CAT RHH-AFC PF 3/822 Operating Manual

Operating manual RHH-AFC PF 3/822 Doc. no.: 0010 297 000 BA 00

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

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

Bucyrus reserves all rights to this publication.

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008E

Contents

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

1.3

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

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

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

1.3 1.4 1.4

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

2.3

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

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

2.3 2.4

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

2.5

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

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

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

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

2.5 2.5 2.5 2.6

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

2.7

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

3.3

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

3.3

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

3.4

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

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

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

3.4 3.4 3.5

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

4.3

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

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

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

4.3 4.3 4.3

Overview - RHH-AFC PF 3/822 . . . . . . . . . . . . . . . . . . . .

4.5

Head gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pan line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 4.7 4.9

How to install drive frames and drive units . . . . . . . . 4.12 Drive frame on the head gate . . . . . . . . . . . . . . . . . . . . . . . .

Drive frame on the tail gate . . . . . . . . . . . . . . . . . . . . . . . . . .

How to mount the drive frame on the drive substructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flange box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to install the flange box . . . . . . . . . . . . . . . . . . . . . . . . .

How to install the curved teeth coupling . . . . . . . . . . . . . . .

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4.12 4.13 4.13 4.18 4.18 4.20

Contents Gearbox P 25/30 and P-30 UEL-R . . . . . . . . . . . . . . . . . . . .

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

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

How to install the plow drive unit . . . . . . . . . . . . . . . . . . . . .

Add-on drive components . . . . . . . . . . . . . . . . . . . . . . . . . . .

Add-on components drive line / substructure . . . . . . . . . . .

Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adaptor pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base plate plow end guides . . . . . . . . . . . . . . . . . . . . . . . . .

4.21 4.21 4.22 4.23 4.23 4.24 4.26 4.27 4.28 4.32

How to install the conveyor pans . . . . . . . . . . . . . . . . . 4.34 Base plate plow pan PF 3/822 . . . . . . . . . . . . . . . . . . . . . . .

Spill plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brackets for emergency stop and loudspeaker . . . . . . . . .

Pan connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.34 4.38 4.39 4.40 4.44 4.44 4.45

How to restrain and tension the chain . . . . . . . . . . . . . 4.46 Auxiliary devices for holding the chain assembly . . . . . . .

Coupling of the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to set the chain pretension . . . . . . . . . . . . . . . . . . . . . .

4.46 4.52 4.53

How to tension the plow chain . . . . . . . . . . . . . . . . . . . . 4.55 How to restrain and tension the plow chain . . . . . . . . 4.55 Auxiliary devices for restraining the plow chain . . . . . . . . .

How to couple and tension the plow chain . . . . . . . . . . . . .

4.56 4.58

Sequencing control of the conveyors . . . . . . . . . . . . . 4.59 Switching conditions of the system components . . . . . . . .

Switching conditions between head gate and tail gate . . .

4.59 4.59

How to start up the conveyor system . . . . . . . . . . . . . . 4.60 Before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Test run and start-up of the plow system . . . . . . . . . . . . . .

Tightening the bolted connections . . . . . . . . . . . . . . . . . . . .

4.60 4.61 4.62 4.63 4.64

Dismantling and withdrawing the conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65 Who is authorized to dismantle and withdraw the conveyor system? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.65

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Chain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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How to install the chain assembly . . . . . . . . . . . . . . . . . 4.44

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

5.3

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

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

5.3 5.3

How to perform maintenance on the conveyor . . . . .

5.4

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

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

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

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

5.4 5.4 5.4 5.8

How to replace wear parts . . . . . . . . . . . . . . . . . . . . . . . .

5.9

Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to dismantle the drive unit . . . . . . . . . . . . . . . . . . . . . .

How to mount the new drive unit . . . . . . . . . . . . . . . . . . . . .

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

Wear parts on the RHH end guides . . . . . . . . . . . . . . . . . . .

5.9 5.9 5.10 5.14 5.15 5.16

When faults occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 Bucyrus DBT Europe GmbH, Lünen 2008

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Identifying the cause of faults . . . . . . . . . . . . . . . . . . . . . . . .

5.19

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

6.3

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

6.3

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

6.5

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

Identification of the drive frame . . . . . . . . . . . . . . . . . . . . . .

6.5 6.6

tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

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

6.7

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

6.8

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

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

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

6.8 6.10 6.12

7. For your information

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

7.3

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

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

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

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

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

7.3 7.4 7.4 7.4 7.5

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

7.6

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

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

7.6 7.6

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Contents

RHH-AFC PF 3/822

1

About this manual

Before starting work

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

Before starting work applicable operating manual

conveyor type

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

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

This operating manual is designed for: RHH-AFC PF 3/822 ID. No.: 0010 297 000 00 00 It should be used only for a conveyor of this type!

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category according to. Atex directive

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

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

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

new operating manual

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

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

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

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

Supervisory personnel who: J initiate and/or, J supervise the activities named above.

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1.3

Before starting work Purpose of this operating manual efficiency

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

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

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

service

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

safety

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

Observe this information and follow the instructions.

Characters and symbols used

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 conveyor or in the immediate vicinity.

Important!

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

J

Items in lists are marked with bullets.

–

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

.

1.4

Points in the text marked in this way describe individual work steps.

Follow this manual step-by-step. This will help you carry out your work faster and, more importantly, more safely.

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Try to memorize the symbols and their meanings.

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

.

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2.3

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

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

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

2.4

RHH-Förderer PF 3/822

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

Use the conveyor only as intended.

Intended uses are: J the transport of coal and tailings away from the face, J the following conveyor operations:

– advancing, – pulling back, – lifting or lowering using the boom steering system, J to perform the following with the face support:

– pulling up, J forming a thrust bearing for:

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– face, part and block anchorage.

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

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

vidual props, boards, replacement parts etc.

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

Ambient conditions Suitable measures must be taken by the operator to combat 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 water spraying systems.

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

It may only be restarted by an authorized person.

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

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

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2.5

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

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

The M2 equipment/conveyor may only be operated when the safety requirements according to DIN EN 1552 have been met. These include, among other things: J systems preventing unauthorized starting, J startup warning systems, J water spraying systems in areas where there is a danger of ex-

plosion, such as – chain guides, J safe lockout command systems, J EMERGENCY STOP systems, J dust extraction systems, J noise protection, J warning messages, etc.

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

2.6

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– inlet guides at the drive frame,

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

noise emissions

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

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

safety equipment

Start the conveyor only when it is in 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.

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

Observe the symbol plates on the conveyor.

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

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

lock out

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

Never enter a conveyor, if the conveyor and the mining equipment have not been locked out. cordon off working area

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

moving parts

Never allow parts of your body to come between machine components which could move, such as e.g.: J conveyor chains, J flights, J spill plates, J chain sprockets, J tensionable drive frames, J pushing devices.

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2.7

Safety instructions danger of explosion

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

Observe the separate operating manuals for the components used.

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 devices

Ensure that the transport safety devices have been correctly installed.

Fix all moving parts with transport locks.

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.

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

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

floor conveying devices

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

Installation and start-up

inclined faces

On an inclined face secure all individual parts using chains, e.g. on the shields.

Secure the installed E-motors during installation against unauthorized or inadvertent switching on.

The conveyor must be anchored in order to prevent it from shifting sideways.

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.

2.8

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Bucyrus DBT Europe GmbH, Lünen 2008

means of attachment

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Never stand under unsecured components or suspended loads.

Safety instructions Operation Operate the control system only when you have extensive knowledge of the operating elements and its method of operation. You must have been trained on the control system concerned.

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

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

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

Keep the floor clear of debris.

Check to determine whether the shields are set sufficiently tight between the roof and floor.

Maintenance and repair

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Be sure to observe the prescribed maintenance and inspection intervals.

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

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

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

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

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, 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

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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.

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2.9

Safety instructions disconnecting the relay bar assembly

Before disconnecting the support and the conveyor you must: J block your working area for the mining equipment and J relieve the load on the components which are under hydraulic

pressure or mechanical stress. raising the conveyor

Secure your working area against falling rock. This measure is especially important if the conveyor must be lifted on the faceside.

If you must raise the conveyor in the area of several shields, lifting gear should not be attached to supports which are located next to one another.

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

Only lift the conveyor using shields which are connected to the conveyor with shifting beams. 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 can penetrate the skin and cause serious infections.

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

2.10

protective equipment - hydraulic system

When removing protective devices which include hydraulic components, keep in mind that these hydraulic components may be pressurized. 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

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

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

Only use 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.

E

Reset the shields in the area where the conveyor is to be raised.

Check the setting pressure again. Under no circumstances should you disengage the canopy from the roof. It must always be in full contact over the entire length.

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 sockets, J the connections are leak-tight.

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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

Use only hydraulic hose lines approved for the prevailing pressures.

Do not use any hydraulic 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

5

4

4 Standard 5 nominal diameter 6 Flame-resistant and antistatic

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

Doc. no.: 0010 297 000 BA 00

VRVT / 01

2.11

Safety instructions Never try to repair damaged hydraulic hoses.

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

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

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

Laying hydraulic hoses, slack RIGHT

WRONG

J are not twisted Fig. 3:

Laying hydraulic hoses, twisting WRONG

J are not bent directly behind the connections (distance minimum

1.5 x nominal diameter) Fig. 4:

Installing hydraulic hose lines, bending RIGHT

WRONG

J cannot chafe Fig. 5:

2.12

Installing hydraulic hose lines, crossing RIGHT

WRONG

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

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RIGHT

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

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

When installing the hydraulic hoses, ensure that they cannot be: J torn out, J kinked, J crushed, J driven over or, J twisted by the movement of the equipment (Fig.: 6).

Fig. 6:

Laying hydraulic hoses, connections on moving parts WRONG

Bucyrus DBT Europe GmbH, Lünen 2008

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RIGHT

Doc. no.: 0010 297 000 BA 00

VRVT / 01

2.13

Bucyrus DBT Europe GmbH, Lünen 2008

E

Safety instructions

2.14

RHH-Förderer PF 3/822

3

Storage and transport

Storage

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

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

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

Storage

Bucyrus DBT Europe GmbH, Lünen 2008

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Storing the equipment corrosion protection

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.

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

short-term storage

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

long-term storage

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

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

This inspection can be carried out by Bucyrus upon request.

natural aging

Even with proper storage, seals and hose lines are subject to natural aging. 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.

Doc. no.: 0010 297 000 BA 00

VRVT / 01

3.3

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

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

Warning!

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

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

Use only suitable load handling devices.

Transport of equipment at temperatures between -21 °C and -40 °C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

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

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

electrical and electronic components

3.4

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

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

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

temperatures below freezing

E

Before transport

Transport Transport of the components machine parts

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

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

Danger!

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

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

Fig. 7:

Drive frame MR 25/30-800 on the head gate and tail gate, Transport sketch

Bucyrus DBT Europe GmbH, Lünen 2008

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a

b a

L

H

B L = Length B = Width H = Height

a Lifting eye (load capacity = 8000 kg) 1) b Transport equipment drive unit 1)

Tab. 1: Principal dimensions on the drive frame MR 25/30-800

1)

Doc. no.: 0010 297 000 BA 00

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

1980

1058

900

5975

Remove after transport.

VRVT / 01

3.5

Transport Warning!

During transport and installation only use the lifting points provided.

Always use all four lifting points.

The transport securing device (a) used for securing the bottom plate insert may only be removed after transport.

The sidewalls of the drive frame may not be used as points of attachment for traction devices.

Important!

Also observe the separate operating manuals for machine parts not listed here, such as motors, gearboxes etc. pans

Some of the conveyor pans are equipped with lifting points (lifting eyes). The lifting points can be on the sides or at the front ends of the pans. The lifting eyes at the end of the pans have to be removed again after transport.

Bucyrus DBT Europe GmbH, Lünen 2008

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

3.6

RHH-Förderer PF 3/822

4

Installation

Points to observe prior to installation

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

Installation work is only allowed to be carried out by personnel having received sufficient training.

Work on: J the safety components (pressure relief valves, fire extinguishing

equipment etc.), J the electrical equipment (control units, signaling devices etc.), J the hydraulic equipment (cylinders, directional control valves,

hoses etc.), shall only be carried out by service engineers from Bucyrus or by specially trained personnel.*

Which tools are required for installation?

Bucyrus DBT Europe GmbH, Lünen 2008

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tool box

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

We recommend that you deposit the toolbox supplied at the drive.

In addition, various items of auxiliary equipment and machines are required at the point of installation. These include: J lifting tackle with sufficient lifting capacity, J hoisting gear with sufficient lifting capacity, J impact wrenches including accessories, J drill including accessories.

Instructions concerning installation Caution!

Incorrect installation can result in significant damage to the conveyor and the drive units.

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

Caution!

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

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

special pans

Special conveyor pans such as adaptor pans, switching pans and transfer pans etc. are located in the face conveyor transfer areas, between the drive frame and the standard conveyor pans. They must be installed in the order specified. The arrangement can be seen in the overview at the beginning of this chapter.

standard conveyor pans

Doc. no.: 0010 297 000 BA 00

The standard conveyor pans, adaptor pans and switching pans are located between the transfer areas. Do not fail to ensure during the installation of the panline that adaptor pans and switching pans are installed at their intended locations.

VRVT / 01

4.3

Points to observe prior to installation laying of the conveyor pans

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

Important!

During installation, one draw rope each must be laid in the bottom race and in the upper plow chain guide of the conveyor with which the conveyor chain and/or the plow chain can later be drawn back in!

