CAT Operating Manual Rock Feeder RM900 - PDF DOWNLOAD

EM009341-02-EN April 2013

Translation of the original operating manual

Operating manual Rock Mover RM900 Doc. No.: 5445 001 000 BA 00

Caterpillar Global Mining Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@cat.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.mining.cat.com

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

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

Caterpillar does not assume any liability for direct or indirect consequences of printing errors.

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

Caterpillar Global Mining Europe GmbH, Lünen 2012E A Caterpillar Inc. Company

Table of content

Table of content 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4 1.4

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

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

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

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

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

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

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

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

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

2.3 2.3 2.4

2.5 2.5 2.5 2.5 2.5

2.7

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

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

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Load units, dimensions and weights . . . . . . . . . . . . . . . . . .

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

Transporting the components . . . . . . . . . . . . . . . . . . . . . . . .

Transport units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.4

3.5 3.5 3.5 3.6 3.7

4. Installation What you need to observe prior to installation . . .

Who is allowed to perform the installation? . . . . . . . . . . . . .

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

Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.3 4.3

Overview - Rock Mover RM900 . . . . . . . . . . . . . . . . .

4.4

Installing drive frame and drive units . . . . . . . . . . .

4.5

Drive frame MR 35-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting E-motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequencing control of the conveyor system . . . . . . . . . . . .

Installation of the conveyor pans . . . . . . . . . . . . . . .

Tensionable return unit U-1200 . . . . . . . . . . . . . . . . . . . . . . .

Install pan connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.5 4.5 4.7 4.8

4.9 4.11 4.12

Table of content How to install the chain . . . . . . . . . . . . . . . . . . . . . . .

Pulling in the chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the flights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Preliminary chain pre-tension . . . . . . . . . . . . . . . . . . . . . . . .

Pulling and holding the chain . . . . . . . . . . . . . . . . . . . . . . . . .

Shortening the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting-up the conveyor system . . . . . . . . . . . . . . .

Before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conveyor test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Re-tightening bolted connections . . . . . . . . . . . . . . . . . . . . .

Removing and withdrawing the conveyor system Who is authorized to remove and lower the conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13 4.13 4.15 4.18 4.18 4.19 4.20 4.21

4.24 4.24 4.25 4.26 4.27

4.28 4.28

How to operate the conveyor system . . . . . . . . . . .

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

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

How to operate the conveyor . . . . . . . . . . . . . . . . . . . . . . . .

How to operate the tensionable return unit . . . . . . . . . . . . .

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

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

Information on maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Replacing the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When faults occur . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.3 5.3 5.3 5.4 5.4

5.9 5.9 5.9 5.9 5.10 5.13 5.14

5.16 5.16 5.18 5.23 5.24

5.29 5.29

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

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

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

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

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

Identification of the tensionable return unit U-1200 . . . . . .

6.3 6.3

6.4 6.4 6.4 6.5

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5. Operation

Table of content Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screws and bolts with ISO metric thread . . . . . . . . . . . . . . .

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

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Greases and lubricating pastes . . . . . . . . . . . . . . . . . . . . . .

6.6 6.6

6.7 6.7 6.7 6.8

7. For your information Standards and directives . . . . . . . . . . . . . . . . . . . . . .

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Applied standards and directives . . . . . . . . . . . . . . . . . . . . .

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Table of content

Rock Mover RM900

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 also provides you with information about the structure of the manual and the symbols and signs 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.

Make sure the information on the conveyor complies with that given in the operating manual.

This operating manual is for: Rock Mover RM900 ID no.: 5445 001 000 00 00 It is only permissible for a conveyor of this type.

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

There should always be a copy of the conveyor operating manual at the place of operation. new operating manual

Request a new operating manual immediately if the current 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.

Each one of these persons must read this operating manual.

This includes persons who: are in charge of transport, perform installation/removal work, operate the conveyor, rectify malfunctions, perform daily routine work, carry out maintenance work, carry out repair work.

Supervisory personnel who: initiate the activities mentioned above and/or supervise them.

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1.3

Before starting work Purpose of this operating manual efficiency

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

Read this operating manual in its entirety and at your leisure. Pay special attention to the corresponding safety instructions.

Familiarize yourself well with the appearance and meaning of the safety and information symbols.

service

Should you have any questions, please contact our service department.

safety

Carefully read through the chapter entitled “Your safety”. This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

Signs and symbols used

Make sure you know what they mean.

Danger!

Passages in the text marked with this symbol indicate an imminent danger. Possible consequences are: very serious injury or even death.

Warning!

This symbol indicates information on hazardous situations.

The possible consequences are very serious injury or even death.

Caution!

This symbol draws your attention to hazardous situations.

Possible consequences are light to minor injuries and damage to machinery.

Notice!

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

Important!

Passages in the text marked with this symbol contain useful tips and information intended to make work easier for you.

They do not warn about harmful or hazardous situations.

Items in lists are marked with bullet points.

– Items in sub-lists are indicated by a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

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The following signs and symbols are used for safety instructions and important information in this 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 avoid hazardous situations and perform the necessary work as safely as possible. state of the art

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

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

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

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

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The European directives/standards which appear in this operating manual must be applied when the conveyor is used within the member states of the European Union. When used outside the EU, the directives and standards applicable in the countries in question must be complied with.

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

Observe the safety and accident prevention regulations of the following parties: of the mining company, of the mines inspectorate and of the employers' liability insurance association for mining. additional operating manuals

Please also read the operating manuals for the components required for operation, e.g. Rock Feeder RF300, gearbox, E-motor etc. carefully and thoroughly. Clarify any questions before starting work.

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

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

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

Personnel must possess sufficient knowledge of the mechanical system, the hydraulic system and the control system and be able to demonstrate this.

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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: the safety components (pressure relief valves, extinguishers, etc.), the electrical components (controls, signaling devices, etc.) and the hydraulic system

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

2.4

Rock Mover RM900

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

It may only be used in non-explosive areas. Use the conveyor only as intended!

Intended use: the transport of copper ore and debris on downstream conveyor systems.

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

Unauthorized uses are: the transport of persons.

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the transport of objects of any kind such as for instance boards, spare parts etc. using the conveyor in explosive atmospheres. the operation of the conveyor opposite to the conveying direction.

Caterpillar assumes no liability for damage caused by unauthorized use.

Ambient conditions fire protection

Suitable measures must be taken by the operator to combat potential explosion hazards in a mine due to the ignition of dust and operating resources, such as hydraulic oil and lubricants.

These include: water spraying systems fire protection equipment, such as – fire alarm equipment – extinguishing equipment etc.

The atmosphere in the mine must be monitored permanently at hazardous points to allow all necessary fire protection and extinguishing measures to be initiated immediately in the event of damage.

The conveyor is to be stopped immediately and secured against restarting if the monitoring and fire protection devices are found to be damaged.

It may only be restarted by an authorized person.

Prerequisites for operation It is prohibited to comission the conveyor until it has been established that the overall system in which this conveyor is installed complies with all safety and accident prevention regulations in the country of use.

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Operating conditions As the conveyor is only part of an overall system, the operator must meet the necessary safety requirements or install the safety equipment required for the devices/components not included in the scope of delivery of this device or required for operation. These shall be marked according to legal provisions applicable at the time they are placed on the market.

The conveyor may only be operated once all safety requirements are met. These include: systems that prevent unauthorized start-up startup warning systems safe lock-out command systems EMERGENCY STOP systems noise reduction equipment dust extraction systems water spraying systems

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The electrical equipment required to operate the conveyor must also be labeled according to the legal provisions which apply in the country of use at the time it is placed on the market.

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fire protection equipment etc.

Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your 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).

safety equipment

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

Keep the signaling and lighting systems in proper working order.

Pay special attention to the conveyor's acoustic and visual start-up warnings.

information signs

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EMERGENCY STOP

Observe the information signs on the conveyor.

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

Actuate the EMERGENCY STOP switch also if safety equipment fails.

protection against being switched back on again

Secure the conveyor against being switched back on again while carrying out: maintenance work inspection work repair work Never enter a conveyor that has not been locked out.

cordoning off the working area moving parts

Cordon off your working area extensively for monorails and mobile handling systems (e.g. wheel loaders).

Never reach into or enter areas between components which can move, such as: conveyor chains flight chain sprockets tensionable return unit

danger of explosion

Hot surfaces can cause the ignition of dust. Regularly remove any dust deposits from all drive components and assemblies whose surfaces can become hot during operation.

oil binding agent

Oil pollutes the environment as soon as it enters the soil. Immediately bind any escaping oil with a suitable oil binding agent.

Keep a sufficient quantity of oil binding agent in hazardous areas.

environmental acceptability

Dispose of auxiliary equipment which has been soiled with oil, grease or other chemical substances in an environmentally acceptable manner.

When working with oil, grease and other chemical substances, observe the safety regulations and safety data sheets which apply to the product.

Observe the separate operating manuals for the components used.

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Safety instructions Storage and transport Observe the prescribed 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 transport. transport safety device

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

Lock all moving components in place.

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

means of attachment

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

Only use means of attachment which are in perfect 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.

For lifting, only use: the intended lifting points, lifting gear of adequate load-carrying capacity.

Installation and commissioning Secure the E-motors against unauthorized or unintentional startup during the installation.

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

Operation Operate the control only if you have comprehensive knowledge of the operating elements and their method of operation. You need to have been instructed on the control concerned.

Make sure no-one is inside the conveyor before switching it on.

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

Clean the operating plates regularly. Make sure that the operating symbols are clearly recognizable in order to avoid any operating errors and accidents that could result.

Maintenance and repairs Inform the supervisory personnel about any maintenance and repair work. Provide them with information on the intended work and its probable duration.

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Never walk or stay under unsecured components or suspended loads.

Safety instructions Inform your colleagues of: your exact location the work you are carrying out. the amount of time you will probably require. securing

Cordon off your working area over a wide range to avoid endangering other persons.

