CAT Bucyrus Gearbox p-45 UEL-R Operation Manual - PDF DOWNLOAD

Operating manual

Translation of the original operating manual

Gearbox P-45 UEL-R Doc. No.: 1946 034 000 BA 00

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

Translation of the original operating manual.

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

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

Bucyrus assumes no liability for direct or indirect consequences of misprints.

We reserve the right to introduce modifications obtained by technical development without previous notice!

Bucyrus Europe GmbH, Lünen 2009 E

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

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

2.3

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

2.4

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

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

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

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

2.4 2.4 2.4 2.5

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

2.6

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

3.3

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

3.3

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

3.4

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

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

Transport plan for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 3.4 3.5

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

4.3

Cooling water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installing the E-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 4.7 4.8 4.9

How to start-up the gearbox . . . . . . . . . . . . . . . . . . . . . . 4.13 Before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13

Dismantling and removing equipment . . . . . . . . . . . . . 4.16 Important instructions for dismantling . . . . . . . . . . . . . . . . .

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4.16

Contents 5. Operation Electrical control system . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Chain tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Gearbox maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Checking bolted connections . . . . . . . . . . . . . . . . . . . . . . . .

Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Maintaining the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the hydraulic system . . . . . . . . . . . . . . . . . . . . .

Replacing the gearbox bearing . . . . . . . . . . . . . . . . . . . . . . .

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

5.5 5.5 5.6 5.7 5.7 5.8 5.8

How to replace components . . . . . . . . . . . . . . . . . . . . . .

5.9

Gearbox sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 5.11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 5.13 5.14

6. Technical data Main dimensions and connections . . . . . . . . . . . . . . . .

6.3

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

6.5

Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

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

6.8

Hydraulic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slippage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 6.10 6.11

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 Hose connection for oil drainage . . . . . . . . . . . . . . . . . . . . .

6.11

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.12

Oil levels and oil quantities . . . . . . . . . . . . . . . . . . . . . . . 6.13 Oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 6.13

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 Recommended oil for gearboxes . . . . . . . . . . . . . . . . . . . . .

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

Requirements for the cooling water quality . . . . . . . . . . . . .

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

Quality of the process water . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.15 6.16 6.17 6.18 6.20 6.21

Marking of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23

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

Troubleshooting the hydraulic control . . . . . . . . . . . . . . . . .

Contents 7. For your information 7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

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

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

7.6 7.6

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

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Contents

Gearbox P-45 UEL-R

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

gearbox type

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

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

This operating manual is designed for: Gearbox P-45 UEL-R ID no.:

1946 034 000 00 00 1946 035 000 00 00

It is only permitted to be used for gearboxes of this type.

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category acc. to Atex directive

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

Bucyrus Europe GmbH, Lünen 2009

Explanation of abbreviations P-45 UEL-R Sliding clutch Overload protection Parameters, max. perm. torque 450 kNm at the output Planetary gear (double reduction)

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

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

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

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

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

This includes persons who: J are in charge of transport, J prepare the rise heading, J perform installation/removal 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.

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1.3

Before starting work Supervisory personnel who: J initiate and/or supervise the above activities.

Purpose of this operating manual efficiency

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.

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.

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 minor injuries and damage to machinery.

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

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

1.4

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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

Try to memorize the symbols and their meanings.

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Characters and symbols used

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

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

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

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

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

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

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

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

Please also read carefully and thoroughly the operating manuals of the components required for operation, e.g. electric motors, etc.

Clarify any questions before starting work.

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

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

may only be carried out by Bucyrus service engineers or by specially trained personnel of the mining company.

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2.3

Operating conditions Operating conditions Intended use The gearbox is exclusively designed and manufactured to be used as part of a drive unit to drive a conveyor or plow.

J It reduces the speed and transmits the torque of a fixed electric

motor to the drive shaft of the plow drive or of the conveyor.

J When combined with additional equipment, the gearbox can be

used to couple or clamp the plow or conveyor chain.

Permissible equipment for this is the hydraulic or pneumatic chain tensioner as a tail gate drive on the drive connection assembly of the gearbox, if the drive connection assembly has been prepared for this.

Use the gearbox only as intended.

Unauthorized use Uses not listed explicitly as intended uses are unauthorized and must not be carried out with the gearbox: J coupling or clamping the plow or conveyor chain using the plow

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

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

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

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. duc It may only be switched on again 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 shut down immediately and secured against being switched back on again if damage to the firedamp protection systems is detected.

2.4

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or conveyor drive units.

Operating conditions Prerequisites for operation Putting the gearbox into service is prohibited until the machine into which this gearbox is installed has been found to comply with the European Directive 94/9/EC and the Standard DIN EN 1710.

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

The M2 equipment/gearbox may only be operated once the safety requirements according to DIN EN 1552 have been met. These include: J systems preventing unauthorized startup, J startup warning systems, J water spraying systems, J safe lockout command systems,

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J emergency stop systems, J dust extraction systems, J noise protection, J warnings etc.

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

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

Always wear personal protective equipment. This includes wearing ear protection since the noise produced by the mining equipment conveyor is greater than 85 dB(A).

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

safety equipment

Start the mining equipment and the conveyor only when they are in a good and safe condition and all safety equipment, e.g.

EMERGENCY STOP devices, cover plates, etc. are correctly installed.

symbol plates EMERGENCY STOP

Pay attention to the plates on the gearbox itself.

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

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

lock out

Lock out the mining equipment and the conveyor during: J maintenance work, J inspection work, J repair work.

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 moving machine components, such as: J plow and conveyor chains, J flights, J spill plates, J chain sprockets.

danger of explosion

2.6

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

Gearbox P-45 UEL-R

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Observe the acoustic and optical startup warnings of the mining equipment and the conveyor.

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Maintain the signaling and lighting systems in a functional order.

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

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

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

Ensure that the transport safety devices have been correctly installed.

Secure all moving parts so that they are stationary.

Never stay 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.

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When attaching means of attachment to round components that are not equipped with lifting points, always use transport belts. Never use chains or steel cables for this purpose.

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

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

Installing and putting the conveyor into service

inclined faces

environmental acceptability

On inclined faces, secure all components by chains e.g. on the supports.

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 sound manner.

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.

Stop work on the gearbox before the mining equipment reaches your working area.

securing

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

Prior to any work, secure the mining equipment and the conveyor against unauthorized or unintentional restarting.

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2.7

Safety instructions work in the mining area

You may only carry out work in the mining area if J the roof has been secured against falling rock, J the coal face has been secured against collapsing and J the mining equipment and conveyor have been shut down and

locked out. replacing components

Before replacing defective parts, shut down the conveyor and mining equipment and lock it out.

Remove any defective components from the face immediately to avoid hindering the face crew. Moreover, this measure prevents inadvertent reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

Secure the components to be replaced against slipping on inclined faces by using chains or lifting gear, for example.

original parts

Only use spare parts which satisfy the specified technical requirements. Only original parts from Bucyrus ensure that these requirements are satisfied.

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

J the intended attachment points, J lifting tackle of adequate load-carrying capacity.

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

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

Fasten the lifting tackle only to shields that are joined to the conveyor by the relay bar. Shields that have been disconnected could tip over. 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 which penetrates the skin can cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids pose a very serious danger to health.

protective equipment - hydraulic system

Note that when dismantling protective devices that includes hydraulic components, those components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. Therefore, it is imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repair

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

pressure relief valves

2.8

Take care to ensure that pressure relief valves are always equipped with protective caps. Replace any defective protective caps without delay.

