CAT Gearbox P-30 UEL-R Operating Manual

Operating manual Gearbox P-30 UEL-R Doc. no.: 1946 032 000 BA 00

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

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

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

Bucyrus does not accept any liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications as a result of technical developments without previous notice.

Bucyrus DBT Europe GmbH, Lünen 2008 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

2. Your safety 2.3

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

2.3

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

2.4

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

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

Surrounding area conditions . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.4 2.4 2.4 2.5

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

2.6

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Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3

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

3.3

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

3.4

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

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

Transport plan for gearbox P-30 UEL-R . . . . . . . . . . . . . . .

3.4 3.4 3.5

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

4.3

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

Connection assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 4.5 4.6

How to start-up the gearbox . . . . . . . . . . . . . . . . . . . . . .

4.7

Before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting the UEL coupling cylinder . . . . . . . . . . . . . . . . . . . .

Applying pressure to the UEL coupling . . . . . . . . . . . . . . . .

Checking the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 4.7 4.8 4.9 4.9 4.10 4.10

Dismantling and withdrawing equipment . . . . . . . . . . 4.11 Important instructions for dismantling . . . . . . . . . . . . . . . . .

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4.11

Contents 5. Operation How to tension the conveyor and plow chain . . . . . .

5.3

How to tension the chain using a chain tensioner . . . . . . .

5.3

How to maintain the gearbox . . . . . . . . . . . . . . . . . . . . .

5.5

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

Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Checking the gearbox bearings . . . . . . . . . . . . . . . . . . . . . .

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

5.5 5.6 5.6 5.7 5.8 5.8 5.8

How to exchange defective components . . . . . . . . . . .

5.9

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

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

5.9 5.10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

6. Technical data Version characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.3 6.3

Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 6.5

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

6.6

Drive speed n1 = 1480 rpm, 50 Hz . . . . . . . . . . . . . . . . . . .

6.6

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

6.7

Gearbox P-30 UEL-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic controlsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6.7 6.8 6.11 6.11

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Used sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 6.12

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Hose connection for oil drainage . . . . . . . . . . . . . . . . . . . . .

6.12

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

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

Oil level mark lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 6.13 6.13

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5.12 5.12

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

Troubleshooting, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

6.15 6.16 6.17 6.18 6.19

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

Screws with fine metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.23 6.23

Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . 6.24

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7. For your information

Doc. no.: 1946 032 000 BA 00

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

7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.6

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

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

7.6 7.6

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Contents

Gearbox P-30 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-30 UEL-R ID. no.:

1946 032 000 00 00 1946 033 000 00 00

It is only permitted to be used for gearboxes of this type. category acc. to Atex directive

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

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Explanation of abbreviations Bucyrus DBT Europe GmbH, Lünen 2008

P-30 UEL-R Sliding clutch Overload protection Parameters, max. perm. torque 300 kNm at the output Planetary gear (two-stage)

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 assembly/disassembly work J operate the conveyor J eliminate faults 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 authorize and/or supervise.

Purpose of this operating manual efficiency

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

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 potential 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 moderately serious injuries and machine damage.

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

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

1.4

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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 vital 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 was manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

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

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

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

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The European guidelines/standards which appear in this operating manual must be applied when the gearbox is being used within the member states of the European Union.

If the device is used outside of 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 J of the mining supervisory authorities. additional operating manuals

Also read the operating manuals of the components required for operation, e.g., of E-motors, etc., carefully and thoroughly. 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 adequately trained for these particular requirements.

Installation and repair work on: J safety components (pressure relief valves, extinguishers, etc.)

J the electrical systems (controls, signaling devices, etc.)

J the hydraulic system

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

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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 face conveyor or plow.

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

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

J When combined with additional equipment, the gearbox can be

used to couple or clamp the conveyor chain or plow chain.

Permissible equipment for this are: – hydraulic or pneumatic chain tensioner as a tail-end drive on the drive connection assembly of the gearbox, if the drive connection assembly has been prepared for this (see Chapter 4, section “Connection assembly”).

– Parking brake (arresting brake) Use the gearbox only as intended.

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

J coupling or clamping the conveyor chain to the conveyor drives.

J coupling or clamping the plow chain to the plow drives.

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

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

These include: 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.

It may only be restarted by an authorized person.

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

The M2 equipment is to be stopped immediately and secured to prevent a restart if the firedamp protection systems are found to be damaged.

2.4

Gearbox P-30 UEL-R

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Unauthorized use includes:

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.

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

The M2 equipment/gearbox is only allowed to be operated when the safety requirements according to DIN EN 1552 have been met.

These include, among other things: J systems preventing unauthorized starting J start-up warning systems J water-sprinkling systems J safe lock-out command systems J EMERGENCY STOP systems

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J dust extraction systems J noise protection J warning messages, 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 your personal protective clothing and equipment. This includes wearing ear protectors 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 J the time which you will probably require.

safety equipment

Start the conveyor or mining equipment 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.

Maintain the signaling and lighting systems in a functional order.

Pay special attention to the acoustic and visual start warnings of the conveyor and for the mining equipment.

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 J failure of safety equipment, e.g.:

– firedamp protection. cordon off working area

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

moving parts

Ensure that parts of your body do not get caught between movable machine components, such as: J plow and conveyor chains J flights J spill plates J chain sprockets.

2.6

danger of explosion

Comply with 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.

hot surfaces

The gearbox casing can heat up to 85 °C during normal operation.

If you have to work on the gearbox, the temperature is not permitted to be higher than 60 °C. Wait until the gearbox has cooled down if required.

Gearbox P-30 UEL-R

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EMERGENCY STOP

Observe the symbol plates on the gearbox.

Bucyrus DBT Europe GmbH, Lünen 2008

symbol plates

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 securing device

Ensure that the transport securing devices have been correctly installed.

Fix all moving parts with transport locks.

Never stand under unsecured components or suspended loads.

means of attachment

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

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

Only use transport straps to attach round parts that do not have any lifting points. Never use chains or steel cables for this purpose.

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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.

Installation and start-up

inclined faces

If the face is inclined, secure all individual parts with chains to the supports, for example.

environmental acceptability

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

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

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 working on the gearbox before the mining equipment has reached your working area.

securing

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

Secure the conveyor and the mining equipment against unauthorized or unintentional restarting before commencing any work activities.

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2.7

Safety instructions working 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 immediately from the face 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 replacement parts 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. This is only ensured with original Bucyrus replacement parts.

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

For lifting the gearbox, only use:

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.

Only fasten the lifting tackle to shields that are connected to the conveyor with relay bars. 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 represent a very serious health hazard.

protective devices - hydraulic system

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

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

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

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

J lifting gear with adequate load-carrying capacity.

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J the lifting points provided for the purpose

Safety instructions Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check 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 sheath 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 hydraulic system during repair work.

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

If staples are difficult to remove or can’t be removed at all, the hydraulic line may still be pressurized. Do not fail to depressurize the line.

Only secure the coupling sockets of the hydraulic elements with the proper staples. Always fasten the staples completely with both sides.

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

Observe the date of manufacture stamped on the hydraulic hoses.

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

Fig. 1:

Example: 4SP hydraulic hose, identification 3 2 1

6

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

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5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

2.9

Safety instructions Never try to hold a hydraulic hose that is thrashing about Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

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

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted Laying hydraulic hoses, twisting WRONG

Bucyrus DBT Europe GmbH, Lünen 2008

RIGHT

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Fig. 3:

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter) Fig. 4:

Laying hydraulic hoses, bending RIGHT

2.10

WRONG

Gearbox P-30 UEL-R

Safety instructions J cannot chafe Fig. 5:

Laying hydraulic hoses, crossing RIGHT

WRONG

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

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

When installing the hydraulic hoses, ensure that they can not be: E

J torn out Bucyrus DBT Europe GmbH, Lünen 2008

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 RIGHT

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WRONG

2.11

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Safety instructions

2.12

Gearbox P-30 UEL-R

3

Storage and transport

Storage

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

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

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

Storage Storing the equipment Components coated with temporary anticorrosive are protected for around six months.

avoid direct exposure to sunlight

Protect the equipment against direct exposure to sunlight.

Store the electrical equipment, electronic components, replacement parts made of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures from 15 °C to 25 °C.

moisture and dirt

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

Bucyrus DBT Europe GmbH, Lünen 2008

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corrosion protection

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

Electrical components do not have to be removed during short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

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

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

This inspection can be carried out by Bucyrus upon request.

natural aging

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

Important!

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

frost protection for the oil cooler

Doc. no.: 1946 032 000 BA 00

Before storing gearboxes with oil coolers at ambient temperatures below the freezing point, flush out the oil cooler with antifreeze.

VPVT / 02

3.3

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

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

Warning!

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

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

Use only suitable load handling devices.

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

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

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

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

3.4

frost protection for the oil cooler

Before transporting gearboxes with oil coolers at ambient temperatures below the freezing point, flush out the oil cooler with antifreeze.

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 carefully protected against transport damage and soiling of the connections.

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

temperatures below freezing

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Before transport

Transport Transport plan for gearbox P-30 UEL-R Fig. 7:

Transport plan - gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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1088

1480

1

950

1140

500

S

1 lifting eye for transport S center of gravity Weight without oil filling: ca. 3400 kg

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3.5

Bucyrus DBT Europe GmbH, Lünen 2008

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Transport

3.6

Gearbox P-30 UEL-R

4

Installation

Installing the gearbox

Installation Installing the gearbox Caution!

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

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

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

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

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Notice!

Dirt could get into the gearboxes if the O-rings for the flange plates are inserted incorrectly. This can cause considerable damage to the gearboxes.

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

Bucyrus DBT Europe GmbH, Lünen 2008

Important information on installing the gearbox: J Remove the transport protection from the drive and output

shafts.

Fig. 8:

3

Transport protection

2

1

1 gearbox P-30 UEL-R 2 protective cover 3 hex. head screw M 36x260-8.8

5

4

4 shaft protection 5 hex. head screw M 20x180-8.8

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

must be clean and free from 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 All gearbox connections must be sealed with O-rings.

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4.3

Installing the gearbox J The screw dimensions must be accurately chosen in accor-

dance with the respective gearbox.

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

exactly opposite one another to ensure that they mesh smoothly. Avoid damaging the gearing and canting the gearbox during installation.

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

gearbox and drive frame or between the drive shafts.

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

ing torque.

Gearbox support The gearbox torque is supported via two pins which are positioned between the gearbox and the flange plate.

Fig. 9:

Y

Bucyrus DBT Europe GmbH, Lünen 2008

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Y

Gearbox support - P-30 UEL-R

1

X Y X Y 1 pin X these under-lying screw bores are not required during installation.

Y tightening torque of the M 36 x 3-10.9 mounting bolts; MA = 2890 Nm

4.4

Gearbox P-30 UEL-R

Installing the gearbox Cooling water supply position 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 “cooling water inlet” heat exchanger 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.

A shut-off valve is to be placed in front of the cooling water inlet in order to prevent back pressure in the heat exchanger.

Fig. 10: Cooling water ports a

Bucyrus DBT Europe GmbH, Lünen 2008

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2

b 1 heat exchanger 2 pressure relief valve

pressure relief valve

1 a cooling water inlet, DN 12 insert b cooling water outlet, DN 12 insert

The cooling water inlet temperature may not exceed 25 °C. The required amount 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.

The pressure relief valve mounted on the gearbox is set to a triggering pressure of 30 bar. The working pressure should not exceed 25 bar.

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

Connection assembly The connection assembly comprises all components arranged between the gearbox and the electric motor. It mainly consists of a protective hood and an elastic coupling.

The protection cover of the connection assembly is bolted onto the gearbox.

Caution!

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

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4.5

Installing the gearbox E-Motor Caution!

Only install electric motors with performance specifications (torque, speed) permissible for the attached gearbox and the drive frame.

If you prefer to install electric motors other than those approved by us, please contact our service department in advance.

W5 dimension from the motor flange to the shaft collar

Caution!

If the flange position “W5” on the E-motor is larger than on the connection assembly, the motor shaft and gearbox shaft bearings can become strained. This can result in damage to the gearbox and the E-motor!

Particular attention must therefore be paid to the following instructions before installing the motor: J The E-motor’s exact flange position “W5” must be measured

before installation.

J If the flange position “W5” of the E-motor is larger than that of

the connection assembly, a component of the connection assembly (e.g. hub of the flexible coupling) must be shortened accordingly.

Notice!

Please make sure you observe the instructions in the E-motor’s separate operating manual.

4.6

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 11: Flange position “W5” on E-motor

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

Caution!

Observe the respective information on start up in the separate operating manual on the entire conveyor system. Serious damage to the machine resulting in high costs can result from errors made during startup.

Read all operating manuals on the conveyor system thoroughly.

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

J Apply pressure to the UEL coupling

J Vent the UEL coupling cylinder

J Check the gearbox

Checking the oil level E

Check the oil level of the gearbox before starting up. The gearbox is delivered without oil.

Bucyrus DBT Europe GmbH, Lünen 2008

Caution!

Defined oil levels must be complied with depending on the inclination of the gearbox. A plate on the gearbox specifies the oil level mark line that applies to the respective tilt (see “Oil levels” and “Oil quantities” in the “Technical Data” section).

Fill the gearbox with oil until it reaches the correct oil level marking line on the dipstick.

Insufficient oil impairs lubrication of the gears and roller bearing.

Excessive oil results in high churning loss, oil foam and an increase in heat development.

Oil can be filled from above (a) or the side (b) into the gearbox.

Fig. 12: Oil filling screw 34

35, 65

Oil drainage C-D 65 63 36

b

a

C

d

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34 breather plug 35 dipstick 36 valve screw 63 screw plug, M 30x1.5-8.8 65 sealing ring, A 30x36 a oil filling screw (on top) b oil filling screw (on side) For parts not listed here, please refer to the parts list included with delivery.

4.7

How to start-up the gearbox Venting the UEL coupling cylinder The coupling cylinder must be vented every time the gearbox is reinstalled.

Fig. 13: Venting the coupling cylinder For hydr. control For electr. control For UEL coupling 8 16 6 6 20

9

4

15

29 15

26

7

I

b II

a I ball valve open II ball valve closed 1 hydraulic control system 4 protective casing 6 cover plate 7 cover (not shown) 8 spacing piece 9 side protection 15 hex. head screw M 12x25-8.8

16 hex. head screw M 16x180-8.8 20 temperature sensor 26 distribution box 29 pressure sensor a ball valve b screw plug

The ball valve (a) must be open.

. Check whether the ball valve (a) is open. . Open the screw plug (b) until air can flow out. . Allow hydraulic fluid to flow into the hydraulic chamber via the hydraulic proportional control until this escapes at the screw plug.

. Afterwards, you must retighten the screw plug (b).

4.8

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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Z

1

How to start-up the gearbox 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 Ratio i = 16

i = 21

i = 28

i = 33

i = 50

30

30

35

42

38-40

Nominal pressure in bar

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

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

Fig. 14: Ball valve I

a

Bucyrus DBT Europe GmbH, Lünen 2008

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II

I ball valve open II ball valve closed a pressure gauge

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!

During operation, the ball valve must be open.

The ball valve must be closed only while the chain is being tensioned after the required pressure has been built up.

See also Chapter 5, section “Tensioning a conveyor or plow chain” or Chapter 6, section “Hydraulic control”.

Checking the gearbox

. Check whether the gearbox is equipped 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. 12 in the section “Filling oil”. 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 electric control. Check whether the system is switched on and is working perfectly.

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4.9

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

Danger!

Make sure that all personnel has left the hazardous area of the conveyor system. Make sure to maintain sufficient distance between you and the conveyor system during the test operation and start up. In these phases for example, installation errors may cause hazards that would not arise during normal operation.

. The conveyor must be aligned before beginning the start up procedure.

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

. Check all bolted connections, especially on the drives, for completeness and secure fit.

. Check the electrical connections.

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

When the gearbox is started up, the preservatives in the gear oil dissolve. They can remain in the gearbox until the next oil change without adversely affecting the ability of the oil to lubricate.

Preservatives must be removed from the breather plug before start up if required. Gasoline, paraffin, diesel oil, wax remover or alkali media can be used to do this.

Test run Check and inspect the following points: J Carefully check the gearbox for leakage. Before checking, re-

sidual oil must be thoroughly removed from the gearbox. This is the only way to inspect for minimal leakage.

J After a test run of two hours, the temperature of the gearbox

may not exceed 85 °C.

J Whether the gearbox is running smoothly.

4.10

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

. Check the cooling water supply for gearbox and e-motor.

E

. Check the rotational direction of the motors.

Dismantling and withdrawing equipment Dismantling and withdrawing 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.

J When dismantling the drive set, protect all exposed shafts,

hubs, labyrinth channels and flanges from corrosion, contamination and damage.

J When removing lines, seal the separation points using protec-

tive caps or plugs.

J Separate loose parts, screws, etc. should be stored in contain-

Bucyrus DBT Europe GmbH, Lünen 2008

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ers in which they can be clearly arranged and protected from dirt, dust and damage.

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4.11

Bucyrus DBT Europe GmbH, Lünen 2008

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Dismantling and withdrawing equipment

4.12

Gearbox P-30 UEL-R

5

Operation

How to tension the conveyor and plow chain

Operation How to tension the conveyor and plow chain The plow or conveyor chain can be tensioned with a hydraulically or pneumatically actuated chain tensioner via the UEL gearbox.

A parking brake (arresting brake) designed for the occurring forces can also be used.

To securely hold the separated conveyor or plow chain during tensioning, mechanical chain locking devices, such as ratchet pawls, chain locking devices, claws, etc. are used. Make sure that you observe the operating instructions for the conveyor or plow.

How to tension the chain using a chain tensioner To tension the chain using a chain tensioner, a higher pressure must be applied to the UEL coupling than the preset nominal operating 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.

Bucyrus DBT Europe GmbH, Lünen 2008

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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 or the shutoff valve of the hand pump while you’re tensioning the chain.

Always check whether there is sufficient pressure on the pressure gauge.

The required pressure is built up using the hydraulic proportional control (see section “Applying pressure to the UEL coupling”. The control is done via the pressure gauge (a).

Fig. 15: Ball valve I

a

II b I ball valve open II ball valve closed a pressure gauge b ball valve

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

Doc. no.: 1946 032 000 BA 00

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5.3

How to tension the conveyor and plow chain . Apply pressure to the UEL coupling via the proportional control until the required pressure of 65 bar has been reached.

. Afterwards, connect the ball valve (b). . Tension the chain using the chain tensioner.

Caution!

Note that the clutch pressure is only maintained when the ball valve is closed.

Check the pressure via the pressure gauge.

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 Chap. 4, section “Applying pressure to the UEL coupling”).

It is mandatory that you observe the operating instructions of the used chain tensioner: J Hydraulic chain tensioner

Doc.No.: 1955 001 000 BA 00 or J Pneumatic chain tensioner

5.4

When using a parking brake, pressure must also be applied to the UEL coupling as described in the previous section.

Always observe the separate operating manual from the manufacturer of the used parking brake.

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

parking brake

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Doc. No.: 1955 002 000 BA 00.

How to maintain the gearbox How to maintain the gearbox Warning!

The casing temperature of the gearbox can reach 85 °C. You can burn or scald yourself on hot surfaces, the components screwed into them (dipstick, breather plug, gearbox sensors, heat exchanger, etc.) or hot, leaking oil (oil change).

Check the gearbox temperature and wait until the temperature has dropped to at least 60 °C, if necessary.

Observe the symbol plates on the gearbox.

The gearbox temperature can be read off of the system computer.

Maintenance at regular intervals increases the operational safety and prolongs 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

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J Checking the oil level Bucyrus DBT Europe GmbH, Lünen 2008

J Changing the oil J Maintaining the filter J Maintaining the hydraulic system J Checking the gearbox bearings J Cleaning the gearbox casing

Use only proper tools for maintenance work.

Important!

You should place a container with the tools required and the most useful replacement parts in the vicinity of the point of operation. Adequately protect the contents from dirt, dust and moisture.

Checking bolted connections tightening torque

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

tightening bolts

The bolted connections listed in the following must be tightened 60 hours after initial start up and then once every 500 hours.

J Connection assembly (motor and gearbox side) J Gearbox (attachment on the drive frame)

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5.5

How to maintain the gearbox Checking the oil level The oil level must be controlled every week. Here, foreign objects must be prevented from getting into the gearbox.

Insufficient oil impairs lubrication of the gears and roller bearing.

Excessive oil results in high churning loss, oil foam and an increase in heat development.

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 oil of a new or completely rebuilt gearbox must changed for the first time after 300 operating hours. After this, the gearbox should be thoroughly cleaned and filled with fresh oil after every 2000 operating hours - but at least semi-annually. Observe the information in Chapter 4, section “Filling oil”.

Notice!

Vent the gearbox before you release the oil drain plug. The breather plug must be removed before venting the gearbox.

Make sure that foreign bodies do not penetrate the gearbox.

5.6

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

Important!

Change the oil when the gearbox is at operating temperature so that the warm, thin oil can wash away the oil sludge more effectively.

How to maintain the gearbox Fig. 16: Oil drainage via valve screw Closed

1 - with hex head wrench size 50

2 3 - with hex socket wrench size 17

1 valve screw 2 sealing ring A30x36 DIN 7603-Cu

915 898 014 000 0403 6011

3 screw plug DIN 908 - M30x1.50214 2003 4 hose connection (accessory)

912 958 100 020

Opened (approx. 3 turns)

Bucyrus DBT Europe GmbH, Lünen 2008

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4 - with hex head wrench size 41

An earlier oil change is required if: J The level of contamination has reached the value of 0.1% for-

eign parts.

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 neutralization NNUsed oil - NNFresh oil = ∆ NN has exceeded the value ∆ NN = 2.0 mg KOH/g Oil.

Determine the J neutralization number according DIN 51 558 J water content according to DIN 51 582 J percentage of foreign substances according to DIN 51 592 J sulfate ash according to DIN 51 575

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

Notice!

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

Used breather plugs may not be reused. Dispose of them in an environmentally-friendly manner.

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5.7

How to maintain the gearbox Maintaining the hydraulic system Observe the safety instructions in Chapter 2.

Daily maintenance J Check whether the ports fit securely and tighten them if re-

quired.

J Replace leaky components, such as control elements, lines,

Steck-0 parts, etc., immediately.

Notice!

Seal open connections with protective plugs immediately so that they are protected from being damaged or penetrated by dirt and dust.

J Make sure the connection and securing devices are in perfect

condition.

J Replace damaged components.

J Replace missing components.

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

Checking the gearbox bearings Pay attention to unusual gearbox noises because they often indicate damage to bearings. Defective bearings can cause serious damage to the gearbox and overheating of the gearbox.

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

Important!

You should have the bearings replaced as a precautionary measure if they reach the maximum bearing service life within a removal phase. Bearing service life data is listed in Chapter 6 “Technical data”. acoustic emission monitoring

To detect bearing damage at an early stage, continuous acoustic emission monitoring can be used.

Cleaning the gearbox casing Excessive dust deposits cause heat accumulation, which can cause the gearbox casing to heat up significantly.

In extreme cases, this can cause the coal dust to self-ignite.

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

5.8

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

Caution!

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

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ated operating manual.

How to exchange defective components How to exchange defective components Gearbox sensors The sensors can be exchanged as needed.

Fig. 17: Sensors a 8 16 6 6 9 4

29

26

15

c

7

b

8 spacing piece 9 side protection

16 hex. head screw M 16x180-8.8 26 distribution box 29 pressure sensor a cable to the electr. control b plow path sensor

15 hex. head screw M 12x25-8.8

c slippage sensor

Bucyrus DBT Europe GmbH, Lünen 2008

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4 protective casing 6 cover plate 7 cover (not shown)

Exchanging the slippage sensor (speed sensor)

. Shut down the system and secure it against being switched on again unintentionally or without authorization.

– E-motors “off”.

– Disconnect the electronics power supply.

. Disconnect the cable of the defective slippage sensor: – Dismantle the cover plate (6).

– Open the cover of the UEL distribution box (26) and disconnect the cable.

. Dismantle the cover (1) of the slippage sensor (Fig. 18). . Dismantle the support (4) incl. the sensors.

Fig. 18: Slippage sensor Slippage sensor

1 9 4

18 8 16 20

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1 cover 4 support 8 cyl. head screw M 10x20-8.8 9 cyl. head screw M 10x40-8.8 16 o-ring 34.2x3 18 sealing ring A 30x36 20 proximity switch

5.9

How to exchange defective components The new slippage sensor must be installed as described above, but in the opposite order.

. Connect the sensor cable as specified in the circuit diagram (see Chapter 6, section “Circuit diagram”).

. Put the system into operation and check whether the sensor is working perfectly.

Exchanging the plow path sensor

. Shut down the system and secure it against being switched on again unintentionally or without authorization.

– E-motors “off”.

– Disconnect the electronics power supply.

Dismantle and install the new sensor as described in the section “Exchanging the slippage sensor”.

. Put the system into operation and check whether the sensor is working perfectly.

Fig. 19: Heat exchanger Right installation position a

Left installation position a

b

b

1 heat exchanger ** 2 reducing piece 3 cyl. head screw M 16x80-8.8 4 cover 6 pressure relief valve 8 hex. screw M 16x40-8.8 10 screw plug G 3/4 11 sealing ring A 27x32 13 screw plug M 42x1.5 14 sealing ring A 42x49

5.10

16 sealing ring A 33x39 18 o-ring 100X3 20 screw-in socket G 3/4 21 staple DN 12 25 hose line a cooling water inlet, DN 12 insert b cooling water outlet, DN 12 insert * installed on top ** can be installed either from the right (as shown in the cross section) or from the left

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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.

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Heat exchanger

How to exchange defective components Exchanging the heat exchanger

. Shut down the system and secure it against being switched on again unintentionally or without authorization.

– E-motors “off”.

– Disconnect the electronics power supply.

. Drain the gear oil. . Dismantle the water supply and connection lines. . Loosen the mounting bolts (3). . Afterwards, pull the cooler out of the housing. . Before installing the new cooler, you should remove the cover (4). This makes it easier to install the cooler.

Further installation must be done in the opposite order of the dismantling. Observe the direction of flow of the heat exchanger. Always install the pressure relief valve (6) in the upper cooler.

Bucyrus DBT Europe GmbH, Lünen 2008

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. Afterwards, fill the gearbox according to the oil level mark line.

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5.11

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

– The cylinder seal on the UEL coupling is leaking.

If the gearbox temperature is too high, you should... ... check the oil cooling system Check the cooling water feed; required quantity of water: approx. 10 to 15 liter/min.

Important!

When it enters the system, cooling water may not be warmer than 25 °C. ... provide sufficient radiation of heat Nutty slack on the gearbox housing functions like an insulating layer, preventing radiation of heat.

Remove nutty slack, including the sides and bottom. ... check the oil level If the oil level is too low, the lubrication of the roller bearing and gears can be adversely affected, which contributed to increased in heat development (see oil level plate).

An oil level that is too high results in heat-generating churning loss and gear oil foaming. Foam prevents heat dissipation. ... determine whether overload exists When the gearbox is continuously overloaded, the gearbox temperature rises. Measure possible overload using an ammeter.

If the gearbox is losing oil, you should ... ... make sure there are no leaking connection surfaces and covers Tighten casing screws, cover bolts, and oil drain plugs.

5.12

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

E

Troubleshooting, gearbox

Troubleshooting Important!

Remove any oil that has leaked earlier. This allows you to determine whether oil is leaking or whether the connection is sealed. ... make sure oil is not leaking from the breather plug Check the installation position of the breather plug.

It has to be installed in the uppermost opening. The installation position depends on the inclination of the gearbox.

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

Notice!

When in doubt, always insert a new breather plug. Do not try to clean the breather plug.

Doc. no.: 1946 032 000 BA 00

VPVT / 02

5.13

Bucyrus DBT Europe GmbH, Lünen 2008

E

Troubleshooting

5.14

Gearbox P-30 UEL-R

6

Technical data

Technical data This chapter contains the most important technical data for the gearbox. Additional information about tightening torques, types of oil, HFA fluids, greases etc. is given at the end of this chapter. Take time to read this entire chapter carefully. Pay special attention to the safety instructions.

Version characteristics The gearbox is designed with external hydraulics and is used for mining as a plow and conveyor gearbox. The output shaft is equipped with internal toothing (N 220x10x30x20 DIN 5480). Gearbox ratio according to the RAG standard 335 000: i = 16; 21; 24,4; 28; 33; 39 and 50.

Technical data sheet

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 2: Technical data sheet

Permissible continuous input power 1) max. at n1 = 1500 rpm . . . . . . . . . . . . . . . . . . .

Max. permissible torque at output . . . .

Max. permissible input speed . . . . . . . .

PIN = 500 kW T2max = 300.000 Nm n1 max = 1800 rpm

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

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

Oil temperature at rated power . . . . . . .

M = 3400 kg Q = 300 l t = 60 - 65 °C

Service life of bearing (continuous operation at rated power) . . . . . . . . . . . .

Q = 13500 h 2)

Required cooling water quantity . . . . . .

Q ~

Pressure relief valve set to . . . . . . . . . .

Connection thread of the water supply for the heat exchanger, inlet and outlet Maximum cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . .

Maximum cooling water dirt particle size Required pH value of cooling water . . .

Pü

1) 2)

Doc. no.: 1946 032 000 BA 00

10 to 15 l/min = 30 bar 12 DN plug-in

tmax = 25 °C max = 0.25 mm pH ~ 7

Applies for ratios i = 16, 21; 24.4, 28; 33 Corresponds to 90% of the calculated nominal bearing service life Lh10

VPVT / 02

6.3

Main dimensions Main dimensions Mounting dimensions 890 400

220

65

*

38 60 65 deep

400

400

400

*

350

*

100 m5

680

*

350

800

520 f8

450

125

260

*

0 50

120

70

*

285

285

*

400

288 255

0 0

88

Fig. 20: Mounting dimensions

10 * 380 430 480

270

0

480 430 380

1140

270

45

15

*

15 15 *

15 *

*

*

6.4

*

*

280

*

195 215

*

25

0

M36

825

635

0

15 *

*

*

225

(480)

15

* M30, 60 deep

Toothed hub DIN 5480 * N 220x10x30x20

E

*

*

Mounting dimensions in acc. with RAG standard

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

22

(480)

View drawn without item 4

Main dimensions Connections Fig. 21: Connections A

4 1) 47,54,60 80,87 3)

5) Z

29

C

a

6) d

4) 34,65

B

8) 35,65

Bucyrus DBT Europe GmbH, Lünen 2008

E

12)

Z

9)

11)

10) 75,76

XX 3)

13)

37

View drawn without item 4

7)

Item nos. 34 and 35 installed on top

C-D 65

X

X 63 2) 36

X

Oil drainage for hose connection (installed at the bottom)

Doc. no.: 1946 032 000 BA 00

4 control and lines 1) tghtening torque MA = 380 Nm 29 lateral cover 2) oil drain plug 34 breather plug 3) oil filling screw 35 dipstick 4) breather plug 36 valve screw 5) cooling water inlet, DN 12 plug-in 37 magnetic rod 6) cooling water outlet, DN 12 plug-in 47 washer 7) magnetic rod 54 hex. head screw M 20x240-8.8 8) dipstick 60 hex. nut V M 20-10 9) UEL ventilation 63 screw plug, M 30x1.5-8.8 10) hydraulic UEL supply 65 sealing ring 11) leakage oil outlet 75 hose line 12) oil temperature sensor 76 fitting connection DN 10 plug-in 13) disk temperature sensor 87 grooved drive stud 3x6-ST 50 a set of signs x can be mounted either on the left or right side XX label attached

VPVT / 02

6.5

Performance data

Performance data Drive speed n1 = 1480 rpm, 50Hz Fig. 22: Continuous power and continuous torques at n1 = 1480 rpm; 50 Hz 500

3200

2600

400

2400

370

2200 330 2000

1800

1600

21 16

28

39

24.4 33

E

435

Bucyrus DBT Europe GmbH, Lünen 2008

2800

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

Permissible continuous input torque T1 [Nm]

3000

50 Ratio of reduction i

Permissible continuous torque at output T2: 110000 Nm to i = 33 and 130000 Nm at i = 50 Water cooling is generally required.

Tab. 3: Performance data at n1 = 1480 rpm; 50 Hz Ratio of reduction

inom 16 21 24.4 28 33 39 45 50

6.6

Drive speed n1 = 1480 rpm Continu- Continuous ous input torque at power input

Output speed

P [kW]

T1 [Nm]

500

3220

435 370 400

2800 2400 2600

n2 [rpm] 92.2 70.6 61.0 52.6 44.3 37.6 33.0 29.7

Ratio Actual ratio I iactual 16.055 20.946 24.268 28.152 33.382 9.343 44.944 49.826

Stage I

Stage II

iI 4.250 4.312 4.758 5.520 6.545 7.741 8.812 8.471

iII 3.777 4.857

5.100

5.882

Gearbox P-30 UEL-R

Technical description

Technical description Gearbox P-30 UEL-R The P-30 UEL-R planetary gear has two stages and is designed for a constant rated power of P = 500 kW up to a ratio of i = 33 and can be operated in both rotational directions.

The maximum output torque permitted short-term (3 seconds) is Tmax = 300 000 Nm. The ratio range is i = 16 to i = 50.

Bucyrus DBT Europe GmbH, Lünen 2008

E

construction

The gearbox construction is comparable to that of a conventional planetary gear. 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 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 has internal toothing N 220x10x30x20 DIN 5480 and is sealed with a maintenance-free face seal.

The symmetrical design of the output is saves a lot of space and requires no swiveling of the gearbox when installed at the right or left. The torque is supported via two pins in the flange mounting surface of the gearbox.

use

The P-30 UEL-R planetary gear is suitable for installation on drive frames and plow drive units with bearing-supported shafts.

lubrication

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.

water cooling

The gearbox is equipped with water coolers which can be exchanged from the outside. The water coolers are protected against overpressure with a pressure relief valve set to 30 bar. The volume of cooling water is approx. 10 to 15 l/min. The cooling water must be filtered before it enters the gearbox (dirt particle size max. 0.25 mm) and should not exceed the input temperature of max 25 °C.

tension chain

For safely tensioning the chain, the connection assembly of the planetary gear is equipped with a chain tensioner.

plow path sensor

To measure the plow path, two inductive proximity switches 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.

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 with a pressure sensor or pressure gauge.

exchanging sensors

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

Doc. no.: 1946 032 000 BA 00

VPVT / 02

6.7

Technical description Hydraulic controlsystem Hydraulic circuit diagram UEL-R Ventilation coupling

The UEL-R 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.

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 (see Chapter 4, section “Venting the UEL coupling cylinder”) must be closed.

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 control unit.

construction

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.

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.

6.8

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

tension chain

E

This pressure is adapted to the operating conditions via a PMC-D control unit. It depends on the size of the gearbox, the ratio, the chain size, the number of teeth on the chain wheel and the drive motors.

Technical description Fig. 23: Hydraulic control - gearbox 1946 032 000 00 xx and 1946 033 000 00 xx * For hydr. control

For UEL coupling

For electr. control

8

16

15

6

17

20, 21, 23, 24 X 9

4 1 15

15

Bucyrus DBT Europe GmbH, Lünen 2008

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7

26

29

12

17

Illustration without items 6 and 7

X Z b

a

Y

1 hydraulic control system 4 protective casing 6 cover plate (not shown) 7 cover (not shown) 8 spacing piece 9 side protection 12 screw pin M 12x40-12.9 15 hex. head screw M 12x25-8.8 16 hex. head screw M 16x180-8.8 17 hex. screw M 30x40-8.8

*)

Doc. no.: 1946 032 000 BA 00

20 temperature sensor 21 temperature sensor mounting device 23 sealing ring 22x27 PA-A 24 sealing ring 42x49 CU 26 distribution box 29 pressure sensor a ball valve b manometer Y lever position: ball valve closed Z lever position: ball valve open

The hydraulic control for gearbox 1946 033 000 00 xx also contains the components shown in Fig. 24

VPVT / 02

6.9

Technical description Fig. 24: Hydraulic control - gearbox 1946 033 000 00 xx (additional components *) DC

AC

PMC-D

iVK

5

SPLITTER

Prop.

Station

R (p < 2bar)

26 30,31

31 32

26 Lmax = 15000 UELgearbox

iVKG

33

P

A

34 39

5 hydraulic control PMC-D with PROP technology 26 hose line 10x10000 ST/ST 30 coupling hub 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

*) The components listed in Fig. 23 also belong to the hydraulic control of the gearbox 1946 033 000 00 xx

6.10

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

E

40

Technical description Slippage monitoring Slippage monitoring diagram

1 2

1 proximity switches 2 switching ring

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.

Circuit diagram Fig. 25: Circuit diagram

ROT/RED

8

BLAU/BLUE

7

VIOLETT/PURPLE

10

SCHWARZ/BLACK

9

TRANSPARENT

12

ORANGE

11

ROSA/PINK

6

GRAU/GRAY

5

GELB/YELLOW

4

GRUEN/GREEN

3

BRAUN/BROWN

2

WEISS/WHITE

1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

NAMUR

NAMUR

NAMUR

1

2

1

2

PLOW PATH

Doc. no.: 1946 032 000 BA 00

PT100

NAMUR

PT100

BLAU/ BLUE BLAU/ BLUE BLAU/ BLUE BLAU/ BLUE BRAUN/ BROWN GRUEN/ GREEN BRAUN/ BROWN GRUEN/ GREEN BRAUN/ BROWN GELB/ YELLOW WEISS/ WHITE BRAUN/ BROWN BRAUN/ BROWN BRAUN/ BROWN BRAUN/ BROWN

Bucyrus DBT Europe GmbH, Lünen 2008

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SKK212

VPVT / 02

PPT100

SLIPPAGE

6.11

Sensors Sensors Used sensors Tab. 4: Used sensors Gearbox:

1946 032 000 00 xx 1946 033 000 00 xx

Order no.

Plow path measurement

Plow path sensor with two inductive proximity switches

1970 005 040 00 00

Slippage monitoring

Slippage sensor with two inductive proximity switches

1970 005 060 00 00

Pressure measurement

One pressure sensor Type PPT 100

4008 040 120 00 0X

Temperature measurement

One temperature sensor Type TF-100, PT 100

0000 006 509 00 99

One temperature sensor Type TRA106/PT100 (optional)

1970 005 140 00 00

One distribution box

4008 036 370 00 0X

Accessories

Sensor parameters

Slippage sensor (for I=16:1): Frequency of the inductive proximity switches f = 50 Hz for drive speed n1 = 1500 rpm, slippage tmax = 2 seconds, then motor switchoff.

Accessories Hose connection for oil drainage Fig. 26: Hose connection

1 hose connection order No.: 912 958 100 022 sealing ring order no.: 04 03 6011

6.12

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

For every revolution of the output shaft 24 pulses per proximity switch.

E

Plow path sensor (for I=16:1):

Oil levels and oil quantities Oil levels and oil quantities Oil levels Defined oil levels must be complied with depending on the inclination of the gearbox. A sign on the gearbox indicates the required oil level mark line for the respective tilt (see Fig. 28, “Oil level mark lines”).

Dipstick Fig. 27: Dipstick Reference edge 100

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) (see Fig. ).

The dipstick is inserted into the dipstick hole vertically and screwed in. The minimum oil level may not be more than one mark line below the required oil level mark line (see “Technical data - main dimension” for the position of the dipstick).

Oil level mark lines

Inclination inconveying direction

Inclination in mining direction

Bucyrus DBT Europe GmbH, Lünen 2008

E

1 cm

Fig. 28: Oil level mark lines

Dipstick, 685 long Order no.: 1970 001 050 00 04 View of the drive shaft

Output high

Output low

Dipstick deep

Dipstick high

Important!

The values apply to the dipstick that is screwed in.

The permissible deviation is ±1 mark line.

Doc. no.: 1946 032 000 BA 00

VPVT / 02

6.13

Oil levels and oil quantities Fig. 29: Oil quantities /(values in liters) Inclination inconveying direction

View of the drive shaft

Inclination in mining direction

Output high

Output low

Dipstick deep

Bucyrus DBT Europe GmbH, Lünen 2008

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Dipstick high

Caution!

The oil quantities are indicative values.

The oil level mark lines must be complied with.

6.14

Gearbox P-30 UEL-R

Permissible media Permissible media Recommended oil for gearboxes Only the recommended gear oils or products certified as equivalent may be used. gear oil on mineral oil basis

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

gear oil on synthetic basis

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

Only synthetic oils with EP characteristics may be used. In GRC special test A/16.6/140 sudden changes in the upper wear profiles in all 12 power levels are not permitted.

changing the type of oil

concerning the gear oil table

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.

The different types of gear oil listed in the two columns of the table are comparable. 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 DBT Europe GmbH, Lünen 2008

E

Tab. 5: Oil types for gearboxes Manufacturer

ARAL

BP

ESSO

KLÜBER

MOBIL

SHELL

TEXACO

WINTERSHALL

Gear oil 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 032 000 BA 00

VPVT / 02

Gear oil 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 Choosing the correct gear oil and carefully monitoring lubrication are important prerequisites for trouble-free operation. These factors also contribute to prolonging the service life of the gearbox.

Load-bearing capacity For mechanically testing gear oil according to DIN 51354, sudden changes in the upper wear profiles in all 12 power levels are not permitted in the GRC normal test A/8, 3/90 and the GRC special test A/16, 6/120. This means that the critical power level must be above 12.

In addition, the “specific change in weight” of the test gears ms (specific wear) may not exceed 0.27 mg/kWh. Ageing resistance The gear oil must possess outstanding “thermostability” and “ageing resistance” for the oil changing interval after 2000 hours of operation.

Fig. 30: Neutralization number curve

E

Turning point

Fresh oil 1000 NN = neutralization number

2000

Operating period in hours

The neutralization number (NN) 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 Fig.).

Kinematic viscosity The gear oil should remain within the viscosity range of 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-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

∆NN

Used oil

Oil change

NN

Permissible media Lubricating greases and pastes Important!

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

Lubricating greases properties

lubricating grease A1

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

Temperature of application:

-20 to +120 °C

Flashpoint:

≧ 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).

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 6: Lubricating greases for general application

lubricating grease A2

Flashpoint in °C

Supplier

Model

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load Tab. 7: Lubricating greases with additives Flashpoint in °C

Supplier

Model

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Important!

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

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

*) EWN = Bucyrus works standard

Doc. no.: 1946 032 000 BA 00

VPVT / 02

6.17

Permissible media 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. 8: Lubricating pastes free of molybdenum disulphide Supplier

Model

Base

gleitmolybdän

gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 is used in accordance with the works standard EWN 7068: Gleitmolybdän “Gleitmo 805”

Requirements for the cooling water quality

Tab. 9: Requirements for cooling water Criterion

Requirement

Appearance, color, smell

Clear, without deposit, no odor

pH value

7 – 8,5

Water hardness

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

Temporary 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 above 25 °C, even if the temporary hardness value is low, deposits and the consequences listed above can be expected.

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.

*) The products listed in table 6 are suitable lubricating greases for filling of adjacent cavities.

6.18

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

To secure operation, comply with the requirements specified in the following table.

E

To prevent damage to heat exchangers, the cooling water should not contain aggressive substances or dirt particles. In addition, it may not contain components which may form deposits due to the increase in temperature in the heat exchanger, thus reducing cooling performance or, in the worst case, leading to complete failure of the system.

Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

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

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

In addition, when operating this equipment national and sometimes also regional health and safety at work regulations and any environmental regulations must be observed.

Bucyrus DBT Europe GmbH, Lünen 2008

E

If a mine only uses individual hydraulic components without using 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 drive units, etc.

The respective exemption permit will be issued by Bucyrus on request.

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

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

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

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

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

Doc. no.: 1946 032 000 BA 00

VPVT / 02

6.19

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

The following illustration shows a typical certificate.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 31: Typical certificate

6.20

Gearbox P-30 UEL-R

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

In a special case, the operator of the system must draw up a maintenance concept for the hydraulic fluid in cooperation with the manufacturer of the concentrate and apply this consistently.

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

Target value: 7.5 to 9.5 J Concentration ratio

Target value: see certificate J Microbial load

Target value: ≤ 105 Kol/ml

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following Table 10 lists limit values for the essential properties and components of the water.

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

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

Additional water treatment may also be required.

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

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

Doc. no.: 1946 032 000 BA 00

VPVT / 02

6.21

Permissible media Tab. 10: Properties of the process water, limit values Limit value

Appearance, color, smell

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

Electrical conductivity

< 1800 µS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml

Ratio of solid foreign matter at 1.2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

-/18/14

Bucyrus DBT Europe GmbH, Lünen 2008

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Test criterion

6.22

Gearbox P-30 UEL-R

Tightening torques Tightening torques Screws with ISO metric thread Tab. 11: Tightening torques at µtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm)

Fine thread

8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

20 m

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Bucyrus DBT Europe GmbH, Lünen 2008

Tightening torque 4)

Pitch P

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3.5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3.5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

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

Screws with fine metric thread Tab. 12: Tightening torques at µtotal = 0.14

1) 2) 3) 4)

Doc. no.: 1946 032 000 BA 00

Thread

Pitch

Tightening torque

(mm)

(mm)

MA (Nm)

d

P

8.8

24 m

2

M 27

2

10.9

12.9

-

1100

-

-

1600

-

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

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

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

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

VPVT / 02

6.23

Identification of the gearbox Identification of the gearbox Manufacturer:

Bucyrus DBT Europe GmbH

Type:

P-30 UEL-R

Year of construction: MM/YY (e.g.: 01/08 ≙ January 2008) ID No.:

1949 032 000 00 XX *) or..

1949 033 000 00 XX *)

Weight:

3 400 kg (without oil)

The gearbox is identified with the following information. The location of the identification markings are illustrated in Fig. 32.

Fig. 32: Markings on gearbox Gearbox data P-30 UEL-R

No xxx / xx

1 2 3

I = xx

4 5

Label attached 1 type 2 ID no.

3 ser. no/const. yr.

G = 3400 kg 4 ratio 5 weight

CE-marking

The design of the gearbox meets the requirements of the European Directive 94/9/EC and of DIN EN 1710. It is suitable for use in potentially explosive atmospheres.

*) X = place holder for variant ID number

6.24

Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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1946 032 000 00 XX or 1946 033 000 00 XX

7

For your information

Service addresses

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

Service addresses Europe Germany

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

Great Britain

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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

Russia

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

Bucyrus DBT Europe GmbH Office Moscow Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

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

Doc. no.: 1946 032 000 BA 00

VPVT / 02

7.3

Service addresses North America, Canada, South America USA

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

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

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

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

Africa South Africa

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

7.4

Gearbox P-30 UEL-R

Service addresses Asia China

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

Bucyrus DBT Europe GmbH, Lünen 2008

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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

Doc. no.: 1946 032 000 BA 00

VPVT / 02

7.5

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 13: National standards and directives, extract

Designation

Title

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

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

EWN 6003 1)

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

Referenced European standards and directives Tab. 14: European standards and directives, extract

Designation

Date of issue

Title

EC Directive of the European Parliament and Council on Directive 98/37/EWG the streamlining of the laws of the Member States with regard to machinery EC Directive of the European Parliament and Council on the streamlining of the laws of the Member States with re94/9/EC directive gard to devices and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of Machinery DIN EN ISO 12100-2 Safety of Machinery Non-electrical devices for use in potentially explosive atDIN EN 13463-1 mospheres -Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces Creating manuals DIN EN 62079 - Structure, content and presentation Petroleum products and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Equipment and components for use in areas susceptible to DIN EN 1710 firedamp in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 ments for shearer loaders and plough systems

1998-06-22

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

1) EWN = works standard

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Gearbox P-30 UEL-R

Bucyrus DBT Europe GmbH, Lünen 2008

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

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