Secure the conveyor against being switched on unintentionally or by unauthorized persons prior to any work.

Make sure you observe the prescribed maintenance and inspection intervals.

replacing components

Stop and lock out the conveyor to secure it against restarting before replacing any defective components.

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Immediately remove any defective components in order to avoid hindering other persons. This measure also prevents the unintentional reinstallation of these components elsewhere.

Immediately pass on the components for servicing. original parts

Only use spare parts which meet the technical requirements. This is only ensured with original Caterpillar spare parts.

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

protective devices

Reattach removed protective devices immediately after completing the work, and check they are functioning correctly.

Hydraulic system

handling hydraulic fluids

protective devices - hydraulic system

Avoid direct skin contact with hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infections.

When dismantling protective devices which include hydraulic components, bear in mind that these hydraulic components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. It is therefore imperative that you depressurize the hydraulic components before removing the protective devices.

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids are very harmful to your health.

maintenance, repairs

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 any defective protective caps immediately.

Carry out a visual inspection of all hydraulic components at regular intervals. In particular, check that: the hoses are not pinched. the hoses have no swollen parts or blisters. the hoses or the outer sheaths of the hoses are not abnormally rigid or hard. the outer sheath of the hoses is not damaged. the connectors are firmly seated in the coupling connectors. connections are leak-tight.

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Safety instructions Make sure that no dirt penetrates the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage to the entire system. Backflush the hydraulic lines thoroughly before installing them.

Before removing the staples for disconnecting the hydraulic hoses, turn the hose at the connector to check whether the line is still pressurized. If the hose is difficult to turn or does not turn at all the line is still pressurized. Do not fail to depressurize the hydraulic line.

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Do not fail to depressurize the hydraulic line.

Check all connectors and connections of the system for leaks after finishing repair work. permissible hoses

Only use hydraulic hoses approved for the prevailing pressures.

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

Only replace hydraulic hoses with hydraulic hoses of the same or higher quality.

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

Fig. 1:

Example: Hydraulic hose, identification 2

3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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All screw connections at the hydraulic system can be reused.

Tighten the screw connections with approx. 20-30 Nm (by hand) without twisting the hose. Then use a suitable wrench to turn the screw connections another quarter to half turn.

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Always secure the coupling connectors of the hydraulic elements with the corresponding staples only. Always fasten the staples completely with both sides.

Never use nails, wire or similar materials.

Safety instructions laying hydraulic hoses

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

Lay hydraulic hoses so that: they are always slightly slack, Fig. 2:

Laying a hydraulic hose, slack RIGHT

WRONG

they are not twisted, Fig. 3:

Laying a hydraulic hose, twisted WRONG

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RIGHT

they are not bent directly behind the connections (minimum distance 1.5 x nominal diameter), Fig. 4:

Laying a hydraulic hose, bending RIGHT

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WRONG

2.11

Safety instructions they cannot chafe, Fig. 5:

Laying a hydraulic hose, crossing RIGHT

WRONG

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

torn out, kinked, pinched, driven over or twisted by the movement of the equipment (Fig.: 6).

Fig. 6:

Laying a hydraulic hose, connections on moving parts RIGHT

2.12

WRONG

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When laying hydraulic hoses, ensure that they cannot be:

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Only push hydraulic hoses into the connector sockets by hand.

Never try to drive the hydraulic hoses in with a tool as this will damage the connectors.

3

Storage and transport

Storage

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

The service life of the conveyor will be increased if you observe the information and instructions. You will be able to carry out transport work more safely and quickly.

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

Storage Storing the equipment anticorrosion protection

protection against direct sunlight/artificial light with a high UV portion

Protect the equipment from exposure to direct sun light and artificial light with a high UV portion. Only store the electrical equipment, electronic components, spare parts made out of rubber or plastic such as seals and hoses, as well as hydraulic fluids in closed rooms at 15C to 25C. A red or orange coating should be additionally applied to the windows of the storage rooms.

dirt and moisture

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

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

The mounting surfaces of hydraulic components must be protected from corrosion and sealed with blind plates. Protect the hydraulic connections and the connections of the electrical cables with the intended caps and plugs. short-term storage

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

long-term storage

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

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

The inspection can be carried out by Caterpillar upon request.

storage of the chains

natural aging

The chains are protected for a maximum of three months by the anticorrosion protection applied (e.g. Tectyl 506). They must not be stored outdoors, but rather in a covered, dry location at temperatures above freezing.

The chains must not be stored underground in the entry.

The chain must be cleaned, dried and have anticorrosion protection, such as Tectyl 506, applied to it when changing to another face.

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

Important!

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

Doc. No.: 5445 001 000 BA 00

VRSP / 03

3.3

Storage Storing used equipment The points previously specified in the section “Storing the equipment” can be applied analogously to the storage of hydraulic components already used. Please also observe the following information: The entire system and all components must be emptied completely if the hydraulic system is to be removed temporarily from service.

Any open connections and hose lines must be sealed.

Do not place any hydraulic components into storage which are filled with hydraulic oil - fire hazard!

frost protection

Equipment parts carrying water must be emptied completely and, if necessary, filled with antifreeze fluid.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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fire protection

3.4

Rock Mover RM900

Transport Transport Load units, dimensions and weights Observe the separate transport sheets for the respective transport units. They include information on: dimensions weights lifting points centers of gravity etc.

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

Warning!

Only use load handling devices which comply with the technical and legal regulations to transport loads.

Observe the permissible load-bearing capacities of the lifting points and keep a safe distance away from suspended loads.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 7:

Lifting eye and load ring example

Lifting eye

eye

load capacity (5000 kg)

Load ring

welded onto component

load capacity (5000 kg)

screwed onto component

Before transport temperatures below freezing

Hydraulic components must be emptied completely before being transported at temperatures below freezing.

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

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

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

Doc. No.: 5445 001 000 BA 00

VRSP / 03

3.5

Transport electrical and electronic components

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

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

Transporting the components machine parts

Drive frames, gearboxes, motors and other machine parts are equipped with lifting eyes or load rings. In some cases you will have to insert the lifting eyes into the holes provided before transport and remove them again immediately after transport. The lifting points and the corresponding load capacities are specified further on in the document for the respective machine parts.

RIGHT

Correct transport of machine parts

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 8:

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Danger!

Always use all the lifting points provided to transport loads.

Components may come loose due to incorrectly or insufficiently attached loads. Falling components can cause serious injury or even death.

WRONG

Danger!

Falling components can cause serious injury or even death.

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

3.6

Rock Mover RM900

Transport transport protection

Components may be transported only if all intended transport safety devices, protection covers and other covers etc. have been completely and properly installed.

Do not remove the side panel and shaft protection until immediately before the installation of the drive.

Important!

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

pans

The pans are equipped with lifting points (lifting eyes or load rings).

The lifting points can be on the sides or at the ends of the pans.

Important!

Remove the lifting eyes after transport. Fill the tapped holes with grease and close them with protective plugs.

Transport units

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Important!

Observe the separate transport sheets also for the machine parts and accessories not specified here.

Head gate drive unit Fig. 9:

Drive frame MR 35-1200, DK 30x108-78, item 1 S1

1

S1 S1

S1

1 1 protection cover Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 (max. load capacity in kg)

3177

2621

1295

12863

8000

Important!

Remove the protection covers (shaft protection) only directly before installing the drives!

Doc. No.: 5445 001 000 BA 00

VRSP / 03

3.7

Transport Fig. 10:

Drive line, items 10, 15 and 16 10

15

16

Item

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

10

2350

765

1150

3950

15

E

16 N-Eupen clutch A180 from Flender

See separate operating manual from Siemens.

16

180 Ø

80

-

12

Important!

Please take the other dimensions, individual weights and transport information from the separate operating manuals of the manufacturers.

Tail gate return unit U-1200, tensionable Fig. 11:

Return unit U-1200, tensionable, item 2 S1

S1 S1

S1

3.8

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 (max. load capacity in kg)

3270

2270

1023

9775

10000

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

10 gearbox KDEH550-X from KWE 15 E-motor 90 kW, from Siemens

Transport Pan line section RM-pans Fig. 12:

RM-pan with adaptor spill plate 1, item 3 S1

S1

1

S1

Caterpillar Global Mining Europe GmbH, Lünen 2013

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S1

1 adaptor spill plate Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 (max. load capacity in kg)

3000

2078

1520

5712

8000

Fig. 13:

RM-pan with adaptor spill plate 2, item 4 S1 1 S1

S1 S1

1 adaptor spill plate Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 (max. load capacity in kg)

3000

1938

1249

5163

8000

Important!

The adaptor spill plates 1 and 2 must be transported separately, not as illustrated here!

Doc. No.: 5445 001 000 BA 00

VRSP / 03

3.9

Transport Fig. 14:

RM-pan PF 1200, item 7 S1

S1

S1

3.10

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

S1 (max. load capacity in kg)

3000

1800

1012

5085

8000

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

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S1

4

Installation

What you need to observe prior to installation

Installation What you need to observe prior to installation Who is allowed to perform the installation?

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

Work on: the safety components (pressure relief valves, extinguishers, etc.) the electrical components (controls, signaling devices, etc.) and the hydraulic system (cylinders, directional control valves, hoses etc.) may only be carried out by service engineers from Caterpillar or by specially trained personnel.

tool box

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Which tools are required for installation?

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

We recommend that you keep a tool box with different standard tools at the drive.

In addition, various items of auxiliary equipment and machines are required at the points of installation. These include: lifting gear with sufficient load capacity means of attachment with sufficient load capacity impact wrench incl. accessories drill incl. accessories

Notes on installation Caution!

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

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

Caution!