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For raising the gearbox, use only:

Safety instructions Carry out a visual inspection of all the hydraulic components at regular intervals. Check, in particular, 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 abnormally-

rigid or hard, J the outer sheathing of the hose is not damaged, J the connectors are securely inserted into the coupling 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 the hydraulic lines thoroughly before installing them.

Before removing staples to disconnect hydraulic hoses turn the hose at the connector 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. Make sure the line is depressurized.

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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.

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

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

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 hoses only with hydraulic hoses of the same or higher quality.

Observe the date of manufacture stamped on the hose fittings of the hydraulic hoses. Never use hydraulic hoses which are more than 2 years old, even if they show no visible signs of damage.

Fig. 1:

Example hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

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4 3 year 4 max. working pressure

2.9

Safety instructions Never try to hold a hydraulic hose that is thrashing about. Immediately depressurize the section in concern.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. 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 CORRECT

WRONG

J are not twisted, CORRECT

WRONG

J are not bent directly behind the connectors (distance minimum

1.5 x nominal diameter) Fig. 4:

Laying a hydraulic hose, bend CORRECT

2.10

WRONG

Gearbox P-45 UEL-R

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Installing hydraulic hoses, twisting Bucyrus Europe GmbH, Lünen 2009

Fig. 3:

Safety instructions J cannot chafe Fig. 5:

Installing hydraulic hoses, crossing CORRECT

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.

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When installing the hydraulic hoses, ensure that the movements of the conveyor will not cause them to be: Bucyrus Europe GmbH, Lünen 2009

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

Fig. 6:

Laying hydraulic hoses, connections on moving parts CORRECT

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WRONG

2.11

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Safety instructions

2.12

Gearbox P-45 UEL-R

3

Storage and transport

Storage

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

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

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

Storage Storage of the equipment Components with a temporary anticorrosion coating are protected for about six months.

avoid direct exposure to sunlight

Protect the equipment against direct exposure to sunlight. Store all electrical equipment, electronic components, spare parts made of rubber or plastic (such as seals and hoses) and hydraulic fluids only in closed rooms at 15C to 25C.

moisture and dirt

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

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corrosion protection

The connecting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs. 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 needs to be stored in a dry, well-ventilated room.

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

This inspection can be carried out by Bucyrus upon request.

natural aging

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

Important!

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

frost protection for oil cooler

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

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3.3

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

The load units are provided with suitable attachment points for transport and installation as far as technically possible.

Warning!

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

Falling components can cause serious injury and death.

Use only suitable load handling devices.

It is only permitted to transport equipment at temperatures of -21C to -40C if certain requirements for these conditions have been taken into account during the design and production of the equipment. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden 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.

frost protection for oil cooler

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

electrical and electronic components

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

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

3.4

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

freezing temperature

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Before transport

Transport Transport plan for gearbox Transport plan gearbox P-45 UEL-R

118 5

Fig. 7:

Bucyrus Europe GmbH, Lünen 2009

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1475

700

center of gravity

1

1120

2

1 1 lifting eye (load capacity = 8000 kg) 2 lifting eye (load capacity = 10000 kg)

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Weight: 5400 kg (without oil)

3.5

Bucyrus Europe GmbH, Lünen 2009

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Transport

3.6

Gearbox P-45 UEL-R

4

Installation

Installing the gearbox

Installation Installing the gearbox Caution!

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

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

Depending on the application the gearbox is mounted on the plow drive unit or the flange plate of the conveyor drive unit.

Notice!

Observe the operating manual for the conveyor and the plow drive unit (if installed).

Check all bolted connections and tightening torques between: J plow drive unit and plow flange plate or J drive frame and flange plate

Bucyrus Europe GmbH, Lünen 2009

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Important!

Make sure that the screws for fastening the gearbox to the flange plate/plow drive unit have been inserted.

Fig. 8:

Drive line - Plow (schematic diagram)

1 2 3

1 E-motor 2 drive connection 3 gearbox

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4

5

4 plow drive unit 5 drive frame

4.3

Installing the gearbox Important information for installation of the gearbox: J All transport safety devices of the drive and output shaft are to

be removed.

2

1

1 gearbox P-45 UEL-R 2 protective cover 3 hex. head screw M 24x240-8.8

5, 6

4

4 shaft protection 5 hex. head screw M 12x40-8.8 6 locking washer VSK 12

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

must be clean and free of burrs.

J Before mounting the flange, the gearing must be well greased -

lubricating paste B3 in accordance with Chapter 6, section “Recommendations for lubricating greases and pastes”.

J The gearbox must be positioned accurately on the centering

bores, connectors, and parallel keys when being installed.

J The appropriate screw dimensions must be selected, depend-

ing on the gearbox.

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

exactly opposite one another to allow them to be joined perfectly. Damage to the gearing and tilting of the gearbox must be prevented when mounting.

J After installing the gearboxes, there must be no tension

between the gearbox and the plow drive unit or between the gearbox and the drive shaft.

J The mounting bolts must be tightened to the specified tighten-

ing torque (see fig. 10).

4.4

Gearbox P-45 UEL-R

E

3

Transport safety device

Bucyrus Europe GmbH, Lünen 2009

Fig. 9:

Installing the gearbox Gearbox support The gearbox torque is supported via two pins (2) which are positioned between the gearbox and the plow drive unit or between the gearbox and the flange plate. The screw bores that are underneath are not required during installation. The tightening torque for the mounting bolts M 42 (Y) is MA = 3750 Nm. Fig. 10: Gearbox support - P-45 UEL-R Y

Y

1

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2

Y

X

1 gearbox P-45 UEL-R

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X

Y 2 pin

4.5

Installing the gearbox Cooling water supply location of the inlet and outlet lines

The cooling water ports must be mounted in accordance with the symbol plates attached to the gearbox.

The heat exchangers (1) are labeled with a “cooling water inlet” or “cooling water outlet” plate.

The heat exchanger “cooling water inlet” is equipped with a pressure relief valve (2) for protecting the entire cooling system.

The heat exchangers can be installed on the gearbox either at the left or right before the gearbox is filled with oil.

The cooling water inlet temperature may not exceed 25C. The required quantity of cooling water (see Chapter 6, Section “Technical data”) must be ensured during operation. The cooling water should continue to flow during brief operation downtimes. Install a shut-off valve upstream of the cooling water inlet, in order to interrupt the flow of water during longer operation downtimes.

pressure relief valve

The pressure relief valve (2) mounted on the cooling water inlet is set to a triggering pressure of 30 bar. The working pressure should not exceed 25 bar.

Fig. 11: Cooling water ports Bucyrus Europe GmbH, Lünen 2009

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Cooling water inlet port DN 12 insert 2

Cooling water outlet port DN 12 insert 1 heat exchanger

1 2 pressure relief valve

For additional information on the cooling water supply for the heat exchanger, see Chapter 6, “Technical data” section.

4.6

Gearbox P-45 UEL-R

Installing the gearbox Drive connection The drive connection includes all the parts between the gearbox and the electric motor. It mainly consists of the protection cover and a flexible shaft coupling.

The protection cover of the drive connection is screwed onto the gearbox.

Caution!

Blows on the motor shaft and gearbox shaft will damage the roller bearings. Therefore always use a mounting and pullingoff device for installation and removal of the coupling pieces. gearbox side of coupling

The internal toothing on the gearbox side coupling half is coated with B3 lubricating paste, according to Chapter 6, “Recommendations for greases and lubricating pastes” section, and pushed onto the gearbox drive shaft as far as it will go to the shaft collar.

This coupling half is centered on a guide ring (1) and fixed axially with a retaining ring.