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

instructions for handling - junction points

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

Bucyrus DBT Europe GmbH, Lünen 2008

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screw tightening torques

4.4

RHH-Förderer PF 3/822

Overview - RHH-AFC PF 3/822 Overview - RHH-AFC PF 3/822 Head gate Fig. 8:

Head gate - 0010 297 100 00 00 124, 129, 135

132

131

127

101 107 221 256

120, 121

122 124, 125, 129

127

Bucyrus DBT Europe GmbH, Lünen 2008

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228

541 143

110

140

146

Plow stop

143

104 554

Doc. no.: 0010 297 000 BA 00

VRVT / 01

215

215

4.5

Overview - RHH-AFC PF 3/822 Tab. 2: Head gate: Main components, dimensions and weights Item Quantity Designation

Length (mm)

Width (mm)

Height (~ mm)

Weight (~kg)

101 104 110 107

1 1 1 1

DRIVE FRAME MR 25/30-800 COVER FOR MR 25/30 AND HK 30 DRIVE SUBSTRUCTURE MRHA 25/30 RATCHET PAWL DEVICE MR 25/30 AND HK 30-3

1980 370 2535

1058 620 9278

900 376 747

5975 78 17770

1225

1404

945

832

110 116*)

1 1

2000

Provided by Fite 415 1310

1276

120

1

1264

770

639

578

121

1

Base RETAINING PANEL HEAD GATE FLANGE BOX MR 25/30 AND GEARBOX P 25/30 CURVED TEETH COUPLING 200/220X10X20 WITH ADAPTOR SHAFT SHORT

702

420

420

346

122

1

see separate operating manual

3200

124

2

510

357

125 127 129 131

1 2 2 1

132 135

1 1

140

1

143 146 215 221 228

1 1 2 1 1

240*)

1

242*)

1

247*) 256 260*)

1 1 1

541*)

1

596*)

1

4.6

SENSOR PROTECTIVE LINE MR 25/30 - HK 30-3 AT HEAD GATE LOCKING DEVICE PF 3/822-34X126 CENTRAL LUBRICATION COVER ACCESSORIES WATER DISTRIBUTION - DRIVE LINE SUPPORT BRACKET WITH CABLE DUCT 1500 LONG SEPARATING AID FOR HBK 200 - MR 25/30

800

see separate operating manual see separate operating manual 705 see separate operating manual

48 E

1853

800

see separate operating manual see separate operating manual 3182

1261

974

4780

1145 1553 490 1980 3325

1101 1218 276 180 351

1105 428 260 300 680

431 1558 70 256 161

-

-

-

-

-

-

-

-

680 990 -

285 172 -

218 195 -

112 92 -

1674

306

224

54

-

-

-

-

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

GEARBOX P-25/30, I=39 DRIVE CONNECTION ASSEMBLY EK-S300-M800/100-G800/100 PNEUMATIC TENSIONING DEVICE 3-PHASE MOTOR 135/400 KW / 1000 V/ 50 HZ COVER PLATE G20/25-S 300-M 800 PLOW DRIVE UNIT HK30-3 WITH FASTENING SET GEARBOX P-30 UEL-R; I=21,6 FOR PMC-D PNEUMATIC TENSIONING DEVICE RHH ADAPTOR PAN PF3/822, LEFT WITH LOADING RAMP AND RHH END GUIDE COAL LOADING RAMP, LEFT RHH PAN PF 3-822;1505 LG bracket FOR ROOF SUPPORT SPILL PLATE MR 25/30, LEFT END SPILL PLATE HEAD GATE LEFT CENTRAL LUBRICATION MR 25/30 - HK 30-3 AT HEAD GATE

Overview - RHH-AFC PF 3/822 Tail gate Fig. 9:

Tail gate - 0010 297 300 00 00

314 124, 125, 129 120, 121

127 122

101, 307

(presentation without Item 311 - deflector)

104 124, 135, 129 132

309

316

Bucyrus DBT Europe GmbH, Lünen 2008

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343 340

127

131

146 428 541

215

310

311

Plow stop

Doc. no.: 0010 297 000 BA 00

VRVT / 01

4.7

Overview - RHH-AFC PF 3/822 Tab. 3: Tail gate: Main components, dimensions and weights Item Quantity Designation

Length (mm)

Width (mm)

Height (~ mm)

Weight (~kg)

101 104

1 1

1980 370

1058 620

900 376

5975 78

120

1

1264

770

639

578

121

1

DRIVE FRAME MR 25/30-800 COVER FOR MR 25/30 AND HK 30 FLANGE BOX MR 25/30 AND GEARBOX P 25/30 CURVED TEETH COUPLING 200/220X10X20 WITH ADAPTOR SHAFT SHORT

702

420

420

346

122

1

see separate operating manual

3200

124

2

GEARBOX P-25/30, I=39 DRIVE CONNECTION ASSEMBLY EK-S300-M800/100-G800/100

510

357

125 127 129 131

1 2 2 1

132 135 146 215 247*)

1 1 1 2 2

260*)

2

307

1

309

1

310 311 312*) 313*)

1 1 1 1

DRIVE SUBSTRUCTURE MRHI 25/30, RIGHT DEFLECTOR MR 25/30 COAL FACE PUSHING DEVICE TAIL GATE HYDRAULIC SYSTEM FOR TAIL GATE PUSHING DEVICE

2535 4149

-

-

-

-

314 316

1 1

2200 2050

500 690

1490 1687

402 1417

340

1

3130

1261

975

4712

343 428

1 1

1100 2570

1145 606

1105 429

419 182

440*)

1

-

-

-

-

442*)

1

BRACKET FOR CABLES AND HOSES RETAINING PANEL ON THE TAIL GATE RHH ADAPTOR PAN PF3/822, RIGHT WITH LOADING RAMP AND RHH END GUIDE COAL LOADING RAMP, RIGHT END SPILL PLATE TAIL GATE RIGHT CENTRAL LUBRICATION MR 25/30 - HK 30-3 AT HI SENSOR PROTECTIVE LINE MR 25/30 - HK 30-3 AT HI

-

-

-

-

541

1

1647

306

224

54

4.8

BAFFLE PLATE MR 25/30-800-LW694 WITH RATCHET PAWL DKB 34X126-7Z-KA=150 INLET GUIDE SET PF 3/822 FOR MR 25/30-800-LW694

SUPPORT BRACKET WITH CABLE DUCT 1500 LG

1553 490 680

see separate operating manual see separate operating manual 705 see separate operating manual see separate operating manual see separate operating manual 1218 428 276 260 285 218

48

1558 70 112

-

-

-

-

1025

1050

1140

1197

1360

280

341

380

9278 747 17770 1266 1440 1587 see separate operating manual

RHH-Förderer PF 3/822

E

1853

800

Bucyrus DBT Europe GmbH, Lünen 2008

PNEUMATIC TENSIONING DEVICE 3-PHASE MOTOR 135/400 KW / 1000 V/ 50 HZ COVER PLATE G20/25-S 300-M 800 PLOW DRIVE UNIT HK30-3 WITH FASTENING SET GEARBOX P-30 UEL-R; I=21,6 FOR PMC-D PNEUMATIC TENSIONING DEVICE RHH PAN PF 3-822;1500 LG bracket FOR ROOF SUPPORT LOCKING DEVICE PF 3/822-34X126 ACCESSORIES WATER DISTRIBUTION - DRIVE LINE

800

Overview - RHH-AFC PF 3/822 Pan line Fig. 10: Pan line - 0010 297 500 00 00 505

519

501

590

557

556

Bucyrus DBT Europe GmbH, Lünen 2008

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217, 218

Tab. 4: Pan line: Main components, dimensions and weights Item

Quantity Designation HYDRAULIC CIRCUIT DIAGRAM 4-BLOCK FOR BOOM STEERING SYSTEM

213

15

214

2

HYDRAULIC CIRCUIT DIAGRAM 3-BLOCK FOR BOOM STEERING SYSTEM

217 218 501 505 519

66 66 127 2 4

541

131

HYDRAULIC CYLINDER ZE-125/63-95-SO-CR FRONT JOINT SHELL, COMPLETE RHH PAN PF 3/822 LG1505 RHH PAN PF 3/822 750LG RHH PAN PF 3/822 S1500 LG. SUPPORT BRACKET WITH CABLE DUCT 1500 LG

543

2

555*)

12

557

17

560 561

8 6

SUPPORT BRACKET WITH CABLE DUCT 1500 LG BRACKET FOR EMERGENCY STOP AND LOUDSPEAKER bracket FOR HYDRAULICS FOR BOOM STEERING SYSTEM AND EMERGENCY STOP CHAIN 34X126-2-793 CHAIN 34X126-2-77

Doc. no.: 0010 297 000 BA 00

VRVT / 01

Length (mm)

Width (mm)

Height (~ mm)

Weight (~kg)

-

-

-

1022

-

-

-

973

380 290 1505 803 1564

220 120 1280 1218 1280

196 166 428 428 428

41 14 1333 757 1349

1647

306

224

54

934

572

224

72

660

256

350

21

584

270

328

17

-

-

-

-

4.9

Overview - RHH-AFC PF 3/822

562*) 563*) 564*) 565*) 566*) 567*) 568*) 569*) 570*) 571*) 576*) 577 581 582*)

24 4 2 2 2 2 2 2 580 2 17 50 1 3

583*)

1

584

1

585 587 589 591*) 594 595 597

1 1 2 1 10 2 2

Length (mm)

Width (mm)

Height (~ mm)

Weight (~kg)

BLOCK CONNECTOR 34X126 T-CLASS CHAIN 42x137-751 T-CLASS CHAIN 42x137-71 T-CLASS CHAIN 42x137-45 T-CLASS CHAIN 42x137-23 T-CLASS CHAIN 42x137-9 T-CLASS CHAIN 42x137-7 T-CLASS CHAIN 42x137-5 FLIGHTS PF3/822 DKB 34X126 T-CLASS CHAIN 42x137-11 SPECIAL CHAIN LOCK 42x137 EMERGENCY STOP LINE SUPPORT TOOL SET RH INSTALLATION9-38 PULLING-OFF DEVICE FOR BUSHING PULLING DEVICE FOR PLOW CHAINS RHH-42 TOOL SET FOR HYDRAULIC TENSIONING NUTS

150 -

682 -

115 -

62 9

TOOL FASTENING P/KP 30 MOUNTING AND PULLING-OFF DEVICE CONNECTION SOCKET TYPE PE3490 SET OF BITS DBT2003, RHH-42, 1350-1650H UNIVERSAL TOOL W1 DBT99 COMPRESSED AIR BANDSAW HOIST WITT 2.5 T

300 -

see separate operating manual see separate operating manual 32 33 see separate operating manual

E

Quantity Designation

0,5 -

The following figure shows the installation plan for the entire conveyor with specifications for J emergency stop equipment, J loudspeaker, J plow end switch, J cylinder for the boom steering system, J valves for the boom steering system and J auxiliary control station (retaining panels).

4.10

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

Item

Doc. no.: 0010 297 000 BA 00

Coal Face

Head Gate

VRVT / 01 RHH-pans RHH-pans w. switch RHH special pans Outrigger steering

Coal Block 160 m

Coal Block 160 m

E

Tail Gate

Coal Face

Bucyrus DBT Europe GmbH, Lünen 2008

Auxiliary Control panel

Outrigger Steering Control Valve

Outrigger Steering Cylinder

Loudspeaker + Emergency Stop

Plow Limit / Synchronization Switch

Conveying Direction

Overview - RHH-AFC PF 3/822

Fig. 11: Installation plan

4.11

How to install drive frames and drive units How to install drive frames and drive units Caution!

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

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

Caution!

Lubricate the drive frames completely before commissioning the conveyor.

The lubrication points are marked in red.

The drive frames are identical on the head gate and tail gate.

Drive frame on the head gate Fig. 12: Drive frame MR 25/30-800-LW694 - head gate, Item 101

Bucyrus DBT Europe GmbH, Lünen 2008

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c

3

1

d a b 2 1 drive frame 2 drive unit 3 chain stripper a grease inlet b grease outlet

4.12

c lifting eye (load capacity = 8000 kg) d transport equipment for drive unit For parts not listed here, please refer to the replacement parts list supplied.

RHH-Förderer PF 3/822

How to install drive frames and drive units Drive frame on the tail gate Fig. 13: Drive frame MR 25/30-800-LW694 with inlet guides - tail gate , Item 301 c

309

3

Bucyrus DBT Europe GmbH, Lünen 2008

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1 d 2

a b

1 drive frame 309 inlet guide 2 drive unit 3 chain stripper a grease inlet b grease outlet

c lifting eye (load capacity = 8000 kg) d transport equipment for drive unit For parts not listed here, please refer to the replacement parts list supplied.

How to mount the drive frame on the drive substructure The drive substructures on the head gate and tail gate connect the drive stations with the shield units in the drive areas.

Important!

The drive substructure must be bolted to the drive frame before installing the gearbox, in order to ensure that all bolts are accessible.

Drive substructure at head gate The drive substructure is comprised of several segments (bottom plate and raised sides) which are screwed together.

The rocker (4) is used to mount the drive frame.

Doc. no.: 0010 297 000 BA 00

VRVT / 01

4.13

How to install drive frames and drive units To assemble the drive frame on the substructure on the head gate, proceed as follows:

. Place the raised side 1 (2) and raised side 2 (3) on the bottom plate (1) and screw them together with the 32 fastening elements (9, 10, 11). The pin (6) centers the components.

. Place the rocker (4) on the raised side and fix it in place with the pins (7).

Ensure the pin is secured.

. Lift the drive frame onto the rocker. The pins (8) must engage in the holes of the drive frame while doing so.

. Screw it together with the 14 fastening elements (9, 10, 11).

Fig. 14: Drive substructure head gate, Item 110

10, 11

9 8

4

6 10, 11

7

9 3 1 2

1 bottom plate 2 raised side 1 3 raised side 2 4 rocker 5 drive frame

4.14

6 pin

10 hex. nut M 30-8

7 pin

11 retaining ring

8 pin

a lifting eye (load capacity = 8000 kg)

9 hex. head screw M 30x90-8.8

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

5

E

a

How to install drive frames and drive units Drive substructure at tail gate The individual segments are screwed together for the tail gate the same as for the head gate.