Please do not fail to observe the corresponding separate operating manuals (e.g. for gearboxes, motors, etc.). installation plan

The operator must compile a risk assessment with respect to the environment in which the conveyor is to be installed. The sequence of operations during installation must be adapted to the individual conditions on site. Before starting work a detailed list of all steps to be taken with respect to transport and installation should be prepared and a corresponding installation plan compiled.

installing the conveyor pans

Place the pans as straight and centered as possible in the haulway.

Important!

During installation of the conveyor, a drawing-in rope must be laid in the bottom race of the conveyor with which the conveyor chain or the steel rope of the rope winch can be drawn into the bottom race.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

4.3

Overview - Rock Mover RM900 tightening torques

Tightening torques which are not specified when installing the components can be found in the “Tightening torques” section. Also observe the tightening torques listed in the spare parts list included in delivery.

handling instructions - connection points

Pins, holes, screws and securing devices must be lubricated with grease A1 (see section “Greases and lubricating pastes”) prior to installation.

Overview - Rock Mover RM900 Fig. 15:

Overview, Rock Mover RM900 2 7 7 4 3

15

1

16 10

Items 17, 18, 19, 21, 22, 23 and 24 not shown.

Tab. 1: Main components, dimensions and weights Item Quantity Description

4.4

Length (mm)

Width (mm)

Height (mm)

Weight (~kg)

1

1

Drive frame MR 35-1200, DK 30x108-78

3459

3372

663

11883

2

1

Return unit U-1200, tensionable

3187

2270

1023

9774

3

1

RM pan with adapter spill plates 1

3000

2078

1520

5712

4

1

RM pan with adapter spill plates 2

3000

1938

1249

5163

5

1

Drive frame attaching sidewalls

3498

325

1780

2694

7

22

RM-pan PF 1200

3000

1800

1012

5085

10

2

Bevel helical gearbox KDEH550-x

2350

765

1150

3950

15

2

Low-voltage motor 90 kW IM B5

16

2

N-Eupex clutch A180 75/55

180 Ø

80

-

17

268

RM 900 flight

1353

110

148

125

18

6

TSD super flat chain 42x146/107

-

-

-

1949

19

6

Block connector 42x146/107, super flat chain

-

-

-

10

21

1

RM 900 clamping hydraulics

-

-

-

-

22

1

RM 900 conveyor control

-

-

-

-

23

2

Screw set drive frame - gearbox

-

-

-

-

24

2

Screw set gearbox - clutch

-

-

-

-

see separate operating manual 12

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

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5

Installing drive frame and drive units Installing drive frame and drive units Caution!

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

Drive frame MR 35-1200 The drive frame serves as a mounting device of the drive sets, the drive unit and the first RM pan of the pan line section.

Fig. 16:

Drive frame MR 35-1200, Item 1 3

1

8 7

4

Caterpillar Global Mining Europe GmbH, Lünen 2013

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15

2 15

a 5

1 drive frame 2 drive unit incl. chain sprocket DKB 42x148, z = 7, KA 1200 3 chain stripper 4 tie-bar, right 5 tie-bar, left

7 bottom plate 8 sidewall 15 lubrication connections, (plug-in elbow socket, DN12) a transport protection (both sides) for drive unit

Caution!

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

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

Caution!

Thoroughly lubricate the drive frame before starting-up the conveyor (see the “Lubrication points” section in the “Operation” chapter).

Installing the gearbox Notes on installation All flange surfaces, centering bores, parallel keys and slots must be clean and free of burrs.

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

Notice!

Note the separate operating manual for the gearbox in use.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

4.5

Installing drive frame and drive units Installing gearbox on the drive frame Proceed as follows:

. Remove the transport protection (shaft protection). . Lubricate the gearing of the shaft and the gearbox with B3 paste (see chapter 6, section “Greases and lubricating pastes” section).

Important!

Check the correct installation position and fastening of the parallel key at the drive frame before you install the gearbox.

. Lift the gearbox and carefully push it on the shaft gearing until

. Insert ten mounting bolts (in the direction of the arrow) in the gearbox and insert the hexagonal nuts into the screw pockets of the drive frame.

. Tighten the mounting bolts in the specified sequence (1, 2, 3 ...

10; detail X) with the required tightening torque.

Fig. 17:

Installing the gearbox

Detail X 1

1

7

5 3

9

2

10

5 4

4 2

3 1 drive frame 2 gearbox 3 clutch case (preassembled)

6

8

4 hex. head screw M 36x220-8.8 tightening torque MA = 2290 Nm 5 hex. nut M 36-8

Important!

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

4.6

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

Avoid damage to the gearing.

The gearing has to be aligned in such a way that tooth and tooth space are exactly opposite one another to ensure that they mesh smoothly.

Be sure that the gearbox is not tilted during installation.

E

the gearbox is on the sidewall of the drive frame.

Installing drive frame and drive units Mounting E-motors Notice!

Only install E-motors with performance data (torque, speed) permissible for the conveyor system. The use of E-motors other than approved ones requires the approval of Caterpillar.

Installing the clutch on the gearbox Important!

Before the motor is installed at the gearbox, the clutch has to be preassembled at the motor.

Please observe the separate operating manuals for the E-motors and the clutches used.

Installing the E-motor onto the gearbox Proceed as follows:

. Raise the motor with preassembled clutch and carefully place it at the gearbox.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Important!

The motor has to be installed in such a way the switch box is positioned on top.

. Open the flap at the clutch housing and turn the clutch until the gearbox shaft can be pushed into the clutch.

. Insert eight mounting bolts (in the direction of the arrow) into the motor flange (1a) and turn into the tapped holes of the coupling flange (2b).

. Tighten the mounting bolts in the specified sequence (1, 2, 3 ...

8; detail X) with the required tightening torque.

Fig. 18:

Install E-motor

Detail X

3 2

6

1 7

4

3

2

2a

1a 1 E-Motor with preassembled clutch (clutch not shown) 1a motor flange 2 clutch housing (clutch case)

8

5

1

2a coupling flange 3 hex. head screw M 16x40-8.8 tightening torque MA = 195 Nm

Important!

After installing, there must be no tension between the E-motor and the clutch.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

4.7

Installing drive frame and drive units Sequencing control of the conveyor system Switching conditions between conveyors and downstream systems The downstream systems (belt system, crusher etc.) always have to be started up before conveyor.

switching off

The conveyor always has to be switched off before the downstream systems.

malfunction

If the downstream systems are switched off due to a malfunction, then the conveyor must be switched off automatically without delay.

delay

A delay time of around 10 seconds should be allowed for startup.

Be sure to adapt the delay time to the conditions in the mine. The time of 10 seconds stated here should be regarded as an indicative value only.

Caterpillar Global Mining Europe GmbH, Lünen 2013

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switching on

4.8

Rock Mover RM900

Installation of the conveyor pans Installation of the conveyor pans The pan line section between the drive frame and the return unit is composed of two RM pans with adapter spill plates and 22 RM pans for the type PF 1200.

Important!

During installation, ensure that the pan line section is installed in as straight a line as possible.

Position the pans so that the overlapping part of the bottom plate is facing in the conveying direction (FR) (see detail X). tip

Fig. 19:

During installation, lay a rope (steel, at least Ø 8 mm) under the conveyor from the drive frame to the return unit. The rope will be needed for the subsequent installation of the chain to pull the traction rope as well as the required rope winch from the return unit to the drive frame.

Pan line section between drive frame and return unit 4

3

7 7

7

X

Caterpillar Global Mining Europe GmbH, Lünen 2013

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FR

Y Detail X

3 RM pan with adapter spill plate 1 4 RM pan with adapter spill plate 2 7 RM pan PF 1200 a underlapping

FR a b

b underlapping Y pan connection, see fig. 24 FR = conveying direction

RM pan with adapter spill plate 1 Fig. 20:

RM rim with adapter spill plate 1, Item 3 8

5 1 3 7

4

2 6 17, 21 1 RM pan 2 upper race pan 3 bottom plate 4 sidewall 5 spill plate 6 spill plate

Doc. No.: 5445 001 000 BA 00

VRSP / 03

7 spill plate 8 spill plate 17 hex. head screw M 24x70-8.8 1) 21 hex. nut M 24-8 1) tightening torque MA = 655 Nm

4.9

Installation of the conveyor pans RM pan with adapter spill plate 2 Fig. 21:

RM rim with adapter spill plate 2, Item 4 3 1

5

6

2

4

6 sidewall 17 hex. head screw M 24x70-8.8 1) 21 hex. nut M 24-8 1) tightening torque MA = 655 Nm

RM-pan PF 1200 Fig. 22:

RM pan PF 1200, Item 7 3

1

4

5

2

17, 21 1 RM pan 2 upper race pan 3 spill plate 4 bottom plate

4.10

5 sidewall 17 hex. head screw M 24x70-8.8 1) 21 hex. nut M 24-8 1) tightening torque MA = 655 Nm

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

1 RM pan 2 upper race pan 3 spill plate 4 spill plate 5 bottom plate

E

17, 21

Installation of the conveyor pans Tensionable return unit U-1200 To tension the conveyor chain, the return bearing is slide-mounted in the return frame of the return unit.

The return unit is connected to the pan line section using five mounting bolts per side.

Important!

For the pan connection, two hexagonal head screws of different lengths are used. Correctly insert the hexagonal head screws.

Tensioner cylinder at the return unit The return unit is equipped with two tensioner cylinders for tensioning the chain. The maximum cylinder stroke is 600 mm.

Further information about the return unit can be found in chapter 5, section “How to operate the return unit”.

Install return unit

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Fig. 23:

15

16

20, 28

21, 27

Doc. No.: 5445 001 000 BA 00

15 pin 80x72 16 washer 100x15 20 hex. head screw M 30x135-10.9 1)

27 hex. nut M 30-8 28 hex. nut M 30-10 1) tightening torque MA = 1450 Nm

21 hex. head screw M 30x110-8.8 2)

2) tightening torque MA = 1131 Nm

VRSP / 03

4.11

Installation of the conveyor pans Install pan connection The pans, the return unit and the drive frame are each connected to each other by five mounting bolts on each side. One pin on each side ensures that the components are correctly aligned to each other during installation.

