CAT Bucyrus BSL PF 4/1132 Operating Manual

Operating manual BSL PF 4/1132 Doc. no.: 0010 306 600 BA 00

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

Amendments and alterations to this publication are not subject to notification.

Bucyrus reserves all rights to this publication.

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

Bucyrus declines all liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications obtained by technicaldevelopment without prior notice!

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Contents

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.3 2.4

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

2.5

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

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

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

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

2.5 2.5 2.5 2.6

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

2.7

3. About storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storing the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

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

3.4

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

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

Transport of the components . . . . . . . . . . . . . . . . . . . . . . . .

3.4 3.4 3.5

4. Installation Points to observe prior to installation . . . . . . . . . . . . . .

4.3

Who is allowed to carry out installation? . . . . . . . . . . . . . . .

Which tools are required for installation? . . . . . . . . . . . . . . .

Instructions concerning installation . . . . . . . . . . . . . . . . . . .

Overview - Beam stage loader PF 4/1132 . . . . . . . . . . . . . .

4.3 4.3 4.4 4.5

How to assemble the tensionable drive frame and drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

Tensionable drive frame SPR 3 . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control system on the SPR 3 . . . . . . . . . . . . . . . .

Flange plate between the tensionable drive frame gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for the installation of the gearbox . . . . . . . . . .

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

Electric motor (E-motors) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.8 4.11 4.13 4.14 4.15 4.16

Contents How to install the conveyor pans . . . . . . . . . . . . . . . . . . 4.17 Adaptor pan PF 4/1132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SL pan PF 4/1132-1500 MT . . . . . . . . . . . . . . . . . . . . . . . . . .

SL pan PF 4/1132-1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SL pan PF 4/1132-1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SL pan PF 4/1132-750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return unit PF 4/1132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.18 4.19 4.20 4.20 4.21 4.22 4.23

How to install the drive substructure . . . . . . . . . . . . . . 4.24 How to install the chain . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 Fitting flights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the chain connector . . . . . . . . . . . . . . . . . . . . . . . .

4.25 4.26 4.26

How to tension the chain assembly . . . . . . . . . . . . . . . . 4.28 Auxiliary devices for holding and pulling the chain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to tension the chain assembly . . . . . . . . . . . . . . . . . . .

4.29 4.30

Sequencing control of the conveyors . . . . . . . . . . . . . . 4.33 How to start-up the conveyor system . . . . . . . . . . . . . . 4.34 Before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test run of the conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test operation of the conveyor . . . . . . . . . . . . . . . . . . . . . . .

4.34 4.35 4.36

After the initial operating hours . . . . . . . . . . . . . . . . . . . 4.37 Tightening the bolted connections . . . . . . . . . . . . . . . . . . . .

4.37

Dismantling and withdrawing the conveyor system . 4.38 Who is authorized to dismantle and withdraw the conveyor system? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.38

5. Operation How to operate the conveyor system . . . . . . . . . . . . . .

5.3

Who is allowed to operate the conveyor? . . . . . . . . . . . . . .

When may conveying be started? . . . . . . . . . . . . . . . . . . . .

How to operate the drive frame SPR 3 . . . . . . . . . . . . . . . . .

5.3 5.3 5.3

How to maintain the conveyor . . . . . . . . . . . . . . . . . . . .

5.5

Temperature and acoustic emission monitoring . . . . . . . . .

Important instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to maintain the steel structure . . . . . . . . . . . . . . . . . . .

Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to maintain the hydraulic system . . . . . . . . . . . . . . . . .

5.5 5.5 5.5 5.6 5.8

How to replace wear parts . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 5.12

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Switching conditions of the system components . . . . . . . .

Contents When faults occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 Identifying the cause of faults . . . . . . . . . . . . . . . . . . . . . . . .

5.13

6. Technical Data Main components of the conveyor system . . . . . . . . .

6.3

Technical Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Identification marking of the conveyor . . . . . . . . . . . . . . . . .

Identification marking of the tensionable drive frame . . . . .

6.4 6.5

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

6.6

Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.6

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.7 6.10

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7. For your information

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Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

North America, Canada, South America . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.5

Standards and Guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.6

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

Referenced European standards and directives . . . . . . . . .

7.6 7.6

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Contents

BSL PF 4/1132

1

About this manual

Before starting work

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

Before starting work applicable operating manual

conveyor type

Take care to ensure that the operating manual available to you is applicable for the type of conveyor used. Failure to do so can result in a safety hazard for yourself and others.

Ensure that the data on the conveyor comply with the data given in the operating manual.

This operating manual is designed for: BSL PF 4/1132 ID No.: 0010 306 600 00 00 It is only permitted to be used for a conveyor of this type!

category according to Atex directive

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

There should, if possible, always be an operating manual for the conveyor available at the place of operation.

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

new operating manual

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

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

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

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

Supervisory personnel who: J initiate and/or J supervise

the activities named above.

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1.3

Before starting work Purpose of this operating manual cost-effectiveness

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

Read this operating manual completely and at your leisure.

Pay special attention to the safety instructions.

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

service

Should you have any questions, please contact our Service Department. Our service address can be found in the chapter titled “For your information”.

safety

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

Observe this information and follow the instructions.

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

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

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

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

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

1.4

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Danger!

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

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Try to memorize the symbols and their meanings.

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

The conveyor has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

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

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

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

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The European directives/standards in this operating manual must be applied when the conveyor is being used within the member states of the European Union (EU).

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

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

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

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

Personnel Operation The conveyor may be operated only by trained personnel. training

The conveyor may only be operated by qualified personnel who can provide proof of having been trained on the control system installed.

Reading of the operating manual, especially the chapter on safety, must constitute a part of this training.

They must possess and furnish proof of adequate familiarity with the J mechanical system, J hydraulic system and J control system.

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2.3

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

Installation and repair work on: J safety components (pressure relief valves, extinguishers, etc.), J electrics (controls, signaling devices, etc.), J the hydraulic system,

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may only be carried out by Bucyrus service engineers or by specially trained mine personnel.

2.4

BSL PF 4/1132

Operating conditions Operating conditions Intended use The conveyor has been exclusively designed and manufactured for use as a conveyor unit in entries.

Use the conveyor only as intended.

Intended uses are: J the transport of coal and tailings between face conveyor and

belt conveyor system.

Unauthorized use Applications not explicitly listed as intended uses are unauthorized uses and are not allowed to be performed with the conveyor.

Unauthorized use includes: J the transport of persons, J the transport of objects of any kind such as for instance

individual props, boards, replacement parts etc.

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

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

These include among other things: J sufficient and consistent ventilation, J water spraying systems.

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

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 is to be stopped immediately and secured to prevent a restart if the firedamp protection systems are found to be damaged.

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2.5

Operating conditions Prerequisites for operation Putting the conveyor into service is prohibited until the complete system in which the conveyor is installed complies with the requirements of European Directive 94/9/EC and standard DIN EN 1710.

As 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. These shall be marked according to the legal provisions applicable at the time they are placed on the market.

The M2 equipment/conveyor may only be operated when the safety requirements according to DIN EN 1552 have been met. These include, among other things: J systems preventing unauthorized starting, J start-up warning systems, J water spraying systems at hazardous locations where there is a

danger of explosion, such as – inlet guides on the drive frame, J safe lock-out command systems, J emergency stop systems, J dust extraction systems, J noise protection, J warning messages, etc.

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

2.6

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– chain assembly guides,

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear personal protective clothing and equipment. This also includes ear protectors as the noise emitted by the conveyor may at times exceed 85 dB(A), (e. g. when the conveyor is being emptied).

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

safety equipment

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

Maintain the signaling and lighting systems in a functional order.

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Pay special attention to the conveyor’s acoustic and optical start-up warnings. symbol plates EMERGENCY STOP

Observe the symbol plates on the conveyor.

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

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

lockout

Lockout the conveyor while carrying out: J maintenance work, J inspection work, J repair work.

Never enter a conveyor that has not been locked-out. cordon off working area

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

moving parts

Ensure that parts of your body do not get caught between movable machine components, such as: J conveyor chains, J flights, J chain sprockets, J tensionable drive frames.

danger of explosion

Always observe the intervals specified maintenance and checks of the conveyor as hot surfaces may ignite explosive atmospheres and dust.

Observe the separate operating manuals for the components used.

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2.7

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

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

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

Ensure that the transport safety devices have been correctly installed.

Fix all moving parts with transport locks.

Never stand under unsecured components or suspended loads.

means of attachment

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

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

floor conveying devices

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

Installation and start-up Secure the installed E-motors during installation against unauthorized or inadvertent switching on.

environmental acceptability

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

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

Operation Operate the control system only when you have extensive knowledge of the operating elements and its method of operation.

You must have been trained on the control system concerned.

Before switching on the conveyor, ensure that there are no persons in it.

Check that all protective devices are installed on the conveyor and that they are in proper working order.

Clean the operating plate at regular intervals. Ensure that the operating symbols are clearly recognizable in order to avoid any operator errors and accidents that may result.

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

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

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

Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its probable duration. securing

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

Secure the conveyor against unauthorized and unintentional restarting prior to any work.

replacing components

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

Defective components should immediately be transported away from the face, in order to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

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original parts

Only use replacement parts which satisfy the specified technical requirements. This is only ensured with original Bucyrus replacement parts.

Please refer to the replacement parts lists for the order numbers.