The drive substructure is comprised of several segments (bottom plates and shackles) which are screwed together.

First screw the floor elements and shackles together.

The upper box (1) is used to mount the drive frame.

Fig. 15: Drive substructure on the tail gate, Item 310

17, 22

11

16, 22

3

1

19, 22

12

17, 22 6

16, 22

Bucyrus DBT Europe GmbH, Lünen 2008

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5

18, 22 18, 22

20, 21, 22 7

2

17, 22

4

9

17, 22

10 16, 22

1 upper box 2 lower box 3 bottom plate 4 bottom plate 5 bottom plate 6 corner piece II 7 rear stop II

Doc. no.: 0010 297 000 BA 00

9 shackle 10 shackle 11 shackle 12 shackle 16 hex. head screw M 30x140-10.9 17 hex.head screw M 30x90-10.9

VRVT / 01

18 hex. head screw M 30x100-10.9 19 hex. head screw M 30x120-10.9 20 hex. head screw M 30x115-10.9 21 washer 31 22 hex. nut V M 30-10

4.15

How to install drive frames and drive units After you have screwed the segments to one another, mount the receptacle for the drive frame. To accomplish this, proceed as follows:

. Place the lower box (2) with its recesses on the pins (a) of the bottom plate (3) and fasten it in place with the 14 fastening elements (20, 21, 22).

Fig. 16: Installation of lower box - drive substructure 2

a

3

22

21

2 lower box 3 bottom plate 20 hex. head screw M 30x115-10.9 21 washer 31

22 hex. nut V M 30-10 a pins For parts not listed here, please refer to the replacement parts list supplied.

. Then place the upper box (1) on the lower box (2) in such a way that the pins (b) lie in the recesses of the upper box.

. Fasten the upper box with the 14 fastening elements (20, 21, 22).

Fig. 17: Installation of upper box - drive substructure 1

b

20

3 2 1 upper box 2 lower box 3 bottom plate 20 hex. head screw M 30x115-10.9

4.16

22

21

21 washer 31 22 hex. nut V M 30-10 a pins For parts not listed here, please refer to the replacement parts list supplied.

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

E

20

How to install drive frames and drive units To install the drive frame on the tail gate proceed as follows:

. Lift the drive frame (c) onto the substructure. . Place the drive frame with the recesses onto the two pins (b) and onto the ribs (a).

. Insert the screws (20) with the washers (21) and the nuts (22) in the holes provided.

. Tighten the bolts to their respective torques (see Chapter 6 Section “Tightening torques”).

Fig. 18: Drive frame installation MR 25/30 - substructure - tail gate d

c

Bucyrus DBT Europe GmbH, Lünen 2008

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b

a

21, 22

20

20 hex. head screw M 30x115-10.9 21 washer 31 22 hex. nut M 30-10 a rib b pin

c drive frame MR 25/30 d lifting eye (load capacity = 8000 kg) For parts not listed here, please refer to the replacement parts list supplied.

Important!

After you have mounted the drive frame on the tail gate on the substructure, unbolt the two lifting eyes, in order to be able to mount the baffle plate later.

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4.17

How to install drive frames and drive units Flange box The flange box acts as the connection element between the drive frame and gearbox. The hole pattern matches the respective frame and gearbox models. The installation of the flange box is identical on the head-end and tail gate drives. before installation

The anticorrosion material must be removed prior to installation.

The locations concerned must be cleaned with a solvent until they are grease-free and then be treated with a solid lubricant which does not contain molybdenum disulfide (see Section “Greases and lubricating pastes”).

loose parts

Moreover, ensure that the parallel keys or pins which are necessary to absorb the torque are fitted and screwed in properly.

working pressure

Pump pressure is applied to the hydraulic tensioning nuts for fixing the flange box. Observe the maximum applicable working pressure for each of the tensioning nuts. Also follow the separate operating manual of the respective manufacturer for hydraulic tensioning nuts.

How to install the flange box

. Guide the expansion bolts (Fig. 19, Item 4a) out of the drive frame through the bore holes.

. Thread the expansion bolt (Fig. 19, Item 4b) into the T-groove. . Place the flange box on the drive frame (centering by means of the pin (Fig. 19, Item 2)).

. Hand tighten the relevant tensioning nuts (4) on the expansion bolts.

. Fix the flange box on the drive frame properly using the tensioning nuts.

Notice!

For this, follow the separate operating manual of the hydraulic tensioning nuts of the respective manufacturer.

Caution!

The tensioning nuts are tightened using pump pressure. Observe the working pressure required for tightening each individual tensioning nut. The working pressure must not exceed 2275 bar under any circumstances.

. Guide the expansion bolts (Fig. 19, Item 3) for fastening the flange box to the gearbox through the bore holes in order to mount the gearbox later.

4.18

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

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Please proceed as follows:

How to install drive frames and drive units

Fig. 19: Installation of the flange box - head-end and tail gate drives, Item 120 b

4A

a

4b

2

E

1 flange box MR25/30 Bucyrus DBT Europe GmbH, Lünen 2008

2 pin 3 hydraulic connection set for gearbox with expansion bolt M 36x250 3) Hydraulic tensioning nut M 36x4 4 hydraulic connection set for drive frame with 4a expansion bolt M 30x290 1) 4b expansion bolt M 30x178 2)

1

c

4

3

7 hydraulic tensioning nut M 30x3.5 7 parallel key a drive frame b curved teeth coupling half machine frame side c load hook (load capacity = 3000 kg)

The cover (8) can be dismantled by means of the screws (5) and nuts (6). This will make the curved teeth coupling accessible.

Fig. 20: Flange box installed

5, 6

8

5 hex. head screw M 20x55-8.8 6 hex. nut M 20-8

8 cover

1) working pressure M 30x260 = 2275 bar 2) working pressure M 30x150 = 1172 bar 3) working pressure M 36x250 = 2275 bar

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4.19

How to install drive frames and drive units How to install the curved teeth coupling Observe the separate operating manual for correct installation of the curved teeth coupling from Renk.

Caution!

The special purpose screws for the curved teeth gear coupling may only be fitted when the gearbox has been installed. The special purpose screws can become damaged while installing the gearbox.

Install the gearbox before screwing the special screws into the curved teeth coupling.

Refer to chapter 5, section “How to dismantle the drive unit” for further information on special purpose screws.

Bucyrus DBT Europe GmbH, Lünen 2008

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Caution!

The coupling is supplied without a grease filling. The coupling must be filled with grease after installation.

Use a grease gun to press the prescribed amount of grease (1.3 kg “Longlife” from Renk) into the lubricating nipples.

4.20

RHH-Förderer PF 3/822

How to install drive frames and drive units Gearbox P 25/30 and P-30 UEL-R Notice!

Observe the separate operating manuals for the gearboxes used.

Important general information on installing the gearbox: J All flange surfaces, centering bores, parallel keys and grooves

must be clean and free of burrs.

J The gearing must be well-greased before being mounted.

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

actly opposite one another to ensure that they mesh smoothly.

Try to avoid damage to the gearing. Take special care to ensure that the gearbox is not tilted during installation.

J 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. The vari-

ous O-ring sizes can be obtained from the spare parts documentation for the gearbox utilized.

E

J Ensure you use the correct screw sizes corresponding to the

Bucyrus DBT Europe GmbH, Lünen 2008

gearboxes used.

J The gearbox is fixed to the flange plate using hydraulic tension-

ing nuts. Pay attention to the working pressure for the tensioning nuts (Fig. 19, Item 3).

Notice!

For this, follow the separate operating manual of the hydraulic tensioning nuts of the respective manufacturer.

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

gearbox and drive frame or between the drive shafts.

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

Flange position “W”

Flange position “W” of the E-motor means the distance between the motor flange and the shaft collar. On the drive connection the flange position is the distance between the contact surface of the protection cover (motor side) and the contact surface of the coupling (see Fig. 22).

Caution!

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

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4.21

How to install drive frames and drive units Fig. 21: Drive connection

4 1

7, 16, 20

1 protection cover EK-S300-FL800-510 4 coupling S 300 ST-VKR 7 crown gear

Flange position “W” on E-motor

Flange position “W” at the drive connection

E-motor

“W”

“W”

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

fore installation.

J if the flange position “W” of the E-motor is larger than that of

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

J the connecting pieces must be installed using the mounting and

pulling-off device.

Caution!

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

Electric motor (E-motors) Notice!

Do not fail to observe the separate operating manuals for the E-motors used.

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Bucyrus DBT Europe GmbH, Lünen 2008

Fig. 22: Flange position “W” at the E-motor and at the drive connection

E

16 retaining ring 190X4 20 parallel key For parts not listed here, please refer to the replacement parts list supplied.

How to install drive frames and drive units How to install the plow drive unit Notice!

Please follow the instructions in the separate operating manual for the used plow drive unit.

The assembly of the plow drive unit on the drive frame is described in the separate operating manual for the plow drive unit.

Add-on drive components The drive frame is equipped with several covers: J Cover MR 25/30 and HK 30-3 J Spill plate of the drive frame MR 25/30 (at the head gate) J Cover for the central lubrication (at the head gate)

When installing individual covers, make sure that you install the spill plates of the drive frame (1) and the cover for the plow drive unit (2) before installing the cover for the central lubrication (3).

Fig. 23: Covers on the drive frame - head gate

Bucyrus DBT Europe GmbH, Lünen 2008

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1

4

5

2 2 3

1 spill plate MR 25/30 2 cover for MR 25/30 and HK 30-3 3 cover for central lubricationunit

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4 drive frame MR 25/30 5 plow drive unit HK 30-3 6 flange plate

4.23

How to install drive frames and drive units Add-on components drive line / substructure Retaining panel on the tail gate A retaining panel is mounted on the tail gate at which various system control units can be fastened, e.g. prop hydraulics and PMC-D. The retaining panel is screwed onto the drive superstructure at the retaining frame (1) using the hex. head screws and nuts (3, 4).

a 1 retaining frame 3 hex. head screw M 24x80-10.9

1

3, 4

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

4 hex. nut V-M24-8

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Fig. 24: Retaining panel on the tail gate, Item 316

How to install drive frames and drive units Deflector on the tail gate A deflector is mounted on the substructure in order to shield the drive line. A bracket for the pushing device cables and hoses is also mounted.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 25: Deflector on the tail gate, Item 311

3

13, 32 16, 22

2

9

5 12, 32

314

8 17, 23, 28

1

f

g

1 protective plate 2 deflector sheet I, right 3 deflector sheet II, left 5 support bar 6 bracket 8 connecting sheet 9 side plate 12 pin D 50x175 13 pin D 50x210 16 hex. head screw M 24x90-10.9

Doc. no.: 0010 297 000 BA 00

d

e, c

a, b, c

17 roundhead screw M 16x45-8.8 18 hex. head screw M 24x110-8.8 22 hex. nut M 24-10

6, 18, 24

b hex. head screw M 30x220-10.9 c hex. nut V M 30-10 d clip

23 hex. nut M 16-8

e hex. head screw M 20x55-8.8

24 hex. nut M 24-8

f protective hose

28 washer 16 32 spring clip for size 50 pin

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

314 brackets for cables and hoses a base sheet

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4.25

How to install drive frames and drive units Baffle plate The baffle plate is bolted to the front side of the drive frame at the tail gate. flap

The flaps (5, 6) permit inspection work in the area of the chain sprocket.

Danger!

Never open covers and flaps while the conveyor is in operation!

Materials being conveyed could be thrown off or parts of the body could be pulled in by the rotating chain sprocket located below. As a result, you could be suffer serious injury or even be killed!

Do not open the covers and flaps until the conveyor has come to a complete stop and you have secured it against being switched on again!

The swivel-bearing ratchet pawl (7) is used to block the chain (e.g. when shortening the chain, see Section “Chain tensioning”). If the ratchet pawl does not engage in the chain when the flap (5) is open, it must be secured using the round rod (3) and the spring cotter (13).

Fig. 26: Baffle plate - tail gate, Item 307 5 4

16

7

15

a

8, 14

13

3 round rod 4 baffle plate 5 flap 6 flap 7 ratchet pawl 8 locking pins 13 spring cotter 14 spring cotter

17 3

6

15 square-head bolt M 24x2x80-10.9 16 collar nut M 24x2 with securing element, SW 30; D=46 1) 17 hex. head screw M 30x280-8.8 a drive frame For parts not listed here, please refer to the replacement parts list supplied.

1) tightening torque MA = 785 Nm

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Bucyrus DBT Europe GmbH, Lünen 2008

ratchet pawl

E

Caution!

The flap in the baffle plate opens downwards after the locking pins (8) have been removed.

Secure the flap against falling down before you remove the locking pins.

How to install drive frames and drive units Cooling system The cooling system prevents the conveyor gearboxes and motors from overheating.

Caution!

Never operate the conveyor without the cooling system. Check all of the cooling system components for correct function at least once a shift.

Fig. 27: Cooling system head gate and tail gate 6, 11, 15, 21 6, 11, 15, 21 c b

5, 20, 21 a 3

6, 10, 21 b

3

A

Bucyrus DBT Europe GmbH, Lünen 2008

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B

C

6, 12, 21 d d

1, 25

A water distribution panel1) B gearbox C E-motor D flow control monitor a output DN 20 b cooling water inlet DN 12 or 3/4”

c 6, 10, 21

3

c cooling water outlet DN 12 or 3/4” d outlet DN 12 1 flow control monitor Novafix 3 hose line 12x5000 5 reducing socket DN 20/12 6 screw-in socket G 3/4”A / DN 12 rotatable

10 sealing ring 27x32-St 11 sealing ring 27x32-Cu 12 USIT ring 27.2x36x2 15 plug-in angle socket 20 staple DN 20 21 staple DN 12 25 cable Liycy 4x0.5 mm2, blue

Notice!