Important!

In the following text, only pans are discussed, but the information also applies to the return unit and the drive frame.

Install the pans as follows:

. Push the pans together.

Important!

The pins (5) of the first pan have to be pushed into the mounting device of the following pan when pushing together.

. Push the hexagonal head screw (1) with washer (4) through the hexagonal head screw and tightened by hand.

Important!

For the pan connection, two hexagonal head screws of different lengths are used. Correctly insert the hexagonal head screws.

. Push the hexagonal head screw (2) though the mounting holes of the pans.

. Place the hexagonal nut (3) onto the hexagonal head screw and tighten by hand.

Important!

After you have inserted all ten bolted connections on both sides of the pans, you have to tighten them with the necessary tightening torque.

Fig. 24:

Pan connection, detail Y from Fig. 19

2

1

3

4

5 1 hex. head screw M 30x135-10.9 1) 2 hex. head screw M 30x105-10.9 1) 3 hex. nut M 30-10

4.12

4 washer 100x15 5 pin 80x72 1) tightening torque MA = 1450 Nm

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

. Place the second washer (4) and hexagonal nut (3) on the

E

pin (5).

How to install the chain How to install the chain Pulling in the chains You can pull in the chains as soon as the complete conveyor is preassembled and aligned. Some components have to be previously removed

. Remove the supporting plates and the rear cover of the return unit.

. Remove the attaching sidewalls of the first RM pan at the return unit.

When the components have been removed, you can start to install the chain. Proceed as follows:

. Set up and connect the rope winch (with two rope drums) behind the return unit.

. Make a pulling loop at the end of the rope of the drawing-in E

rope in the supplied bottom race. The size of the loop has to be adjusted to the size of the securing hooks being used in the steel ropes of the rope winch.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

Insufficiently fastened loops can suddenly loosen during the pulling of the chains.

This can lead to serious injuries to you and others!

The mounting material has to be designed accordingly for the used rope thickness (rope diameter) and the occurring pulling force.

Only use permitted mounting material (e.g. rope clamps) to form the pulling loop.

. Suspend the coupling hooks of the steel ropes in the pulling loop of the drawing-in rope.

. Using the drawing-in rope, pull the steel ropes of the rope winch through the bottom race over to the drive frame.

. Pull the steel rope two to three meters upwards through the drive frame and place in the chain pockets of the chain sprocket.

. Using the drawing-in rope, pull the steel ropes through the upper race over to the return unit.

. Suspend the coupling hooks of the steel ropes in the chains. . Use the rope winch to pull in the chains bit by bit in the upper race.

. Insert the flight in the assembly area of the return unit at a distance of 584 mm (4-pitch chain) in the horizontal chain link and secure (see the section “Mount the flight”).

Caution!

When installing the flights, be sure that the chain strands are not twisted.

Chain strands that are installed with a twist lead to severe damage to chain sprockets and the whole system!

Only install the chain in a proper fashion. Check you work before you switch on the conveyor!

Doc. No.: 5445 001 000 BA 00

VRSP / 03

4.13

How to install the chain After installation of the flight, the chain has to be pulled further until the next flight in the chain can be installed.

. Transpose the coupling hooks about three meters before they reach the chain sprocket in the direction of the return unit.

Caution!

The coupling hooks may not be pulled along over the chain sprocket into the bottom race.

That leads to serious damage to the chain sprocket and the drive frame.

Shift the coupling hooks in such a way that the chains can be pulled over the chain sprocket through the drive frame downwards.

. Using the rope winch and the head gate, pull in the chains bit by bit into the bottom race over to the return unit.

Caution!

When pulling in, be sure that the chains are seated properly in the chain pockets of the chain sprocket and feed in correctly to the pan profile of the bottom race.

Install the chain as previously described (flight at a distance of 584 mm) until it is completely preassembled and is in the bottom race of the return unit.

. Pull the chain out of the return unit far enough that you can place it on the chain sprocket of the return unit.

Important!

Before you can combine the two chain ends, you must completely retract the return unit!

. Combine the chain ends (see the section “Install the chain connector”).

If the chain is combined, the flights that are still missing have to be installed.

After complete installation of the chain, the attaching sidewalls, the supporting plates and the rear cover are installed again.

The installation of the chain is complete.

Important!

Then you have to pre-tension the chain over the tensionable return unit (see section “How to operate the tensionable return unit”).

If there is too much slack chain, you have to correspondingly shorten the chain (see the section “Shortening the chain”). If the preliminary chain pre-tension is too high, adjusting chains have to be inserted in the chain (see the section “Adjusting chains”).

4.14

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

As soon as the chains are in the chain pockets of the chain sprocket in the drive frame and the chain ends in the bottom race are connected with the traction ropes of the rope winch, the chains can be pulled through the bottom race to the return unit.

E

. Suspend the coupling hooks of the steel ropes in the chains. . Insert the chains in the pan profile of the bottom race.

How to install the chain Installing the flights The flights have to be installed at horizontal chain links at a distance of 584 mm (4-pitch chain) and secured with two heavy-duty dowel pins.

Fig. 25:

Flight RM900 1

2

a

a 1 flight PF 5/1542 2 heavy-duty dowel pin S 22x140 Fig. 26:

Special mandrels

2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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1

a recess

Special tools Two different special mandrels have to be used for the installation and removal of the heavy-duty dowel pins. The installation mandrel is used to drive the heavy-duty dowel pins into the boreholes of the flights. Heavy-duty dowel pins can be driven downwards out of the flight using the removal mandrel.

Notes about installation and removal of the flights

1 installation mandrel 2 removal mandrel

Before the installation or removal of the flights, the heavy-duty dowel pins, the mounting holes and the special mandrels always have to be lubricated with a generous amount of grease B1 (see the section “Greases and lubricating pastes”, chapter 6).

Installation of the flights The installation of the flights is only possible in the return unit in the area of the slotted holes of the stiffening plate (5).

Before the installation, the following components have to be removed: Return unit's support plates Attaching side walls of the first RM pan at the return unit Fig. 27:

Removing the support plates and the attaching sidewalls

3 4 a

b

5

1

2 1 return unit 2 RM pan 3 attaching sidewall 4 supporting plate

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5 stiffening plate a installation area b passage openings (slotted holes in the stiffening plate)

4.15

How to install the chain Install the flight as follows:

. Position the horizontal chain links over the slotted holes of the stiffening plate.

. Push the recess of the flight onto a chain strand (any side). . Lift the flight and the second chain strand. . Push a horizontal chain link into the second recess of the flight. . Lower the chain strand and flight onto the upper race.

Important!

In order that the heavy-duty dowel pins can be installed, the flight has to be positioned above the passage openings (b) in the return unit.

. Lubricate the heavy-duty dowel pin, installation mandrel and

. Push the heavy-duty dowel pin onto the installation mandrel and put it on the borehole of the flight.

Fig. 28:

Position the installation mandrel and the heavy-duty dowel pin

1

1 installation mandrel

4.16

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

Do not reuse heavy-duty dowel pins!

Insufficiently tightened flights may become loose and jump out of the guide. This can lead to blocking the conveyor and to serious damage to the entire system.

Only use new heavy-duty dowel pins for the installation and use these pins properly!

E

borehole of the flight with grease B1.

How to install the chain . Drive in the heavy-duty dowel pin with a percussion hammer as far as it will go in the mandrel in the flight.

Fig. 29:

Drive in the heavy-duty dowel pin

a

E

a percussion hammer Caterpillar Global Mining Europe GmbH, Lünen 2013

. Install the heavy-duty dowel pin on the other side of the flight in the same way.

If you have installed both heavy-duty dowel pins, then the installation of the flight is complete.

Removal of the flights The removal of the flights is only possible at the return unit in the area of the slotted holes of the stiffening plate (5) (see Fig. 27). Before removal, the support plates and the attaching sidewalls have to be removed (see the section “Installation of the flights”). Then the removal of the flights can be started.

Remove the flight as follows:

. Position the flight over the slotted holes of the stiffening plate. . Lubricate the removal mandrel with grease B1. . Position the removal mandrel on the heavy-duty dowel pin.

Fig. 30:

Position the removal mandrel

1

1 removal mandrel

Doc. No.: 5445 001 000 BA 00

VRSP / 03

4.17

How to install the chain . Drive out the heavy-duty dowel pin with a percussion hammer.

Fig. 31:

Drive out the heavy-duty dowel pin a

a percussion hammer

. Remove the heavy-duty dowel pin on the other side of the flight . Lift the chain on one side (any side). . Pull horizontal chain links out of the recesses of the flight. . Take the removed flight out of the return unit.

Once you have taken away the flight and the removed heavy-duty dowel pins from the return unit, the removal of the flight is complete.

Caution!

The heavy-duty dowel pins fall through the stiffening plate into the return unit during the removal. Forgotten heavy-duty dowel pins can lead to serious damage to the conveyor!

Take away the driven-out heavy-duty dowel pins immediately after removal and before you carry out further work.

Installing the chain connector The individual chain strands of the chain are joined using chain connectors.

Block connector Block connectors must always be installed in such a way that they pass over the sprocket drum in a vertical position. The assembled connector halves are held together by spring pins.

Important!

Please observe the separate operating manual of the block connector being used.

Adjusting chains Adjusting chains are used to adjust the chain to the conveyor length in order to shorten the chain if the chain is too slack for example.

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in the same way.