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

Under no circumstances should brackets of cylinders be used as they are not designed to withstand tensile loads. protective devices

Refit any removed protective devices immediately after completing the work and check that they work properly.

Hydraulic system

handling hydraulic fluids

Avoid direct contact between your skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective devices hydraulic system

When removing protective devices which include hydraulic components, keep in mind that these hydraulic components may be pressurized. You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective equipment.

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids represent a very serious health hazard.

maintenance, repair

Only persons who have and can demonstrate special knowledge of hydraulics are allowed to work on the hydraulic system.

pressure relief valves

Make sure that pressure relief valves are always provided with protective caps. Replace defective protective caps without delay.

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2.9

Safety instructions Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, make sure that: J the hoses are not pinched.

J the hoses have no bubbles or blisters.

J the hoses or the outer sheaths of the hoses are not

abnormallyrigid or hard.

J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the sockets.

J the connections are leak-tight.

Ensure that no dirt enters the hydraulics system during repair work.

Dirt in the hydraulic system can cause serious damage to the whole system. Flush out the hydraulic lines thoroughly before connecting.

Before removing staples to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is pressurized.

If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the line.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hose lines approved for the prevailing pressures.

Do not use any hydraulic hose lines with damaged connectors or worn O-rings.

Replace hydraulic hose lines only with hose lines of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Fig. 1:

Example: 4SP hydraulic hose, identification 3 2 1

6

1 manufacturer 2 hose type 3 date of manufacture, 1st Quarter 2002

2.10

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

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Secure the connectors of the hydraulic elements with the proper coupling clips only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials to secure the connectors.

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If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Make sure the line is depressurized.

Safety instructions Never try to hold a hydraulic hose that is thrashing about.

Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses even if you only suspect they have been damaged. laying hydraulic hoses

Lay the hydraulic hose lines correctly behind the brackets and clips provided for them.

Always lay hydraulic hoses so that they: J always have a little slack, Fig. 2:

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted, Fig. 3:

Laying hydraulic hoses, twisting WRONG

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RIGHT

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter), Fig. 4:

Installing hydraulic hose lines, bending RIGHT

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WRONG

2.11

Safety instructions J cannot chafe, Fig. 5:

Installing hydraulic hose lines, crossing RIGHT

WRONG

J are not kinked, J do not have to withstand tensile loads, J are protected against thermal radiation, J are accessible at all times.

Only push hydraulic hoses into the sockets by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: J torn out, Bucyrus DBT Europe GmbH, Lünen 2008

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J kinked, J crushed, J driven over or J twisted by the movement of the equipment (Fig.: 6).

Fig. 6:

Laying hydraulic hoses, connections on moving parts RIGHT

2.12

WRONG

BSL PF 4/1132

3

Storage and transport

Storage

About storage and transport This chapter contains important information on the correct storage and transport of the conveyor.

Following the instructions and tips will increase the life cycle and service life of the conveyor. You will also be able to carry out the transport work quicker and more safely.

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

Storage Storing the equipment corrosion protection

Components coated with temporary anticorrosive are protected for around six months.

The hydraulically actuated equipment is run with a test medium before delivery and is emptied as thoroughly as possible before shipping. The internal parts are also protected against corrosion by the residual film for at least six months.

Protect the equipment against direct exposure to sunlight.

Only store the electrical equipment, electronic components, replacement parts made out of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15 °C to 25 °C.

moisture and dirt

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

avoid direct exposure to sunlight

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied. short-term storage

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

long-term storage

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

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. A storage period of approximately two years is therefore quoted as an indicative value for these parts.

Important!

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

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VAVT / 01

3.3

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

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

Warning!

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

You could be seriously injured or even killed by falling components.

Use only suitable load handling devices.

Transport of equipment at temperatures between -21 °C and -40 °C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages.

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

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

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

electrical and electronic components

3.4

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

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

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

temperatures below freezing

E

Before transport

Transport Transport of the components machine parts

Drive frame, gearboxes, motors, etc. are equipped with lifting eyes or lifting points for transport.

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

Danger!

You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting eyes and keep a safe distance away from suspended loads.

Fig. 7: a

Transport dimensions drive frame SPR-3

Bucyrus DBT Europe GmbH, Lünen 2008

E

H

L B

L length = 2100 mm B width = 1840 mm H height = 680 mm pans

a lifting eye (load capacity = 8000 kg) 1)

Conveyor pans are equipped to some extent with lifting points. The lifting points can be on the sides or at the front ends of the pans.

The lifting eyes at the end of the pans have to be removed again after transport.

For pans without lifting eyes, you must use transport containers for transport.

1) remove the lifting eye after transport.

Doc. no.: 0010 306 600 BA 00

VAVT / 01

3.5

Bucyrus DBT Europe GmbH, Lünen 2008

E

Transport

3.6

BSL PF 4/1132

4

Installation

Points to observe prior to installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation work may only be carried out by persons who have been adequately trained for these particular requirements.

Work on: J safety components (pressure relief valves, extinguishers, etc.), J electrics (controls, signaling devices, etc.) and J the hydraulics (cylinders, directional control valves, hoses etc.)

shall only be carried out by service engineers from Bucyrus or by specially trained personnel.

Which tools are required for installation? tool box

You need a number of tools in order to be able to install the conveyor properly.

We recommend that you deposit a tool box at the drive. The box should contain the following tools:

Bucyrus DBT Europe GmbH, Lünen 2008

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J 1 fitter’s hammer 1500 gr.

J 1 fitter’s hammer 1000 gr.

J 5 cross chisels 200 x 20 x 12 mm J 5 flat chisels 200 x 23 x 13 mm J 3 hex. screwdrivers 1.0 x 5.5 x 100 mm J 3 hex. screwdrivers 1.6 x 10 x 175 mm J 5 water pump pliers J 1 set of split-pin drifts 5, 6, 8, 10, 3 and 16 mm J 1 metal-cutting saw bow with wooden handle J 3 metal-cutting saw blades, HSS FLEX 24 teeth J 1 pliers for retaining rings I VPJ-6 J 1 pliers for retaining rings A VPA-6 J 1 hex. socket offset screwdriver, 1000 CV N/SB J 1 set of hex. socket offset screwdrivers, 12 mm - 27 mm J 1 torque wrench 100 - 500 Nm J 1 torque wrench 20 - 100 Nm J 1 torque multiplier 3500 Nm J 1 set of hex. sockets 22 mm - 60 mm J 1 power holder for repl. hex. 26809, 1 drive x 22 hex.

J 1 set of hex. pins for power holder 14 mm - 27 mm x 22 hex.

J 1 250 mm extension for power holder J 1 socket spanner set 1481 06 MM C

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4.3

Points to observe prior to installation J 1 socket spanner set 1672 09 MM C J 1 converter for sockets 1539 C J 1 set of sledge type ring spanners SG 41, 46, 55, 65 and

75 mm In addition, various items of auxiliary equipment and machines are required at the point of installation. These include, among other things: J lifting gear with adequate load capacity, J means of attachment with adequate load capacity, J impact wrenches incl. accessories, J drills incl. accessories.

Instructions concerning installation

installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of all steps to be taken with respect to transport and installation should be prepared and a corresponding plan established.

Important!

During assembly, a draw rope must be laid in the bottom race of the conveyor with which the conveyor chain can later be drawn into the bottom race.

laying the conveyor pans

4.4

Take care during installation of the pans that the pans are laid in as straight a line as possible.

tightening torques

For tightening torques not stated in the installation instructions for the components, please refer to the list in Chapter 6. Please also observe the tightening torques specified in the replacement parts lists provided.

instructions for handling junction points

Pins, bore holes, screws and securing devices should be greased with grease A 1 (see Chapter 6, section “Greases and lubricating pastes”) prior to installation.

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

Caution!

Please take care to observe the corresponding separate operating manuals (e.g. for gearboxes, motors, etc.).

E

Caution!

Serious damage can be caused to the drive frame and the drives as a result of incorrect installation.

The drive frame and its drive units should therefore only be installed under the direction of specialists from Bucyrus.