Do not fail to observe the separate operating manuals for the installed subassemblies. These provide detailed instructions concerning the connections, among other things.

Caution!

Never operate the conveyor without the flow control monitor.

The cooling system could be insufficient or even fail if the flow control monitor is not connected.

The drive components could be severely damaged as a result.

1) in included in the scope of delivery

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4.27

How to install drive frames and drive units Adaptor pans The adaptor pans connect the drive frame with the panline of the face conveyor.

The connection of the adaptor pan with the drive frame head and tail gates is established using a frame dogbone (Fig. 29, c, d), the connection to the pan line is established via dogbone (b) and is shown in the section “Pan connection”.

The upper guide (d) for the plow chain is a component part of the adaptor pan. The lower end guide is mounted with the fastening element (11, 14, 16).

Fig. 28: Adaptor pan with RHH end guide - head gate - Item 140

7 6

Bucyrus DBT Europe GmbH, Lünen 2008

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2

5 b, c d

a

11 14

16

1

1 lower end guide I, left 2 lower end guide II, left 5 wear part III 6 claw 7 cover flap 11 hex. head screw M 30x80-10.9 14 hex. nut V M 30-10

4.28

16 washer 31 a adaptor pan, left b dogbone c dogbone retainer, faceside d GH-plow upper guide For parts not listed here, please refer to the replacement parts list supplied.

RHH-Förderer PF 3/822

How to install drive frames and drive units Fig. 29: Adaptor pan with loading ramp and coal ramp - Head gate

a

c, d 1

10, 11

e, f, g

h, i, j b

Bucyrus DBT Europe GmbH, Lünen 2008

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1 loading ramp 10 hammer head bolt M 24x65 11 hex. nut V M 24-10 adaptor pan b coal ramp c frame dogbone d dogbone retainer

End spill plate

e hammer head bolt M 27X2X65 f hex. nut V M 27x2-10 g washer 28x58x4 h hex. head screw M 24X140-10.9 i hex. nut V M 24-10 j washer 25x58x4 For parts not listed here, please refer to the replacement parts list supplied.

The end spill plate is used as a receptacle for cables and supply lines. The bolts and screws for installing the spill plate on the adaptor pan are accessible when the cover plate (a) is folded open.

Fig. 30: End spill plate - Head gate

a b

c, d

35 26

16, 31

16 roundhead screw M 20x75-8.8 26 hex. nut V M 20-8 31 washer 20 35 hex. protective cap a cover plate

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b roundhead screw M 20x75-8.8 c washer 20 d hex. nut V M 20-8 For parts not listed here, please refer to the replacement parts list supplied.

4.29

How to install drive frames and drive units The construction and the add-on components of the adaptor pan of the tail gate are identical with those of the head gate.

Fig. 31: Adaptor pan - Tail gate, in Item 340

d, e

1 c 1 RHH adaptor pan, right 3 RHH end guide a coal loading ramp b end spill plate

4.30

3 b

c dogbone RHH d frame dogbone e dogbone retainer For parts not listed here, please refer to the replacement parts list supplied.

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

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a

How to install drive frames and drive units Rerailer Rerailers are installed in the bottom race on both sides of the adaptor pans on the head and tail gate.They are used to guide flights, that are below the bottom race, into the bottom race again before they enter the drive frame. The flight flips the rerailing flap (2) up and the flight moves onto the inlet supports (c).

Prior to start-up the spring (4) must be tensioned sufficiently so that the rerailing flap is level with the lower profile.

Fill the rerailer with grease before start-up via the lubricating nipple (9). Lubricate once a month during operation.

Fig. 32: Rerailer in the adaptor pan 8

a 2

Bucyrus DBT Europe GmbH, Lünen 2008

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c

b

Detail rerailer (diagram without rerailing flap) 5, 7

4

3

9

10

6, 7

2 rerailing flap 3 shaft 4 flexible spring for rerailers 5 hex. head screw M 20x60-10.9 6 hex. head screw M 20x90-10.9 7 hex. nut V M 20-10

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8 spring dowel pin 9 lubricating nipple 10 end ring a stop plate b adaptor pan c inlet supports

4.31

How to install drive frames and drive units Base plate plow end guides The base plate plow end guides (RHH end guides) guide the plow chain into the plow chain of the plow chain sprocket. It has two parts. One part is welded to the adaptor pan and the other part is screwed. wear part

Used wear parts (Fig. 33 and Fig. 34, Item 5 and Fig. 35, Item 3 and 4)) can be pulled out to the front and replaced after the clamping piece has been removed (Fig. 33 and Fig. 34, Item. 8) (also see Chapter 5, Fig. 73).

claw

The RHH end guides are equipped with a claw (6). The claw is used to block the plow chain (e.g. when shortening the chain). The claw can be loaded into the plow chain after the hood has been opened (7).

The lower end guide to the adaptor pan is screwed together with the fastening elements (11, 14, 16). It must be dismantled for the assembly of the Reisshaken® - plow (see Fig. 28 and 31).

Observe the separate operating instructions for the Reisshaken® plow (base plate plow).

Fig. 33: RHH end guide - head gate 7 6

a

18, 19, 15

17

9 2 10, 13

1 lower end guide I left 2 lower end guide II left 5 wear part III 6 claw chain 42 x 137 7 cover flap left 8 clamping piece 9 pin D 70x250 10 hammer head bolt M 27x2x110-10.9 1)

8 5

11, 14, 16

1 b 11 hex. head screw M 30x90-10.9 13 hex. nut VM 27x2-10 14 hex. nut V M 30-10 15 hex. nut M 20-8 16 washer 31 17 spring clip for size 70pins 18 roundhead screw M 20x75-8.8 19 washer 20

a adaptor pan b load ring (load capacity = 3000 kg) For parts not listed here, please refer to the replacement parts list supplied.

1) tightening torque MA = 500 Nm

4.32

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Bucyrus DBT Europe GmbH, Lünen 2008

lower end guide

E

Caution!

The claw must be prevented from inadvertently engaging in the plow chain while being operated.

Never start the plow unless the covers are closed and secured!

How to install drive frames and drive units Fig. 34: RHH end guide - tail gate 18, 19, 15

7

6

a

17 9 2

11, 14, 16 Bucyrus DBT Europe GmbH, Lünen 2008

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5 10, 13 b 1 lower end guide I right 2 guide sheet II right 5 wear part III 6 claw chain 42 x 137 7 cover plate right 8 clamping piece 9 pin D 70x250 10 hammer head bolt M 27x2x110-10.9 1)

1

8 11 hex. head screw M 30x90-10.9 13 hex. nut VM 27x2-10 14 hex. nut V M 30-10

a adaptor pan b load ring (load capacity = 3000 kg)

15 hex. nut M 20-8 16 washer 31 17 spring clip for size 70pins 18 roundhead screw M 20x75-8.8 19 Washer 20

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

Fig. 35: RHH end guide - view of wear parts I and II

4

3

3 wear piece I

4 wear piece II

1) Tightening torque MA = 500 Nm

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4.33

How to install the conveyor pans How to install the conveyor pans Base plate plow pan PF 3/822 construction

The base plate plow pan (RHH pan) consists of the pan with gobside welded plow chain guide. The pans have an open bottom race.

The gobside guides are designed such that the hydraulic boom steering system can be attached. For block anchorages, RHH pans are supplied with special fittings on the gobside guides. It is possible to attach spill plates.

plow chain guide

The RHH pans are equipped with two covers on the gobside. They can be opened so that access to both the plow chain races is possible.

adaptor pans

To be able to exactly adjust the position of the drive stations to the face length, adjusting pans are installed. They are shorter and equipped with a T-guide on the gobside. This helps in support of an adjustable clevis.

face end area

Special pans are necessary at the ends of the face. They are modified to the local circumstances such as the position of the plow relative to the conveyor, the construction and arrangement of the conveyor drives, including the adaptor pans.

switching pans

The face end area has so-called switching pans. They are equipped with an electronic limit stop for the plow. Two switching pans are additionally installed twice in the pan line. Here, they help in specifying the position of the plow in the panline.

arrangement of the pans

The arrangement of pans is shown in the overview at the start of this chapter (Fig. 11).

Important!

During assembly, one draw rope each must be laid in the bottom race of the conveyor and in the upper plow chain guide of the conveyor with which the conveyor chain and/or the plow chain can later be drawn back in!

4.34

RHH-Förderer PF 3/822

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The faceside and gobside connection of the pans is given in the section “Pan connection”, page 4.40 .

Bucyrus DBT Europe GmbH, Lünen 2008

pan connection

How to install the conveyor pans The following illustration shows the RHH special pan which follows directly in connection with the adaptor pan. The pan has a removable lower end guide. The lower end guide must be dismantled for installing the Reisshaken® base-plate plow with the mounting elements (11, 14, 15). Observe the separate plow operating instructions for installing the plow.

Fig. 36: RHH special pan PF 3/822, 1500 long, Item 146 4 11

1

14 6 Bucyrus DBT Europe GmbH, Lünen 2008

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19

3

1 RHH pan PF 3/822-1505

15

14 hex. nut V M 30-10 15 washer 31 19 dogbone retainer For parts not listed here, please refer to the replacement parts list supplied.

3 guide sheet 6 dogbone RHH symmetric 11 hex. head screw M 30x80-10.9

The following image shows an RHH normal pan.

The covers (3) can be opened for inspecting the RHH guide by loosening the nuts (12).

Fig. 37: RHH normal pan PF 3/822, 1500 long, Item 501 5 1 11

a 12 9 4

3

1 RHH pan 3 cover 4 dogbone RHH symmetrical 5 dogbone retainer face side 6 dogbone retainer gobside 7 pin connection for clevis

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13

7

6 9 square washer 11 hex. head screw M 20x90-10.9 12 hex. nut M 20-10 13 protective plug a clamping piece (for installation of the spill plates)

4.35

How to install the conveyor pans The following illustration shows an RHH switching pan.

The electronic limit stop for the plow is located behind the cover (a) that is removed via the screw (b) with nut (c) and washer (d).

Fig. 38: RHH switching pan PF 3/822, 1500 long, Item 519 1 9, 11, 12

e

a 7 a cover b roundhead screw M 16x45-8.8 c hex. nut M 16-8 d washer e clamping piece (for assembly of the spill plates) For parts not listed here, please refer to the replacement parts list supplied.

6

1 RHH pan 2 cover with switch 4 dogbone RHH symmetrical 6 dogbone retainer gobside 7 pin connection for clevis 9 square washer 11 hex. head screw M 20x90-10.9 12 hex. nut M 20-10

The pin connection (Fig. 37 and Fig. 38, Item 7) for the clevis can be removed using a detaching device.

To accomplish this, proceed as follows:

. Loosen the nuts (4) and pull them and the washer (3) off. . Put the jacking sleeve (a) with the screw (b) in the recesses of the fixing for the pins (2).

. Turn the detaching device by 45° and take off the fixing. . Rotate the screw (b) for as long as required to free the bushing (a) from the bore hole.

. If the connection is mounted again, the nut (4) is tightened by hand.

Fig. 39: Pin connection with detaching device for sleeve

a b 1 pin 2 fixing for pin 3 washer

1

2

3

4

4 hex. nut M 30-8 1) a jacking sleeve b hex. head screw M 24x65-10.9

1) Tighten the nut by hand

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RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

4

E

2

b, c, d

How to install the conveyor pans The following figure shows an RHH adjusting pan with a variable clevis.

The clevis (b) can be moved along the T-guide (a). The guide is provided with three holes that serve as a support for the pins (d).

For moving, please proceed as follows:

. Remove the spring clip (c) and the pins (d). . Move the bracket (b). . Insert the pin in the hole and secure it again using the spring clip.

Fig. 40: RHH adjusting pan PF 3/822, 750 long, Item 505

Bucyrus DBT Europe GmbH, Lünen 2008

E

f

1

2

e

a

b

c

d

4 1 RHH pan PF 3/822, 750 long 2 dogbone RHH symmetric 4 dogbone retainer gobside a T-guide b bracket for clevis movable c spring clip for size 50 pins

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d plug-in pins e retainer for pins (d) f clamping piece (for assembly of the spill plates) For parts not listed here, please refer to the replacement parts list supplied.

4.37

How to install the conveyor pans Spill plates The pans are equipped with spill plates for supporting the cables and the supply lines.

The spill plate is fastened with the help of the clamping piece (6) to the corresponding receptacle of the RHH pan (Fig. 38, Item e). To accomplish this, proceed as follows:

. Place the spill plate (1) properly on the pan. . Loosen the nut and the protective cap (13, 16) and the screw with the washer (10, 14).

. Pull the support (5) off and fold the middle plate (2) upwards. . Insert the screw (9) in the recess on the pan receptacle. . Move the clamping piece (6) onto the washer so that it surrounds the pan receptacle and the spill plate.

. Fasten the clamping piece and the nut (12) and the protective cap (15).

The overlap plate (3) is used for connecting the spill plates of two adjacent pans.

Fig. 41: Spill plate RHH pan, normal and switching pan 2 3 4

9

5

10 15

14

13

16

12 6 1 6 1 spill plate 2 middle plate 3 overlap plate 4 overlap plate 5 support 6 clamping piece

9 hex. head screw M 20x90-8.8 10 roundhead screw M 16x55-8.8 12 hex. nut M 20-8 13 hex. nut M 16-8 14 washer 16

15 hex. protective cap wrench size 30 16 hex. protective cap wrench size 24 For parts not listed here, please refer to the replacement parts list supplied.

The spill plate for the RHH adjusting pan is mounted in this manner.

4.38

RHH-Förderer PF 3/822

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. Refasten the middle sheet (2) and the support (5).

How to install the conveyor pans Brackets for emergency stop and loudspeaker Brackets acting as receptacles for the J E-Stop apparatus and loudspeakers (Fig. 42), J hydraulic system for outrigger steering system and E-Stop

(Fig. 43) are installed along the length of the face.