How to install the chain Preliminary chain pre-tension correct pre-tensioning

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

Fig. 32:

Chain pre-tension return head

drive unit

X

X 1 1 2 3 2 3 3 slack chain

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1 taut chain 2 optimum chain excessive chain slack

Too much slack promotes the climbing and skipping of the chains on the chain sprockets. This can lead to major damage to the chain, the chain sprockets, the shafts as well as the pans.

excessive chain pre-tension

Excessive tensioning of chains results in high performance losses as the chains rotate around the chain sprockets. This leads to excessive wear on chains and chain sprockets, as well as to damaged bearings. In addition, excessive strain on the chains causes extreme noise levels.

changes in chain pre-tension as the face advances

monitoring the chain

Doc. No.: 5445 001 000 BA 00

The chain pre-tension changes as the face advances. The change results from fluctuations in the properties of the material conveyed, e.g. changes in moisture content or debris content. Finally, the chain pre-tension is changed by the increasing permanent elongation of the chain.

In order to ensure trouble-free operation with favorable performance 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 needs to be re-tensioned or shortened.

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4.19

How to install the chain Pulling and holding the chain To secure supporting and pulling of the chain, the following auxiliary devices are used: Pulling shackle Chain hoist (maximum 7.5 t pulling force) Rope winch Steel ropes Schematic diagram for using the pulling shackle

a drive unit b pulling shackle

b

c

c chain's pulling direction

Pulling shackle To connect the chain ends or to remove slack chain (shortening of the chain), the upper conveyor chain is pulled together using the pulling shackle.

Warning!

You or others could be seriously injured if the pulling shackle suddenly releases.

When installing the pulling shackle, be sure that the pulling shackle is properly installed and secured.

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c a

Caterpillar Global Mining Europe GmbH, Lünen 2013

Fig. 33:

How to install the chain Shortening the chain testing

repair and maintenance

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

Damaged components may only be repaired by Caterpillar!

Important!

If pulling shackles are not serviced by Caterpillar service personnel, then any liability by Caterpillar is excluded.

Danger!

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

The C-links could break off due to the excess load.

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

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

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Please proceed as follows:

. Move the section of chain with chain connector in the area of the return unit.

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

Danger!

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

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

. Remove the locking pins at the return unit (see chapter 5, section “How to operate the tensionable return unit”).

. Retract the tensioner cylinders completely. . Depressurize the tensioner cylinder.

Caution!

You or others could be injured if the return unit cylinder is extended while work is being performed on the chain.

Make sure that the cylinder is depressurized and the hydraulic system is secured against being switched on again by unauthorized persons.

. Remove the support plates of the return unit. . Remove the attaching sidewalls of the first RM pan at the return unit.

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4.21

How to install the chain . Install the first half (see Fig. 35, Item x) of the pulling shackle on one flight.

. Pull the slack chain using the pulling shackle half and a hoist in the upper race of the return unit.

Fig. 34:

Moving the slack chain into the upper race

a

b

x

a drive unit b return unit

x half 1

. Install the second half (see Fig. 35, Item y) of the pulling

. Hang a chain hoist in the lifting eye of the pulling shackle and pull the chain together.

Fig. 35: a

Pulling the slack chain together

b c

y

a drive unit b pulling shackle c pulling direction

x

x half 1 y half 2

Important!

Ensure that the slack chain is completely in the RM pan area of the return unit and that none of the chain links are tilted in the return unit area.

. Shorten the chain.

Caution!

Incorrectly shortened chain strands cause severe damage to the conveyor. Always remove the chain links by the pair (one horizontal and one vertical chain link). The same number of chain links have to be removed from both chain strands. Check the shortened chain before you switch on the conveyor.

. Couple the chain using chain connectors (see section “Installing the chain connector”)

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Warning!

You or others could be seriously injured if a part of the pulling shackle is released suddenly.

When installing the pulling shackle, be sure that the fasteners of the pulling shackle on the flight are correctly installed and secured.

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shackle on a flight in the area of the slack chain at the return unit (see Fig. 35).

How to install the chain . Remove the pulling shackle.

Notice!

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

Remove the pulling shackle before restarting the conveyor.

. Apply pressure to the tensioner cylinders. . Extend the tensioner cylinder of the return unit until the pressure in the clamping system is between 120 - 195 bar (see pressure gauge on the pretensiometer).

. Lock the return unit (see chapter 5, section “How to operate the tensionable return unit”).

. Depressurize the return unit's clamping system.

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After the chain has been pre-tensioned, you can continue with the commissioning of the conveyor. When doing this, observe the section “Starting-up the conveyor system”.

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4.23

Starting-up the conveyor system Starting-up the conveyor system The conveyor system must be initially commissioned according to the instructions of Caterpillar technicians.

Warning!

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

During initial startup, hazards may occur which would not occur during normal operation.

Keep a safe distance from the conveyor.

Notice!

Furthermore, observe the instructions in the separate operating manuals for the conveyor components, such as electric motors, gearboxes, drive connections etc.

Before startup

and your working area.

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

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

. Check that the supply lines have been properly laid. . Check the hydraulic connections for secure and correct fit. . Check the hydraulic connections and lines for leaks and damage.

Danger!

You could be seriously injured or even killed by a hydraulic hoses that are thrashing about.

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

Never use nails, wire or similar materials.

. Check the oil level of the gearbox. . Check the direction of rotation of the E-motors. . Check the electrical connections. . Check whether both drive motors run synchronously. . Test the sequencing control of the whole system (conveyor, belt system, crusher etc.).

. Test the functioning of all safety equipment, such as EMERGENCY STOP equipment, signaling devices and the intercom system.

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

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The following work has to be performed before starting up the system:

Starting-up the conveyor system . Check the water spraying system and fire protection equipment as well as fire detectors, fire extinguishers, etc., to ensure they are all working perfectly.

. Lubricate the entire system at the lubrication points.

Important!

The following test run may only be performed if all checks and tests do not reveal any faults (e.g. installation faults etc.).

Conveyor test run

empty conveyor test run

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Danger!

Make sure nobody is inside the hazardous area of the conveyor system during the test run.

Due to installation errors, hazards may occur which would not occur during normal operation.

Such a hazard could cause severe injuries or even death.

Make sure that you keep at a sufficient distance from the conveyor system in particular during the test run.

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

Check the following points: steady and identical current consumption of the E-motors sufficient cooling of the E-motors sufficient cooling and proper oil filling of the gearboxes smooth running of the gearboxes steady rolling of the chain at the chain sprockets even feed-in of the chain in the drive frame and in the return unit steady entry of the flights into the chain guides correct flight spacing complete number and installation position of flights correct seating and installation position of the chain connectors optimum chain pre-tension sequencing control function function of the safety equipment, such as the signaling devices, EMERGENCY STOP equipment, etc. function of the water spraying system and fire protection equipment as well as fire detectors, fire extinguishers, etc.

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4.25

Starting-up the conveyor system after the test run

Secure the conveyor against being switched on again and perform the following work:

. Shorten the chain until an optimum chain pre-tension is established.

. Eliminate any defects discovered.

Important!

If the check does not turn up any problems or if the problems have been corrected and all the functions can be carried out without any problem, the test run with the loaded conveyor can be performed.

test run of the loaded conveyor

Carry out a test run of the loaded conveyor (for about six hours) and pay attention to the following:

. Gradually increase the load on the conveyor. . Check that the chain passes over the chain sprockets properly. . Monitor the conveyor continuously for slack chain. . Monitor the current consumption of the E-motors. . Check the gearbox for heat build-up. . Check all hydraulic connections and lines for leaks and damage. after the test run

After the test run, run the conveyor completely empty.

Please observe the following points before releasing the conveyor for operation:

. 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

4.26

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

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

Danger!

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

Due to installation errors, hazards may occur which would not occur during normal operation.

Such a hazard could severely injure or even kill you.

Keep a sufficient distance away from the conveyor in particular during the test run.

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Test run of the conveyor

Starting-up the conveyor system Re-tightening bolted connections Bolts may become loose or even released when bolted connections or components settle.

This is why you have to re-tighten the following bolted connections of the conveyor after an initial operating time of about 60 hours. In doing so, observe the respective torque required or the required tensioning force.

Drive connection (motor, gearbox and clutch) Gearbox attachment to the drive frame Chain strippers on chain sprockets Inlet plate and lower end guide in the drive frame Anti-wear strips at the drive frame Guide strip at the return unit Fasteners at the drive substructure etc.

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selecting the tightening torque

Doc. No.: 5445 001 000 BA 00

Refer to the appropriate spare parts drawing for the tightening torque of the respective bolted connection. If the spare parts drawing does not contain any other information, the tightening torques in chapter 6 “Technical data” apply.

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Removing and withdrawing the conveyor system Removing and withdrawing the conveyor system drawing up a removal plan

A removal plan must be drawn up before the conveyor system can be removed. The removal plan helps you to coordinate removal and transport work.

Removing should be carried out in the most practical sequence, generally in reverse installation order. Removing depends on the respective local conditions.

Who is authorized to remove and lower the conveyor system Removing and lowering operations may only be performed by persons with sufficient knowledge of the work to be performed and who have been adequately trained for these particular requirements.

Important instructions for removal

. Protect all exposed shafts, hubs, labyrinth channels and E

flanges from corrosion, dirt and damage.

. Completely drain the hydraulic system. . Seal all exposed lines and separating points with protective caps or plugs.

. Pack loose parts, screws, etc. in suitable containers. This protects the components from dirt and damage.

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handling sensitive components

5

Operation

How to operate the conveyor system

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

Please read this chapter carefully and thoroughly. Make sure you observe the safety instructions in chapter 2, “Your safety”.

How to operate the conveyor system Danger!

Incorrect operation will endanger yourself and others.

Incorrect operation of the machine is often the cause of severe 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 sufficient knowledge of the complete conveyor system.

This includes knowledge of: what safety equipment is installed on the system, where this safety equipment is located, how this safety equipment is to be operated.

When may conveying be started?

Conveying may not be started until the perfect condition and proper working order of the entire conveyor system has been checked and the daily maintenance operations have been performed.

Danger!

When you start up the conveyor make sure that nobody is present in the conveyor's hazardous area.

Do not allow the conveyor to run backwards without any important reason.