Points to observe prior to installation Overview - Beam stage loader PF 4/1132 Fig. 8:

Overview - Beam Stage Loader (BSL)

632

699

616

615

697

615

618

700 611, 696

A

614

606, 607, 609, 613

A

Bucyrus DBT Europe GmbH, Lünen 2008

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617 616

685, 686 698 601, 602, 603 605 604

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4.5

Points to observe prior to installation Tab. 1: Main components, dimensions and weights Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

2100

1840

680

7700

601

1

TENSIONABLE DRIVE FRAME SPR 3-1100, 3-CYLINDER

602

1

RETAINING ANGLE FOR CONSOLE

-

-

-

12.2

603

1

CONTROLS AND LINES FOR THE SPR 3

-

-

-

29

604

1

FLANGE PLATE SPR 3/KP-25/30; 0 DEGREES

1220

122

670

354

605

1

GEARBOX KP-25/30 : i=24:4

See separate operating manual

606

1

DRIVE CONNECTION ASSEMBLY EK-S300-M800/100-G800/100

607

1

FITTING CONNECTION R 3/4”-R 3/4”

609

1

TENSIONING DEV. PNEUM. EWA3B-450 Z I

See separate operating manual

160

611

1

3-PHASE MOTOR 250/500 KW/1000 V/50 Hz

See separate operating manual

3400

613

1

COVER PLATE G20/25-S 300-M 800

614

1

615

27

616

-

-

-

-

-

-

407 0.7

-

-

-

48

ADAPTOR PAN PF4/1132

3303

1370

745

4951

SL PAN PF 4/1132-1500

1500

1132

309

1239

7

SL PAN PF 4/1132-1500 MT

1500

1132

284

1242

617

4

SL PAN PF 4/1132-750

750

1132

309

1237

618

1

SL PAN PF 4/1132-1500

1500

1132

284

1139

632

1

RETURN UNIT PF 4/1132

3318

1700

745

5642

685

3

CHAIN PF 4/1132;34x126; 43.7 M

-

-

-

686

12

CHAIN PF 4/1132;34x126; 6.14 M

-

-

-

695

1

CHAIN LOCKING DEVICE DMK 34X126

696

1

ACCESSORIES FOR THE COOLING SYSTEM

697

1

DRIVE AND DRIVEWAY-3154 0002 D

See separate operating manual

698

1

POWER UNIT-3154 0003 D

See separate operating manual

699

1

CONVEYOR BEFORE CRUSHER-3154 0004 D

See separate operating manual

700

1

COAL CRUSHER DF 09-12/P4 - WIDTH 1200

See separate operating manual

4.6

See separate operating manual -

-

112

-

BSL PF 4/1132

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Quantity Designation

Bucyrus DBT Europe GmbH, Lünen 2008

Item

How to assemble the tensionable drive frame and drive unit How to assemble the tensionable drive frame and drive unit Caution!

Serious damage can be caused to the conveyor and the drive units as a result of incorrect installation. The conveyor and its drive units should therefore only be installed under the direction of specialists from Bucyrus.

The following illustration (Fig. 9) offers an overview of the subassemblies which are mounted on the tensionable drive frame.

Fig. 9:

Overview of the subassemblies on the tensionable drive frame 614

Bucyrus DBT Europe GmbH, Lünen 2008

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601

611

606

604

605

601 tensionable drive frame SPR 3 604 flange plate 605 gearbox KP-25/30 606 drive connection assembly

Doc. no.: 0010 306 600 BA 00

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611 3-phase motor 614 adaptor pan

4.7

How to assemble the tensionable drive frame and drive unit Tensionable drive frame SPR 3 The tensionable drive frame acts as a retainer for the drive unit set, the flange plate, the chain sprocket and the adaptor pan.

The head part (5) is positioned in the movable sliding frame (6) to tension the conveyor chain. Tensioning is carried out using three hydraulic cylinders.

The head part and sliding frame must be locked to one another on their sides with pins during operation.

Lubrication is carried out by a central lubrication system.

Fig. 10: Tensionable drive frame SPR 3-1100, Item 601 1 13 5 2 8 20 A

1368 1028 KA

10

E

F

345

680

1840

6

19* 345

2100****

345 B

19*

**

19*

4

1444 Bucyrus DBT Europe GmbH, Lünen 2008

E

19* 17

12 600 1288 1476

d

7

E-F

11 3

1 cable set SPR 3 2 flushing system 3 tensioner cylinder 400 mm stroke 4 central lubrication 5 head part 6 sliding frame 7 chain stripper 8 drive shaft 11 chain sprocket 34x126-7-130

**

13 pin

* grease the lubrications points marked with red prior to commissioning

17 restraint PF4 with deflector plate

** utilize lubricating paste B3 EWN 2068

19 lubricating nipple

*** not shown

20 lifting eye (load capacity = 8000 kg) 1)

**** cylinder stroke 400 mm, mechanical locking with socket pins at intervals of 12 mm

12 spacer ring, split

KA = 130

Caution!

During transport and installation use only the attachment points provided. Always use all of the lifting eyes!

The sidewalls of the drive frame may never be used as attachment points for traction devices.

Caution!

Lubricate the drive frames completely before commissioning the conveyor.

The lubrication points are marked in red.

1) remove the lifting eye after transport.

4.8

BSL PF 4/1132

How to assemble the tensionable drive frame and drive unit Fine materials in the guideways (tensionable drive frame - base frame) can be rinsed out via a central connection. The terminal block can be attached to the tensionable drive frame either on the left-hand or the right-hand side.

rinsing device

Fig. 11: Rinsing device SPR 3-900

4, 5

6, 7

3

20 18 1

17

21

13, 16 19

13, 16

Bucyrus DBT Europe GmbH, Lünen 2008

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2

13, 14, 15 8 9, 10

b

a

d

c 1 cover, left 2 cover, right 3 retaining angle for terminal block gear 4 hex. head screw. M 30x50-8.8 5 washer 6 hex. screw M 24x45-8.8 7 washer 8 terminal block 9 hex. head screw M 10x170-8.8

Doc. no.: 0010 306 600 BA 00

11, 12, 13

10 hex. nut. M 10-8 11 sealing ring 14x18 12 screw-in socket DN 10 13 staple DN 10 14 rotatable angle socket DN 10 15 plug 16 plug-in elbow socket DN 10 17 hex. head screw M 20x30-8.8 18 flat steel nozzle 19 hose line 10x800

VAVT / 01

20 hose line 10x1400 21 hose line 10x1100 a auxiliary lubrication port b water line port c rinsing device port d gearbox shown in exemplary fashion For parts not listed here, please refer to the replacement parts list supplied.

4.9

How to assemble the tensionable drive frame and drive unit Tensioner cylinder in the SPR 3 The tensionable drive frame SPR 3 is equipped with three tensioner cylinders for tensioning the chain. The maximum cylinder stroke is 400 mm. The tensioner cylinders are extended or retracted via a hydraulic control system.

Fig. 12: Tensioner cylinder in SPR 3

8 axle mount 11 hex. head screw M 16x40-8.8 12 washer

Bucyrus DBT Europe GmbH, Lünen 2008

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1 hydraulic cylinder ZS-100/80-400 3 rod head 7 bolt

4.10

BSL PF 4/1132

How to assemble the tensionable drive frame and drive unit Hydraulic control system on the SPR 3 Hydraulic control unit The main components of the hydraulic control unit (Fig. 13) are the valve housing (3) and the dual 3/2 directional control valve (1).

The control valves can be switched when pressure is applied. The valves are actuated manually and return automatically when the operating lever is released.

Important!

The head part of the tensionable drive frame is mechanically locked to the sliding frame with socket pins during operation (see section “Tensionable drive frame”).

Remove the mechanical shield support unit before you extend or retract the cylinders.

Fig. 13: Hydraulic control unit 3

18 B

T

A

P

Bucyrus DBT Europe GmbH, Lünen 2008

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1

1 4/3 port directional control valve 3 valve housing

18 protective plug NW 8/10

Fig. 14: Circuit diagram for the hydraulic control unit A

B T P A = port: extend cylinders B = port: retract cylinders P = pressure supply T = return

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4.11

How to assemble the tensionable drive frame and drive unit Hydraulic lines and circuit diagram of the hydraulic control system on the SPR 3 component functions

The piloted check valve (6) is used to close the piston spaces of the cylinders pressure-tight. A pressure relief valve (8) in the “Extend cylinders” supply line is designed for overload protection.

It is set to operate at 350 bar.

Fig. 15: Installation diagram SPR 3 1, 25

2, 3, 4 6, 15, 23

14, 23

22

16, 23

8

10, 11 9

7, 15

16

7 line filter 4 UC 1329-003 DN 10 (40 micron) 8 pressure relief valve (350 bar) 9 pressure gauge

18, 19, 20

10 hydr. control unit (2-way)

21 16, 17

For parts not listed here, please refer to the replacement parts list supplied.

Fig. 16: Circuit diagram for the SPR 3

1

2

A = port: extend cylinders B = port: retract cylinders P = pressure supply T = return 1 3/2 port directional control valve - retract cylinders 2 3/2 port directional control valve - extend cylinders

4.12

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

18, 19, 20

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1 bracket 5 ball valve 6 check valve DN 10

21

How to assemble the tensionable drive frame and drive unit Flange plate between the tensionable drive frame gearbox The flange plate is the connection element between the tensionable drive frame and the gearbox. loose parts

tightening torque

Ensure that the parallel keys which are to absorb the torque are fitted and screwed in properly.

The tightening torque of the M 30x2-10.9 mounting bolts is 1450 Nm. The tightening torque of the M 36x3-10.9 mounting bolts is 2900 Nm. How to install the flange plate

. Remove the rust preventive before installing the flange plates and treat the points marked with an (X) with a solid lubricant (lubricating paste B3 according to EWN 7068).

Be sure to clean the points of oil with a suitable solvent first.

Fig. 17: Flange plate between tensionable drive frame SPR 3 and gearbox KP 25/30, Item 604 (122)

A

(670)

A

11

2, 4

1 7, 8

3, 4

5, 6

63

134

1)

X 70

70

Bucyrus DBT Europe GmbH, Lünen 2008

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(1220)

X 10 2)

1 flange plate 2 expansion bolt M 30x2x150 3 expansion bolt M 30x2x215 4 hex. nut M 30x2-10 5 expansion bolt M 36x3x145

Doc. no.: 0010 306 600 BA 00

6 hex. nut M36x3-10 7 parallel key F 50x28x250 8 hex. socket head cap screw M12x30-8.8 9 O-ring 470x4 2) 10 O-ring 520x5 2)

VAVT / 01

11 lifting eye, TWAGK 3 20 lubricating paste EWN 7068-B3 1)

back-off thread (filled with grease)

4.13

How to assemble the tensionable drive frame and drive unit Notice!