The reference dimension “Z” has a tolerance of ±2 mm and includes the required axial clearance.

The following condition applies Z = X - 48 = W.

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Fig. 12: Drive connection “X”

“W”

1 “Z”

2 1 guide ring 2 gearbox 3 drive connection 4 E-motor

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3

4 “W” = dimension from motor flange to shaft collar “X” = thickness of intermediate flange “Z” = reference dimension

4.7

Installing the gearbox Installing the E-motor Notice!

It is imperative that you follow the separate operating manuals for the electric motors used.

Before installing the E-motor, pay special attention to the following information: Before the E-motor is installed, the axial clearance of the coupling must be checked. To do this, dimension “W” of the e-motor and dimension “X” of the intermediate flange must be determined (Z = X - 48 = W).

If reference dimension “Z” is smaller than dimension “W” of the E-motor, the shaft bearings of the E-motor and gearbox could become warped. This would automatically lead to motor and gearbox failure. In this case, the coupling half on the motor side must be shortened.

Example: X = 78 mm W = 38 mm Z = 78 - 48 = 30 < W = 38

Caution!

Only install E-motors with performance data (torque, speed) permissible for the conveyor system/plow system.

If you prefer to install E-motors other than those we have approved, please contact our Service Department in advance.

4.8

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

If reference dimension “Z” is larger than dimension “W” of the E-motor, a suitably thicker intermediate ring must be pushed onto the drive shaft of the E-motor to prevent the axial clearance from being too large.

E

In this case, the coupling half on the motor side must be shortened by 8 mm.

Installing the gearbox Hydraulic control system Fig. 13: Proportional control and PMC-D

a

b

7

c

15

16

6 20, 21, 23, 24 d 4 1

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15

26 29

17

1 hydraulic control 4 protective casing 6 cover plate 7 spacing piece 15 hex. head screw M 12x25-8.8 16 hex. head screw M 16x130-8.8 17 hex. head screw M 30x40-8.8 20 temperature sensor (L = 850, ½” screw connection PT 100) 21 temperature sensor mounting device

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23 sealing ring 22x27 24 sealing ring 42x49 26 distribution box UEL 29 pressure sensor a to the electrical control b to the hydraulic control c to the UEL coupling d lever position: ball valve closed

4.9

Installing the gearbox Fig. 14: Proportional control 15, 16, 18, 19 8

12

12

7

4, 19

12 z to the pressure sensor

to the coupling 8

16 9

22

1 2

9 plug 12 recess clamp DN 10 15 glycerine pressure gauge 16 connection piece R ¼” DN 10 insert 18 sealing ring 19 o-ring 10x2 22 ball valve

Fig. 15: Diagram of hydraulic control of gearbox/PMC-D DC

AC 5 B

A

d

C R (p < 2 bar)

26

30, 31

31 32 26

E F

33, 34, 39, 40

5 hydraulic control PMC-D with proportional technology 26 hose line 10x10000 1) 30 straight socket DN 10 31 recess clamp DN 10 32 HP ball valve 33 reducing T-socket DN 25/10 34 reducing T-socket DN 32/10/32

39 staple DN 32 40 recess clamp DN 25 A PMC-D B splitter C prop. station D terminal box (iVK) E distribution box (iVKG) F gearbox UEL

1) maximum length 15000 mm

4.10

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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1 bracket 2 cyl. head screw M 8x60-8.8 4 double nipple DN 10 6 T-socket DN 10 rotatable 7 plug-in T-socket DN 10 rotatable 8 plug-in elbow socket DN 10 rotatable

Installing the gearbox Fig. 16: Hydraulic control 27

31

14

15

8

28

8

30

15 18 24 1

16

26

9 4, 5

a

29

10 25

6, 7

2, 3

12 20 21

32 22 38 16

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22

11

23 raise

11

13

lower

1 control cabinet housing 2 housing lid 3 housing seal 4 main filter 5 main filter insert 6 prefilter 7 prefilter insert 8 flange pressure reducing device 9 pressure relief valve 10 prop valve plate 11 proportional valve 12 shut-off valve 13 return filter 15 pressure gauge 400 bar 16 pressure gauge 100 bar 18 terminal box

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20 trumpet shaped entry 21 feed through for gearbox 22 hose DN 10 23 hose DN 10 24 elbow union 25 check valve 26 ball valve 27 tube 28 valve plate 29 bulkhead union 30 lifting eye 31 screw-in socket SKK 21 32 cable feed-through 33 plug DN 10 a pressure sensor PT 100

4.11

Installing the gearbox Fig. 17: Hydraulic circuit diagram proportional control

6

4

A 15

14 26

8

15

33 16

11

12

B

9

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E

13 16

25 P

R

A

C d

4 main filter 6 prefilter 8 flange pressure reducing device 9 pressure relief valve 11 proportional valve 12 shut-off valve 13 return filter 15 pressure gauge

16 pressure gauge 100 bar 25 check valve 26 ball valve A valve plate 1 B valve plate 2 C gearbox D face hydraulic system 1) E prop valve

Important!

Observe the separate operating manual of the electrical control used (PMC-D).

1) face hydraulic system: p = 100 - 300 bar

4.12

Gearbox P-45 UEL-R

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

Caution!

It is imperative that you observe the respective information on startup in the separate operating manuals on the entire conveyor system. Serious damage to the machine resulting in high costs can result from errors made during start up.

Carefully read all operating manuals for the conveyor system.

Before startup before startup

The following work has to be performed on the gearbox before beginning with the actual start-up: J Check the oil

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

The gearbox is delivered without oil.

Bucyrus Europe GmbH, Lünen 2009

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Caution!

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

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

The oil is filled into the gearbox from above (a).

Fig. 18: Oil filling screw a Cross-section C–D

b

a 8 screw plug M 42x1.5-5.8 12 sealing ring A 42x49 26 dipstick 31 valve screw

38 screw plug M 30x1.5-5.8 39 sealing ring A 30x36 a oil filling screw b oil drain plug 1)

1) positioned below, can be installed either on the right or left

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4.13

How to start-up the gearbox J Venting the UEL coupling cylinder

The coupling cylinder must be vented every time the gearbox is reinstalled.

The ball valve (2) must be open.

Pressure gauge (3) must display the pressure specified in table 1.

If no pressure is present, check if the hydraulic control is in operation.

. Check whether the ball valve (2) is open. The ball valve is located below the cover plate (6).

. Open the screw plug (49) until air can flow out. . The screw plug should remain open until hydraulic fluid escapes.

. Then tighten the screw plug (49) again.

Fig. 19: Venting the coupling cylinder For UEL coupling

Bucyrus Europe GmbH, Lünen 2009

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For hydr. control

Z I

3

2 II

I = open II = closed

1 hydraulic control 2 ball valve 3 pressure gauge 4 protective casing 6 cover plate 7 spacing piece 16 hex. head screw M 16x180-8.8 29 pressure gauge 49 screw plug G 1/2 50 sealing ring A 22x27

The UEL coupling cylinder is now vented and ready for operation.

4.14

Gearbox P-45 UEL-R

How to start-up the gearbox J Applying pressure to the UEL coupling

For safely transferring the torque, a defined pressure must be applied to the UEL coupling. The amount of pressure depends on the gearbox ratio.

Tab. 1: Nominal pressure - UEL coupling

Nominal pressure in bar

Ratio

Ratio

I = 16

I = 24.4

20 3

35 3

The required pressure is built up using the hydraulic proportional control.

The optical control is done via the pressure gauge (3).

Fig. 20: Ball valve I

3

2

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II

29

2 ball valve 3 pressure gauge 29 pressure sensor

I open II closed

Note that the clutch pressure is controlled via the hydraulic proportional control during operation. In this operating state, the ball valve must be open.

Caution!

The ball valve must only be closed while tensioning the chain (see Chapter 5, section “Chain tensioning” or Chapter 6, section “Hydraulic control”).

Check the gearbox

. Check that the gearbox is fitted with a breather plug.

The breather plug is located below the protective plate of the hydraulic control. It can be screwed in either at the left or the right (see fig. 28 in the section “Main dimensions and connection dimensions”. water connection electr. control

. Check the installation of the water connections. . Check whether the outputs of the gearbox electronics are connected with the factory's electrical control. Check whether the system is switched on and is working perfectly.

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4.15

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

Important instructions for dismantling Be especially careful handling sensitive machine parts.

J Hydraulic components and lines must be depressurized before

removing.

The hydraulic pressure in the gearbox circuit can be released by opening the ball valve (see page 4.15, “Applying pressure to the UEL coupling”).

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

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

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

tion points with protective caps or plugs.

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

Bucyrus Europe GmbH, Lünen 2009

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ized containers and protected from contamination and damage.

4.16

Gearbox P-45 UEL-R

5

Operation

Electrical control system

Operation Warning!

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

Check the gearbox temperature and wait until the temperature has fallen to at least 60C. Observe the symbol plates on the gearbox.

The gearbox temperature can be read off the electrical control.

Electrical control system The gearbox is controled and monitored by sensors. An electrical control (PMC-D) is used to do this. The PMC-D must be programmed with the parameters required for controling and monitoring.

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Important!

Please refer to the separate operating manual of the electrical control used for operation and parameter entry.

Chain tensioning The chain can be tensioned via the UEL gearbox using a hydraulic or pneumatic chain tensioner.

To tension the chain using a chain tensioner, a higher pressure must be applied to the UEL coupling than the preset nominal pressure. The coupling could slip when the pressure is too low.

Increase the pressure on the UEL coupling to 65 bar before the tensioning procedure.

The required pressure is built up using the hydraulic proportional control (see page 4.15, “Applying pressure to the UEL coupling”).

Monitoring is carried out via the pressure gauge (3).

Fig. 21: Ball valve I

3

2 II

29

2 ball valve 3 pressure gauge 29 pressure sensor

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I open II closed

5.3

Chain tensioning Observe that during the tensioning procedure, the ball valve must be closed.

Danger!

The chain relaxes due to a sudden pressure drop and springs back.

This could seriously injure or kill you.

Never open the ball valve of the hydraulic system while you're tensioning the chain. Check regulary whether there is sufficient pressure on the pressure gauge.

. Apply pressure to the UEL coupling via the proportional control until the required pressure of 65 bar has been reached.

. Then close the ball valve (Fig. 21, Item 2). . Tension the chain with the chain tensioner.

5.4

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

After the tensioning procedure, the ball valve must be opened again so that the UEL coupling can be set to the required nominal operating pressure (see page 4.15, “Applying pressure to the UEL coupling”).

E

Important!

It is imperative that you observe the operating manual of the hydraulic or pneumatic chain tensioner used.

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

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

Maintenance includes: J checking the functions, J checking bolted connections, J checking the oil level, J changing the oil, J maintaining the filter, J maintaining the hydraulic system, J replacing the gearbox bearing, J cleaning the gearbox casing.

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Use only suitable tools for maintenance work.

Important!

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

Checking bolted connections tightening torque

For bolted connections, the tightening torques of which are not listed in the corresponding operating manual or spare parts list, the tightening torques according to EWN 6003 apply (list in Chapter “Technical data”).

retightening screws

The bolted connections listed below must be retightened 60 hours after putting into operation for the first time and every 500 hours after that: J drive connection (motor and gearbox side), J gearbox (attachment on the plow drive unit).

Check the oil level The oil level must be checked on a weekly basis (see Chapter 6, section “Oil levels and oil quantities”). Make sure no foreign matter enters the inside of the gearbox when you do this.

Insufficient oil impairs lubrication of the gears and roller bearings.

Too much oil results in large churning losses, foaming, and increased heat generation.

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5.5

Gearbox maintenance Changing the oil Notice!

Gearboxes with UEL-R technology may only be operated with the oil types listed in the “Oil recommendations for gearboxes” section.

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

Notice!

Vent the gearbox before undoing the oil drain plug. The breather plug must be removed before the gearbox can be vented.

Make sure that no foreign matter enters the gearbox.

Bucyrus Europe GmbH, Lünen 2009

Important!

The oil must be changed when the gearbox is at operating temperature (40 - 60C), as the warm thin oil can wash the oil sludge away effectively.

Fig. 22: Oil drainage using valve screw 1

2 3

4

1 valve screw 2 sealing ring A30x36 DIN 7603-Cu

3 screw plug M30x1.5 4 hose connection (accessory)

Notice!

When filling the gearbox, observe the information contained in Chapter 6 regarding oil quantities and oil level mark lines (see page 6.14).

5.6

E

The location of the oil drain plug is illustrated in Chapter 6, section “Main dimensions”.

Gearbox P-45 UEL-R

Gearbox maintenance An early oil change is required if: J the level of contamination has reached the value of 0.1% for-

eign particles, J the water content has exceeded the value of 0.5%, J the aging resistance of mineral oil has diminished to

the level that the increase in the acid number value ANUsed oil - ANFresh oil =  AN has exceeded the value  AN = 2.0 mg KOH/g oil.

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

Maintaining the filter Checking the breather plug

Bucyrus Europe GmbH, Lünen 2009

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Check the breather plug is functioning properly on a weekly basis, and replace if necessary (see section “Troubleshooting”).

Maintaining the hydraulic system Daily maintenance J Check that all connectors are firmly in place and retighten them

where necessary.

J Replace all leaking components such as cylinders, controls,

hose lines, plug-in connection fittings, etc. without delay.

Notice!

Close off all open ports immediately with protective plugs, to protect them from damage and to prevent contaminants from entering.

J Make sure the connecting and securing devices are in perfect

working condition.

J Replace damaged components.

J Replace missing components.

J Check and maintain the pump station according to the associ-

ated operating manual.

Caution!

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

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5.7

Gearbox maintenance Replacing the gearbox bearing Pay attention to unusual gearbox noises because they often indicate damage to bearings. Defective bearings can lead to serious damage to the gearbox and to overheating of the gearbox.

The bearings must be replaced as soon as they have reached their maximum service life. Bearing service life data is listed in Chapter 6 “Technical data”. Forward the gearbox to servicing.

After completing a panel and moving to a new panel, the remaining service life of the bearings must be sufficient for the runtime in the new panel. Should this not be the case the bearings must be replaced. acoustic emission monitoring

For early detection of bearing damage, continuous acoustic emission monitoring can be used. The gearbox is prepared for the use of monitoring units of this kind.

Cleaning the gearbox casing

Bucyrus Europe GmbH, Lünen 2009

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

Therefore clear dust and other deposits from the casing daily.

5.8

Gearbox P-45 UEL-R

How to replace components How to replace components Gearbox sensors The gearbox sensors can be exchanged as needed.

Bucyrus Europe GmbH, Lünen 2009

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Fig. 23: Gearbox sensors to the electrical control

4 protective casing 6 cover plate

15 hex. head screw M 12x25-8.8 16 hex. head screw M 16x130-8.8

7 spacing piece 10 cover 11 support

26 terminal box 27 slippage sensor 34 plow path sensor

Replacing the slippage sensor

. Stop the system, by switching the E-motors off and disconnecting the power supply.