The gearboxes and E-motors of the drive units must always be kept free of dirt in order to prevent overheating and any resulting damage.

Any irregularities, especially regarding defects and damage, are to be reported to the supervisor so that the defects can be rectified as quickly as possible and the necessary repairs can be carried out.

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How to operate the conveyor system How to operate the conveyor The conveyor can only be controlled and operated by means of the system control. The control does not belong to the scope of delivery.

Please observe the separate operating manual of the manufacturer.

How to operate the tensionable return unit The chain pre-tension can be adapted to the operating conditions by retracting or extending the hydraulic cylinders positioned on both sides of the return unit. The max. cylinder stroke is 600 mm.

Fig. 36:

Return unit U-1200, tensionable Retracted tensioner cylinder

1 3

4

2 Extended tensioner cylinder (max. 600 mm)

1 return frame 2 hydraulic cylinder

5.4

3 return bearing, movable 4 hole strips

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

Important!

The chain pre-tension can be measured with the supplied Pretensometer.

Observe the separate operating manual from Thiele.

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The chain is tensioned by extending the hydraulic cylinders and loosened by retracting the cylinders. If, for example, there is too much slack chain on the drive, the hydraulic cylinders must be extended. The chain is tensioned by this.

If the chain is pre-tensioned too much, the hydraulic cylinders must be retracted until the chain has the optimum pre-tension.

How to operate the conveyor system Mechanical locking of the tensionable return unit The return bearing must be locked to the return frame with two locking pins on each side in order to relieve the hydraulic cylinders during operation.

The locking pins can be inserted in the hole strips on the sides at a distance of 12 mm. The pins must be secured in position in the hole strips by mounting links.

You must remove the locking pins before applying pressure to the hydraulic cylinders.

Fig. 37:

Components for locking the return unit U-1200 Magnification of X pin retainer

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X

5 4 1, 2

3 1 hex. head screw M 16x40-8.8 2 hex. nut M 16-8 3 mounting link

4 locking pin 5 return bearing

Hydraulic control at the return unit The hydraulic cylinders of the return unit are extended and retracted via a blast valve (4/3 directional control valve).

Caution!

The return bearing is locked mechanically to the return frame by locking pins during operation.

Remove the mechanical locking before extending or retracting the hydraulic cylinders.

Testing the hydraulic system The entire hydraulic system at the return unit has to be tested before and after each use.

Be sure that the hydraulic system of the return unit is always in good condition. testing system components

. Open the cover box on the return unit. . Check all hydraulic connections, fittings and hoses for damage and leaks.

. Check the supply hoses and connections of the cylinders. . Correct any defects discovered before you use the tensionable return unit.

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How to operate the conveyor system Operating the return unit Operate the return unit as follows:

. Open both manual slides (1, 2) as shown in Fig. 38.

Important!

Be sure that both manual slides are completely opened up to the opening stop.

If both manual slides (1, 2) are completely open, you can either extend or retract the hydraulic cylinders using the hand lever (3a) at the blast valve (3).

Caution!

Prevent the position of the shift from being too skewed!

The return unit and its adjacent components can be damaged or destroyed if the position of the shift is too skewed!

Extend the hydraulic cylinders slowly and evenly! This applies especially when only one enabled hydraulic cylinder is to be moved while the hydraulic cylinder of the opposite side is blocked.

. Move the hand lever (3a) out of the middle position in the desired direction: – Extend the hydraulic cylinders: move the hand lever to the left – Retract the hydraulic cylinders: move the hand lever to the right Important!

The extension speed of the hydraulic cylinders is coupled to the actuation of the hand lever.

The further the hand lever is moved in one direction, the faster the hydraulic cylinders retract or extend.

If the return unit has been extended or retracted as much as necessary, then you have to bolt the shift on both sides of the return unit.

Use the same flush pegging for bolting on both sides.

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In case of a skewed position of the reverse bearing caused by different extension lengths of the hydraulic cylinders or for minimal one-sided compensation of the extended cylinder lengths, the manual slide (ball valve) of the respective opposite side can be blocked and the hydraulic cylinders of the other side can be moved on one side. Move both hydraulic cylinders as evenly as possible.

Caterpillar Global Mining Europe GmbH, Lünen 2013

prevent skewed position

How to operate the conveyor system As soon as the shift is correctly bolted on both sides of the return unit, the manual slides (1) has to be turned up to the blocking stop (in the direction of the arrow).

Then the cover box has to be closed.

Fig. 38:

Hydraulic control for return unit

4

2

1

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3a

3 1 manual slide, right “manual slide open” representation

3 blast valve (4/3 directional control valve) with hand lever (3a)

2 manual slide, left

4 cover box

“manual slide open” representation

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5.7

How to operate the conveyor system Circuit diagram for clamping hydraulics RM900 component functions

A piloted check valve (2) is used to seal the piston spaces of the hydraulic cylinders (1) pressure-tight. Two pressure relief valves (3) in the “extend cylinders” supply lines serve as overload protection and are set to max. pressure. The pressure gauges (4) are used to check the preset pressure subject to the required chain pre-tension.

Fig. 39:

Circuit diagram for clamping hydraulics RM900

1

3

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4

2

L

T A a

B

B

1

2 P

t

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

5.8

L = LS control (load sensing) 1 4/3 directional control valve: retract cylinders 2 4/3 directional control valve: extend cylinders

Rock Mover RM900

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

Make sure you also observe the safety instructions in chapter 2, “Your safety”. danger of explosion

Make sure to observe the maintenance and inspection intervals for the conveyor as hot surfaces can ignite 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: an impermissible temperature is reached, unacceptable structure-borne noise characteristics are indicated.

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Information on maintenance Please observe the following instructions: 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 drawing up a general maintenance plan. You can, for example, create a checklist using this operating manual and the manuals of the other components.

Machine damage can be caused, resulting in considerable costs, if the maintenance work performed is inadequate.

Be sure to observe the specified maintenance intervals.

Only use suitable and approved tools for maintenance work.

Only use original Caterpillar spare parts when replacing components.

How to maintain the steel structure Maintenance of the steel structure includes: Lubrication of the system in accordance with the lubrication schedule.

Inspecting the system for faults and proper operation.

Inspection of wear parts.

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5.9

How to maintain the conveyor Lubrication schedule Tab. 2: Lubrication according to operating time Components

Medium

Drive frame, tensionable return unit - bearing Gearbox

Grease 1) 8

Operating time in hours 1.

2.

3. ...

100

2)

100

...

2)

E-motors

Notice!

During normal operation, the re-lubrication intervals must not exceed 100 hours. Lubrication must always be carried out with the conveyor running so that the grease is distributed evenly.

Lubrication points Drive frame The bearing lubrication connections on the face side can be found on both sides of the drive frame.

fresh grease escapes from the bottom connection (grease outlet 2).

. Then open the top connection (grease outlet 1) and close the bottom connection (grease outlet 2) with a suitable plug.

. Press grease into the middle connection (grease inlet) until fresh grease escapes from the top connection (grease outlet 1).

Then lubricate the bearing on the other side of the drive frame in the same way.

Fig. 40:

Lubrication points on the drive frame, overview Detail X 2

1 3 X 1 grease inlet 2 grease outlet 1

3 grease outlet 2

1) A8 grease, see chapter 6, section “Greases and lubricating pastes”.

2) See separate operating manual.

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. Close the top connection (grease outlet 1) with a suitable plug. . Press grease into the middle connection (grease inlet) until

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Proceed as follows to lubricate the bearings correctly:

How to maintain the conveyor Return unit The bearing caps of the return head are each equipped with a lubricating nipple (grease inlet). Two check valves (grease outlet) can be found in each of the drive bushings between the chain sprockets and bearings.

Before you can lubricate the return bearing, the front side covers must be removed on both sides and the maintenance flap opened on the face side.

Fig. 41:

Return unit, side covers removed and maintenance flap open 2 1

3

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4

1 return unit 2 side cover, left (removed)

3 side cover, right (removed) 4 maintenance flap, open

Proceed as follows to lubricate the bearings correctly:

. Press grease through the lubricating nipple (grease inlet) into the bearing until fresh grease escapes from the check valves (grease outlet).

Fig. 42:

Lubricating nipples in the bearing caps

1

2 1 bearing cap Fig. 43:

2 lubricating nipple (grease inlet)

Check valves in the drive bushings Magnification of X 1

2 X 1 drive bushing

2 check valve (grease outlet)

Then lubricate the bearing on the other side of the return unit in the same way.

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How to maintain the conveyor Inspecting the system Check all components of the system at least once a 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.

Check all functions of the system at regular intervals.

Make sure the connecting elements are fitted firmly.

Inspecting wear parts

Replace the conveyor component bearings (drive frames, gearboxes etc.) once the maximum bearing service life has been reached. Observe the separate operating manuals for the respective components. The bearing service lives of Caterpillar components are specified in chapter 6 “Technical data” of the respective operating manual.

After completing a removal phase and moving to a new removal area, the remaining service life of the bearings must be sufficient for the operating time in the new removal phase. Should this not be the case, the bearings must be replaced.

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replacing bearings

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It is necessary to check all wear parts regularly for their degree of wear in order to tell when you need to schedule a repair shift and in order to avoid damage to other components in good time.

Observe the “maintenance table” (tab. 3) on page 5.14 in this chapter.

How to maintain 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 hydraulic diagrams (the hydraulic diagrams are to be found in the spare parts documentation).

Make sure you also observe the safety instructions in chapter 2, “Your safety”.

Maintenance of the hydraulic system Important!

Check and service all components of the hydraulic systems, such as power packs, pumping stations, filter systems, etc., in accordance with the corresponding supplier documentation of the respective manufacturers.

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

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Make sure the connecting elements and securing devices are in perfect condition.

Check the correct installation of all lines.

Check that all connections are fitted firmly.