The precise distribution of the brackets can be seen in the installation plan in Fig. 11.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 42: Bracket for emergency stop and loudspeaker

13, 14 10

11, 12

1 bracket 10 half-round screw M 20x75-8.8 11 washer 20 12 hex. nut M 20-10

1

13 hex. head screw M 10x30-8.8 14 washer For parts not listed here, please refer to the replacement parts list supplied.

Fig. 43: Bracket for hydraulic system for outrigger steering system and E-Stop 1

13, 14 1 bracket 10 half-round screw M 20x75-8.8 11 washer 20 12 hex. nut V M 20-10

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15

10, 11, 12

13 hex. head screw M 10x20-8.8 14 washer 10 15 hex. head screw M 10x30-8.8

4.39

How to install the conveyor pans Pan connection The pans are connected to each other faceside and gobside with different dogbones.

J Coal face: dogbone retainer with filler piece J Gob: dogbone retainer with locking plates

Dogbone connection - faceside Fig. 44: Dogbone b

2 1

E

1 filler piece 2 filler piece for dogbone 3 lock for dogbone 4 collar nut M 20 with securing element, SW 30

4, 5 5 centering bolt M 20x45-10.9 b dogbone

Mount the dogbone retainer as follows:

. Place the symmetric dogbone (b) in the dogbone pockets (Fig. 45, Item a) of the pans. Here, the “nose” of the dogbone reaches under the dogbone retainer welded with the pan (Fig. 45, Item c).

. Place the filler piece (Fig. 45, Item 2) into the dogbone pockets in the same manner (Fig.45, Item a).

. Move the dogbone retainer (Fig. 45, Item 3) over the “nose” of the dogbone.

. Position the centering bolt (Fig. 45, Item 5) with the head behind the dogbone retainer (Fig. 45, Item 3).

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How to install the conveyor pans Fig. 45: Dogbone connection - face side b

c

2

3

a

2 filler piece for dogbone 3 lock for dogbone 5 centering bolt M 20x45-10.9

5

a dogbone pocket b dogbone c dogbone retainer at the pan

Bucyrus DBT Europe GmbH, Lünen 2008

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. Place the filler piece (1) on the centering bolt (5) and screw the centering screws with the nut (4) tight.

Fig. 46: Dogbone connection - face side

2 1 filler piece 2 filler piece for dogbone 3 lock for dogbone

3

5

1

4

4 collar nut M 20 with securing element, SW 30 5 centering bolt M 20x45-10.9 a dogbone

The connection is now completed and secured.

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4.41

How to install the conveyor pans Dogbone connection - gobside The gobside dogbone connection consists of the following components: J dogbone, J 2 locking plates for the dogbone, J centering screw, J collar nut with securing element.

The dogbone is placed in the dogbone pockets of two adjacent pans and fixed on one pan through a screwed dogbone retainer.

. Place the dogbone (a) in the dogbone pockets of the pans. . Place the locking plate (1) along with the centering bolt (4) in the recess of the dogbone pocket.

. Move the dogbone retainer (2) onto the centering bolt. . Screw the dogbone retainer tight with the lock nut (3).

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 47: Dogbone connection - gobside

a

3

2

1 4

1 locking plate for dogbone 2 locking plate 3 collar nut M 20 with securing element, wrench size = 30

4 centering bolt M 20x45 a dogbone

The dogbone connection is now installed and secured.

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RHH-Förderer PF 3/822

How to install the conveyor pans Dogbone connection adaptor pan - drive frame The dogbone connection is used to connect the adaptor pans on the head gate and tail gate with the drive frame. They are secured using hammer head bolts.

Dogbone connections consist of the following components: J dogbone, J dogbone retainer, J hammer head bolt M 24x65-10.9, J hex. nut V M 24-10. installing dogbones

The dogbone connection is installed as follows:

. Insert the hammer head bolt (10) behind the locking plate (b). . Insert the dogbone (3) into the recesses on the pan. . Place the dogbone retainer (4) on the hammer head bolt and tighten with the hex. nut (11).

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 48: Dogbone connection 3 10 4 11

a b

c

3 frame dogbone 4 dogbone retainer 10 hammer head bolt M 24x65-10.9 11 hex. nut V M 24-10

a drive frame b locking plate c adaptor pan

The dogbone connection is now installed and secured.

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4.43

How to install the chain assembly How to install the chain assembly Chain assembly The chain is comprised of individual chain strands with the following individual elements: J flights with mounting elements, J chain link, J block connector.

The flights are fastened to the horizontal link of the chains. The distance between flights is 756 mm. This corresponds to a 6-pitch chain (every 6th chain link is a flight). The symmetrical design of the flight means the installation is arbitrary.

Fig. 49: Flight PF 3/822 - DMKB 34x126-KA 150, Item 570

4 1

2

3 special-purpose screw 1) 4 collar nut M30x2

1 flight 2 clip

Caution!

Observe the completeness of the connecting elements and their correct fastening (e.g. tightening torque for bolted connections)!

Fig. 50: Chain DMKB 34x126, Sketch Conveying direction

756 3

1 2

1 flight 2 chain link

3 block connector

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

1) tightening torque MA = 1300 Nm

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3

How to install the chain assembly Installing the chain connector The individual chain strands of the chain are joined with chain connectors.

Block connector A block connector must always be installed such that is passes over the sprocket drum in vertical position. The assembled connector halves are held together with spring pins.

Warning!

The block connector and other components of the conveyor system could be destroyed if the block connector is installed opposite to the direction of running! As a result, you or others can be seriously injured or even killed!

Always install the block connector in perpendicular position and with the direction of the arrow in conveying direction.

Fig. 51: Type of chain connector: block connector t 1

1

b

Conveying direction

Bucyrus DBT Europe GmbH, Lünen 2008

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a

Top

Top c

l 1 spring pin

a

a bottom plate

Tab. 5: Dimensions of different block connectors (as per DIN 22258, Part 3) Nominal size of the chain

Fig. 52: Block connector

a

b

c

l

perm. deviation

max.

max.

max.

max.

t

26 x 92

92

±0.9

28

75

28

213

30 x 108

108

±1.1

32

87

32

252

34 x 126

126

±1.3

37

99

36

297

38 x 126

126

±1.3

41

111

40

290

38 x 137

137

±1.4

41

111

40

322

42 x 146

146

±1.5

45

115

46

341

48 x 144 *)

144

±1.5

51

124

54

334

Opening the block connector:

. Drive out the spring pin(s). . Push the block connector halves in the direction of the arrows.

1

2

The block connector is open.

Closing the block connector:

. Push the block connector halves together opposite the direction of the arrow.

1 spring pin 2 directional arrows

. Drive in the spring pin(s).

The block connector is closed. *) Special size specified by Theile.

Doc. no.: 0010 297 000 BA 00

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4.45

How to restrain and tension the chain How to restrain and tension the chain Danger!

When working on chains which are under tension you must take particular care. You or others could be seriously injured or even killed by the recoiling chain!

During the tensioning procedure, ensure that all persons are kept out of the danger area and that the danger area is cordoned off over a wide range.

While the chain is being tightened all personnel must stay out of the danger area, i.e. the longitudinal direction of the chain and in the immediate vicinity of the drive units!

Always work from alongside the conveyor chain!

Auxiliary devices for holding the chain assembly The following auxiliary devices must be used as secure restraints when shortening or connecting the chain: J chain locking device, J ratchet pawl device on the drive frame - head gate, J chain assembly ratchet pawl on the baffle plate - tail gate.

Danger!

The conveyor drive unit generates chain forces that could destroy the chain locking device or the ratchet pawl. As a result, you or others can be seriously injured or even killed!

If the chain locking device or the ratchet pawl is installed, do not use anything except a chain tensioner to move the chain.

Observe the separate operating manual!

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Bucyrus DBT Europe GmbH, Lünen 2008

Important!

The following sections discuss exclusively with the tensioning of the chain with the aid of chain tensioners.

E

Danger!

Never use the non-braked drive units to tighten or couple the chain. The drive units generate chain forces which can destroy the ratchet pawl. As a result, you or others can be seriously injured or even killed!

When the chain locking device is installed, operate the chain only by means of a hydraulic chain tensioneror throttled drive units (holding brake)!

How to restrain and tension the chain Chain locking device

. Place the two outer parts (2, 3) on the adaptor pan and fasten them by inserting the pins (4) into the receptacle bore holes in the upper profile of the pan. The closed end of the outer parts should face in the tractive direction.

Warning!

The chain locking device could suddenly come loose because of damaged receptacle bore holes in the conveyor pans. You could be seriously injured or killed.

Before installing the chain locking device, check that the receptacle bore holes are in perfect condition.

. Secure the side parts from lifting up by turning the pins half a turn.

. Place the center part (1) on a horizontal chain link between two flights and the open side of the side parts.

Fig. 53: Fitting locking device, Item 247

E

Tractive direction

3

Bucyrus DBT Europe GmbH, Lünen 2008

4 2 5 1

6

1 center part 2 side part, left 3 side part, right

4 pin 1 5 pin 2 6 chain

. Next, move the center part slowly into the outer parts until it meets with resistance.

. Insert both pins (5) and secure them in the same way as with the side part pins by turning them one half turn.

Fig. 54: Securing the locking device with pins 5

4

4 pin 1 5 pin 2

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4.47

How to restrain and tension the chain Loosening is carried out in reverse order.

Notice!

Starting a conveyor which is blocked could cause severe damage to the drive units.

Remove the chain locking device before restarting the conveyor.

Ratchet pawl apparatus - head gate The upper conveyor chain is blocked on the chain sprocket by the swivel-mounted ratchet pawl (4) of the locking device. This prevents the chain assembly from slipping over the chain sprocket into the bottom race after it has been separated.

To lower the ratchet pawl onto the chain, the locking clip (9) and the pin (8) must be removed.

Fig. 55: Ratchet pawl device MR 25/30-800 8, 9

2 10

a

11, 12

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1

4 3 5, 6, 7 13 1 tie-bar, right 2 tie-bar, left 3 support for ratchet pawl 4 ratchet pawl DKB 34x126-7Z 5 pin D 60x300 6 washer 7 locking clip 8 pin D 30x254

4.48

5, 6, 7

9 spring clip 10 hex. head screw M 30x240-10.9 11 collar nut M 24x2 with securing element 12 square-head bolt M 24x2x100 13 hex. head screw M 30x130-8.8 a load ring (load capacity = 8000 kg)

RHH-Förderer PF 3/822

How to restrain and tension the chain mounting the locking device

The ratchet pawl apparatus must be mounted as follows to the drive frame of the head gate:

. Insert the square-head bolts (12) laterally into the drive frame (Detail X).

. Undo the screws (b) on the central lubrication cover (a) and the screws (d) from the drive frame (c) spill plates.

. Place the tie-bars (1, 2) on the drive frame. . Fasten the tie-bars to the drive using the hex. head screws (10, 13, b, d) and their respective nuts and washers.

Fig. 56: Ratchet pawl device - Tie-bar installation c

10

11

d Detail X

Bucyrus DBT Europe GmbH, Lünen 2008

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Detail X

a

b 12 1

13 1 tie-bar, right 2 tie-bar, left 10 hex. head screw M 30x240-10.9 11 collar nut M 24x2 with securing element 12 square-head bolt M 24x2x100

Doc. no.: 0010 297 000 BA 00

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2 13 hex. head screw M 30x130-8.8 a central lubrication cover b roundhead screw M 24X65-8.8 c drive frame spill plate d roundhead screw M 20X65-8.8 washer hex. nut V M 20-8

4.49

How to restrain and tension the chain . Place the ratchet pawl support on the tie-bars. . Fasten both sides with the pins (5) and secure the pins with washers (6) and locking clips (7).

Fig. 57: Ratchet pawl device - Support installation 2

1

7 6 5 3

a E

6 washer 7 locking clip a load ring (load capacity = 3000 kg)

. Place the ratchet pawl in the support and fasten it with the pins (5, 8).

. Secure the pins with locking clips (7, 9).

Fig. 58: Ratchet pawl device - Pawl installation

3 4 6

8

5

7

3 support for ratchet pawl 4 ratchet pawl DKB 34x126-7Z 5 pin D 60x300 6 washer

9 7 locking clip 8 pin D 30x254 9 spring clip

The ratchet pawl is installed and can be inserted in the chain.

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Bucyrus DBT Europe GmbH, Lünen 2008

1 tie-bar, right 2 tie-bar, left 3 support for ratchet pawl 4 ratchet pawl DKB 34x126-7Z 5 pin D 60x300

How to restrain and tension the chain Danger!

A ratchet pawl apparatus that has not been fastened properly or sufficiently might come loose during the tightening operation. As a result, you or others can be seriously injured or even killed!

Only use the connecting and securing elements provided. Each time before installation always check the connecting elements for damage.

Warning!

If the ratchet pawl is able to engage in the chain during operation you or others can be severely injured and can cause serious damage to the drives. After work on the chain has been completed, the support with ratchet pawl and all nuts and securing devices must be removed.

Chain-ratchet pawl on baffle plate

Bucyrus DBT Europe GmbH, Lünen 2008

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The pivot-mounted ratchet pawl for blocking the chain is loaded after the flap (5) is opened so that its dead-weight will cause it to lie against the chain strands. If the chain is retracted (head gate), then the vertical chain links will lift the ratchet pawl. The ratchet pawl engages in the openings of the subsequent horizontal chain links and blocks the chain.

Caution!

Once the chain has been tensioned, the ratchet pawl must be folded away to the outside and the flap closed again, so that the ratchet pawl will be prevented from engaging in the chain during operation!

Fig. 59: Chain ratchet pawl on baffle plate - tail gate

5 7

5 flap

Doc. no.: 0010 297 000 BA 00

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7 ratchet pawl

4.51

How to restrain and tension the chain Coupling of the chain Danger!

When working on chains which are under tension you must take particular care. You or others could be seriously injured or even killed by the recoiling chain!

During the tensioning procedure, ensure that all persons are kept out of the danger area and that the danger area is cordoned off over a wide range.

While the chain is being tightened all personnel must stay out of the danger area, i.e. the longitudinal direction of the chain and in the immediate vicinity of the drive units!

Always work from alongside the conveyor chain!

The chain can be coupled and tightened with the hydraulic or pneumatic chain tensioner when the chain locking device and the chain ratchet pawl are being utilized.

Information on the level of tensioning force required for pretensioning the conveyor chain to suit operating conditions can be found in the operating manual for the hydraulic or pneumatic chain tensioner.

The ratchet pawl can only block the chain if it engages with horizontal chain links. Switch the tensioning motor off immediately (after the chain has been sufficiently tensioned) when the ratchet pawl is completely engaged in horizontal chain links.

Caution!

Once the chain has been joined, the chain locking device is to be removed and the ratchet pawl is to be taken out of its point of engagement and secured.

releasing the locking device

releasing the ratchet pawl

4.52

The chain locking device is removed again from the conveyor after the chain moves a short distance forward with the chain tensioner.

To release a ratchet pawl that has become jammed, the chain is retightened slightly with the chain tensioner.

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

tensioning force

E

Danger!

When pulling the ends of the chain together with an additional pulling device, use only the specified chain connectors to connect to the ends of the chain and pull them, and not C-links.

How to restrain and tension the chain How to set the chain pretension Danger!

When working on chains which are under tension you must take particular care. You or others could be seriously injured or even killed by the recoiling chain!

During the tensioning procedure, ensure that all persons are kept out of the danger area and that the danger area is cordoned off over a wide range.

While the chain is being tightened all personnel must stay out of the danger area, i.e. the longitudinal direction of the chain and in the immediate vicinity of the drive units!

Always work from alongside the conveyor chain!

The chain can be coupled and tightened (hydraulically or pneumatically) by using the chain locking device and the ratchet pawl.

The tensioning force required for pretensioning the chain assembly to suit the individual operating conditions is given in the operating manual for the chain tensioner. Set the pressure relief valve to the pressure value determined.

correct pretension

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

To accomplish this, the chain - with the conveyor empty - is tensioned sufficiently to run on the bottom plate of the tail gate, without allowing the chain links to be pushed into one another (see Fig.60).

Bucyrus DBT Europe GmbH, Lünen 2008

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required tensioning force

Fig. 60: Chain pretension - tail gate Taut chain The upper side of the flights runs against the underside of the outlet guides of the drive frame or of the adaptor pan

Slack chain The vertical chain links touch end to end with each other.

Optimally tensioned chain for the conveyor when it is running with no load The chain runs on the bottom plate.

Doc. no.: 0010 297 000 BA 00

VRVT / 01

4.53

How to restrain and tension the chain

excessive chain pretension

Excessive chain tensioning results in a loss in power as the chains pass around the chain sprockets. This will lead to increased wear on the chains and chain sprockets, in addition to increased noise levels.

modification of the chain pretension through loading

Experience indicates that the chain may not exhibit more than a hand’s width of slack at the drive during operation when under the influence of the load. Otherwise the chain will impact too strongly against the entry edge of the lower chain channel. This leads to high noise levels and increased wear. It promotes climbing and jumping of the chains on the chain sprockets.

change in pre-tensioning during the operation

As the face advances, the pretensioning in the chain may change in the event that the conveyor takes on other curvatures in both horizontal and vertical direction. Changes can also be caused by greater compression or stretching of the panline and by changes in the face angle. In addition, load changes caused by fluctuations in the properties of the material being conveyed are possible, e.g. in connection with changes in moisture or debris content.

permanent elongation

monitoring the chain assembly

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

Notice!

If the conveyor is blocked, the drive can suffer major damage.

Remove the chain locking device before restarting the conveyor.

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If too much slack develops, then the climbing and jumping of the chains on the chain sprockets will increase.

Bucyrus DBT Europe GmbH, Lünen 2008

too much slack

How to tension the plow chain How to tension the plow chain During assembly, a draw rope must be laid in the upper plow chain guide with which the conveyor chain can later be drawn into the bottom strand.

If a new chain needs to be tensioned or a broken chain needs to be repaired during operations, then first a distinction must be made as to whether the chain is broken in the upper or bottom race.

If the break in the chain is in the bottom race, then the chain will be tensioned with the aid of the pulling device for base plate plow chains. The precise procedure can be found in the separate operating manual for the pulling device for plow chains.

In the rare event of chain breakage in the upper race, the loose chain ends can be pulled together the same way as with a new plow chain with the aid of a draw rope.

How to restrain and tension the plow chain

Bucyrus DBT Europe GmbH, Lünen 2008

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Danger!

When working on chains which are under tension you must take particular care. You or others could be seriously injured or even killed by the recoiling chain!

During the tensioning procedure, ensure that all persons are kept out of the danger area and that the danger area is cordoned off over a wide range.

While the chain is being tightened all personnel must stay out of the danger area, i.e. the longitudinal direction of the chain and in the immediate vicinity of the drive units!

Always work from alongside the conveyor chain!

Danger!

Never use the non-braked drive units to tighten or couple the plow chain. The drive units generate forces in the chain which could irreparably damage the claw or the ratchet pawl. As a result, you or others can be seriously injured or even killed!

If a plow chain locking device is installed, move the plow chain only with the aid of a hydraulic chain tensioner or throttled drive units (holding brake)!

Important!

The following sections discuss exclusively the tensioning of the chain with the aid of chain tensioners.

Doc. no.: 0010 297 000 BA 00

VRVT / 01

4.55

How to restrain and tension the plow chain Auxiliary devices for restraining the plow chain The following auxiliary devices are to be used for restraining the plow chain securely while tensioning or coupling it: J claw in the RHH end guide, J ratchet pawl in the plow drive unit.

Danger!

The plow drives generate forces in the chain which could irreparably damage the claw or the ratchet pawl.

As a result, you or others can be seriously injured or even killed!

When the claw or the ratchet pawl are engaged, only use the chain tensioner to move the plow chain.

Note the separate operating manual.

Loading the claw

. Remove the screw (18) with the nut (15) and the washer (19) and open the cover plate (7).

. Pivot the claw (6) onto the plow chain.

Notice!

To block the plow chain, the retaining claw must snap in between two horizontal chain link. To do this, it reaches over a vertical chain link.

Fig. 61: Claw - head gate

6

7

6 claw

18, 19, 15

7 hood 15 hex.nut M 20-8

4.56

18 roundhead screw M 20x75-8.8 19 washer 20 For parts not listed here, please refer to the replacement parts list supplied.

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

The claw is used to block the plow chain. The claws on the head and tail gates can be fastened at the RHH end guides (see section “Reisshaken plow end guide”). A pivotable cover plate prevents unintentional engagement of the claw in the plow chain.

The cover plate must be opened before the claw can be loaded.

E

Claw in the RHH end guides

How to restrain and tension the plow chain Ratchet pawl (chain locking device) on the plow drive unit The plow drive unit is equipped with a pivot-mounted locking device (ratchet pawl). The ratchet pawl prevents the chain from moving forward or backward into the plow drive unit when the plow chain is opened.

Important!

Always follow the instructions in the separate operating manual for the plow drive unit!

The pivot-mounted ratchet pawl is loaded in order to block the plow chain, so that its dead-weight will cause it to lie against the chain. If the chain is retracted (moved forwards) the vertical chain link lift the ratchet pawl. The ratchet pawl then engages in the openings of the subsequent horizontal chain link, thus blocking the forward or reverse movement of the plow chain.

. Undo the screw connection (4) and push the ratchet-type lock (1) to the side.

. Move the locking device (ratchet pawl)(2) onto the chain sprocket (3).

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 62: Ratchet pawl in the plow drive unit 4

2

1 3

1 ratchet-type lock 2 ratchet pawl 3 plow chain sprocket

4 hex. nut M 24-10 hex. head screw M 24x75-10.9

Danger!

The ratchet pawl can only block the plow chain if it engages in a horizontal chain link.

Note that the plow chain must also be blocked in the area of the end guide before you open it.

Caution!

After connecting the plow chain, the ratchet pawl must be disengaged and secured against reengaging by fitting the ratchet-type lock.

Doc. no.: 0010 297 000 BA 00

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4.57

How to restrain and tension the plow chain How to couple and tension the plow chain Using the claw and the ratchet pawl, the plow chain can be moved together and coupled with the hydraulic chain tensioner.

Danger!

When pulling the ends of the plow chain together with an additional pulling device, use the specified chain connectors to connect to the ends of the chain and pull them instead of C-links.

Information on the level of tensioning force required for pretensioning the plow chain to suit operating conditions can be found in the operating manual for the chain tensioner.

The plow chain is correctly pretensioned when approx. 1 to 2 links of chain are slack in the upper race of the drive unit that pulls the lower chain, when the plow is mining.

Caution!

After connecting the plow chain, the ratchet pawl and the claw are to be removed from their points of engagement and secured against reengaging by fitting the ratchet-type lock and/or closing the protective flap.

To release the claw or the ratchet pawl, the chain tensioner is briefly switched in the opposite direction. Then the claw or ratchet pawl can be disengaged and secured.

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Bucyrus DBT Europe GmbH, Lünen 2008

Afterwards you can unlink the plow chain, lengthen or shorten it and link it together again.

E

The ratchet pawl can only block the plow chain if it engages in a horizontal chain link. Switch the tensioning motor off immediately (after the plow chain has been sufficiently tensioned) when the ratchet pawl is completely engaged in a horizontal chain link.

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

Important!

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

The main components of the installation must be switched on in the following sequence: J hydraulics supply, J cooling water supply, J belt system, J crusher, J beam stage loader, J face conveyor,

Bucyrus DBT Europe GmbH, Lünen 2008

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J mining equipment. switching off

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

fault

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

Switching conditions between head gate and tail gate On conveyors which are equipped with drive units at the head gate and at the tail gate, the individual drive units must be switched on and off dependently of one another in order to avoid an excessive formation of slack chain. switching on

The head gate must always be started up after the tail gate.

An interlock facility must be provided to ensure that the tail gate always starts before the head gate. If this cannot be guaranteed, then the conveyor may not be started at all.

switching off

The tail gate must always be switched off after the head gate.

Doc. no.: 0010 297 000 BA 00

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4.59

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

Warning!

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

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

A safe distance should be maintained to the conveyor!

Notice!

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

Before start-up

and your working area.

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

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

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

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

Danger!

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

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

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

. Check the oil level and the cooling of the gearboxes. . Check the cooling of the E-motors. . Check the direction of rotation of the E-motors. . Check the electrical connections. . Test the sequencing control of the drive units. . Test the function of the signaling devices and the intercom system.

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

E

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

How to start up the conveyor system Test run of the conveyor Danger!

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

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

These hazards could cause severe injuries or even death!

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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Notice!

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

Ensure you observe the applicable environmental regulations.

. lubricate the overall installation at the lubrication points. . Check and inspect the following points: J Uniform and equal power consumption of the E-motors.

J Sufficient cooling of the E-motors.

J Sufficient cooling and proper oil filling of the gearboxes.

J Steady and quiet running of the gearboxes.

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

J Uniform entry of the chain to the drive frame J Check that the flights enter the chain guides properly.

J Check conveyor flight spacing.

J Correct number and installation position of flights.

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

installation position.

J Optimum chain pretension.

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

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

EMERGENCY STOP circuit, etc.

Only when tensionable tail gate drive frames are being utilized: J Apply full working pressure to the cylinders of the tensionable

drive frame several times for approximately one minute each during the test run. Correct the length of the chain as soon as the required chain pretension is not achieved by tensioning the tensionable drive frame.

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How to start up the conveyor system Notice!

Make sure that excessive slack can not be produced in the chain, if the tensionable drive frame is closed down to a minimum. after the test run

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

. Shorten the chain until an optimum chain pretension is obtained in the chain assembly (see also Fig. 60).

. Eliminate any deficiencies discovered.

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

test operation of the loaded conveyor

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

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

After test operation, empty the conveyor completely.

Observe the following points before releasing the conveyor:

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

. Check the functions of the conveyor and the safety systems once again. releasing the conveyor for operation

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

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Danger!

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

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

These hazards could cause severe injuries or even death!

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

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Test operation of the conveyor

How to start up the conveyor system Test run and start-up of the plow system Danger!

Make sure that all personnel has left the hazardous area of the plow system. Make sure you keep a safe distance from the plow system, particularly during test runs. In these phases, installation errors for example may cause hazards that would not arise during normal operation.

Caution!

Do not fail to observe, in addition to the following instructions, the corresponding special instructions contained in the operating manual of the plow system components, e.g. plow, plow drive unit, E-motor, gearbox, etc. before start-up

The following points need to be checked on the plow drive unit before beginning with the start-up of the plow system: J Protective flaps must be closed.

J The ratchet pawl must be in idle position.

J The bearing must be sufficiently greased.

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J Check the bolted connections for secure fit.

J Check the chain pretension of the plow chain (retension if ne-

cessary). test run

A test run must be carried out without shifting ram pressure after the plow has been installed. Check to see whether the plow chain was not twisted during installation and corresponds to the plow chain eddy on both sides of the plow body.

The chain should be coated with oil in order to avoid dry rubbing between plow chain and chain sprocket.

Notice!

Make sure that you observe environmental protection regulations under all circumstances. Use biodegradable vegetable oils, water pollution class 0, due to total-loss lubrication If the plow chain runs smoothly in the chain channels and free of twists over the drive chain sprockets on the head gate and tail gate, pressure can be applied to the shifting ram for advancing the plow system.

After the plow chain tension has been rechecked, plow operation can be activated when face and beam stage loaders are started at the same time - a low cut specification at the beginning is useful.

Check and inspect the following points during the test run: J uniform and equal power consumption of the E-motors, J rolling behavior of the chain at the chain sprockets, J chain slack formation, J correct fit and position of the chain connectors, J function of the sequencing control of the conveyor drive units, J heating and quiet running of the gearboxes, J emergency stop circuit function.

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How to start up the conveyor system after the test run

When the test run is completed, shorten the chain to eliminate excess slack.

Observe the following points before releasing the plow system:

. Thoroughly inspect the plow system and remedy any faults determined during the test run.

. Check the functions of the plow and the safety systems once again. releasing the plow system

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

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

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

Observe the respectively required torque while doing so!

J drive connection (motor and gearbox side),

J chain sprocket screws on chain drums (chain sprockets), J chain strippers on chain drums, J attachments of the inspection openings in the bottom plate of

the drive frame, J replaceable chain guides, J anti-wear strips on drive frame, J guide strips on the tensionable drive frame, J attachments on the drive substructure, J flight fastenings. selecting tightening torque

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

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J gearbox (attachment on the drive frame),

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

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

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

Who is authorized to dismantle and withdraw the conveyor system?

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

Important instructions for dismantling handling delicate components

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

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. Close off all open lines and separation points with protective caps or plugs.

. Pack loose parts, screws, etc. in suitable containers in order to protect the components against soiling, damage and/or loss.

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Dismantling and withdrawing the conveyor system

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Operation

How to operate the conveyor system

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

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

How to operate the conveyor system Danger!

Incorrect operation endangers yourself and others!

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

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

Should anything be unclear, please contact your supervisor!

Who is allowed to operate the conveyor?

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

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

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

When may conveying be started?

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

Danger!

When you start up the conveyor ensure that nobody is present in the conveyor area of danger.

J Avoid running an empty conveyor and do not run the conveyor

in reverse unnecessarily. If however you do run it in reverse, then take care to ensure that it has first run until it is completely empty.

J Make sure that the conveyor is kept as level as possible.

J The gearboxes and E-motors of drive units must always be kept

free of dirt in order to prevent overheating and any resulting damage.

J The conveyor chain must always have the correct pretension.

Slack chain under the sprocket drum of the head gate is permissible up to approximately the breadth of one hand.

Particular observations, especially regarding faults and damage, are to be reported to the supervisor so that they can be remedied as quickly as possible and the necessary repairs can be carried out.

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

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

Be sure to observe the intervals specified for maintenance and checks of the conveyor as hot surfaces may ignite explosive atmospheres or dust.

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

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

Important instructions J In order to avoid individual components not being serviced or

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

J Inadequately performed maintenance can cause machine dam-

age which can result in considerable costs.

Be sure to observe the specified maintenance intervals.

J Use only suitable and approved tools for maintenance work!

J Use only original Bucyrus replacement parts when replacing

components.

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

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

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Please observe the following instructions:

How to perform maintenance on the conveyor Lubrication of the system in accordance with the lubrication schedule Tab. 6: Lubrication according to runtime Component 1)

Medium

Runtime in hours 1.

Drive frame - head gate - drive bearing

Grease 2)

2.

3.

100

100

8

... ...

Drive frame - tail gate - drive bearing Gearbox E-motors Chain tensioners (pneumatic or hydraulic)

3)

Plow, plow drive unit, etc.

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

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Notice!

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

Lubrication points The bearings on the head gate and tail gate are each supplied with grease via a central lubrication system.

Grease the bearings until fresh grease is visible at the grease outlet.

Fig. 63: Bracket for central lubrication 9

9 lubricating nipples

1) 2) 3)

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The listing is general and does not relate to a particular conveyor system.

Grease A2, see Chapter 6, Section entitled “Lubricating greases and pastes” See information in the corresponding operating manual.

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How to perform maintenance on the conveyor Fig. 64: Central lubrication at tail gate 2 3

4

3 lubrication line 4 grease outlet

Inspecting the system for faults and proper function Check the general condition of the conveyor. Pay particular attention to overheating. The conveyor components must be cleaned to do this. Abnormal discoloration on housings and abnormal noises during operation are signs of overheating.

J Inspect all the components of the system at least once per shift

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

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

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

J Make sure the connection elements are fitted securely.

J Check the water spraying system for correct function at least

once per shift. Alternatively the water spraying system can be equipped with a pressure and volume monitoring system.

Inspecting wear parts weekly

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

Check: J the chain assembly, J the flights, J the chain guides, J the wear parts on the RHH end guides.

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1 bracket for central lubrication 2 grease inlet

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1

How to perform maintenance on the conveyor monthly

With some wear parts it is sufficient to inspect them once per month. These include: J the chain sprockets and J the chain strippers.

replacing bearings

Replace the bearings of the conveyor components (drive frame, gearbox, etc.) after expiration of the maximum bearing service life.

Observe the separate operating manuals for the respective transport units. The bearing service life of Bucyrus components is given in Chapter 6 “Technical Data” of the respective operating manual.

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After completion of a panel and a move to a new panel the remaining service life of the bearings must be sufficient for the runtime in the panel. Should this not be the case the bearings must be replaced.

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

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

Maintenance of the hydraulic system daily

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

J Make sure the connection and securing devices are in perfect

condition.

J Check the proper installation of all lines.

J Check that all connections are fitted securely.

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

Important!

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

Caution!

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

Check emulsion values weekly

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

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

– test method: dip slides.

Important!

DIN 24320 provides you with other important instructions.

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ing pieces, springs, etc. are functioning perfectly.

How to replace wear parts How to replace wear parts It is essential that wear parts are replaced before they reach the lowest wear limit as otherwise damage can be caused to other parts of the machine. Inspect the wear parts at regular intervals (see also section “How to maintain the steel structure” in this chapter.)

Drive unit The main components of the drive unit are: J chain sprockets, J drive shaft, J fixed and movable bearings.

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Fig. 65: Drive unit MR 25/30

20

1, 10

1 chain sprocket 10 drive shaft 20 fixed bearing

40

60

40 movable bearing 60 transport equipment

Chain sprocket The chain sprocket transmits the drive torque from the gearbox via the drive shaft to the chain assembly. The chain sprockets are subject to a high degree of wear due to the high amount of abrasive forces and must therefore be replaced regularly or can be turned once before having to replace them.

The degree of wear can be measured at anytime with a depth gauge. The height H is measured with the depth gauge diagonally over the chain link to the bottom of the groove. The chain sprocket must be exchanged or replaced if the height H is less than 86 mm (98 mm - 12 mm wear).

Caution!

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

Please note that the life of a turned chain sprocket may be much shorter than the “initial period of use” of a chain sprocket. This is due to tolerances in the hardness penetration depth. Therefore check on the wear of the turned chain sprocket at least every 2 weeks!

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How to replace wear parts Fig. 66: Wear measurement on the chain sprocket

How to dismantle the drive unit To accomplish this, proceed as follows:

. Remove the cover of the central lubrication (chapter. 4, Fig. 23, Item 3).

. Remove the cover of the flange box (b). . Remove the tie bars (d) by undoing the screws (e).

Fig. 67: Dismantling drive unit MR 25/30 - Head gate f a c

b

g e a drive unit b sealing cover flange box c hex. head screw M 20X55-8.8 d tie-bar

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d e hex. head screw M 30X180-10.9 f connecting pin g curved teeth coupling

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H

How to replace wear parts . Remove the special purpose screws (4) from the coupling sleeve (3) of the curved teeth coupling.

Fig. 68: Disassembling the special-purpose screws

7

3 4, 8 3 coupling sleeve 4 special-purpose screw M 24x45-10.9

7 lubricating nipple 8 washer 25

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sleeve.

Fig. 69: Installation - Separating aid

2

1 separating aid 2 coupling sleeve

1

a a bore (drive frame)

. Push the coupling sleeve (2) so far out to one side until the drive unit can be pushed out of the drive frame. Use the separating tool (1) to move the coupling sleeve.

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How to replace wear parts Fig. 70: Separating aid

2 1

1 separating aid 2 coupling sleeve

3 drive frame

Danger!

When it is on an inclined face, the drive unit can slide out of the drive frame by itself. Secure the drive unit for instance with a lifting strap to prevent it from sliding out unintentionally before disassembling the tie-bar.

Caution!

The axial face seals can become damaged if the bearing housing is tilted at an impermissible angle.

Use lifting straps or similar to move or lift the drive unit. Only place the lifting straps around the chain sprocket.

. Pull the drive unit out of the drive frame with the aid of the lifting strap.

If a new drive unit is to be utilized, then please follow the steps listed in the “How to mount the drive unit” Section that is included later in this Chapter.

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How to replace wear parts If the drive unit is to be rotated by 180° and then reinstalled, then the following steps must be carried out:

. Remove the clamping cover (51) with the spring dowel pin (58) and the plug (56).

. Loosen the hex. head screw (55), the snap ring (54) and the retaining washer with the spring dowel pin (53).

. Remove the clamping piece (52). . Dismantle the curved teeth coupling on the gearbox side . Grease the gearings of the curved teeth coupling with “Longlife” grease from Renk and set them on the other side of the shaft.

. Mount the clamping piece (52) and the hex. head screw (55) with the circlip (54) and the retaining washer (53) on the other side of the shaft.

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Notice!

Take care to ensure that the gearing and the clamping piece are free of soiling and fill the intermediate areas with A2 grease.

Notice!

When installing the clamping cover (51), make sure that you put the sprung dowel pin (58) back into the clamping cover. Doing so will prevent the bolt (55) from rotating with the drive shaft (prevention against skewing).

Fig. 71: Rotating the MR drive unit 52 54 53 55

51 a 51 clamping cover 52 clamping piece 53 retaining washer with spring dowel pin 54 circlip

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56

58 55 hex. head screw M 36x90-10.9 56 plug 58 spring dowel pin 10x32 a drive unit

5.13

How to replace wear parts How to mount the new drive unit Caution!

Do not raise the drive unit except with the support belts or similar intended for this purpose. Only place the lifting straps around the chain sprocket.

. Remove the transport equipment from the new drive unit (see Fig. 65).

. On the gearbox side, remove the clamping cover and the clamping piece, together with their associated parts (see Section entitled “Turning the drive unit”).

. Grease the gearings of the curved teeth couplings with “Longlife” grease from Renk. Observe the separate operating manual for the curved teeth coupling from Renk.

. Before sliding the drive unit into the drive frame, grease the

. Check that the coupling sleeve has been pushed out far enough so that can you push the drive unit in without any difficulty (see Fig. 70).

. Push the drive unit into the drive frame. Make sure that the guides slide evenly into the drive frame and that they do not cant.

. Install the lubricating nipple (see Fig. 67). . Screw the tie-bars onto the end of the drive frame (see Fig. 67).

. Push the coupling sleeve over the coupling so that it is central and fasten it using special purpose screws (see Fig. 68). The required tightening torque for the M30 bolts is MA = 200 Nm. Caution!

The special purpose screws for the curved teeth gear coupling may only be fitted when the gearbox has been installed. The special purpose screws can become damaged while installing the gearbox.

Install the gearbox before screwing the special screws into the curved teeth coupling.

The sealing cover of the flange box must be remounted as the last step in the process. drive unit tail gate

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The baffle plate must first be removed before the drive unit on the tail gate can be replaced (see Chap. 4, Fig. 26). Subsequent procedures to be followed are the same as for replacing the drive unit on the head gate.

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Caution!

Make sure that the guides and the slide surfaces on the drive frame and on the drive unit are free of dirt and soiling.

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guides on the drive frame with B3 lubricating paste.

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

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

disassembly

After opening the chain and removing the stripper plate (1), the chain stripper (5) can be pulled out toward the top when the chain sprocket is installed. The baffle plate must first be removed before the chain stripper on the tail gate can be replaced (see chapter 4, section “Chain stripper”, Fig. 26).

fastening

The chain strippers are fastened on the support receptacles on the right and the left side. The chain strippers are secured in position in their recesses by means of a round steel bar welded to the stripper plate.

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Caution!

Should the strippers come loose during operation, the chain sprocket or the drive frame could be damaged. Do not fail to tighten the stripper plate with the torque required when mounting the M 24x2-8 collar nuts.

The required tightening torque is 785 Nm. Fig. 72: Chain stripper 3

1

2 5

1 stripper plate 2 square-head bolt M 24x2x80-10.9

3 collar nut M 24x2-8, with retaining part, SW 30 1) 5 chain stripper

1) tightening torque MA = 785 Nm

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How to replace wear parts Wear parts on the RHH end guides The RHH end guides are constructed of two parts. One part is welded to the adaptor pan and the other part is screwed.

Check the four wear parts at the head-end and tail gate every week. The amount of wear must not exceed 10 mm. Replace the used wear parts. The wear parts I and II can be replaced only if wear part III has been removed (see Fig. 74). Proceed as follows:

. Remove the clamping piece (Fig. 73, Item 8) by loosening the nuts (Fig. 73, Item 13).

Danger!

The clamping pieces can suddenly come loose.

This could seriously injure or kill you.

Always remove the hex. nut only after you have ensured that the clamping pieces are tension-free. Loosen the hex. nut only a little (1-2 turns). Beat the safety lug using a hammer until it comes undone..

For replacing the wear part III that is below the cable duct, the cable duct (Fig. 73, Item c) must first be removed from the end spill plate. Hang the cable bracket on a suitable chain hoist in order to protect the supply lines and cables.

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replace them before installing the new wear part III (see Fig. 74). . Place a new wear part III with the pins in the provided holes in the end guide and secure it using nuts (Fig. 73, Item 13).

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. Pull the used wear part III out of the RHH end guide. . Check wear parts I and II. If they have worn more than 10 mm,

How to replace wear parts Fig. 73: Wear part III end guide head gate c

a

5

13 8

10

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5 wear part III 8 clamping piece 10 hammer head bolt M 27x2x100 1) 13 hex. nut M 27x2-10

b a adaptor pan b lifting eye (load capacity = 3000 kg)

1) tightening torque = 785 Nm

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How to replace wear parts Replace wear parts I and II as follows:

. Loosen the nuts (22) and the washer (21). . Pull out the screw (20) upward. . Replace wear parts I and II. . Place the wear parts with the pins in the provided holes in the end guide and secure them using the fastening set (20, 21, 22).

. Mount wear parts III and the cable duct.

Fig. 74: Wear part I and wear part II, head gate end guide

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3

22 21

20

3 wear piece I 4 wear piece II 20 hex. head screw M 24x60-10.9

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21 washer 25 22 hex. nut V M 24-10

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When faults occur When faults occur Identifying the cause of faults In the event of faults, you can use these tables to determine the possible causes and take remedial action. Should you not find the cause of faults, please contact our field service department (see Chapter 7 “Service addresses” Tab. 7: Fault table 1 Fault

Cause

Remedy

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

1. Electrical circuit failed.

1. Check the electrical circuit.

2. Voltage failure.

2. Check the voltage.

3. Contactor failure due to overload.

3. Check the overload protection.

4. Switching sequence time less than 1.5 seconds.

4. Check switching sequence time.

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

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

2. Insufficient cooling water.

2. Check the cooling circuit.

Are all shut-off valves open?

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

3. Check oil level in gearbox.

4. Oil is too old.

4. Carry out an oil change. (oil quantity and oil type see separate operating manual for gearbox)

5. Bearings damaged.

5. Have bearings repaired by specialist personnel.

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

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

- temperature >85°C.

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

Conveyor chain jumps over chain sprocket.

1. Grease bearings.

2. Grease too old.

2. Clean bearings and pack with fresh grease.

3. Bearings damaged.

3. Have bearings replaced by specialist personnel.

1. Conveyor is overloaded.

1. Reduce the load on the conveyor.

2. Bottom race clogged with mine material.

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

3. Transfer point clogged.

3. Clear clogging at transfer point.

1. Too much slack chain.

1. Shorten and retension the conveyor chain.

2. Chain strand twisted.

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

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

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

Replace chain strands only in pairs.

4. Twisted flights.

4. Replace any flights which are excessively twisted.

5. Insufficient pretension.

5. Adjust the pretension according to the conveyor length.

1) not applicable on single-center chain assemblies

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When faults occur Tab. 8: Fault table 2 Fault

Cause

Remedy

Conveyor chain suddenly jams.

1. Foreign matter in the conveyor.

1. Remove foreign matter.

2. Flight jammed.

2. Free the jammed flight.

1. The chain is blocked by foreign mat- 1. Remove foreign matter, ter. couple chain ends and transport to the drive unit; lock the conveyor chain, replace chain strands in pairs, tension the conveyor chain.

Conveyor chain jumps out of the chain assembly guide.

1. Conveyor is crooked.

1. Straighten the conveyor.

2. Too much slack chain.

2. Shorten and retension the chain assembly.

3. Pan guide worn.

3. Replace conveyor pans.

4. Flights worn.

4. Replace flights.

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Chain assembly breakage.

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Technical data

Main components of the conveyor system

Technical Data This chapter contains the most important technical data for the conveyor. Further information is given in the spare parts lists and in the separate operating manuals for the individual components e. g. the gearboxes and the E-motors. At the end of this chapter, you will find information on tightening torques, hydraulics fluids, greases, etc. Read the chapter thoroughly and pay special attention to the safety instructions.

The maximum conveyor rating for the mining machine described here is 2 x 400 kW. The maximum conveyor rating is 2 x 400 kW. The stated ratings are continuous power ratings. They apply to E-motors with a nominal rpm of 1470 min-1. The stalling torque of 2.5 may not be exceeded when starting up the E-motors.

No modifications may be made to the components listed unless they are inspected and approved by Bucyrus.

Main components of the conveyor system Bucyrus DBT Europe GmbH, Lünen 2008

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Technical Data Sheet general

head gate

special conveyor pans on the head gate

Conveyor length: . . . . . . . . . . approximately 160 m Noise level: . . . . . . . . . . . . . . . > 85 dB(A) 1) Drive frame: . . . . . . . . . . . . . .

Service life of bearings: . . . . .

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

Flange plate drive frame . . . . . . . . . . . . . . .

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

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

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

Flange plate - Plow: . . . . . . . .

Plow drive unit: . . . . . . . . . . . .

Gearbox - Plow: . . . . . . . . . . .

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

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

RHH adaptor pan: . . . . . . . . .

RHH pan: . . . . . . . . . . . . . . . .

MR 25/30 10,000 h 2) DKB 34x126-7Z, KA=150 Flange box with curved teeth coupling KP-25/30, i=39 3) EK-S300-M800/100-G800/100 135/400 kW Gearbox direct flanging HK 30-3, 42X137-6Z, Bucyrus 3) P-30 UEL-R, i=21.6, Bucyrus 3) EK-S300-M800/100-G800/100 135/400 kW 3) PF 3/822, left PF 3/822, 1500 long

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

2) corresponds to 90% of the calculated nominal bearing service life.

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

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Main components of the conveyor system MR 25/30 DKB 34x126-7Z, KA=150 Flange box with curved teeth coupling KP-25/30, i=39 3) EK-S300-M800/100-G800/100 3) 135/400 kW Gearbox direct flanging HK 30-3, 42X137-6Z, Bucyrus 3) P-30 UEL-R, i=21.6, Bucyrus 3) EK-S300-M800/100-G800/100 135/400 kW 3) PF 3/822, right PF 3/822, 1500 long

pans

RHH pan: . . . . . . . . . . . . . . . . PF 3/822, 1500 mm long RHH pan: . . . . . . . . . . . . . . . . Switching pan, PF 3/822, 1500 mm long, with electronic plow stop RHH pan: . . . . . . . . . . . . . . . . Adjusting pan, PF 3/822, 750 mm long with variable clevis RHH guide RHH-42 Hydraulic cylinder: . . . . . . . . . ZE-125/63-95-SO-CR

chain

Chain - conveyor: . . . . . . . . . . DKB 34 x 126 Flight: . . . . . . . . . . . . . . . . . . . . PF 3/822-DKB 34x126, KA=150 Distance between flights: . . . 756 mm

plow

Plow: . . . . . . . . . . . . . . . . . . . . RHH 42; 600-1385H Bit set: . . . . . . . . . . . . . . . . . . . DBT 2003 Chain - plow: . . . . . . . . . . . . . . . . 42 x 137

pan connections

Faceside: . . . . . . . . . . . . . . . . . Dogbone PF 3 with filler piece Gobside: . . . . . . . . . . . . . . . . . Dogbone PF 3 with locking plate Boom steering system: . . . . . every second pan in the panline Tensioning device: . . . . . . . . . Pneumatic chain tensioner, Bucyrus) 3) Locking device: . . . . . . . . . . . Chain locking device, Bucyrus 3) Tool: . . . . . . . . . . . . . . . . . . . . . Pulling device RHH-42, Bucyrus 3)

3) Further information can be found in the separate operating manuals or spare

parts documentation from the respective manufacturer or supplier.

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RHH-Förderer PF 3/822

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special conveyor pans on the tail gate

Drive frame: . . . . . . . . . . . . . .

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

Flange plate drive frame . . . . . . . . . . . . . . .

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

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

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

Flange plate - Plow: . . . . . . . .

Plow drive unit: . . . . . . . . . . . .

Gearbox - Plow: . . . . . . . . . . .

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

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

RHH adaptor pan: . . . . . . . . .

RHH pan: . . . . . . . . . . . . . . . .

Bucyrus DBT Europe GmbH, Lünen 2008

tail gate

Identification Identification The following contains the designations of the conveyor and the individual components .

Identification of the conveyor Manufacturer: . . . . . . . . . . . . . . . Bucyrus DBT Europe GmbH Type: . . . . . . . . . . . . . . . . . . . . . . . RHH-AFC PF 3/822 Year of manufacturing: . . . . . . . . MM/YY (e. g. : 04/08 ≙ April 2008) ID. No.: . . . . . . . . . . . . . . . . . . . . . 0010 297 000 00 XX *) Weight: . . . . . . . . . . . . . . . . . . . . 379,287 kg The conveyor has the following specifications : Fig. 75: Example type plate and CE-marking

Bucyrus DBT Europe GmbH

Bucyrus DBT Europe GmbH, Lünen 2008

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05/08 0010 297 000 00 00 PF 3/822

337,398 kg

The design of the conveyor meets the requirements of the European Directive 94/9/EC and EN1710 and has been designed for use in potentially explosive atmospheres.

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

*) X = Placeholder for variant ID number

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Identification Identification of the drive frame DRIVE FRAME MR 25/30-900 Manufacturer: . . . . . . . . . . . . Bucyrus DBT Europe GmbH Model: . . . . . . . . . . . . . . . . . . Drive frame MR 25/30 Year of manufacturing: . . . . . MM/YY (e.g.: 01/07 ≙ January 2007) ID No.: . . . . . . . . . . . . . . . . . . 5322 169 010 00 XX *) Weight: . . . . . . . . . . . . . . . . . 5976 kg The drive frames are marked with the following information : Fig. 76: Example type plate and CE-marking

Bucyrus DBT Europe GmbH

01/08 MR 25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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5322 169 010 00 01 5976 kg

The design of the drive frame meets the requirements of the European Directive 94/9/EC and EN1710 and has been designed for use in potentially explosive atmospheres.

*) X = Placeholder for variant ID number

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RHH-Förderer PF 3/822

tightening torques tightening torques Screws with ISO metric thread Tab. 9: Tightening torques at μtotal = 0.14 Thread 1) (mm)

(mm)

d

Coarse thread

M8

E

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1,25

23

32,5

39

17

23

M 10

1,5

46

65

78

34

45

M 12

1,75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2,5

270

380

455

202

270

20 m

2,5

380

535

640

285

380

(M 22)

2,5

510

720

865

384

512

24 m

3

655

920

1100

490

654

-

1100

-

24 m

Bucyrus DBT Europe GmbH, Lünen 2008

Tightening torque 4)

Pitch P

Fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3,5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

42 m

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

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

1) 2) 3) 4)

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

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

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

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

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6.7

Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

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

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

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

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

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

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

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

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RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

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

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

The following illustration shows a typical certificate.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 77: Typical certificate

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6.9

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

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

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

– target value: 7.5 to 9.5 J concentrate ratio

J microbial load

– target value: ≤ 105 col/ml.

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

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

Quality of the process water using hydraulic fluids

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

If the limits shown in the Table 10 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.

using as spraying water

6.10

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

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

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– target value: see certificate

Permissible media limit values

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

Caution!

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

Bucyrus DBT Europe GmbH, Lünen 2008

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Tab. 10: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, smell

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

Electrical conductivity

< 1800 μS/cm

pH value

6.5 to 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

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

Cl- - content

≤

201 mg/l

SO42- - content

≤

145 mg/l

NO3- - content

≤

20 mg/l

Fe content

≤

1 mg/l

Bacteriological requirements

≤

105 col/ml 1)

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

≤

10 mg/l 1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1)

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

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

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6.11

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

Base:

Lithium soap

NLGI Class:

2

Worked penetration:

265 to 295 (0.1 mm)

Behavior in the presence of water: practically non-soluble in water

lubricating grease A1

Temperature range of application:

-20 to +120 °C

Flash point :

≧ 200 °C

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

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load Tab. 12: Lubricating greases with additives Flash point in°C

Supplier

Type

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.

*)

6.12

EWN = Bucyrus works standard

RHH-Förderer PF 3/822

Bucyrus DBT Europe GmbH, Lünen 2008

grease A2

Flashpoint in °C

Supplier

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Tab. 11: Lubricating greases for general application

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. 13: Lubricating pastes free of molybdenum disulfide Supplier

Type

Base

Gleitmolybdän

Gleitmo 805 *)

Li

NLGI Class

Flash point in°C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B3 is used in accordance with the Bucyrus standard EWN 7068: gleitmolybdän ”gleitmo 805”

Bucyrus DBT Europe GmbH, Lünen 2008

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lubricating paste B6

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

Behavior in the presence of water:

non-soluble in water

Temperature of application:

-34 to +120 °C

When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B6 in accordance with the Bucyrus works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flash point 132 °C) Important!

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

*)

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The products listed in table 11 are suitable lubricating greases for filling of adjacent cavities.

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6.13

Bucyrus DBT Europe GmbH, Lünen 2008

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Permissible media

6.14

RHH-Förderer PF 3/822

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

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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.

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

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

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Customer Service 20 Killara Close, Beresfield, New South Wales 2322

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

RHH-Förderer PF 3/822

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

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7.5

Standards and Guidelines Standards and Guidelines Referenced national standards and guidelines Tab. 14: National standards and directives, extract

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

Quality of drinking water Documentation system Hydraulic system plug connections Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - design principles Determination of the acid number Determination of sulfphate ash Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 15: European standards and directives, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on 1998-06-22 the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the laws of the member states concerning equipment and 94/9/EC directive 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery 2004-04 DIN EN ISO 12100-2 Safety of machinery 2004-04 Non-electrical devices for use in potentially explosive DIN EN 13463-1 2002-04 atmospheres - Part 1: Basic methods and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 2004-12 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface 2000-08 Creating manuals DIN EN 62079 2001-11 - Structure, content and presentation Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water content - Distillation method Equipment and components intended for use in potentially DIN EN 1710 2006-01 explosive atmospheres in underground mines Mobile extraction machines on the face - safety DIN EN 1552 2003-09 requirements for shearers and plane systems 98/37/EC directive

1)

7.6

EWN = Bucyrus works standard

RHH-Förderer PF 3/822

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Title

Bucyrus DBT Europe GmbH, Lünen 2008

Designation