Dirt could get into the gearboxes and couplings if the O-rings for the flange plate are inserted incorrectly. This could result in serious damage to the gearboxes and couplings!

Make sure when mounting the flange plate that the O-rings are installed in the correct position.

Instructions for the installation of the gearbox Notice!

Observe the separate operating manuals for the gearboxes used.

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

must be clean and free of burrs.

J Before mounting the flange, the gearings must be well greased

- B3 grease (see Chapter 6, section “Lubricating greases and pastes”).

J The gearing must be aligned so that tooth and tooth gap are

exactly opposite one another to ensure that they mesh smoothly. Try to avoid damage to the gearing. Take special care to ensure that the gearbox is not tilted during installation.

J Ensure you use the correct screw sizes corresponding to the

gearboxes used.

J After installing the gearboxes, there must be no strain between

gearbox and drive frame or between the drive shafts.

4.14

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

bores, connectors, and parallel keys when being installed.

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J The gearbox must be positioned accurately on the centering

How to assemble the tensionable drive frame and drive unit Drive connection The drive connection comprises all components arranged between the E-motor and the gearbox. It mainly consists of a protection cover and a coupling.

Important!

The drive connection assembly is equipped with an additional crown gear. It possible as a result to use a hydraulic chain tensioner for tightening the chain assembly. With the help of this apparatus, you can couple the chain assemblies more quickly and securely and set the optimum chain pretension.

The tensioning device is flanged onto the protection cover.

Please do not hesitate to contact us about this should you need any further information!

Fig. 18: Drive connection, Item 124 Motor side

Gearbox side 30

7, 16, 20

Bucyrus DBT Europe GmbH, Lünen 2008

E

9 8 4

10, 14, 22

1

1 protection cover 4 coupling 7 crown gear 8 spacer ring 9 spacer ring flange position “W”

10 washer 35

22 washer 31

14 hex. head screw M 30x60-8.8

30 adaptor ring S 300

16 retaining ring 190x4 20 parallel key 22x14x80

Flange position “W” of the E-motor means the distance between the motor flange and the shaft collar. On the drive connection it is the distance between the contact surface of the protective cover (motor side) and the contact surface of the flexible coupling (see Fig. 19).

Caution!

If flange position “W”on the E-motor is larger than on the drive unit connection assembly, the motor shaft and gearbox drive shaft bearings can become strained This can result in damage to the gearbox and the E-motor!

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4.15

How to assemble the tensionable drive frame and drive unit Fig. 19: Flange position “W” at the E-motor and at the drive connection Flange position “W” on E-motor

Flange position “W” at the drive connection

E-motor “W”

“W”

Particular attention must therefore be paid to the following instructions before installing the motor: J The motor’s exact flange position “W” must be measured

before installation.

J 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.

J The connecting pieces must be installed using the mounting

Electric motor (E-motors) Notice!

Observe the separate operating manuals for the E-motors used.

4.16

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

Caution!

Blows to the motor shaft and gearbox shaft will damage the roller bearings! Therefore, always use a mounting and pulling-off device for installing and removing the connecting pieces.

E

and pulling-off device.

How to install the conveyor pans How to install the conveyor pans panline

The beam stage loader pan line consists of: J 1x adaptor pan for the SPR 3 (614), J 27x SL pan PF4/1132-1500 (615), J 7x SL pan PF4/1132-1500 MT (616), J 4x SL pan PF4/1132-750 (617), J 1x SL pan PF4/1132-1500 (618), J 1x return unit PF4/1132 (632).

construction

The bottom plate and the side profiles of the SL pans act as a guideway for the conveyor chain. The bottom race is closed.

pan connection

Dogbones are used to connect the pans to one other. The dogbones for the BSL are not included in the Bucyrus scope of delivery. Information concerning technical data can be obtained from the technical documentation provided by the Fite Co.

inspection door

Pans equipped with inspection doors facilitate the elimination of faults in the bottom race of the conveyor. The inspection openings are secured using a locking flap.

Bucyrus DBT Europe GmbH, Lünen 2008

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The following overview drawing gives you an overview of the configuration of the conveyor pans.

Fig. 20: Overview of the pan line 4 x 615

616

616 4 x 615 616

632

4 x 615 616 4 x 615 615

616

616

614

2 x 615 4 x 617 618 4 x 615 4 x 615

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616

4.17

How to install the conveyor pans Adaptor pan PF 4/1132 The adaptor pan connects the tensionable drive frame SPR 3 to the panline of the beam stage loader.

The connection between the adaptor pan and the tensionable drive frame is accomplished with screw bolts (4 and 5).

Fig. 21: Adaptor pan PF 4/1132, Item 614

Bucyrus DBT Europe GmbH, Lünen 2008

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View X

1

4, 5

1 adaptor pan PF4/1132 4 screw bolt M 42x317

4.18

5 hex. nut M 42-10

BSL PF 4/1132

How to install the conveyor pans SL pan PF 4/1132-1500 MT The SL pans are equipped with inspection flaps which are secured with retainers.

Fig. 22: SL pan PF 4/1132-1500 MT, Item 616

2 1

7

Bucyrus DBT Europe GmbH, Lünen 2008

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8

1 SL pan PF 4/1132-1500 MT 2 cover

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7 retainer 8 spring dowel pin

4.19

How to install the conveyor pans SL pan PF 4/1132-1500 Fig. 23: SL pan PF 4/1132-1500, Item 615

Bucyrus DBT Europe GmbH, Lünen 2008

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1

1 SL pan PF4/1132-1500

SL pan PF 4/1132-1500 Fig. 24: SL pan PF 4/1132-1500, Item 618

1

1 SL pan PF4/1132-1500

4.20

BSL PF 4/1132

How to install the conveyor pans SL pan PF 4/1132-750 Fig. 25: SL pan PF 4/1132-750, Item 617

Bucyrus DBT Europe GmbH, Lünen 2008

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1

1 SL pan PF4/1132

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4.21

How to install the conveyor pans Return unit PF 4/1132 The return unit is comprised of the SL adaptor pan and the return head. The return head serves to reverse the beam stage loader chain assembly in free-running operating mode. The return head is connected with the adaptor pan by means of an anchor dogbone.

Fig. 26: Return unit PF 4/1132, Item 632

3

2 1

4

1 SL adaptor pan PF 4/1132 2 return head 1100 DKB 34x126-5Z-KA=130 3 cover 4 substructure return unit 10 hex. head screw M 30x85-10.9 11 hex. head screw M 20x70-8.8

4.22

10, 15, 16

12 hex. head screw M 20x8-8.8 13 hex. nut V M 20-8 14 washer 15 hex. nut V M 30-10 16 washer

BSL PF 4/1132

E

11, 13, 14

Bucyrus DBT Europe GmbH, Lünen 2008

12, 13, 14

How to install the conveyor pans Return head The chain sprocket spherical bearings are equipped with a constant service life supply of oil.

Dirt and water is prevented from entering the bearings by axial face seals which need to be lubricated regularly (see Chapter 5, Section “Lubrication points”).

The axial faces seals are lubricated on both sides via the lubricating nipples in the bearing caps. The bearing caps are each equipped with a grease inlet (lubricating nipple) and a grease outlet.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 27: Return head 1100

b

a a grease inlet b grease outlet

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for further parts, please refer to the replacement parts list supplied

4.23

How to install the drive substructure How to install the drive substructure The drive substructure connects the face conveyor with the BSL. The two elements of the drive substructure are connected to one another with bolts.

Proceed as follows:

. Connect the two elements of the drive substructure. Take care to ensure that bore holes are flush with one another (Fig. 1).

. Place the two bolts in the bore holes (Fig. 2). . Secure the bolts on each side with spring clips (Fig. 3). . Connect the drive substructure with the pans of the BSL using the bolted connections on the side profiles (Fig. 4).

Further information concerning the drive substructure can be obtained from the technical documentation provided by the Fite Co. Fig. 28: Mounting the drive substructure

E

Figure 2

1 2

Figure 3

Figure 4

a

b

1 bolt 2 spring clip

4.24

a beam stage loader b drive substructure

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

Figure 1

How to install the chain How to install the chain The chain is comprised of preassembled individual chain strands which are comprised of the following individual parts: J flights with mounting elements, J chain link, J chain connector.

Fitting flights The distance between the flights, when fitted on every 4th chain link (every 4th link a flight), is 504 mm. The flights are fitted onto the horizontal chain links.

Notice!

Flights that have been insufficiently tightened may come loose and jump out of the guides. This may lead to the conveyor becoming jammed.

Tighten the screws on the flights with the required torque of 1300 Nm. Fig. 29: Flight PF 4/1132, DKB 34 x 126 - KA 130

Bucyrus DBT Europe GmbH, Lünen 2008

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3

1

a 4 1 flight 2 clip 3 collar nut M 30x2

2

4 special-purpose screw a flat chain

Fig. 30: Chain assembly (DKB) with flight (4-pitch chain), Item 685 3

2

1

Conveying direction

504 1 flight 2 flat chain 34x126

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3 flat connecting chain link 34x126

4.25

How to install the chain Caution!

Take care to ensure that the pans of the BSL are pulled apart from one another before you connect the chain assembly.

Proceed as follows:

. Pull the individual pans so far away from one another that the dogbone connections have no more free room to move.

. Afterwards, connect the individual chain lengths with the chain connectors to make a closed chain assembly.

a

1 chain assembly 2 chain connector

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 31: Schematic diagram

c

b

c conveyor pan

Notice!

Make sure the connecting elements are complete and fixed correctly (e. g. tightening torque for bolted connections)!

Adjusting chains Adjusting chains are provided for adapting the length of the chain to the length of the conveyor and for reducing the length of the chain in the event of too much slack having developed.

Installing the chain connector The individual chain strands of the chain are joined with chain connectors. The chain connectors described here are flat connecting chain links.

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How to install the chain

vertical installation

Flat connecting chain link The flat connecting chain link can be installed either horizontally or vertically.

Observe that dimension b of the flat connecting chain links is larger than the dimension b of the associated round steel chain in accordance with DIN 22252.

For that reason, do not fail to check the passage width with vertically installed flat connecting chain links, e. g. in the bottom race of the conveyor, between drive frame and coal deflector, etc.

Also observe the position of the chain link in the flight.

Flat connecting chain links may not be installed vertically in conveyors with flat chains according to DIN 22255.

Fig. 32: Type of chain link: flat connecting chain link FL-B, pre-assembled Co.

a

Fig. 33: Flat connecting chain link

b

t

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c

1 l Tab. 2: Dimensions of different flat connecting chain links (according to DIN 22258, part 1) 2

Nominal size of the chain

a

t

b

c

l

Perm.

Maximum Maximum Maximum Maximum deviation

26 x 92

92

±0.9

28

96

33

147

3

30 x 108

108

±1.1

32

111

37

171

1 flat connecting chain link half 2 locking bolt 3 spring pin

34 x 126

126

±1.3

37

122

41

198

38 x 137

137

±1.4

41

134

46

217

42 x 146

146

±1.5

45

151

53

235

Closing the flat connecting chain link:

. Hook the halves of the flat connecting chain link into each other.

. Knock the locking bolts in until they are flush. . Knock in spring pin.

The flat connecting chain link is closed.

Opening the block connector:

. Knock out the spring pin. . Remove the locking bolts.

The flat connecting chain link is open.

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4.27

How to tension the chain assembly How to tension the chain assembly correct pretension

For trouble-free operation, the chain assembly in an empty conveyor must have such a pretension that only a moderate amount of slack chain is created under load during operation.

Fig. 34: Chain pretension Return head

Drive unit

X

X 1 1 2 3 2 3

excessive chain pretension

changes in chain pretension as the face advances

monitoring the chain

4.28

If too much slack develops, then the climbing and jumping of the chains on the chain sprockets will increase. Major damage could occur to the chain and to the pans as a result.

Excessive tensioning of chains results in power losses as the chains pass around the chain sprockets. This could lead to excessive wear of chains and chain sprockets, in addition to damaged bearings. as well as extreme noise levels caused by the excess strain on the chain.

As the face advances, the chain assembly pretension can change as the conveyor takes on different curvatures in both horizontal and vertical directions.

Changes can also be caused by compression or stretching of the panline and by changes in the face angle.

In addition, changes in load are possible due to fluctuations in the properties of the material conveyed, e. g. changes in moisture content or in the debris content.

Finally, the chain pretension changes due to increasing permanent elongation.

In order to ensure trouble-free operation with favorable power rating and long service lives of chains and chain sprockets, the chain must therefore be constantly monitored with respect to the criteria slack chain and noise level. This can give an early indication as to when a chain needs to be shortened.

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excessive slack chain

3 slack chain

Bucyrus DBT Europe GmbH, Lünen 2008

1 taut chain 2 optimal chain

How to tension the chain assembly Auxiliary devices for holding and pulling the chain assembly The following auxiliary devices must be used to holding and pulling the chain assembly while it is being shortened: J harness for chain installation, J chain hoist (maximum 7.5 t pulling force), J chain tensioner on the drive unit (hydraulic or pneumatic).

Fig. 35: Schematic diagram for using the harness c

a drive unit b harness for chain installation

c

b

a

c chain tractive direction

E

Harness for chain installation Bucyrus DBT Europe GmbH, Lünen 2008

To connect the ends of the chain assemblies or to remove the slack chain, the upper conveyor chain is pulled together with the aid of the harness.

Fig. 36: Harness for chain installation a

a

a

b Cross-section A-A 1

1

1

5 1 harness 5 hex. head screw M 20x60-8.8

a chain 34 x 126 b chain hoist (maximum pulling force = 7.5 t)

Warning!

You can badly injure yourself or others by abruptly releasing one of the elements of the harness.

Make sure when installing the harness that the hex. head screw for fastening the harness is screwed in completely.

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4.29

How to tension the chain assembly How to tension the chain assembly checking

repair and maintenance

A correspondingly trained person must check the condition of the harness before the harness is put to use. You may not use the harness until after the inspection has established that it is in perfect working condition.

Damaged components may only be repaired by Bucyrus!

Important!

If harnesses are not serviced by Bucyrus service personnel, any liability on the part of Bucyrus is excluded.

Danger!

When coupling the chain assembly using an additional pulling device, do not use so-called C-links (chain links that are cut open).

The C-links could break off due to the load being too great.

You could be seriously injured or even killed by a recoiling chain.

Only use the specified chain connectors and harness for coupling or pulling the chain ends.

Please proceed as follows:

. Switch off the conveyor and secure the installation against being switched back on.

Danger!

You or others could be seriously injured or even killed if the conveyor is switched back on while making repairs.

Make sure that the conveyor system is secured and cordon off a large zone around the working area!

. Remove the socket pins (mechanical locking) on the tensionable drive frame (see Chap. 5, Section “How to operate the tensionable drive frame SPR 3”).

. Retract the tensioner cylinders completely. . Depressurize the cylinders of the tensionable drive frame.

Caution!

You or others could be injured if the tensionable drive frame is extended while work is being performed on the chain.

Make sure that the cylinders are depressurized and initiate appropriate measures in order to prevent the pressure from being switched on again by unauthorized individuals.

. Move the slack chain backward into the upper race with the aid of the chain tensioner.

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into the area of the movement pans, so that you have sufficient room to work in.

E

. Move the range of the chain assembly with chain connector

How to tension the chain assembly Fig. 37: Move the slack chain into the upper race a

a

a drive unit

Important!

Always observe the separate operating manual of the chain tensioner used!

. Fasten both parts of the harness (see Fig. 36).

Bucyrus DBT Europe GmbH, Lünen 2008

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Warning!

You can badly injure yourself or others by abruptly releasing one of the elements of the harness.

Make sure when installing the harness that the hex. head screw for fastening the harness is screwed in completely.

. Fasten a chain hoist (maximum pulling force 7.5 t) to the load rings1) and pull the chain assembly together.

Fig. 38: Pulling the slack chain together a

a drive unit b harness for chain installation

c

b

c tractive direction

Important!

Take care to ensure that the slack chain is located completely within the area of the movement pans and that no chain links are kinked in the area of the tensionable drive frame.

. Shorten the chain assembly. . Reconnect the chain assembly with the chain connectors (see Section “Mounting chain connector”)

. Dismantle the harness. . Switch the conveyor system back on.

1) Maximum load capacity of the load ring = 7500 kg

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4.31

How to tension the chain assembly Notice!

Starting a conveyor with harness installed could cause severe damage to the drive units.

Remove the harness before restarting the conveyor.

. Apply pressure to the tensioner cylinders. . Extend the tensioner cylinders of the tensionable drive frame, until you are able to observe some slack chain formation (see Fig. 34).

. Please lock the tensionable drive frame with the socket pins.

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Important!

Take care to ensure that the tensioner cylinder in the tensionable drive frame still has sufficient residual stroke to be able to retighten the chain during operation.

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BSL PF 4/1132

Sequencing control of the conveyors Sequencing control of the conveyors Switching conditions of the system components The switching on of the system components takes place automatically and is controlled to some extent by monitoring components.

Important!

Also make sure you observe the separate operating manual for the face control system. switching on

The main components of the installation must be switched on in the following sequence: J Hydraulics supply J Cooling water supply J Belt system J Crusher J BSL (Beam stage loader) J AFC (Face conveyor)

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J Mining equipment switching off

The main components of the installation must be switched off in the reversed sequence:

fault

If system components switch off because of a malfunction, then the other components must immediately be switched off automatically.

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4.33

How to start-up the conveyor system How to start-up the conveyor system The conveyor system must be started up under the instruction of Bucyrus technicians.

Warning!

Make sure that nobody is present in the hazardous area of the conveyor system when you start operating the conveyor.

Particularly during the first start-up a safe distance should be kept with respect to the conveyor as e. g. due to installation errors hazards may occur which would not occur during normal operation.

A safe distance should be maintained with respect to the conveyor!

Notice!

In addition, observe the instructions in the separate operating manuals for the conveyor components, e. g. E-motors, gearboxes, drive connections, etc.

Before start-up

and your working area.

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

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

. Check the hydraulic connections and lines for leakage or damage.

. Check that all supply lines are laid properly. . Check the hydraulic plug connectors. In particular, check that the coupling clips are completely pushed in.

Danger!

You could be seriously injured or even killed by a hydraulic hose that is thrashing about!

Secure the plug connectors of the hydraulic elements with the proper coupling clips. Always fasten the clips completely and with both sides.

Never use nails, wire or similar materials to secure the connectors.

. Check the oil level and the cooling of the gearboxes. . Check the cooling of the E-motors. . Check the direction of rotation of the E-motors. . Check the electrical connections. . Test the sequencing control of the conveyor drive units.

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. Align the conveyor. . Remove all tools, auxiliary equipment, etc. from the conveyor

E

The following work has to be performed before beginning with the actual start-up:

How to start-up the conveyor system . Test the function of the signaling devices and the intercom system.

Test run of the conveyor Danger!

Make sure that nobody is present in the hazardous area of the conveyor system during the test run.

In this phase, a safe distance should be kept with respect to the conveyor as e. g. due to installation errors hazards may occur which would not occur during normal operation.

These hazards could cause severe injuries or even death!

Make sure that you keep sufficient distance between you and the conveyor system during the test operation. est run of the empty conveyor

When you have checked the conveyor and remedied any faults discovered, the proper interaction of the individual components of the complete system must be checked. For this purpose, carry out a test run with the empty conveyor for approximately ½ hour).

. As the conveyor is running empty, you have to lubricate the chain at the chain sprockets, in order to avoid excessive wear of the chain sprockets.

Bucyrus DBT Europe GmbH, Lünen 2008

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Notice!

Use biodegradable vegetable oils, Water Pollution Class 0, to lubricate the chain sprockets due to total-loss lubrication.

Ensure you observe the applicable environmental regulations.

. Lubricate the overall installation at the lubrication points. . Check and inspect the following points: J Uniform and equal power consumption of the electric motors.

J Sufficient cooling of the E-motors.

J Sufficient cooling and proper oil filling of the gearboxes.

J Steady and quiet running of the gearboxes.

J Steady rolling behavior of the chain at the chain drums.

J Uniform entry of the chain to the drive frame.

J Check that the flights enter the chain guides properly.

J Check conveyor flight spacing.

J Correct number and installation position of flights.

J Check that chain connectors are fitted correctly and in the right

installation position.

J Optimum chain pretension.

J Function of the sequencing control of the conveyor drive units.

J Function of the safety devices such as the signaling devices,

Emergency Stop circuit, etc.

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4.35

How to start-up the conveyor system after the test run

Secure the conveyor to prevent restarting and carry out the following operations:

. Shorten the chain until an optimum chain pretension is obtained in the chain assembly

. Eliminate any deficiencies discovered.

As soon as all deficiencies have been eliminated or remedied, the test run with the conveyor loaded can commence.

Test operation of the conveyor Danger!

Make sure that nobody is present in the hazardous area of the conveyor system during the test run.

In this phase, a safe distance should be kept with respect to the conveyor as e. g. due to installation errors hazards may occur which would not occur during normal operation.

These hazards could cause severe injuries or even death!

Make sure that you keep sufficient distance between you and the conveyor system during the test operation.

Carry out a test operation of the loaded conveyor for approximately 6 hours paying attention to the following points: E

. Increase the load on the conveyor gradually. . Check that the chain passes over the chain drums properly. . Monitor the conveyor continuously for slack chain. . Monitor the current consumption of the E-motors. . Check gearboxes for heat buildup. . Check all hydraulic connections and lines for non-leakage and damage. after test run

After test operation, empty the conveyor completely.

Observe the following points before releasing the conveyor:

. Inspect the conveyor once again thoroughly for installation errors, damage or other faults.

. Check all of the functions once more, in particular those of the safety systems. releasing the conveyor for operation

4.36

When the inspection reveals no further faults and all the functions can be performed without problems, the conveyor can be released for operation.

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

test operation of the loaded conveyor

After the initial operating hours After the initial operating hours Tightening the bolted connections Screws can become loose or even detached due to the placing of bolted connections or components!

This is why you have to tighten the following conveyor bolted connections after an initial operating time of approx. 60 hours.

In doing so, observe the respective torque required or the required tensioning force.

J Drive unit connection (motor and gearbox side).

J Gearbox (attachment on the drive frame).

J Chain sprocket screws on chain sprockets.

J Attachments on flights.

J Chain stripper on chain sprockets.

J Attachments of the inspection openings.

J Guide strips on the tensionable drive frame.

J Attachments on the drive substructure.

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selecting tightening torque

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Refer to the appropriate replacement parts list for the tightening torque of the respective bolted connection. If the replacement parts list should have no other details on this, then the tightening torque in chapter 6 “Technical Data” will apply.

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4.37

Dismantling and withdrawing the conveyor system Dismantling and withdrawing the conveyor system draw up dismantling plan

Before the conveyor system is to be dismantled, a dismantling plan should be drawn up. The plan helps you to coordinate dismantling and transport operations.

Dismantling should be carried out in the most favorable sequence, generally in reverse assembly order. Dismantling depends on the conditions prevailing in the mine.

Who is authorized to dismantle and withdraw the conveyor system?

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

Important instructions for dismantling handling delicate components

. Protect all exposed shafts, hubs, labyrinth channels and flanges against corrosion, contamination and damage.

. Close off all open lines and separation points with protective to protect the components against soiling, damage and/or loss.

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. Pack loose parts, screws, etc. in suitable containers in order

E

caps or plugs.

5

Operation

How to operate the conveyor system

Operation This chapter contains important information on the operation and maintenance of the system. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the conveyor system Danger!

Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the conveyor only when you have been sufficiently trained on the installed control unit and have read and understood all the operating manuals on the conveyor system.

Should anything be unclear, please contact your supervisor!

Who is allowed to operate the conveyor?

The conveyor may only be operated by persons with a sufficient knowledge of the whole conveyor system.

This also entails knowing: Bucyrus DBT Europe GmbH, Lünen 2008

E

J which safety systems are installed on the system, J where these safety systems are located, J how these safety systems are to be operated.

When may conveying be started?

Conveying must not be started until the safe condition and proper function of the whole conveyor system has been checked and the daily maintenance operations have been carried out.

How to operate the drive frame SPR 3 The chain assembly pretension can be adapted to the production conditions by retracting or extending the cylinders in the tensionable drive frame. If, for example, there is too much slack chain on the head gate, the cylinders must be extended. The chain assembly is tensioned by this. If the chain is too taut, the cylinders must be retracted until the chain assembly has the optimum pretension.

The cylinder stroke is 400 mm.

Important!

The head part of the tensionable drive frame is locked mechanically during operation with the sliding frame by means of socket pins.

Remove the mechanical shield support unit before you extend or retract the cylinders (see Fig. 39).

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5.3

How to operate the conveyor system Mechanically lockout of the tensionable drive frame The head part of the tensionable drive frame must be locked on both sides to the sliding frame with locking pins in order to relieve the hydraulic cylinders during operation.

The locking pins can be set into the hole strip in the tensionable drive frame at a distance of 12 mm apart from one another.

Fig. 39: Components for tensioning and locking the drive frame SPR 3 3

Bucyrus DBT Europe GmbH, Lünen 2008

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13

3 hydraulic cylinder 13 locking pins

5.4

BSL PF 4/1132

How to maintain the conveyor How to maintain the conveyor Maintenance at regular intervals increases the operational safety and prolongs the service life of the system.

In particular, also observe the safety instructions in chapter 2 “Your safety”. danger of explosion

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

Temperature and acoustic emission monitoring Drive frames, gearboxes and similar components of the conveyor can be equipped with temperature and/or acoustic emission monitoring.

The operator can use continuous monitoring system to switch off the drives if: J impermissible temperatures are reached, J impermissible acoustic emission characteristics are indicated.

Important instructions Please observe the following instructions: Bucyrus DBT Europe GmbH, Lünen 2008

E

J In order to avoid individual components not being serviced or

being only inadequately serviced during maintenance work on the conveyor system as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operating manual and the manuals of the other components.

J Inadequately performed maintenance can cause machine

damage which can result in considerable costs.

Be sure to observe the specified maintenance intervals.

J Use only suitable and approved tools for maintenance work!

J Use only original Bucyrus replacement parts when replacing

components.

How to maintain the steel structure Maintenance of the steel structure includes: J lubrication of the system in accordance with the lubrication

schedule, J inspecting the system for faults and proper function, J inspection of wear parts.

Lubrication schedule Tab. 3: Lubrication according to runtime Components Tensionable drive frame - Bearing - Guideways Return head - bearing

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Medium

Grease

Runtime in hours 1.

2.

3.

...

100

...

100

100

5.5

How to maintain the conveyor Pump grease into the central lubrication points with the conveyor running until fresh grease emerges.

Notice!

During operation, the relubrication intervals must not exceed 100 hours. Lubrication must be carried out with the conveyor running, as only then will the grease be distributed uniformly.

Lubrication points Central lubrication - tensionable drive frame The central lubrication system enables the drive frame to be lubricated from a central point. The bearings and guide beams on the tensionable drive frame are supplied with grease by a central lubrication system.

The lubrication distributor can be attached on the tensionable drive frame either on the left-hand or the right-hand side.

Fig. 40: Lubricating points on the tensionable drive frame

c

b

e

a

d a grease inlet b lubrication of bearings on the right c lubrication of beam on the right

5.6

d lubrication of beam on the left e lubrication bearing left f gearbox shown in exemplary fashion

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f

How to maintain the conveyor Central lubrication - return unit The return unit bearing is lubricated on both sides by means of the lubricating nipples in the retaining panel. The retaining plate is equipped respectively with a grease inlet (lubricating nipple) and a grease outlet.