Check that all operating levers, rod assemblies, cylinders, locking pieces, springs, etc. are working perfectly.

Caution!

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

Replacing and cleaning filters as required

Dirty hydraulic fluid causes serious damage to the hydraulic system.

Check all filters according to the details of the manufacturer.

Special measures The function of all pressure relief valves should be checked at least once a year.

For reasons of safety and to maintain correct system function, all high-pressure hydraulic hose lines must be replaced every two years, regardless of whether there is any visible damage.

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5.13

How to maintain the conveyor Maintenance table Tab. 3: Maintenance checklist Item

Maintenance points

Maintenance intervals Before shift

Daily

Weekly

Monthly Service life (in hours)

As required

xxxxx

xxxxx

Conveyor F10 Flight Check for wear and replace if necessary.

Check for damage and replace if necessary.

F20

Chain pre-tension Check the chain for excessive slack chain formation and noise development.

Check the chain pre-tension using a pretensiometer.

F30

Chain, chain connectors Caterpillar Global Mining Europe GmbH, Lünen 2013

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Check for wear and replace if necessary.

Check for damage and replace if necessary.

F40

Drive frame and return unit, chain sprockets Check for wear and replace if necessary.

Lubricate bearing.

F50

100

Drive frame, chain stripper Check for wear and replace if necessary.

F60

Hydraulic cylinder Check for damage and leaks. Replace if necessary.

F70

Hydraulic hose lines Check for damage, leaks and tight fitting. Replace if necessary.

F80

Gearbox Conduct noise test and check oil temperature and tightness.

Check the oil level.

1st oil change

400

2nd, 3rd, 4th ... oil change

4000

Clean vent filter (each time oil is changed).

4000

Open gearbox and clean the complete interior.

Press in more grease.

a 1)

2a 1000

Check clutch for sufficient lubrication and wear.

a

Conduct complete gearbox inspection (open and clean gearbox, check gearing etc).

2a

Check oil and change it, if necessary, in the event of foaming/discoloration and increased noise development.

1) a = yearly, 1/2a = every six months, 1/4a = every three months etc.

2) In the first eight weeks after commissioning, check weekly, thereafter monthly.

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Rock Mover RM900

How to maintain the conveyor Item

Maintenance points

Maintenance intervals Before shift

F90

F100

F110

Drive lines (gearbox, clutch and motor) Check function.

Both drives must run synchronously at low vibration and noise level.

Check drive shaft for damage and even circulation.

Check all screw connections between drive frame/ gearbox and gearbox/motor for damage and correct fitting.

Check the tightening torques!

Inlet plate in drive frame Check for wear and replace hard facing if necessary.

Daily

Weekly

Monthly Service life (in hours)

As required

xxxxx

xxxxx

2a

a

Bottom plates, sidewalls, spill plates, attachment spill plates

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Check for wear and replace if necessary.

Electrical components of conveyor EF10 Cables Check for damage.

EF20

Cable connections Check for damage and tight fitting.

EF30

Sensors, actuators Check the function.

EF40

1/4a

E-motor, terminal box Check for damage.

Important!

Check and service all components in accordance with the supplier documentation of the respective manufacturers.

Observe the manufacturers' details!

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5.15

How to replace wear parts How to replace wear parts It is essential to replace wear parts before they reach the lowest wear limit, which is the only way to prevent damage to other parts of the machine. Check all wearing parts on a regular basis.

Chain sprocket The chain sprockets transmit the drive torque from the gearbox via the drive shaft to the chain. The chain sprockets are subject to extreme wear due to the high frictional forces to which they are exposed.

Important!

The chain sprockets are part of a drive unit. The complete drive unit has to be replaced and overhauled when the chain sprockets are worn. Please contact our service personnel!

Wear measurements at the chain sprocket The degree of wear of the chain sprocket must be determined using two measurements: vertical wear measurement to determine the height H horizontal wear measurement to determine the length V vertical measurement

The degree of wear can be measured with a depth gauge. The height H is measured diagonally from the chain link to the bottom of the groove with the depth gauge.

The chain sprocket must be turned, as soon as the height Hmin1 is reached.

The chain sprocket must be replaced as soon as the height Hmin 2 is reached.

Fig. 44:

Measuring the vertical wear of the chain sprocket t d

d diameter of chain wire t chain pitch

5.16

H

H measuring height

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

Check for wear of the chain sprockets at least every four weeks.

Please note that the service life of a turned chain sprocket may be much shorter. This is due to tolerances in the hardness penetration depth. Therefore check the turned chain sprockets for wear at least once every two weeks.

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The service life can be optimized by removing the drive unit and then turning it 180 degrees and reinstalling it. This moves the chain links over to the sides of the chain sprocket pockets subjected to less wear.

Each drive unit can only be reinstalled once after being turned.

How to replace wear parts horizontal measurement

To determine the degree of wear, the length V of the tooth must be measured.

The chain sprocket must be turned as soon as the length Vmin1 is reached.

The chain sprocket must be replaced as soon as the length Vmin2 is reached.

Fig. 45:

Measuring the horizontal wear of the chain sprocket Round steel/flat chain

Power chain Vnew

Vnew

Vmin1

Vmin1

Vmin2

Caterpillar Global Mining Europe GmbH, Lünen 2013

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Vmin2

Caution!

A new chain may only be used with new chain sprockets.

Always replace the chain and chain sprockets together. Almost new chain sprockets should also only be used after consulting Caterpillar.

Wear and reference dimensions on the chain sprocket Tab. 4: Wear dimensions at the chain sprocket, round steel chain type Nominal chain size (d x t)

30 x 108

34 x 126

Number of teeth of chain sprocket

Hnew

Hmin1

Hmin2

5

73

67

61

6

78.5

72

66

7

82.5

76

70

8

92.5

86

80

5

85

67

73

6

94.5

86

82

7

98.5

92

86

Vnew

Vmin1

Vmin2

38

26

14

50

38

26

Vmin1

Vmin2

41

29

17

52

40

28

40

28

16

Tab. 5: Chain sprocket wear dimensions, flat chain type Number of teeth of Nominal chain size Hnew Hmin1 Hmin2 Vnew (d x t) chain sprocket 38 x 126

42 x 146

48 x 144/160

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5

91

85

79

6

88.5

82

76

7

102

96

90

5

94

88

82

6

92

86

80

7

105.5

99

93

5

103

97

91

7

105.5

99.5

93.5

8

103.5

85

91

5.17

How to replace wear parts Tab. 6: Chain sprocket wear dimensions, power chain type 1) Number of teeth of Nominal chain size Hnew Hmin1 Hmin2 Vnew (d x t) chain sprocket 34 x 110 42 x 140 52 x 177 60 x 200

Vmin1

Vmin2

18

10

2

23

12

2

7

77

71

65

5

94

88

82

6

93

87

81

6

111

105

99

30

16

3

7

110

104

98

32

19

6

7

123

117

111

35

20

5

Vmin1

Vmin2

44

32

Tab. 7: Chain sprocket wear dimensions, F-class chain type 2) Number of teeth of Nominal chain size Hnew Hmin1 Hmin2 Vnew (d x t) chain sprocket 60 x 181/197 FCC 2)

7

115

109

103

56

Replacing the drive unit The drive unit in the drive frame consists basically of the following components: two chain sprockets one drive shaft two fixed bearings Fig. 46:

Drive unit 6

2 1 6

b

a b 5

1

3

b 1 drive unit 2 chain sprocket DKB 42x146-7Z 3 drive shaft 4 transport protection

a b

4

5 lubricant line 6 fixed bearing a grease inlet b grease outlet

1) Power chain = type designation 2) F-class chain (FCC) = type designation

5.18

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Main components

How to replace wear parts Dismantling the drive unit Proceed as follows:

. Relieve the chain tension, open the chain and remove it from the installation area.

. Remove the drive lines on both sides.

Important!

Observe the separate operating manuals for the gearboxes, clutches and motors when removing the drive lines!

. Remove the attachment spill plates from the drive frame. . Remove the lubrication connections.

Fig. 47:

Removing the drive units, attachment spill plates and lubrication connections Detail X

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

1

2 X

Magnification of Y 3

Y

1 attachment spill plates (right and left) 2 drive lines (E-motor/ clutch/gearbox)

3 lubrication connections

You can continue with the removal of the drive unit after removing the attachment parts (see Fig. 48):

. Install the transport protection device (3) with four hex. head screws (4) on each side of the drive unit to prevent damage to the gearing during the removal.

Warning!

On an inclined face, the drive unit can slide out of the drive frame of its own accord!

This could cause serious injuries or even death!

Secure the drive unit against sliding out inadvertently before removing the tie-bars.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5.19

How to replace wear parts . Undo the hex. head screws (2) on both sides of the drive frame and remove the tie-bars (1).

Fig. 48:

Installing the transport protection device and removing the tie-bars

2 1 4

3 transport protection 4 hex. head screw M16x35-8.8

Caution!

Use lifting straps to pull out and raise the drive unit. Place the lifting straps around the drive shaft or chain sprockets.

Do not use any chains or the like!

. Pull the drive unit out of the drive frame.

Fig. 49:

Removing the drive unit

1

2

1 drive frame

5.20

2 drive unit

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

1 tie-bar 2 hex. head screw M 30x170-8.8

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3

How to replace wear parts Installing the drive unit Important!

Before pushing the new or turned drive unit into the drive frame, you must clean the guides and slide surfaces and lubricate them sufficiently with lubricating paste B2.

See chapter 6, section “Grease and lubricating pastes”.

Fig. 50: Contact surfaces between the drive unit and drive frame

X

X

Caterpillar Global Mining Europe GmbH, Lünen 2013

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X

1 drive frame 2 drive unit

X contact surfaces - apply lubricating paste B2.

. Push the drive unit into the drive frame.

Important!

Make sure the guides of the drive unit slide evenly into the drive frame and do not become jammed.