Important!

Observe the separate operating manuals for the conveyor and the E-motors.

. Remove the cover plate (Fig. 23, Item 6). . Open the cover of the terminal box (Fig. 23, Item 26) and disconnect the cable.

. Remove the cover (Fig. 24, Item 1) of the speed sensor. . Remove the support (Fig. 24, Item 2) together with the sensors. . Insert the new sensor. . Connect the sensor cable according to the circuit diagram (see Chapter 6, section “Circuit diagram”).

. Reinstall the cover (Fig. 24, Item 1) and the cover plate (Fig. 23, Item 6).

. Operate the system in inspection mode to check the slippage sensor.

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5.9

How to replace components . Start up the gearbox with the coupling depressurized.

Important!

For exact details regarding this procedure, refer to the separate PMC®-D UEL gearbox control system operating manual.

Fig. 24: Slippage sensor 6 16

2

1

14

14

8 10

11

10 O-ring 11 spring dowel pin

6 cyl. head screw M 12x25-8.8

14 proximity switches

8 cyl. head screw M 12x40-8.8

16 screwed cable gland

Exchanging the plow path sensor

. Stop the system, by switching the E-motors off and disconnecting the power supply.

Important!

Observe the separate operating manuals for the conveyor and the E-motors.

. Remove the cover plate (Fig. 23, Item 10). . Open the cover of the terminal box (Fig. 23, Item 26) and disconnect the cable.

. Remove the cover (Fig. 25, Item 1) of the plow path sensor. . Remove the support (Fig. 25, Item 2) together with the sensors. . Insert the new sensor. . Connect the sensor cable according to the circuit diagram (see Chapter 6, section "Circuit diagram").

. Reinstall the cover (Fig. 25, Item 1) and the cover plate (Fig. 23, Item 10).

. Operate the system in inspection mode to check the plow path sensor.

. Start up the gearbox with the coupling pressurized.

Important!

For exact details regarding this procedure, refer to the separate PMC®-D UEL gearbox control system operating manual.

5.10

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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1 cover 2 support

How to replace components Fig. 25: Plow path sensor 16

6

1

2

14

14 10 11

8

1 cover 2 support 6 cyl. head screw M 12x25-8.8 8 cyl. head screw M 12x40-8.8

10 O-ring 11 spring dowel pin 14 proximity switches 16 screwed cable gland

Heat exchanger

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The heat exchanger consists of an upper and a lower pipe cooler.

The two coolers are connected by an exterior hose line. In the event of damage to the cooling system, both coolers can be exchanged underground. The heat exchanger can either be installed on the right or left.

Exchanging the heat exchanger

. Drain the gear oil (see section “Changing the oil”, page 5.6).

Warning!

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

Check the gearbox temperature and wait until the temperature has fallen to at least 60C. Observe the symbol plates on the gearbox.

The gearbox temperature can be read off the electrical control.

. Stop the water feed and remove the water feed and connection lines.

. Undo the mounting bolts (Fig. 26, Item 8). . Pull the cooler out of the housing. . Remove the cover (Fig. 26, Item 4). . Remove the new heat exchanger from the transport safety device and insert it in the housing.

. Fasten the cover (Fig. 26, Item 4).

Notice!

Observe the direction of flow of the heat exchanger. The cooling water inlet must always be mounted on top.

. Reconnect the water feed and connection lines. . Check the heat exchanger for leaks using a pressure gauge.

The test pressure is 40 bar.

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5.11

How to replace components The pressure relief valve may not be connected during pressure testing. During installation leave the screw plug supplied in the heat exchanger.

. Replace the screw plug with the pressure relief valve (6).

The set pressure must be 30 bar.

. Fill up the gear oil.

Notice!

Gearboxes with UEL-R technology may only be operated with the oil types listed in the “Oil recommendations for gearboxes” section. When filling the gearbox, observe the information contained in Chapter 6 regarding oil quantities and oil level mark lines (see page 6.14).

Fig. 26: Heat exchanger a

View X

Direction of flow of the cooling water

a

View Y

Bucyrus Europe GmbH, Lünen 2009

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13, 14

25

18

13, 14

8

4 b

b Cross-section A-A

Cross-section B-B

9, 12, 21 6

11, 20, 21 10, 11

14, 15, 16

10, 11

14

11, 20, 21 2, 30

9, 12, 21

2, 30

1 heat exchanger 2 reducing piece 4 cover 6 pressure relief valve 30 bar 8 hex. head screw M 16x40-8.8 9 fitting connection G 3/4 DN 12 10 screw plug G 3/4 11 sealing ring A 27x32 12 plug DN 12 13 screw plug M 42x1.5-5.8

5.12

1

14 sealing ring A 42x49 15 screw plug G 1-5.8 16 sealing ring A 33x39 18 O-ring 100x3 20 screw-in socket G 3/4 DN 12 rotatable 21 recess clamp DN 12 25 hose line 12x600 a cooling water inlet DN 12 insert b cooling water outlet DN 12 insert

Gearbox P-45 UEL-R

Troubleshooting Troubleshooting Gearbox troubleshooting J Gearbox temperature too high

. Check the oil cooling.

The amount of water required for cooling is approx. 20 liters per minute.

Important!

The cooling water must not be hotter than 25C when it enters the system.

. Remove accumulations of fine coal from the surface of the gearbox (also from the sides and from below).

Fine coal on the gearbox casing acts as an insulating layer that prevents heat dissipation.

. Check the oil level (see oil level mark lines, page 6.14).

Bucyrus Europe GmbH, Lünen 2009

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If the oil level is too low, the lubrication of the roller bearings and gearwheels can be adversely affected, which can contribute to increases in heat development.

If the oil level is too high, it will result in heat-generating churning losses and to foaming of the gear oil. Foam hinders heat dissipation.

. Check the gearbox for overloading.

Continual overloading of the gearboxes leads to higher gearbox temperatures. Monitor the current consumption of the E-motors to establish any overloading.

J The gearbox is losing oil

. Check the gearbox connection surfaces and the lid for leaks.

Tighten the casing screws, lid screws and oil drain plugs.

Important!

Remove oil that has already escaped, to help you to see where the leak is or if there is no leak at the connection.

. Remove the breather plug at operating temperature.

If air escapes, the breather plug is defective and has to be replaced.

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

Notice!

If in doubt, always install a new breather plug. Do not try to clean the breather plug.

. Check the installation position of the breather plug.

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

Doc. no.: 1946 034 000 BA 00

VIVI / 02

5.13

Troubleshooting Troubleshooting the hydraulic control It is not possible: J to build up pressure, J to maintain pressure.

Possible reasons J The ball valve of the hydraulics is closed.

. Open the ball valve (See Chapter 4, section “Venting the UEL coupling cylinder”).

J The screw plug for venting the coupling cylinder is not screwed

in tight enough (see Chapter 4, section “Venting the UEL coupling cylinder“).

. Tighten the venting screw.

J An increasing amount of hydraulic fluid is escaping at the leak-

age oil drain of the UEL coupling (see Chapter 6, page 6.4)

Bucyrus Europe GmbH, Lünen 2009

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– The cylinder seal on the UEL coupling is leaking.

5.14

Gearbox P-45 UEL-R

6

Technical data

Main dimensions and connections

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

Main dimensions and connections Fig. 27: Gearbox P-45 UEL-R, connection dimensions

Bucyrus Europe GmbH, Lünen 2009

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deep

W 120x4x30x28x8f DIN 5480

Toothed hub DIN 5480 N 260x10x30x24

Doc. no.: 1946 034 000 BA 00

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6.3

Main dimensions and connections Fig. 28: Gearbox P-45 UEL-R - Connections 2

25

b

26 e

a

f

a

c

E

g

H

I

Cross-section C-D

31, 38, 39

Oil drain for hose connection (mounted at bottom)

55, 56

23 2 control system and lines 23 magnetic rod 25 breather plug 26 dipstick 685 lg 31 valve screw 38 screw plug M 30x1.5-5.8 55 hose line 10x1400 St/St

6.4

56 fitting connection hydraulic UEL supply (DN 10 insert) a oil filling screw b cooling water outlet (DN 12 insert) c cooling water outlet (DN 12 insert) d oil drain plug

e oil temperature sensor f UEL ventilation g disk temperature sensor h dipstick i leakage oil drain

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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Technical data sheet Technical data sheet Version characteristics The gearboxes are intended to be installed on plow drive units and drive frames with separate bearing-supported shafts. general

Output shaft: . . . . . . . . . . . . . . . .

Motor gearbox connection: . . . .

Weight (without oil): . . . . . . . . . .

Volume of the gearbox interior: . . . . . . . . . . . . .

Oil temperature at rated power

Bucyrus Europe GmbH, Lünen 2009

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power and torque

water cooling (water cooler installed)

Permissible continuous input power max. at n1 = 1800 rpm: . . . . . . .

Permissible continuous input power max. at n1 = 1500 rpm: . . . . . . . max. permissible output torque: . . . . . . . . . . . . . . . max. permissible drive speed: Bearing service life (continuous operation at rated power): . . . . . . . . . . . . . . . . . . .

Quantity of cooling water Q approx.: . . . . . . . . . . . . . . . . . .

Cooling water inlet temperature: max. cooling water dirt particle size: . . . . . . . . . . . . . .

Cooling water quality: . . . . . .

Pressure relief valve: . . . . . . .

Cooling water inlet and outlet port: . . . . . . . . . . . . . . . .

Gearing piece N 260x10x30x24 DIN 5480 flexible shaft coupling G = 5100 kg Q = 550 l T = 60C

PAN = 930 kW1) PAN = 800 kW1) T2max = 450000 Nm n1 max= 1800 rpm 13500 h 2)

20 l/min Tmax = 25C3) 0.25 mm3) pH = 73) pü = 30 bar DN 12 insert

sensor parameters

Temperature sensor max. oil temperature: . . . . . . . . .

Pressure sensor: . . . . . . . . . . . .

Plow path sensor: . . . . . . . . . . .

Slippage sensor: . . . . . . . . . . . .

Tmax = 85C pnominal = 20 bar pmin = 17 bar pmax = 23 bar per output shaft revolution 24 pulses per proximity switch for i = 16 Frequency of the inductive proximity switches f = 25 Hz at n1 = 1500 rpm, slippage t = 2 s, then motor switch-off

1) Applies to ratios i = 16 and i = 24.4 2) Corresponds to 90% of the calculated nominal bearing life.

3) also see section “Requirements for the cooling water quality”

Doc. no.: 1946 034 000 BA 00

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6.5

Performance data Performance data Fig. 29: Continuous power and continuous torque at n1 = 1,480 rpm; 50 Hz 800

500 3000

2000 16 21 28 33 39 Nominal ratio i

50

Fig. 30: Continuous power and continuous torque at n1 = 1,780 rpm; 60 Hz 1250

1125

4000

3500 800 3000

2500

Permissible continuous input power at n1 = 1780 rpm P [kW]

Rated continuous input torque T1 [Nm]

5000

2000

28 33 39

50

Nominal ratio i

6.6

Gearbox P-45 UEL-R

E

4000

Bucyrus Europe GmbH, Lünen 2009

700

Rated continuous input power at n1 = 1480 rpm P [kW]

Rated continuous input torque T1 [Nm]

5000

Performance data Tab. 2: Performance data at n1 = 1,480 rpm; 50 Hz Nominal ratio

inom

Drive speed n1 = 1,480 rpm Continuous input power P [kW]

Ratio

Continuous input torque

Output speed

T1 [Nm]

Actual ratio I

Input stage

Output stage

n2 [rpm]

iactual

iinput

ioutput

16

92.2

16.055

4.250

3.77

24.4

60.1

24.624

4.560

52.6

28.137

5.211

44.3

33.353

6.176

28

800

5200

33 39

625

4000

37.6

39.343

7.286

45

540

3500

33.0

44.862

8.308

50

500

3200

29.7

49.846

9.231

5.40

Tab. 3: Performance data at n1 = 1,780 rpm; 60 Hz Nominal ratio

inom

Drive speed n1 = 1,780 rpm Continuous input power P [kW] P [HP]

Continuous input torque

E

Input stage

Output stage

iactual

iinput

ioutput

111

16.055

4.250

3.77

24.4

72.3

24.624

4.560

63.3

28.137

5.211

53.3

33.353

6.176

1250

5000

3600

33

Bucyrus Europe GmbH, Lünen 2009

Actual ratio I

n2 [rpm]

930

T1 [ft.lbs]

Output speed

16 28

T1 [Nm]

Ratio

39

840

1125

4500

3240

45.3

39.343

7.286

45

650

870

3500

2500

39.7

44.862

8.308

50

600

800

3200

2300

35.7

49.846

9.231

Doc. no.: 1946 034 000 BA 00

VIVI / 02

5.40

6.7

Technical description Technical description The gearbox P-45 UEL-R is a two-stage gearbox with planetary input stage and planetary output stage. The ratio is changed by changing the planetary input stage. design

The design of the gearbox is similar to that of a conventional planetary gearbox. The UEL-R gearbox differs in its design of the planetary output stage. The internal gear of the planetary stage is not a component of the housing, but is designed to be rotatable and is more or less held via the installed UEL coupling. If an overload occurs, the UEL coupling slips through with the internal gear and switches off the drive units via the installed slippage monitoring system.

The output shaft is sealed with a maintenance-free, highly wearresistant face seal. The internal toothing of the output shaft N 260x10x30x24 DIN 5480 can be exchanged from the outside in the event of wear.

lubrication

The planetary gear P-45 UEL-R is suitable for installation on plow drive units or on drive frames with bearing-supported shafts.

The gearing and roller bearings are lubricated by means of splash lubrication. The oil chamber is equipped with a dipstick, a breather plug and a magnetic rod.

The oil level depends on the installation position of the gearbox and is determined using the oil level sign fastened to the outside of the gearbox and checked with the dipstick (see “Oil levels and oil quantities” section). The gearbox interior is ventilated with a breather plug.

water cooling

6.8

The gearbox is equipped with heat exchangers which can be exchanged from the outside. The heat exchangers are protected against overpressure with a pressure relief valve set to 30 bar.

chain tensioning

To tension the chain, the drive connection of the planetary gearbox can be equipped with a chain tensioner.

plow path sensor

To measure the plow path, two inductive proximity switches (NAMUR) are installed, which are actuated via gearing on the planet carrier (output shaft). They are aligned so that they detect both the plow path as well as the plow direction.

slippage sensor

The slippage is measured via two redundantly arranged inductive proximity switches (NAMUR).

temperature sensor

The oil sump temperature is monitored with a temperature sensor (PT 100) which is located in the oil sump near the UEL coupling.

pressure sensor

The current clutch pressure is checked using a pressure sensor.

exchanging sensors

All sensors can be exchanged from the outside without having to change the oil level.

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

use

E

The permissible continuous input power varies according to the gearbox ratio P = 800 kW at a drive speed n1 = 1,480 rpm or P = 930 kW at n1 = 1,780 rpm. The maximum rated torque on the output shaft is 450,000 Nm.

Technical description Hydraulic control system Hydraulic circuit diagram UEL-R Ventilation coupling

The gearbox is equipped with a disk coupling as overload protection. The disk coupling is closed hydraulically and holds the internal gear of the planetary output stage.

In the event of an overload, the clutch slips through and the internal gear moves. Cam switches are mounted to the internal gear, above which there are two redundantly switched inductive proximity switches which act as slippage sensors (see section “Slippage monitoring”). If slippage is detected, they switch the motors off.

This keeps peak loads away from the drive unit.

Operating medium: HFA

To safely transfer a specified gearbox torque, a defined pressure is applied to the coupling using an external hydraulic proportional control.

The pressure is adjusted to the operating conditions via an electronic control unit (PMC-D). It depends on the size of the gearbox, the ratio, the chain size, the number of teeth on the chain sprocket and the drive motors.

A pressure gauge indicates the current clutch pressure.

When tensioning the chain, this pressure must be set to 65 bar.

While the chain is tensioned, the block ball valve must be closed (see Chapter 4, section “Venting the UEL coupling cylinder”).

After tensioning, the block ball valve is to be opened again.

The applied clutch pressure is registered via a pressure sensor and is forwarded to the PMC-D.

design

The hydraulic control mainly consists of an external electronic system pressure monitor, a pressure gauge for visually checking the applied clutch pressure, and a block ball valve which must be actuated to tension the chain.

pressure coupling

The gearbox is ready for operation when pressure has been applied to the cylinder chamber of the UEL coupling. This pressure is read in by the control unit.

Bucyrus Europe GmbH, Lünen 2009

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chain tensioning

Pressure fluctuations are system-specific and due to temperature differences in the oil and the components.

If the pressure in the cylinder of the UEL coupling is too low, the motors cannot be switched on. If the pressure drops during operation, the motors are switched off.

Doc. no.: 1946 034 000 BA 00

VIVI / 02

6.9

Technical description Fig. 31: Proportional control and PMC-D

a

b

7

c

15

16

6 20, 21, 23, 24 d 4 1

26 29

17

1 hydraulic control system 4 protective casing 6 cover plate 7 spacing piece 15 hex. head screw M 12x25-8.8 16 hex head screw M 16x130-8.8 17 hex. head screw M 30x40-8.8 20 temperature sensor (L = 850, ½” screw connection PT 100) 21 temperature sensor mounting device

23 sealing ring 22x27 24 sealing ring 42x49 26 distribution box UEL 29 pressure sensor a to the electrical control b to the hydraulic control c to the UEL coupling d lever position: ball valve closed

Slippage monitoring Slippage monitoring diagram

1 2

1 proximity switches 2 switching ring

6.10

The slippage monitoring system consists of two inductive proximity switches and a switching ring. As long as the overload coupling doesn't respond, the switching ring stands. The proximity switches are arranged geometrically so that if one of the proximity switches is in an edge position (changing signal), the other proximity switch is damped by a tooth of the switching ring or is undamped by a tooth gap, so that a constant signal is delivered to the electronics (redundant arrangement).

Only when both proximity switches deliver a changing signal (overload - coupling slips through) are the drive motors switched off.

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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15

Accessories Circuit diagram

Plow path

Fig. 32: Gearbox circuit diagram blue

white

blue

brown

blue

green

blue

yellow

black brown gray

gray

Pt 100 gearbox

orange

Pt 100 coupling

white white brown brown

black

yellow

purple

white

blue

brown

red

NAMUR

Slippage

NAMUR

NAMUR

NAMUR

Pt 100

pink

transparent

brown E

brown Bucyrus Europe GmbH, Lünen 2009

brown

Accessories Hose connection for oil drainage Fig. 33: Hose connection

1

Wrench size 41 2

Doc. no.: 1946 034 000 BA 00

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1 hose connection 2 sealing ring

6.11

Tightening torques Tightening torques Screws with ISO metric thread Tab. 4: Tightening torques at tot. = 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

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1,100

490

654

-

1,100

-

M 24

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1,360

1,630

-

1,600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1,310

1,845

2,215

-

1,450

-

M 30 3)

2

(M 33)

3.5

1,780

2,500

3,000

M 36

4

2,290

3,220

3,860

(M 39)

4

2,970

4,170

5,000

M 42

4.5

3,670

5,160

6,190

(M 45)

4.5

4,590

6,450

7,740

M 48

5

5,540

7,790

9,350

E

Coarse thread

Bucyrus Europe GmbH, Lünen 2009

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Important!

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

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

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

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

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

6.12

Gearbox P-45 UEL-R

Oil levels and oil quantities Oil levels and oil quantities Oil levels The required oil level varies depending on the incline on which the gearbox is positioned. A sign on the gearbox indicates the required oil level mark line for the respective tilt (see fig. “Oil level markings” for the oil level markings required).

See “Technical data - Main dimensions” for the location of the dipstick.

Dipstick There are markings on the dipstick every 1 cm that are numbered from 100 to 0, based on a reference edge of 100 (sealing surface dipstick).

The dipstick is inserted into the dipstick hole vertically and screwed in. The minimum oil level must not be more than one mark line below the required oil level mark line.

Fig. 34: Dipstick 685 long

1 cm

Bucyrus Europe GmbH, Lünen 2009

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Reference edge 100

Doc. no.: 1946 034 000 BA 00

VIVI / 02

6.13

Oil levels and oil quantities

Fig. 35: Oil level mark lines 1)

0°

Output shaft low 5° 10° 15°

Dipstick low

15°

71

67

63

58

60

62

64

10°

67

63

59

54

56

58

60

5°

64

60

56

51 53 55

57

0°

61

57

53 48

50

52

54

5°

58

54

50 45 47

49

51

10°

55

51

47 42

44

46

48

15° 51

47

43 38

40

42

44

Dipstick high

Bucyrus Europe GmbH, Lünen 2009

Output shaft high 15° 10° 5°

View of the drive shaft

E

Inclination in mining direction

Inclination in conveying direction

Fig. 36: Oil levels Inclination in mining direction Inclination in conveying direction Output shaft high 15° 10° 5°

View of the drive shaft Dipstick low

0°

Output shaft low 5° 10° 15°

15°

10° 5° 0° Dipstick high

250

5° 10°

15°

1) The values apply to a screwed-in dipstick. The permissible deviation is ±1 mark line.

6.14

Gearbox P-45 UEL-R

Permissible media Caution!

The oil quantities are indicative values.

The oil level mark lines must always be adhered to.

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

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

gear oils on synthetic basis

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

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

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

gear oil table

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

Bucyrus Europe GmbH, Lünen 2009

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changing the type of oil

Tab. 5: Oil types for gearboxes Manufacturer

ARAL

BP

ESSO

KLÜBER

MOBIL

SHELL

TEXACO

WINTERSHALL

Gear oils on mineral oil basis

Kinematic viscosity mm2/s (CST)

Flashpoint

at 40_C

_C

Aral Degol BG 220

220

265

Aral Degol TU 220

220

255

BP Energol GR-XP 220

218

240

BP Energol GR-XP 320

315

245

SPARTAN EP 220

210

236

SPARTAN EP 320

300

237

Klüberoil GEM 1-220

220

> 200

Klüberoil GEM 1-320

320

> 200

Mobilgear 630

206

>232

Mobilgear 632

302

>232

Shell Omala 220

220

240

Shell Omala 320

320

245

Universal gear lubricant EP SAE 85 W/90

195

225

Meropa 220

220

245

Ersolan 220 Ersolan 320

220 320

240 245

Doc. no.: 1946 034 000 BA 00

VIVI / 02

Gear oils on synthetic basis

Kinematic viscosity mm2/s (CST)

Flashpoint

At 40_C

_C

Aral Degol GS 220

230

215

BP Energol SG-XP 220

240

250

Klübersynth GH 6-220

220

>300

MOBIL SHC 632

300

250

Shell Tivela Oil WB

234

320

6.15

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

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

In addition, the “specific change in weight” of the test gears ms (specific wear) may not exceed 0.27 mg/kWh. Aging resistance The gear oils must have excellent “thermostability” and “aging resistance” at the prescribed oil change times after 2,000 hours of operation.

Fig. 37: Acid number curve

E

Turning point

Fresh oil

1000 AN = acid number

2000

Hours of operation

The acid number (AN) curve of mineral oils at actual operation of 2,000 hours and the permissible continuous temperatures must be prevented from reaching the point of inflection (see figur).

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

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

Suitability J Compatibility with commercial sealing elements.

6.16

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

AN

Used oil

Oil change

AN

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

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

Bucyrus Europe GmbH, Lünen 2009

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Tab. 6: Requirements of the cooling water Criterion

Requirement

Appearance, color, smell

Clear, no sediment, no odor

pH value

7 – 8.5

Total water hardness

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

Carbonate hardness

≤ 20 °dH (≤142 mg/l Ca2+)

Input temperature

≤ 25C

Max. dirt particle size

≤ 0.25 mm

Bacteriological requirement

≤ 105 col/ml (dip slide)

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

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

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

Doc. no.: 1946 034 000 BA 00

VIVI / 02

6.17

Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Only use 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.

Only those hydraulic fluids are allowed to be used for the operation of hydraulic components from Bucyrus for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption certificate from Bucyrus. Bucyrus will not accept any claims under warranty for components which have been or are operated using a different hydraulic fluid.

Suitability test Before Bucyrus will issue a certificate 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.

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

The suitability test is 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.

Furthermore, a chemical “fingerprint” of the concentrate is created in order to rule out or verify any possible changes in the composition of the concentrate if necessary.

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

6.18

Gearbox P-45 UEL-R

Bucyrus Europe GmbH, Lünen 2009

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 for example to hydraulic chain tensioners, hydraulically tensionable drives etc. A corresponding certificate of exemption will be issued

by Bucyrus upon request.

E

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

Permissible media Certificate The customer receives a certificate on 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 is no longer 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.

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Fig. 38: Typical certificate

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6.19

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 and should be performed with special care. Ideally, the most important properties of the hydraulic fluid are monitored automatically and documented continuously in order to directly counter any harmful development.

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

– Target value: 7.5 to 9.5 J concentrate ratio

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 maximum 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 use for hydraulic fluids

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.

If the limits shown in table 7 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.

Furthermore, water treatment may also be necessary.

However, the customer shall in any case 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 lead to the loss of the certificate even if they are within the limit values mentioned.

use as spraying water

6.20

Water used for this purpose may not contain aggressive components and dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100 m. In order to protect the components, the limit values listed in the table must not be exceeded

Gearbox P-45 UEL-R

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– target value: see certificate

Permissible media limit values

The following table lists limit values for the essential properties of the process water.

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulics system. Use only water that conforms to the specified limit values.

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

Limit value

Appearance, color, smell

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

Electrical conductivity

< 1800 S/cm

pH value

6.5 ..... 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



145 mg/l

NO3- content



20 mg/l

Fe content



1 mg/l

Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter at 1.2 m filtering in accordance with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

Lubricating greases and pastes Important!

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

Greases properties

Basis of grease:

lithium soap

NLGI class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presenceof water: Practically non-soluble in water

grease A1

Service temperature range:

-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).

1) *)

Doc. no.: 1946 034 000 BA 00

The values listed must be observed during the production of hydraulic liquids.

They do not apply when the water is used exclusively as spraying water.

EWN = works standard

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Permissible media Tab. 8: Lubricating greases for general application

lubricating grease A2

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Flashpoint °C

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

Tab. 9: Greases with additives Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

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 Supplier

Type

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI Class

Flashpoint in °C

2

220

The following lubricant type is used as B3 lubricating paste in accordance with the EWN 7068 works standard for the initial lubrication at the factory: gleitmolybdän “gleitmo 805” Important!

The instructions for mixing greases likewise apply to the lubricating pastes.

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

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Bucyrus Europe GmbH, Lünen 2009

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. If in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

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Flashpoint in °C

Marking of the gearbox Marking of the gearbox Manufacturer:

Bucyrus Europe GmbH

Type:

Gearbox P-45 UEL-R

Weight:

5100 kg (without oil)

The gearbox is identified with the following information: Fig. 39: Identifying details on the gearbox

1 type 2 ID number

1 2

3 serial no. / year of manufacturing

3

4 reduction ratio

5

4

5 weight

P-- 45 UEL-- R 1946 034 000 00 XX No xxx / xx I = xx G = 5100 KG

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Atex identification - Shield

The gearbox is compliant with European Directive 94/9/EC and DIN EN 1710 in its design and construction and is engineered for use in explosive atmospheres.

Fig. 40: Identification location

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Marking of the gearbox

6.24

Gearbox P-45 UEL-R

7

For your information

Service addresses

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

Service addresses Europe Germany

Bucyrus 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.

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Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK Bucyrus Europe GmbH, Lünen 2009

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 Europe GmbH, Moscow office 125009 Moskau ul. Tverskaja, dom 9/17, str. 7, office 315 Tel.: +7 (495) 9409209 Fax: +7 (495) 9407145 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Kirzavodskaja 4/8 654004 Novokuzneck Tel.: +7 (3843) 991381 Fax: +7 (3843) 991384 E-mail: Andrey.Ravnyushkin@ru.bucyrus.com

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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 Europe GmbH, Lünen 2009

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

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Gearbox P-45 UEL-R

Service addresses Asia China

Bucyrus 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.

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No. 4 Gangyao Road Tangshan 063027 Hebei Province 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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Standards and directives Standards and directives Referenced national standards and guidelines Tab. 11: National standards and directives, extract

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 Hydraulics Fire-resistant hydraulic fluids List for attendance and inspection of hydraulic equipments Hydraulic Systems - Design Principles Determination of the neutralization number Determination of the sulfated ash Tensioning forces, tightening torques and surface pressure for steel pins Hammer head bolts Greases & solid lubricants Nonmetallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

EWN 6003 1) 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 1985-02 1985-02 1992-06 1985-02 2005-03

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

Designation

Date of issue

Title

Directive of the European Parliament and the Council on 1998-06-22 the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the approximation of the laws of the Member States conDirective 94/9/EC 1994-03-23 cerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery 2004-04 DIN EN ISO 12100-2 Safety of machinery 2004-04 Non-electrical equipment for potentially explosive atmoDIN EN 13463-1 2002-04 spheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 2004-12 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces 2000-08 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water content - Distillation methods Equipment and components intended for use in potentially DIN EN 1710 2006-01 explosive atmospheres in underground mines Mobile extracting machines at the face - Safety requireDIN EN 1552 2003-09 ments for shear loaders and plough systems Directive 98/37/EEC

1) EWN = Bucyrus works standard

7.6

Gearbox P-45 UEL-R

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Title

Bucyrus Europe GmbH, Lünen 2009

Designation