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Fig. 41: Lubrication point-return unit

a

c

b

a grease inlet b grease outlet

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c return unit shown in exemplary fashion

5.7

How to maintain the conveyor System inspection J Inspect all the components of the system at least once per shift

for visible signs of damage or faults! Damaged flights (deformation, cracks) could, for example, cause serious damage to the chain sprockets.

For this reason, defective or missing parts must be replaced immediately.

J Check all the functions of the system at regular intervals.

J Make sure the connection elements are fitted securely.

Inspecting wear parts weekly

In order to be able to determine in good time when a repair shift has to be scheduled and to avoid damage to other components, it is essential to inspect all the following wear parts once per week as to their degree of wear: J the chain, J the flights, J the chain guides.

With some wear parts it is sufficient to inspect them once per month. These include: E

J the chain sprockets and J the chain strippers.

How to maintain the hydraulic system Exact knowledge of the hydraulic system is essential for its maintenance. You must, therefore, familiarize yourself with the wiring diagrams for the control elements and with the installation plans (the installation plans are found in the replacement parts documentation).

In particular, also observe the safety instructions in chapter 2 “Your safety”.

Maintenance of the hydraulic system daily

The hydraulic system must be maintained regularly. Carry out the following work: J Check that all components are in perfect condition.

J Make sure the connection and securing devices are in perfect

condition.

J Check the proper installation of all lines.

J Check that all connections are fitted securely.

J Check that all operating levers, rod assemblies, cylinders,

locking pieces, springs, etc. are functioning perfectly.

Important!

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

Caution!

Report any damage, defective components or other faults to your supervisor immediately!

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monthly

How to maintain the conveyor Special measures J After the first 100 operating hours have elapsed, the filter

cartridges on the control block, if available, must be replaced.

J All pressure control valves are to be checked for correct

functioning at least once a year, or, in any case, after every face move.

J Due to reasons of safety and to ensure correct system function,

all high-pressure hydraulic hose lines must be replaced every two years, regardless of whether there is any visible damage.

Check emulsion values weekly

Check at least once a week: J the pH value, J the concentrate ratio

– test method: in consultation with the manufacturer of the concentrate, J the microbial load

– test method: dip slides.

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Important!

DIN 24320 provides you with other important instructions.

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5.9

How to replace wear parts How to replace wear parts It is essential that wear parts are replaced before they reach the lowest wear limit as otherwise damage can be caused to other parts of the machine. Check all wear parts on a regular basis.

Chain sprocket The chain sprocket transmits the drive torque from the gearbox via the drive shaft to the chain. The chain sprockets are subject to extreme amounts of wear because of the great frictional forces to which they are exposed.

The service life can be optimized by dismantling the drive unit and rotating it by 180 degrees and reassembling it. The chain links thus move over the sides of the chain sprocket pockets having less wear.

Fig. 42: Wear measurement on the chain sprocket

H

installation

The threaded holes M 24 in the chain sprocket halves are designed for screwing in the ring bolts as assembly aids. After completion of installation they have to be sealed using plugs (Item 12, Fig. 43).

Before installing the chain sprocket, you must remove the rust preventative and apply a solid lubricant B3 (see Chapter 6) to the points marked (X). These positions need to be cleaned of all grease with a suitable solvent beforehand.

tappet

chain sprocket screw

5.10

To ensure a trouble-free functioning of the axial face seal, the tappet of the axial face seal must extend into the respective groove of the chain sprocket.

Take care during assembly that the tappet of the axial face seal cover is flush with the groove of the parallel key (see marking :).

The following guidelines must be observed when mounting the chain sprocket screws:

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The degree of wear can be measured with a depth gauge. The height H is measured with the depth gauge diagonally over the chain link to the bottom of the groove. The drive unit must be exchanged or replaced if the height H is less than 90 mm (98 mm - 8 mm wear).

E

Caution!

Check on wear of the chain sprockets at least every four weeks!

Please note that the life of a turned chain sprocket may be much shorter, due to tolerances in the hardness penetration depth. Therefore check on the wear of the turned chain sprocket at least every 2 weeks!

How to replace wear parts J Only use original chain sprocket screws, J threads and contact surfaces of bolts and nuts must be applied

with grease B36 (see Chapter 6), J tighten bolts with torque (e. g. torque multiplier and torque

wrench).

Never use an impact wrench!

The torque required for tightening the chain sprocket screws M 33x2x144 used is 2400 Nm.

tightening torque

Fig. 43: Chain sprocket DKB 34x126-7 130 12

1

Z

5,9

15 M24

405

X

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X

820

: 1 sprocket drum 5 chain sprocket bolt M 33x2x144 9 washer

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12 plug 15 spring dowel pin

5.11

How to replace wear parts Chain stripper The tensionable drive frames are provided with chain strippers which assist in releasing the circulating chain from the chain pockets of the sprocket. replacement

When replacing a worn chain sprocket always replace the chain strippers as well.

The stripper plate (2) is screwed onto the tensionable drive frame.

The chain strippers (1) are secured in their recesses by a profile bar welded onto the stripper bracket and onto the stripper plate (2).

disassembly

With the chain sprocket in place, remove the stripper plate and pull the chain stripper out to the top.

Caution!

Should the stripper come loose during operation, the chain sprocket or the tensionable drive frame could be damaged.

Be sure to tighten the M 24-8.8 mounting bolts without fail to the specified torque during installation!

The required tightening torque is 655 Nm. Fig. 44: Chain stripper self 1

2 5 Bucyrus DBT Europe GmbH, Lünen 2008

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4

3

1 chain stripper 2 stripper plate 3 hex. screw M 24x70-8.8

5.12

4 collar nut M 24 5 protective plug

BSL PF 4/1132

When faults occur When faults occur Identifying the cause of faults In the event of faults, you can use these tables to determine the possible causes and take remedial action. Should you not find the cause of faults, please contact our Field Service Department (see chapter 6 “Service addresses”).

Tab. 4: Fault Table, Part 1 Fault

Cause

Remedy

E-motors do not start, or start and then stop again.

1. Electrical circuit failed.

1. Check the electrical circuit.

2. Voltage failure.

2. Check the voltage.

3. Contactor failure due to overload.

3. Check the overload protection.

4. Switching sequence time less than 1.5 seconds.

4. Check switching sequence time.

1. Motors/gearboxes can not dissipate heat if they are soiled.

1. Clean motors/gearboxes and keep free of dirt.

2. Insufficient cooling water.

2. Check the cooling circuit. Are all shut-off valves open?

3. Too much or too little oil in the gearbox.

3. Check oil level in gearbox.

4. Oil is too old.

4. Carry out an oil change.

(For amount of oil and type of oil, see separate operating manual for t he gearbox)

5. Bearings damaged.

5. Have bearings repaired by specialist personnel.

Bucyrus DBT Europe GmbH, Lünen 2008

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Electric motors and/or gearboxes run too hot - temperature >85°C.

Grease-lubricated bearings run too hot 1. Too little grease in the bearings.

- temperature >85°C.

Conveyor jams and can only be moved a short distance forwards and backwards.

Conveyor chain jumps over chain sprocket.

1. Grease bearings.

2. Grease too old.

2. Clean bearings and pack with fresh grease.

3. Bearings damaged.

3. Have bearings replaced by specialist personnel.

1. Conveyor is overloaded.

1. Reduce the load on the conveyor.

2. Bottom race clogged with mine material.

2. Remove mine material from the conveyor, raise the conveyor and clean the bottom race.

3. Transfer point clogged.

3. Clear clogging at transfer point.

1. Too much slack chain.

1. Shorten and retension the conveyor chain.

2. Chain strand twisted.

2. Loosen the twisted chain strands and install again correctly.

3. Different number of links in parallel chain strands1).

3. Check chain strands for excess elongation. Chain strands with more than 2% elongation should be removed and replaced by chain strands with an odd number of left.

Replace chain strands only in pairs.

4. Twisted flights.

4. Replace any flights which are excessively twisted.

5. Insufficient pretension.

5. Adjust the pretension according to the conveyor length.

1) not applicable on single-center chain assemblies

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VAVT / 01

5.13

When faults occur Tab. 5: Fault Table, part 2 Cause

Remedy

Conveyor chain suddenly jams.

1. Foreign matter in the conveyor.

1. Remove foreign matter.

2. Flight jammed.

2. Free the jammed flight.

Chain failure.

1. The chain is blocked by foreign matter.

1. Remove foreign matter, couple the chain ends and transport to the drive end; lock conveyor chain, replace chain strands in pairs, tension the conveyor chain.

Conveyor chain jumps out of the chain assembly guide.

1. Conveyor is crooked.

1. Straighten the conveyor.

2. Too much slack chain.

2. Shorten and retension the chain assembly.

3. Pan guide worn.

3. Replace conveyor pans.

4. Flights worn.

4. Replace flights.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fault

5.14

BSL PF 4/1132

6

Technical data

Main components of the conveyor system

Technical Data This chapter contains the most important technical data for the conveyor. Further information is given in the replacement parts lists and in the separate operating manuals for the individual components such as e. g. the gearboxes and the electric motors.