Fig. 51:

Pushing in the drive unit

1

2

1 drive frame

Doc. No.: 5445 001 000 BA 00

VRSP / 03

2 drive unit

5.21

How to replace wear parts . Screw the tie-bars onto the face side of the drive frame.

Important!

Tighten the hex. head screws with the required tightening torque!

. Remove the transport protection device from the drive unit.

Fig. 52:

Installing the tie-bars and removing the transport protection device X

2

X 1 tie-bar 2 hex. head screw M30x170-8.8 tightening torque MA = 1310 Nm 3 transport protection

3 4 hex. head screw M16x35-8.8 X contact surfaces - apply lubricating paste B3

. Install the lubrication connections. . Install the drive lines on both sides.

Important!

Observe the separate operating manuals for the gearboxes, clutches and E-motors when installing the drive lines!

. Place the attachment spill plates on the drive frame and screw them together.

Important!

Tighten the hex. head screws with the required tightening torque!

. Couple, connect and pre-tension the chain using the harness.

Important!

The chain must be shortened if the tension path (max. 600 mm) of the return unit is insufficient to apply the required chain pretension to the chain.

See chapter 4, section “How to install the chain” and “How to tension the chain”.

The drive unit is now completely installed.

Warning!

You may only release the conveyor after checking the overall system and all safety equipment for perfect condition and establishing that there are no defects!

5.22

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

4

E

1

How to replace wear parts Chain strippers The drive frame and return unit are equipped with chain strippers in order to release the circulating chain from the pockets of the chain sprockets in good time.

Replacing the chain strippers at the drive frame replacement

fastening

dismantling

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

The chain strippers are secured in position in their recesses by means of profile rods welded into the drive frame and onto the stripper plate.

The chain stripper can be pulled out upwards with the chain sprocket installed after removing the stripper plate.

Fig. 53:

Replacing the chain strippers 1

E

4

Caterpillar Global Mining Europe GmbH, Lünen 2013

3

3

a

2

1 stripper plate 2 chain stripper 3 hex. head screw M 36x115-10.9 tightening torque MA = 3220 Nm

4 hex. nut M 36-10 a recess

The new chain strippers are reinstalled in the reverse order of their removal.

Caution!

If the strippers become loose during operation, the chain sprocket and/or the drive frame could be damaged.

It is imperative that the mounting bolts of the stripper plate are tightened with the required tightening torque.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5.23

How to replace wear parts Chain Typical marks of wear on chains are: mechanical wear resulting in a reduction of the diameter hinge wear in the transition zone from one chain link to the next incipient cracks and fractures excessive chain elongation During operation of the conveyor, the chain links may temporarily heat up at points with a high mechanical resistance. This heating results in the formation of a martensite layer on its surface, which appears to be full of small cracks.

Important!

The formation of martensite on the surfaces of chain links and the resulting surface changes do not impair the properties of the chain.

Check the chain, its flights and chain connectors every week for visible mechanical damage.

monthly

Check the wear dimensions of individual chain links every month on a random basis.

every 2 months

Check the overall elongation of the chain regularly every 2 months.

Caution!

Damaged and worn chain components pose an increased safety risk. Replace worn or damaged chain components immediately!

Caution!

A new chain may only be used with new chain sprockets.

Always replace the chain and chain sprockets together!

Almost new chain sprockets can also be used, however only after consulting Caterpillar.

data sheet

We recommend that you create a data sheet to facilitate the inspection of the chain and identify any relationships between the chain and the conveyor.

The data sheet should contain the following information: operating time in hours or raw mining in tons drive power of the motors face length, chain type and date of installation reference dimensions of the unused chain (diameter and length) chain connectors: – number, date of installation and operating time since the last change, schematic overview of the unit, so that in the event of a cracked chain the position of the crack can be determined.

5.24

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

weekly

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Inspection intervals

How to replace wear parts Maximum wear dimensions of chain strand The complete chain strand needs to be replaced if the total elongation is 3.5%.

Chain strand wear measurement Chain wear measurements can be carried out using two different methods: difference value measurement (recommended) basic value measurement Always measure chains in a cold and slightly pre-tensioned condition. The chain should always be in the straight strand. difference value measurement

Measure the length across as high a number of links as possible without adjusting chains.

After mounting the gauge provided, please proceed as follows:

. Hold the gauge parallel to the chain.

E

. Press the fixed measuring side against an external chain link

Caterpillar Global Mining Europe GmbH, Lünen 2013

curve (A).

. Press the moving measuring side against a chain link curve in the same position (B).

Fig. 54:

Difference value measurement

. Read the measured value on the millimeter scale. . Repeat the measurement at different chain sections and note down the individual values.

. Select the highest individual value and compare it with the values in the wear tables provided from the chain manufacturer.

Example of a chain 42 x 146 (measurement across 4 links): Measured values (difference from the original length) read on the gauge: ≙

0.86% elongation

10 mm ≙

1.71% elongation

15 mm ≙

2.57% elongation

20 mm ≙

3.42% elongation

5 mm

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5.25

How to replace wear parts basic value measurement

To measure the basic values, you must calculate or measure the length of a chain section of a new chain as the reference dimension for subsequent wear measurements. Use suitable and sufficiently accurate measuring equipment for this (unit of measure in mm) e.g. a sufficiently dimensioned slide gauge.

Measure the length across a high number of odd chain links (3, 5, 7, ...) without adjusting chains.

Prepare your measuring instrument accordingly and hold it parallel to the chain.

. Apply your measuring instrument in such a way that it has contact at the chain link curve at point (A).

. Press the moving part of your measuring instrument against the chain link curve at point (B).

Basic value measurement

. Repeat the measurement at different chain sections and note down the individual values.

The smallest individual value measured is used as the reference dimension.

As an alternative, the reference dimension of the chain can also be calculated by adding 7 x chain link length + 2 x chain diameter.

Example of a chain 38 x 137 (measurement across 7 links): (7 x 137 mm) + (2 x 38 mm) = 1035 mm 1035 mm is the length across 7 links for the new, unused chain.

Based on this reference value, the wear can be calculated.

. Create a table specifying the wear in [%] according to your measurement.

Example: chain 38 x 137 1035 mm

Reference dimension of this chain

1045 mm

1% elongation

1050 mm

1.5% elongation

1056 mm

2% elongation

1066 mm

3% elongation

1071 mm

3.5% elongation

The chain must be replaced at a length of 1071 mm (= 3.5% elongation).

The largest measured individual value of a chain section is decisive for the decision as to whether a chain needs to be replaced due to elongation.

5.26

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Fig. 55:

How to replace wear parts Important!

Always replace chain units in pairs.

Chain link wear measurement Measure the chain links in new condition to determine a reference dimension for subsequent wear.

. Measure the diameter of a chain link always next to or opposite the weld.

Chain measurement

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Fig. 56:

1 diameter with weld 2 round steel chain

3 flat chain 4 measurable diameter

. Repeat the measurement at different chain links and note down the individual values.

. Create a table specifying the wear in [%] according to your measurement.

. Select the highest individual value and compare it with the wear criteria.

. Replace the chain when the specified wear dimensions have been reached.

Maximum wear dimensions of chain links Chains may no longer be used if one of the following wear criteria applies: Elongation of a chain link of more than 3.5% compared to new condition.

Fig. 57:

Doc. No.: 5445 001 000 BA 00

VRSP / 03

Chain elongation

5.27

How to replace wear parts Rubbing wear of the sides exceeding 30% (in terms of the smallest diameter) compared to new condition.

Fig. 58:

Abrasion wear

Formation of “ducktails” exceeding 15% (in terms of the smallest diameter) compared to new condition.

“Ducktail”

Important!

Change the chain's driving direction to remove the “ducktails” from the chain sprocket's transmission of force. To do this, turn the chain 180° in the longitudinal direction to distribute the rubbing wear to the opposite sides.

Important!

Always replace chain units in pairs.

5.28

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Fig. 59:

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 rectify them. Please contact our service personnel if you cannot find the causes.

Tab. 8: Fault table Fault

Cause

Measure

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

1. Electrical circuit failed.

1. Check the electrical circuit.

2. Voltage drop.

2. Check the voltage.

3. Contactor failure due to overload.

3. Check the overload protection.

4. Switching sequence time below 1.5 seconds.

4. Check the switching sequence time.

1. Motors/gearboxes cannot dissipate heat due to soiling.

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

2. Too much or insufficient oil in the gearbox.

2. Check the oil level.

3. Oil is too old.

3. Change the oil. (refer to the separate operating manual for oil quantity and oil type)

4. Bearings are damaged.

4. Have bearings repaired by a specialist

1. Insufficient grease in the bearings.

1. Lubricate the bearings.

2. Grease too old.

2. Clean bearings and pack with fresh grease.

3. Bearings are damaged.

3. Have bearings replaced by a specialist.

1. Conveyor is overloaded.

1. Unload the conveyor.

2. Transfer point clogged.

2. Clear clogging at transfer point.

1. Too much slack chain.

1. Shorten and re-tension the conveyor chain.

2. Chain strand twisted.

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

3. Different number of links in parallel chain strands.

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 severely twisted.

5. Insufficient pre-tension.

5. Adjust the pre-tension according to the conveyor length.

1. Foreign matter in the conveyor.

1. Remove the foreign matter.

2. Flight jammed.

2. Release the jammed flight.

Chain broken.

1. The chain is blocked by foreign matter.

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

Conveyor chain jumps out of chain guide.

1. Conveyor is crooked.

1. Straighten the conveyor.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

E-motors and/or gearboxes become too hot – temperature > 85°C.

Lubricated bearings become too hot temperature > 85C.

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

Conveyor chain skips chain sprocket.

Conveyor chain jams abruptly.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

5.29

When faults occur Cause

Measure

2. Chain too slack.

2. Shorten and re-tension the chain.

3. Pan guide worn.

3. Replace conveyor pans.

4. Flights worn.

4. