation

4 Assembly 4.1 Gearbox installation NOTICE Gearbox installation Incorrect installation of the gearbox can result in significant damage to the drive units!

1. The gearbox and its drive units should therefore only be installed under the direction of specialists from Caterpillar!

Notice on work safety

Check whether all bolted connections between the drive frame and the flange plate are at hand and check the tightening torques. Make sure that all screws for fastening the gearbox to the flange plate are fitted.

Remove the transport protectors from the drive shaft and the output shaft.

All gearbox connections must be sealed with O-rings.

4.1.1 Before installation Attachment parts

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

The breather plugs are supplied loose.

Install and tighten the two breather plugs (4) at the top, before the attachment of the gearbox.

Two dipsticks (1,2) must be installed at the top. One dipstick (2) on the main gearbox chamber and another dipstick (1) on the drive shaft bearings of main gearbox chamber.

Magnetic rod (5) is mounted at the bottom in the gearbox.

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Refer to the additional instructions in the operating manual for the conveyor.

Assembly

4

Gearbox installation Fig. 4: Attachment parts

a

1

2

3 3 3

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4

3 5

3 a

6*

Flange plate

*Optional breather for KP 15.1

1

Drive shaft - Dipstick 350 lg

5

Magnetic rod

2

Dipstick 517 lg

6

Drive shaft bearings - Breather plug

3

Sealing ring A 30x36

a

Filter plug installation locations

4

Main gearbox - Breather plug

The flange plate must be installed before the gearbox can be attached.

Check all the bolted connections between the mainframe and the flange plate and check the tightening torque. Make sure that all the screws for fastening the gearbox and the parallel keys are inserted on the flange plate.

Heat exchanger

The heat exchanger are labeled with a “cooling water inlet” or “cooling water outlet” plate on manifold connector.

Depending on the operating conditions on-site, the “cooling water inlet” or “cooling water outlet” heat exchanger can be installed either at the top or the bottom.

The cooling system consists of three heat exchangers, two tube heat exchanger in the main gearbox chamber and one plate heat exchanger in the drive shaft bearing.

The cooling water inlet is installed on the underside. To replace the heat exchanger, "(see section "Replacing the heat exchanger”)" [} 42].

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4

Assembly Gearbox installation

The heat exchanger system is equipped with a pressure relief valve (c) for protecting the entire cooling system. The pressure relief valve must always be installed on the “water inlet” cooler.

Fig. 5: Cooling water ports

1

2

3

4

x

y

B 7

z

A x

C

3

5

y

1

1

Coupling clip DN 12

7

Heat exchanger

2

Screw-in socket G 3/4-DN 12

A

Cooling water inlet DN 12

3

Screw plug G 3/4

B

Cooling water outlet DN 12

4

Screw plug G 1

C

Pressure relief valve

5

Fitting connection G 3/4'' - DN 12

x,y,z

Water ports

Possible connections for the cooling water supply.

Fig. 6: Cooling water ports details

X, Y, Z

Water ports

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

Therefore connect the cooling water supply via ports Y and Z or X and Z only.

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z

Assembly

4

Gearbox installation

NOTICE Risk of overheating the gearbox Insufficient cooling can lead to serious gearbox damage.

1. Connect the cooling water supply port in the correct combination manner.

4.1.2 Installation instructions Fig. 7: Transport protection

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1 2

3

4

1

Protective cover

2

Shaft protection

3

Hex head screw M 30x508.8

4

Hex head screw M 12x208.8

Remove the transport protection from the drive and output shafts.

All flange surfaces, centering bores, parallel keys and grooves must be clean and without burrs.

Before mounting the flange, the gearing must be well greased - B3 grease (see section "Greases and lubricating pastes" [} 56]).

The gearing must be aligned so that tooth and tooth gap are exactly opposite one another to ensure that they mesh smoothly. Avoid damage to the gearing. Take special care to ensure that the gearbox is not tilted during installation.

The gearbox must be positioned accurately on the centering bores, connectors, and parallel keys when installed.

Make sure you use the correct screw sizes that correspond to the gearboxes used.

After installing the gearboxes, there must be no tension between the gearbox and the drive frame or between the gearbox and the drive shaft.

Observe the tightening torque of the connection screws.

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4

Assembly Cooling water supply

4.2 Cooling water supply The connections for the cooling water supply must be attached in accordance with the symbol plates affixed to the gearbox. The location of the cooling water connections is shown in the "Main dimensions and connections" [} 48] chapter. Depending on the on-site conditions, these connections may be made on the right-hand or left-hand side.

NOTICE Filtering the cooling water Unfiltered cooling water can cause severe damage to the gearbox!

1. Filter the cooling water before it enters the gearbox. The size of dirt particles must not exceed 0.25 mm.

4.3 Drive connection The drive connection is made up of all components between the motor and the gearbox. It consists essentially of a protection cover and an elastic coupling.

The drive connection is equipped with an additional crown gear which makes it possible to use a chain tensioner to tension the chain. gearbox side of coupling

flange position

The hole in the gearbox side of the coupling is coated with lubricating paste B3, as described in the “Recommendations for greases and lubricating pastes" section, and pushed onto the gearbox drive shaft until it stops against the shaft collar.

Electric motor Flange position "W" on the electric motor defines the distance between the motor flange and the shaft collar. On the drive connection the flange position "Z" is the distance between the contact surface of the protection cover (motor side) and the contact surface of the coupling. The condition is that the reference dimension for the flange position "Z" be identical to that for flange position "W" or up to 4 mm more (Z-W= 0 up to 4 mm).

NOTICE Note the flange position If the flange position “W" on the E-motor is larger than on the connection assembly, the motor shaft and gearbox shaft bearings can become strained. This may lead to damage to the gearbox and the E-motor.

1. When installing the E-motor and gearbox, make sure that the flange position is correct.

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2. Monitor the inlet temperature of the cooling water; it must not exceed 25°C.

Assembly Drive connection

4

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Fig. 8: Flange position W

1

Gearbox

3

Coupling

2

Drive connection

4

E-motor

W

Dimension from motor flange to shaft collar

Z

Dimension from protection cover contact surface to coupling contact surface

Pay particular attention to the following instructions before installing the E-motor: The electric motor's exact flange position "W" must be measured before installation.

The drive connection's exact flange position "Z" must be measured before installation.

The connecting pieces must be installed using the mounting and pulling-off device.

If the flange position "W" of the E-motor is larger than that of the drive connection, one component of the drive connection (e.g. hub of the flexible coupling) must be shortened accordingly.

If the flange position of the E-motor is less than that of the drive connection by more than 4 mm, an intermediate ring must be shoved onto the drive shaft of the electric motor.

1)

Clearance protective cover/coupling ≥ W5

2)

The order No. covers protective cover, couplings, and intermediate flange.

3)

Delivered without fluid coupling

4.3.1 Drive coupling assembly The following factors determine which drive connection assembly is required: Dimensions of gearbox and motor Motor output motor speed Any additional equipments, if any.

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Assembly

4

Drive connection

Fig. 9: Drive connection assembly Type A - with fluid coupling

Type B - with flexible coupling

gearbox side

motor side

motor side

b

660

D

d

90

90

Type C - with fluid coupling and crown gear gearbox side

1

660

D

Type D - with flexible coupling and crown gear motor side

motor side

b

b

gearbox side

660

660

D

d

90

1

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D

90

Intermediate flange

Gearbox KP-15 & KP-15.1

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1

gearbox side b

Assembly

4

Drive connection

4.3.2 Mounting and pulling device The Voith Turbo fluid coupling can be mounted and pulled off safely from the gearbox drive shaft using the mounting and pulling-off device. Both devices are housed in a protective tube. The protective tube also acts as a mounting and pulling-off device.

Fig. 10: Mounting and pulling-off device 5

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1

2

3

6

7

8

9

10

11

4

12

13

1

Hex. head screw M 6 x 16

8

Protective tube

2

Protective cap

9

Threaded spindle M 30

3

Hex nut M 30 x 8

10

Ball bearing

4

Bush

11

Thrust washer

5

Washer

12

Circlip

6

Hex. head screw M 16 x 70

13

Hex. head screw M 20x50

7

Threaded tube

Mounting and removal of Voith Turbo fluid coupling Fig. 11: Voith Turbo fluid coupling

a b

c d

Gearbox KP-15 & KP-15.1

a

Sprung dowel pin

c

Spring washer VSK 30

b

Retaining washer for coupling

d

Hex. head screw M 30 x 120

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4

Assembly Drive connection

Before Mounting Always position the protection cover intermediate flange on the gearbox flange before mounting, as it is not possible once Voith Turbo fluid coupling is mounted.

Clean and lubricate the gearbox shaft using Molybdenum "Gleitmo 805" or another molybdenum sulfide-free substance of the same type and quality

Mounting Fig. 12: Mounting device

2

3

4

1

Hex. nut

3

Bush

2

Washer

4

Threaded spindle

Push the Voith Turbo fluid coupling onto the gearbox drive shaft.

Insert the threaded spindle (4) with washer (2) and bush (3) into the threaded bore of the gearbox drive shaft through the coupling hub.

Steadily tighten the hex nut (1) until the Voith Turbo fluid coupling can be pushed onto the gearbox drive shaft smoothly.

Lock the drive shaft using the hex nut on the threaded spindle.

Remove the threaded spindle.

Insert the sprung dowel pin (a) and the retaining washer (b) of the Voith Turbo fluid coupling.

Attach the hex head screw (d) and the spring washer (c) of the coupling into the drive shaft and tighten it.

Before Pulling off Make sure that the E-motor, the protection cover and the Tschan coupling are removed before pulling off the Voith Turbo fluid coupling.

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1

Assembly Drive connection

4

Pulling off Fig. 13: Threaded tube with thrust washer

2

1

1

Threaded spindle

2

Thrust washer

Remove the hex head screw (d) and the spring washer (c) from the retaining washer (b) on the gearbox shaft end.

Remove the sprung dowel pin (a) and the retaining washer from the coupling hub.

Insert the threaded spindle (1) into the threaded coupling hub.

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Use wrench and turn the threaded spindle steadily so that the threaded spindle braces against the thrust washer (2) on the gearbox drive shaft end.

Turning the spindle pulls the Voith Turbo fluid coupling off the gearbox drive shaft.

Fig. 14: Voith Turbo fluid coupling, detail

a b

c d

a

Sprung dowel pin

c

Spring washer VSK 30

b

Retaining washer for coupling

d

Hex. head screw M 30 x 120

4.3.3 Flexible coupling for operation Flexible coupling for operation with a fluid coupling The coupling illustrated below is fitted between the E-motor and the Voith Turbo coupling and acts as a flexible connecting element. It compensates for minor radial, angular and longitudinal positioning errors which may arise during installation.

The motor side coupling hub is bored for the E-motor provided.

Installation and removal of the flexible plug-in coupling

Clean the bore on the coupling hub (3) and lubricate using grease free from molybdenum.

After mounting and securing the Voith Turbo coupling, secure the connecting flange (1) on the coupling housing using appropriate bolt.

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Assembly Drive connection

Mount the coupling on the motor shaft ends using a mounting device.

The intermediate ring is fitted in between both coupling halves.

Disassembly is carried out in reverse order.

Fig. 15: Flexible coupling for operation with a fluid coupling

1

2

1

Connecting flange

2

Intermediate ring

3

Coupling hub

Flexible coupling for operation without fluid coupling The coupling illustrated below is fitted between the E-motor and the gearbox and acts as a flexible connecting element. It compensates for minor radial, angular and longitudinal positioning errors which may arise during installation.

Installation and removal of the coupling halves

Clean the bore on the coupling hub and lubricate using grease free from molybdenum.

The intermediate ring (2) is fitted in between the both coupling halves.

The coupling halves (1,3) are mounted on to and pulled off from the gearbox and motor shaft ends using a mounting and pulling-off device.

Disassembly is carried out in reverse order.

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3

Assembly

4

Drive connection Fig. 16: Flexible coupling for operation without fluid coupling

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1

2

1

Coupling halves

2

Intermediate ring

3

3

Coupling halves

Protection covers The protection covers house the high-speed Voith coupling and/or the flexible coupling and connect the gearbox to the E-motor.

Protection cover with a fluid coupling

In addition to the above mentioned function, the cover also serves to shield against jetting fluid when the fusible safety plug is opened.

WARNING Hot fluids!

Be careful when opening the coupling at operating temperature as hot fluid can jet out.

The inspection holes are used to fill the Voith coupling with fluid and to change the fusible safety plug.

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Assembly

4

Gearbox commissioning

The other openings cool the coupling during operation and must always be kept dirt-free.

Fig. 17: Protection cover - fluid coupling

Protection cover without fluid

motor side

Fig. 18: Protection cover - flexible coupling

coupling

gearbox side

motor side

1

2

1 Protection cover intermediate flanges

Protection cover

2

Cover

Intermediate flanges are fitted to bridge the gap between differing centering bores on the drive gear and the protection cover.

4.4 Gearbox commissioning The gearbox must be commissioned under the supervision of technicians from Caterpillar.

NOTICE Before commissioning the gearbox The conveyor as well as the gearbox can be damaged severely as the result of installation errors before and during commissioning!

1. It is essential that you read the associated operating manual for the entire conveyor system and observe the corresponding installation instructions!

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gearbox side

Assembly

4

Gearbox commissioning

Before startup The following work has to be performed on the gearbox before beginning with the actual startup: oil filling

Fill the oil and check the oil level of the gearbox. The gearbox is delivered without oil!

Insufficient oil impairs lubrication of the gearwheels and roller bearings. Excessive oil results in high churning loss, foaming and increased heat development.

NOTICE Maintaining the oil level The required oil level varies depending on the incline on which the gearbox is positioned. A sign on the gearbox indicates the oil level mark line applicable to each incline (see "Oil levels and oil quantities" in the "Technical data" section).

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breather plug

Check the gearbox to see whether the breather plug is installed. The position of the breather plug is shown in the "Technical data" / "Main dimensions and connections" section.

4.4.1 Commissioning The gearbox must be commissioned under the supervision of technicians from Caterpillar.

Remove all tools, auxiliary equipment, etc. from the conveyor resp. plow and your working area.

Check all bolted connections, in particular the connections of the drive units.

Check that all bolted connections are tightened to the correct torque.

Check the hydraulic connections and lines for leakage or damage.

Check that all supply lines are installed properly.

Check the hydraulic connectors. Make sure the staples are pushed in completely.

Check the oil level and the gearbox cooling.

Check the cooling of the electric motors.

Check the rotational direction of the electric motors.

Check the electrical connections.

Test the sequencing control of the drive units.

Test the function of the signaling devices and the intercom system.

During commissioning of the gearbox, the preservative dissolves in the gear oil.

It can stay in the gearbox until the next oil change without reducing the lubricating capacity of the oil.

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

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Assembly Test run

4.5 Test run Check the following: Carefully check the gearbox for leaks. Any oil residue must be thoroughly cleaned from the gearbox before checking. Otherwise, it will not be possible to see if small amounts of oil escape.

After a test run of two hours, the temperature of the gearbox must not exceed 85°C. The smoothness of running of the gearbox.

4.6 Dismantle gearbox

4.6.1 Important instructions for dismantling Dismantling and withdrawing operations may only be performed by persons with sufficient knowledge of the work to be performed and who have been adequately trained for these particular requirements.

Protect all exposed shafts, hubs, labyrinth channels and flanges from corrosion, dirt and damage.

Seal all open lines and separating points with protective caps or plugs.

Pack loose parts, screws, etc. in suitable containers in order to protect the components from dirt and damage.

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Dismantling should be done in the most convenient way, following the reverse order of installation as much as possible, depending on local conditions on site.

Operation

5

Maintaining the gearbox

5 Operation This chapter contains important information on operation and maintenance. It also includes instructions on the replacement of wear parts. Please read this chapter carefully and thoroughly. Be sure to follow the safety instructions in chapter Safety.

5.1 Maintaining the gearbox This chapter contains important information on operation and maintenance of the gearbox. It also includes instructions on the replacement of wear parts.

Please read this chapter carefully and thoroughly.

Maintenance at regular intervals increases operational reliability and the service life of the gearbox. Be sure to follow the safety instructions in chapter Safety.

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5.1.1 Gearbox maintenance WARNING Housing temperature The housing temperature of the gearbox can reach 85°C. You can burn yourself on hot surfaces or the components screwed into them (dipstick, breather plug, etc.) or be scalded by exiting hot oil (oil change)!

1. Check the gearbox temperature and wait until the temperature has fallen to at least 60°C. 2. Observe the warning signs on the gearbox! The gearbox temperature can be read off the system computer.

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

Make sure to comply with the intervals specified for maintenance and inspections of the gearbox, as hot surfaces can result i heat accumulation, which might cause an ignition of explosive atmospheres (air) and dust. Remove dust deposits, etc. from the casing on a daily basis.

DANGER Hot surfaces / explosion hazard Hot surfaces can lead to dust explosions, through which you can be seriously injured or killed!

1. Keep machine and system surfaces free from dust and deposits so their heat can dissipate into the surroundings.

2. Always comply with maintenance and inspection intervals!

Maintenance includes: checking that the breather plug is working, checking bolted connections, checking the oil level, taking oil samples, changing the oil,

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Operation Maintaining the gearbox

maintaining the filter, maintaining the hydraulic system, checking the gearbox bearings, cleaning the gearbox casing.

Only use suitable tools for maintenance work.

Checking bolted connections tightening torque

retightening screws

For bolted connections whose tightening torques are not listed in the corresponding operating manual or spare parts list, the tightening torques according to EWN 6003 apply (list in the chapter "Technical data") The bolted connections listed in the following must be tightened 60 hours after initial start up and then once every 500 hours! drive connection (motor and gearbox side)

Checking the oil level Check the oil level weekly. Make sure no foreign matter enters the inside of the gearbox when you do this.

NOTICE Maintaining the oil level The required oil level varies depending on the incline on which the gearbox is positioned. A sign on the gearbox indicates the oil level mark line applicable to each incline (see "Oil levels and oil quantities" in the "Technical data" section).

Insufficient oil impairs the lubrication of the gears and roller bearings. Excessive oil results in high churning loss, foaming and increased heat development.

5.1.2 Changing the oil The first oil change on a new or overhauled gearbox must be done after 300 hours of operation.

NOTICE Correct oil type Using impermissible oil types voids any warranty claims and may result in severe machine damage.

1. Only use oil types approved by Caterpillar.

Regular checking of the oil level and changing the oil are also part of gearbox maintenance. A crucial role for the service life of the gearbox components is played by contaminants and wear particles as well as the viscosity and the undesired water content of the gear oil. These and other parameters are to be monitored.

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gearbox (attachment on the drive frame)

Operation

5

Maintaining the gearbox

NOTICE Bleeding the gearbox Insufficient gearbox ventilation will result in used oil not being drained completely and fresh oil being contaminated accordingly.

1. Bleed the gearbox by removing the breather plug.

2. Pay special attention that no foreign matter enters the gearbox.

Tip Always change the gear oil while the gearbox is near operating temperature.

The oil is then less viscous and can better wash away the oil sludge.

1. Remove the breather plug; this bleeds the gearbox.

2. Drain the oil via the oil drain on the gearbox.

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The position of the breather plug and the oil drain is shown in the section "Main dimensions and connections" [} 48].

Time-oriented oil change With the time-oriented oil change the oil change interval is based on operating hours. The gearbox is filled with fresh oil every 2000 operating hours after thorough cleaning (backflushing). With this method, any sudden negative changes to the oil cannot be detected at an early stage. This can result in increased wear or damage.

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Operation Maintaining the gearbox

If fully synthetic oil is used, the oil change interval can be extended to as much as 6000 operating hours, provided that all requirements and specifications are met.

Fig. 19: Flow chart: time-oriented oil change

Fresh oil

Hours of Operation - Fill the gearbox Initial filling

Oil quantity depends on inclination

Oil change

- Drain oil - Refill gearbox

Oil change

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Oil change log

- Drain oil Oil change

- Refill gearbox

log

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Fresh oil

Operation Maintaining the gearbox

5

Condition-oriented oil change With the condition-oriented oil change the oil change interval is based on operating hours and on the oil condition. An oil sample is taken from the gearbox every 500 operating hours and analyzed. With this method, any sudden negative changes to the oil cannot be detected. If the limit values are observed, the oil can be used for more than 2000 operating hours.

Fig. 20: Flow chart: condition-oriented oil change

Fresh oil

Hours of Operation

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- Fill the gearbox Initial filling Initial filling Oil quantity depends on inclination

Oil sample log

Fresh oil - Drain oil Change oil

- Perform fresh oil analysis + create oil sample log

Oil change

Oil sample

log

log

-Refill gearbox

- Should an oil analysis be performed?

Analysis?

NO

500 operating hours

YES

after oil change

Analysis?

see "Time-oriented oil change"

- Take oil sample - Analysis of the oil sample

YES

Limit values reached?

- Evaluation of the limit values - Create oil sample log

NO

Oil sample log

Always after 500 operating hours

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Operation Maintaining the gearbox

Fig. 21: Oil sample log

Oil sample log The oil sample must be taken no later than 5 minutes after the gearbox has been switched off.

Once the oil sample has been taken, it must be examined in the laboratory within two weeks.

Waiting too long can have an adverse effect on the values and make the evaluation unusable.

The oil that initially comes out (approx. 0.1 l) must not be used for analysis, since it could be contaminated.

Date of last oil change: …………………………..

System:

Gearbox type:

Gearbox serial number:

……………………………………

……………………………………

……………………………………

Head gate:

Tail gate:

Head gate:

Tail gate:

Installation site: Face conveyor: Beam stage loader Plow drive: Crusher:

Total operating hours: …………………………h

Operating hours since oil change:…………………h

Oil manufacturer: ………………………………………… Oil designation: ……………………………………..

Oil change since last sample was taken?:

Oil refilled since last sample was taken?:

yes:

yes:

no:

no:

Were any special ambient conditions discovered? no: If so, what are they:

....................................................................................................................................

Lab number: …………………………..

Designation of the oil sample: ……………………………………

Name of person filling out log: ……………………………………………………….

Date:……………………...........………

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Signature:……………………...........………

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Date sample was taken: …………………………

Operation

5

Maintaining the gearbox Fig. 22: Oil change log

Oil change log Before being filled with fresh oil, the gearbox must be cleaned and backflushed with the fresh gear oil that will be filled. The flushing oil must then be drained before you begin to fill the gearbox with the fresh oil.

System:

Gearbox type:

Gearbox serial number:

……………………………………

……………………………………

……………………………………

Head gate:

Tail gate:

Head gate:

Tail gate:

Operating hours: …....…………h

Last oil change: ……………

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Installation site: Face conveyor: Beam stage loader Plow drive: Crusher:

Date:……………………

Fresh oil Oil manufacturer: ………………………………………… Oil designation: ……………………………………..

Designation of the fresh oil sample: ……………......

Lab number: …………………………..

Was it filtered when filled?

Filter fineness: …………...μm

yes: no:

Filled volume: ……………………….l Was the gearbox flushed before filling with fresh oil? yes: no:

with: ………….............................................................. ....................................................................................................................................

Name of person filling out log: ……………………………………………………….

Date:……………………...........………

Signature:……………………...........………

Also refer to the information provided in the ""Technical data" [} 52]" chapter.

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Operation Maintaining the gearbox

An early oil change is required if: The degree of contamination has reached the value of 0.1% foreign particles.

The water content has exceeded the value of 0.1%.

The ageing resistance of mineral oil has diminished to the level that the increase in neutralization NNUsed oil - NNFresh oil = NN has exceeded the value  NN = 2.0 mg KOH/g Oil.

Determine the following: Neutralization number according DIN 51 558.

Water content according to DIN 51 582.

Percentage of foreign substances according to DIN 51 592.

Sulfate ash according to DIN 51 575.

2 Permissible media [} 54]

5.1.3 Maintaining the filter The Replacing defective components section gives you additional information on the procedure for replacing components.

NOTICE Changing filters Dirty or defective filters can cause severe gearbox damage!

1. Always replace a defective filter with a new filter element only. Used filters must not be cleaned and reused.

2. Pay attention to the filter label to avoid mix-ups.

3. Always dispose of filters contaminated with oil, grease or other chemical substances in an environmentally acceptable manner.

Checking the breather plug Check that the breather plug is functioning properly on a weekly basis and replace if necessary.

Checking the water filter The water filter is located in the connection and operating unit on the gearbox output (see Chapter 6, "Technical data" / "Hydraulic control"). It must be checked every six months and replaced, if necessary. The system must be depressurized for this.

NOTICE Dirty water filter!

If the gearbox is operated with an extremely contaminated filter element, this can delay or even block the clutch pressure adjustment. The required clutch pressure can then no longer be reliably established. The specific overload protection of the system is no longer guaranteed.

1. Check the water filter for dirt and proper operation as specified.

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For more information, see also

Operation

5

Maintaining the gearbox

5.1.4 Checking the breather plug Check that the breather plug is functioning properly on a weekly basis and replace if necessary.

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

NOTICE Replace a defective breather plug with a new one. Do not try to clean the old filter.

Used breather plugs must not be reused.

Dispose of them in an environmentally acceptable manner.

5.1.5 Maintaining the hydraulic system Media-ID: EM028748-02 / Caterpillar Global Mining Europe GmbH 2021 ©

Exact knowledge of the hydraulic system is essential for its maintenance. You must therefore familiarize yourself with the circuit diagrams for the control elements and the hydraulic diagrams.

DANGER Safety-related defects Machines operated with safety-related defects can cause fatal injuries!

1. Stop the machine immediately if you discover a safety-related defect!

2. Report the malfunction immediately!

3. Place the machine back in operation only when all defects have been repaired.

The hydraulic system must be maintained regularly. Perform the following work daily:

Daily maintenance Check that all components are in perfect condition.

Check that all connectors are firmly in place and retighten them where necessary.

Replace all leaking components such as cylinders, controls, hose lines, plug-in connection fittings, etc. without delay.

Check that all operating levers, locking pieces, springs etc. are functioning perfectly.

Check and maintain all components for the hydraulic system, such as pumping station, filter systems etc. in accordance with the relevant operating manuals.

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

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Operation Replacing defective components

NOTICE Bearing service life Dirty or defective bearings can cause severe gearbox damage!

1. Check the gearbox bearings at least every four weeks. Once the service life of the bearings has been reached, the bearings must be replaced.

2. The service life of the bearings (continuous operation at rated power) is listed in the technical data.

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

Acoustic emission monitoring

5.1.7 Cleaning the gearbox casing WARNING Hot surfaces!

Surfaces can become heated as the result of dirt deposits and cause ignition of explosive atmospheres (firedamp) and dust. Make sure that there are no dust deposits on top of, on the side of or at the bottom of the gearbox.

Excessive dust deposits cause heat accumulation, which can greatly heat up the gearbox casing. In extreme cases, this can lead to spontaneous combustion of the coal dust.

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

5.2 Replacing defective components 5.2.1 Replacing the heat exchanger The cooling system consists of two heat exchangers (1) in the gear chamber.

The heat exchangers are connected to one another by an exterior hose line.

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To detect damage on bearings and rotating parts at an early stage, continuous acoustic emission monitoring can be used. The gearbox is prepared for the use of monitoring units of this kind.

Operation

5

Replacing defective components

NOTICE Risk of contamination when replacing components!

The gearbox is vulnerable to contamination during modifications on the heat exchanger.

1. The heat exchangers must not be removed on-site. Always bring the gearbox in for servicing!

Fig. 23: Heat exchanger

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z

z

1 1

Heat exchanger

z

Water port

The heat exchanger can be replaced in the event of damage to the cooling system. Proceed as follows: Fig. 24: Removing the heat exchanger

1 2

3

4

8

7

6

1

Heat exchanger

5

Hose pipe

2

O-ring 100x3

6

Coupling clip DN 12

3

Cyl. head screw M 16x80-8.8

7

Screw-in socket DN 12

4

Plug-in angle sleeve DN 12

8

O-ring 49.2x3

5

1. Shut down the drive unit and secure it against being switched back on.

2. Drain the gear oil (see Changing the oil).

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Operation Replacing defective components

CAUTION Hot surfaces!

The gearbox casing temperature can be 85 °C. You can burn yourself on hot surfaces or the components screwed into them (dipstick, breather plug, gearbox sensors, heat exchanger, etc.) or be scalded by hot oil coming out of the gearbox (during oil change).

1. Check the gearbox temperature and wait until the temperature has fallen to at least 60 °C. Observe the warning signs on the gearbox! The gearbox temperature can be read off the electrical control.

3. Depressurize the water circuit.

4. Remove the water feed lines.

5. Remove the coupling clips (6) of the hose pipe (5) between the heat exchangers (1). Detach the hose pipe.

7. Pull the heat exchanger (1) out of the casing.

8. Take the new heat exchanger out of the transport safety device. Remove the protective pipe and plugs.

9. Insert the new heat exchanger into the gearbox casing and secure it to the casing with the cylinder head screws (3).

10. Fasten the connecting socket tightly using screw M16X80.

11. Reconnect the connection line between the heat exchangers and install all the required fittings.

Fig. 25: Cooling water ports

1

2

3

4

x

y

B 7

z

A x z

C

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3

5

y

1

1

Coupling clip DN 12

7

Heat exchanger

2

Screw-in socket G 3/4-DN 12

A

Cooling water inlet DN 12

3

Screw plug G 3/4

B

Cooling water outlet DN 12

4

Screw plug G 1

C

Pressure relief valve

5

Fitting connection G 3/4'' - DN 12

x,y,z

Water ports

Gearbox KP-15 & KP-15.1

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6. Loosen the cylinder head screws (3).

Operation Troubleshooting

5

12. The “cooling water inlet“ or “cooling water outlet” heat exchangers can be installed in the gearbox either at the top or at the bottom. Install the cooling water inlet or outlet lines on port X of the heat exchanger.

13. The pressure relief valve (6) must always be installed on the cooling water inlet (port G 1).

14. Seal the open holes with screw plug G 3/4 or G 1.

15. Fill the gear oil.

16. Check the cooling system for leakage.

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

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Fig. 26: Possible connections for the cooling water supply

X, Y, Z

water connections

NOTICE Risk of overheating the gearbox Insufficient cooling can lead to serious gearbox damage.

1. Connect the cooling water supply port in the correct combination manner.

For more information, see also 2 Oil levels and oil quantities [} 52]

5.3 Troubleshooting 5.3.1 Gearbox troubleshooting If the gearbox temperature is too high, you should: check the oil cooling required quantity of water: 10 - 15 liter/min. enable adequate heat dissipation Fine coal on the gearbox casing acts as an insulating layer that prevents heat dissipation. Remove fine coal, including the sides and bottom!

Ensure oil is filled to the correct level If the oil level is too low, the lubrication of the roller bearing and gears can be adversely affected, which can contribute to increases in heat development (see oil level sign)

Gearbox KP-15 & KP-15.1

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5

Operation Troubleshooting

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

If the gearbox is losing oil Make sure there are no leaking connection surfaces and covers .

Tighten casing screws, cover screws, and oil drain plugs.

Tip Checking for leaks Remove oil that has already escaped to help you to see whether or not there is a leak at the port.

Check the installation position of the breather plug! It must be mounted in the uppermost opening. The installation position varies depending on the incline on which the gearbox is positioned.

Check the oil level (see oil level sign) Replace the breather plug! check the breather plug Remove the breather plug at operating temperature. If air escapes as you do this, the breather plug is defective.

Dust can also block wet breather plugs because the moisture makes dust adhere to the filter.

Always install a new breather plug. Do not try to clean the breather plug.

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Gearbox KP-15 & KP-15.1

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make sure oil is not leaking from the breather plug

Technical data Technical data sheet

6

6 Technical data This chapter contains the most important technical data. Further information is given in the spare parts lists and in the separate operating manuals for the individual components. In addition, you can find information on the product IDs, tightening torque, permissible media, etc. in this chapter.

Read this chapter carefully at your leisure. Pay special attention to the safety instructions.

6.1 Technical data sheet The following technical data apply for the ratio i = 16/21/24,4/28/33

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Tab. 1: Technical data sheet Rated continuous input power max. at n1 = 1,500 rpm

PIN

=

320 kW

Rated continuous input power max. at n1 = 1,800 rpm

PIN

=

380 kW

Max. rated output torque

T2max

=

150000 Nm

Max. rated input speed

n1 max

=

1800 min

Motor stalling torque

T motor

=

2.5 x T1

stall

Weight (gearbox without oil)

M

=

2200 kg

Oil temperature at rated power

t

=

60 - 65 °C

Bearing service life (continuous operation at rated power, corresponds to 90% of calculated nominal service life)

Lh10

=

13500 h

Required cooling water volume

Q

~

10 - 15 l/min

Pressure relief valve set to

Pü

=

30 bar

=

G 3/4"

Thread on supply connections for water for heat exchanger (inlet and outlet) Maximum cooling water inlet temperature

tmax

=

25 °C

Maximum cooling water dirt particle size

Max.

=

0.25 mm

Required pH of the cooling water

pH

~

7

Cooling water pressure

P max

~

25bar

Heat exchanger - main chamber

2x

Port for water, inlet and outlet

535 mm long DN 12

Drive shaft

Ø90 with parallel key

Output shaft

Internal spline N190x10x30x18 DIN5480

Gearbox KP-15 & KP-15.1

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6

Technical data Main dimensions and connections

6.2 Main dimensions and connections

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Fig. 27: Port dimensions

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Gearbox KP-15 & KP-15.1

Technical data Main dimensions and connections

6

Fig. 28: Installation parts

1,2

3

2,3

D

E A B D

11

10

8

9

C

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B

2

E

3

inlet

C 12

2,4

12

2,5

XX

12

Gearbox KP-15 & KP-15.1

1

Breather plug

8

Ratio, plate

2

Sealing ring A 30x36

9

Magnetic rod

3

Main gearbox - breather plug

10

Main gearbox - Oil drain

4

Dipstick 517 lg

11

Drive shaft bearings - Oil drain

5

Dipstick 350 lg

12

lifting eye TAWGK 3

6

Breather plug

XX

Marking label

7

Sealing ring A 30x36

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6

Technical data Performance data

6.3 Performance data Tab. 2: Rated continuous input torque Continuous input torque T1, n1=1485 rpm, f=50 Hz or n1=1780 rpm, f=60 Hz Nominal ratio (i)

(Nm)

16

2058

21

2058

28

2058

33

2058

39

1415

50

1030

Rated continuous power

(n1 = 1485 rpm) (f=50 Hz)

(n1 = 1780 rpm) (f=60 Hz)

Nominal ratio (i)

(kW)

(kW)

16

320

380

21

320

380

28

320

380

33

320

380

39

220

260

50

160

190

6.4 Technical description Design

The bevel planetary gear is suitable for underground use for attaching to drive frames and plow casings with separate shafts.

The gearbox can be used in a right-handed or left-handed version simply by relocating the dipstick, breather plug and the magnetic rod. Torque support to the drive frame or plow casing is created by a parallel key.

Maintenance-free axial face seals are integrated into the output stage. The output planet carrier can be refinished when the internal toothing N 190x10x30x18 DIN 5480 is worn and repaired by means of an exchangeable coupling bush.

Power and torque

The permissible continuous input power can be up to 320 kW depending on ratio, at an input speed of 1480 rpm (50 Hz motor) and up to 380 kW at and input speed of 1780 rpm (60 Hz-Motor).

The maximum permissible torque at output for a short time (3s) is 150000 Nm.

Lubrication

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

There is a second separate oil chamber in the area of the drive shaft bearings.

This allows the drive shaft bearings to be lubricated perfectly when the gearbox is positioned on an incline. Each oil chamber has a dipstick and a breather filter.

There is a oil chamber in the area of the drive shaft bearings. This allows the drive shaft bearings to be lubricated perfectly when the gearbox is positioned on an incline. It has a dipstick and a breather filter.

Defined oil levels must be complied with depending on the inclination of the gearbox.

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Gearbox KP-15 & KP-15.1

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Tab. 3: Rated continuous power

Technical data

6

Accessories

The gearbox is delivered without oil.

The oil coolers are secured against overpressure with a pressure relief valve set to 30 bar. The required quantity of cooling water is 10 - 15 l/min.

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

The max. permissible cooling water input temperature is 25 C. The ports on the inlet and outlet sides of the cooler have dimension DN 12.

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

6.5 Accessories 6.5.1 Hose connection for oil drainage Media-ID: EM028748-02 / Caterpillar Global Mining Europe GmbH 2021 ©

Fig. 29: Oil drainage using valve screw

A

Closed

B

Open (about 3 turns)

1

valve screw

2

Sealing ring

with hex head, wrench size 50 mm

Order no. 475-7673

Order no. 478-5578 3

screw plug Order no. 475-7663

Gearbox KP-15 & KP-15.1

4

hose connection Order no. 532-1402

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6

Technical data Oil levels and oil quantities

6.5.2 Mounting and pulling-off device Fig. 30: Mounting and pulling-off device 5 2

3

7

8

9

10

11

4

12

13

1

Hex. head screw M 6 x 16

8

Protective tube

2

Protective cap

9

Threaded spindle M 30

3

Hex nut M 30 x 8

10

Ball bearing

4

Bush

11

Thrust washer

5

Washer

12

Circlip

6

Hex. head screw M 16 x 70

13

Hex. head screw M 20x50

7

Threaded tube

6.6 Oil levels and oil quantities The required oil level varies depending on the incline on which the gearbox is positioned. A sign on the gearbox indicates the required oil level mark line for the respective tilt.

NOTICE Correct oil type Using impermissible oil types voids any warranty claims and may result in severe machine damage.

1. Only use oil types approved by Caterpillar.

Oil Level Dipstick There are markings on the dipstick every 1 cm that are numbered from 100 to 0, based on a reference edge of 100 (sealing surface - dipstick). The dipstick is flexible and is inserted vertically into the dipstick bore and screwed into place.

The minimum oil level must not be more than one graduation mark below the required oil level mark line (for the position of the dipstick, see Main dimensions and connections).

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Gearbox KP-15 & KP-15.1

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1

6

Technical data

6

Oil levels and oil quantities Fig. 31: Oil Level Dipstick

1

Reference edge 100

Order no: Dipstick 517 mm and 350 mm long

6.6.1 Gearbox tilt NOTICE Do not exceed the angle of inclination Media-ID: EM028748-02 / Caterpillar Global Mining Europe GmbH 2021 ©

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

Oil level mark line Tab. 4: Oil level mark lines (value in cm) for KP-15 Inclination in conveying direction

Output high

Output low

Drive shaft

Main gearbox

30° - 79

30° - 70

20° - 79

20° - 70

10° - 78

10° - 64

0° - 78

0° - 63

10° - 83

10° - 66

20° - 86

20° - 65

30° - 91

30° - 65

Permissible inclination in mining direction ± 15° Tab. 5: Oil level mark lines (value in cm) for KP-15.1 Inclination in conveying direction

Output high

Output low

Drive shaft

Main gearbox

-

15° - 68

-

10° - 66

-

5° - 64

0° - 78

0° - 63

5° - 82

-

10° - 83

-

15° - 84

-

Permissible maximum inclination is 15°. If angle exceeds 15 degrees, or the oil discharges from a breather due to rotation direction, that breather must be replaced by a plug as oil is exceeding the level of that breather.

At least one breather must remain in the gear box at all times.

Gearbox KP-15 & KP-15.1

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6

Technical data Permissible media

Oil quantities Tab. 6: Oil quantities (values in liters) for KP 15 Inclination in conveying direction

Output high

Output low

Drive shaft

Main gearbox

30° - 8 l

30° - 75 l

20° - 8 l

20° - 75 l

10° - 8 l

10° - 75 l

0° - 8 l

0° - 75 l

10° - 8 l

10° - 75 l

20° - 8 l

20° - 75 l

30° - 9 l

30° - 75 l

Inclination in conveying direction

Output high

Output low

Drive shaft

Main gearbox

-

15° - 84 l

-

10° - 79 l

-

5° - 75 l

-

0° - 75 l

0° - 75 l

-

5° - 92 l

-

10° - 106 l

-

15° - 120 l

-

Permissible maximum inclination is 15°. If angle exceeds 15 degrees, or the oil discharges from a breather due to rotation direction, that breather must be replaced by a plug as oil is exceeding the level of that breather.

At least one breather must remain in the gear box at all times.

Tip Oil quantities are approximate values.

Oil level mark lines must be observed.

6.7 Permissible media Recommended oil for gearboxes Use only the recommended gear oils or proven equivalents.

The oil types specified in the table are recommendations which meet the required specifications. Other types of oil could be used, assuming that all requirements and specifications are met and fulfilled. When using oil types which do not meet the requirements, the operator and the respective oil manufacturer accept no liability for any damage done to the gearbox.

When changing from one gear oil to another, the gearbox must be cleaned first and flushed with the new gear oil. The oil used for flushing must then be drained out before you begin to fill the gearbox with the new oil. Never mix different oils together under any circumstances.