Information about tightening torques, HFA fluids, greases etc. is given at the end of this chapter.

Please read this chapter carefully and at your leisure. Pay particular attention to the safety instructions.

Main components of the conveyor system Technical Data Sheet The maximum output of the conveyor system described here is 1x500 kW. No modifications may be made to the components listed unless they are inspected and approved by Bucyrus.

Bucyrus DBT Europe GmbH, Lünen 2008

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The stated ratings are continuous power ratings. They apply to E-motors with a nominal rpm of 1470 rpm. The stalling torque of 2.5 may not be exceeded when starting up the E-motors. general drive frame

pans

Noise level: . . . . . . . . . . . . . .

Tensionable drive frame: . . .

Bearing life: . . . . . . . . . . . . . .

Chain sprocket: . . . . . . . . . .

Flange plate: . . . . . . . . . . . . .

Gearbox: . . . . . . . . . . . . . . . .

Drive connection: . . . . . . . . .

E-motor: . . . . . . . . . . . . . . . . .

Adaptor pan: . . . . . . . . . . . . .

SL pans: . . . . . . . . . . . . . . . .

>85 dB(A) 1) SPR 3-1100 10 000 h 2) DKB 34 x 126, Z = 7, KA 130 SPR 3 / KP-25-30 KP-25/30; i=24.4, Bucyrus 3) EK-S300-M800/100-G800/100 250/500 kW, 1000 V, 50 Hz Breuer 3) PF 4/1132 PF 4/1132 - 1500 PF 4/1132 - 1500 MT PF 4/1132 - 750

Return unit . . . . . . . . . . . . . .

PF 4/1132

chain

Chain assembly: . . . . . . . . . .

DKB 34 x 126

accessories

Tensioning device: . . . . . . . .

Pneumatic chain tensioner Bucyrus 3)

1) 2)

3)

Doc. no.: 0010 306 600 BA 00

During certain operating phases (e. g. conveyor empty) the noise emissions may temporarily exceed 85 dB (A).

Corresponds to 90% of the calculated nominal bearing life.

Further information can be found in the separate operating manuals or replacement parts documentation from the respective manufacturer or supplier.

VAVT / 01

6.3

Identification Identification The conveyor and the individual components identification markings are listed below.

Identification marking of the conveyor Manufacturer:

Bucyrus DBT Europe GmbH

Type:

BSL PF 4/1132

Year of manufacturing:

MM/YY (e.g.: 01/08 ≙ January 2008)

ID No.:

0010 306 600 00 00

Weight:

63 300 kg

The markings on the conveyor provide the following information: Fig. 45: Example type plate and CE-marking

Bucyrus DBT Europe GmbH

01/08 Bucyrus DBT Europe GmbH, Lünen 2008

PF4/1132

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0010 306 600 00 00 63 300 kg

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

Information with respect to the components of the conveyor subject to identification marking, but not included here, is given in the respective operating manuals.

6.4

BSL PF 4/1132

Identification Identification marking of the tensionable drive frame Manufacturer:

Bucyrus DBT Europe GmbH

Type:

Tensionable drive frame SPR 3-1100

Year of manufacturing:

MM/YY (e.g.: 01/08 ≙ January 2008)

ID. No.:

5322 115 040 00 xx

Weight:

7 700 kg

The markings on the tensionable drive frame provide the following information: Fig. 46: Example of name plate and CE-marking

Bucyrus DBT Europe GmbH

01/08 5322 115 040 00 XX 7 700 kg

Bucyrus DBT Europe GmbH, Lünen 2008

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SPR 3-1000

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

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6.5

Tightening torques Tightening torques Screws with ISO metric thread Tab. 6: Tightening torques at µtotal = 0.14 Thread 1)

Tightening torque 4)

Pitch P

(mm)

(mm)

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

E

Coarse thread

Bucyrus DBT Europe GmbH, Lünen 2008

d

Important!

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

1) 2) 3) 4)

6.6

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

According to works standard (EWN 6110, February 1985 edition).

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

The tightening torques comply with the works standard (EWN 6003).

BSL PF 4/1132

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Use only hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

In general, for operating hydraulic components from Bucyrus, only such hydraulic fluids are allowed to be used for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

Bucyrus DBT Europe GmbH, Lünen 2008

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If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies, e. g. to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit will be issued by Bucyrus on request.

Suitability test Before the certificate of Bucyrus is issued for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

The suitability test will be carried out by an independent testing institute authorized by Bucyrus. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

In addition if required a chemical “fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive the respective Bucyrus certificate.

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VAVT / 01

6.7

Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate will no longer be valid if one or several of the requirements for obtaining the certificate are no longer fulfilled. This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 47: Typical certificate

6.8

BSL PF 4/1132

Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

These properties include: temperature, foaming, pH value, concentrate ratio and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– target value: 7.5 to 9.5, J concentrate ratio

– target value: see certificate, Bucyrus DBT Europe GmbH, Lünen 2008

E

J microbial load

– target value: ≤ 105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible highest temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used to make the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid.

Accordingly, the requirements for monitoring the water quality are very high.

The following table 7 lists limit values for the essential properties and components of the water.

If the limits shown are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will also lead to the loss of the certificate, even if they are within the limit values mentioned.

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VAVT / 01

6.9

Permissible media Tab. 7: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

No peculiarities permissible, e.g.turbidity, bad odor, etc.

Electrical conductivity

< 1800 µS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

< 750 mg/l CaCO3 equivalent (≤ 42° dH)

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe content

≤

1 mg/l

bacteriological requirements

≤

105 col/ml

ratio of solid foreign matter at 1.2 µm - filtering ≤ in conformity with DIN EN 12662 Contamination class according to ISO 4406: 1999

10 mg/l

-/18/14

Lubricating greases properties

lubricating grease A1

Base:

Lithium soap

NLGI Class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presence of water:

practically non-soluble in water

Temperature of application:

-20 to +120°C

Flash point :

≧ 200°C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *)7068).

Tab. 8: Lubricating greases for general application

lubricating grease A2

Flashpoint in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load Tab. 9: Lubricating greases with additives Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

*)

6.10

Flash point in °C

Supplier

EWN = Bucyrus works standard

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

Important!

The lubricants to be used are specified in the respective chapters, e. g.: Installation, Maintenance.

E

Lubricating greases and pastes

Permissible media Important!

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

Lubricating pastes lubricating paste B3

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

Tab. 10: Lubricating pastes free of molybdenum disulfide Type

Base

Gleitmolybdän

Gleitmo 805 *)

Li

NLGI class

Flash point in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 is used in accordance with the Bucyrus standard EWN 7068:

E Bucyrus DBT Europe GmbH, Lünen 2008

Supplier

Gleitmolybdän “gleitmo 805” lubricating paste B6

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

Behavior in the presence of water: non-soluble in water Temperature of application:

-34 to +120 °C

When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B 6 in accordance with the Bucyrus works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flash point 132 °C) Important!

The instructions for mixing lubricating greases also naturally apply to the lubricating pastes.

*)

Doc. no.: 0010 306 600 BA 00

The products listed in table 8 are suitable lubricating greases for filling of adjacent cavities.

VAVT / 01

6.11

Bucyrus DBT Europe GmbH, Lünen 2008

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Permissible media

6.12

BSL PF 4/1132

7

For your information

Service addresses

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

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestrasse 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

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Tel: +44 / 11 59 51 - 2500 Fax: +44 */ 11 59 32 - 9683 E-mail: info@gb.bucyrus.com Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus DBT Europe GmbH Office Moscow Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: Fax: Email:

+7 / 49 56 23 - 5396 +7 / 49 59 24 - 8363 viktor.sobolev@ru.bucyrus.com

OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

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VAVT / 01

7.3

Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd. Customer Service 20 Killara Close, Beresfield, New South Wales 2322

E

+61 / 24 91 4 - 7144 +61 / 24 91 4 - 7169

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

7.4

BSL PF 4/1132

Service addresses Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

E

No. 4 Gangyao Road Tangshan 063027 Hebei Province Bucyrus DBT Europe GmbH, Lünen 2008

Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

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VAVT / 01

7.5

Standards and Guidelines Standards and Guidelines Referenced national standards and guidelines Tab. 11: National standards and directives, extract

Designation

Title

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation system Plug connectors for hydraulic system Fire-resistant hydraulic fluids Maintenance and inspection for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for pins T-head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1)

1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 12: European standards and directives, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 DIN EN 1710 DIN EN 1552

Date of issue

Title EC Directive of the European Parliament and Council on the streamlining of the laws of the Member States with regard to machinery EC Directive of the European Parliament and Council on the streamlining of the laws of the Member States with regard to devices and protective systems intended for use in potentially explosive atmospheres Safety of Machinery Safety of Machinery Non-electrical equipment for potentially explosive atmospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres - Part 0: General requirements Basic and safety principles for man-machine interfaces Preparation of instructions - Structuring, content and presentation Petroleum products and bituminous materials - Determination of water - Distillation method Equipment and components intended for use in potentially explosive atmospheres in underground mines Mobile extracting machines at the face - safety requirements for shear loaders and plow systems 1)

7.6

1998-06-22

1994-03-23 2004-04 2004-04 2002-04 2004-12 2000-08 2001-11 2003-02 2006-01 2003-09

EWN = Bucyrus works standard

BSL PF 4/1132

Bucyrus DBT Europe GmbH, Lünen 2008

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

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11