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Gearbox KP-15 & KP-15.1

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Tab. 7: Oil quantities (values in liters) for KP 15.1

Technical data

6

Permissible media

Gear oil requirements The correct choice of gear oils and carefully monitoring lubrication are important preconditions for fault-free operation. They also help to lengthen the service life of the gearbox.

NOTICE Kinematic viscosity range Only gear oils may be used which ensure the specified kinematic viscosity ranges of 40°C and 100°C. When using oil types which do not meet the requirements, the operator and the respective oil manufacturer accept no liability for any damage done to the gearbox.

Tab. 8: Oil types for gearboxes

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Manufacturer

ARAL

BP

Type of oil

Base (mineral / synthetic)

Kinematic viscosity mm2/s (cSt) at 40°C

Flash Point

Aral Degol BG 220

mineral

220

265

Aral Degol TU 220

mineral

220

255

Aral Degol GS 220

synthetic

230

215

BP Energol GRXP 220

mineral

218

240

BP Energol SGXP 220

synthetic

240

250

(°C)

ESSO

SPARTAN EP 220

mineral

210

236

KLÜBER

Klüberoil GEM 1-220

mineral

220

>200

synthetic

220

>300

Klübersynth GH 6-220 MOBIL

Mobilgear 630

mineral

206

>232

SHELL

Shell Omala 220 HD

mineral

222

245

synthetic

234

320

Universal gear lubricant EP SAE 85 W/90

mineral

195

225

Meropa 220

mineral

220

245

Ersolan 220

mineral

220

240

Shell Tivela Oil WB TEXACO

WINTERSHALL

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

In addition, the "specific change in weight" of the test gears ms (specific wear) may not exceed 0.27 mg/kWh. Gearbox KP-15 & KP-15.1

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6

Technical data Permissible media

Additives Anti-wear EP protection, Anticorrosion protection, Antifoaming protection.

Suitability Wet brakes, Frictional behavior to prevent stick-slip, Compatibility with commercial sealing elements.

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

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

Tab. 9: Requirements of the cooling water Criterion

Requirement

Appearance, color, odor

Clear, no sediment, no odor

pH

7 – 8.5

Total water hardness

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

Carbonate hardness

≤ 20 °dH (≤ 142 mg/l Ca2+)

Input temperature

≤ 25°C

Max. dirt particle size

≤ 0.25 mm

Bacteriological requirement

≤ 105 kol/ml (dip slide)

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

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

6.7.2 Greases and lubricating pastes Only the recommended lubricants or products certified as equivalent may be used.

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

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6.7.1 Requirements for the cooling water quality

Technical data Permissible media

6

Greases grease A1

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

Tab. 10: Greases A1

grease A2

Supplier

Type

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-40 to +120°C

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

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Tab. 11: Grease A2

grease A8

Supplier

Type

Base

NLGI class

Flashpoint °C

Shell

Alvania E.P. grease 2

Lithium soap

2

205

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble

temperature range of application:

-15 to +120°C

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

Tab. 12: Grease A8 Supplier

Type

Base

NLGI class

Flashpoint °C

Castrol

Molub Alloy 3036/680-1

Lithium soap

1

210

worked penetration:

310 to 340 (0.1 mm)

behavior in the presence of water:

insoluble at 90°C

temperature range of application:

-20 to +120°C

Lubricating pastes lubricating paste B3

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

Tab. 13: Lubricating paste B3

Gearbox KP-15 & KP-15.1

Supplier

Type

Lubricant carrier

NLGI class

Flashpoint °C

Gleitmolybdän

gleitmo 805

Lithium soap

2

220

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

insoluble

temperature range of application:

-20 to +120°C

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6

Technical data Tightening torques

lubricating paste B5

Lubricating and corrosion protection paste containing copper, high-pressure lubricant between slow-running surfaces, anti-fretting agent, e.g. for lubricating bolted and pin connections Tab. 14: Lubricating paste B5 Supplier

Type

Lubricant carrier

NLGI class

Flashpoint °C

Fuchs

PBC TP492

Mineral Oil

2

> 220

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

insoluble

temperature range of application:

-20 to +1200°C

lubricant B6

Parting agents and lubricants with organic lubricating media on synthetic base material for greasing threaded areas and fitting points on legs and hydraulic legs, on pin connections and similar connecting elements on the support.

Tab. 15: Lubricant B6 Supplier

Type

Lubricant carrier

Flashpoint °C

Chesterton

parting agent/lubricant 785

petroleum base

132

behavior in the presence of water:

insoluble

temperature range of application:

-34 to +120°C

6.8 Tightening torques 6.8.1 Screws and bolts with ISO metric thread Tab. 16: Tightening torques at µtot. = 0.14 Thread (mm)

Pitch P (mm)

d

Coarse thread

M8

8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

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Tightening torque MA (Nm) Fine thread

2

DM 24

3

535

-

-

(M 27)

3

965

1360

1630

Gearbox KP-15 & KP-15.1

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Lubricant

Technical data Identification of the gearbox

Thread (mm)

Pitch P (mm)

(M 27)

Tightening torque MA (Nm) 2

-

1600

-

(DM 27)

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30

6

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

NOTICE Media-ID: EM028748-02 / Caterpillar Global Mining Europe GmbH 2021 ©

Tightening torques Incorrect torque may cause considerable machine damage.

1. Also follow the tightening torques for installation and maintenance stated in the spare parts lists.

6.9 Identification of the gearbox Manufacturer:

Caterpillar Global Mining Europe GmbH

Type:

KP-15/15.1

Year of manufacture:

MM/YY (e.g.: 01/20 ≙ January 2020)

ID No.:

777594 to 777601 & 4921926

Weight:

2200

The gearbox is identified with the following information.

Fig. 32: Identifying markings on the gearbox

Gearbox KP-15 & KP-15.1

1

Type

2

ID number

3

Weight

4

Year of manufacturing

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6

Technical data Identification of the gearbox

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The gearbox is compliant with European Directive 2014/34/EU and DIN EN 1710 in its design and construction and is engineered for use in explosive atmospheres.

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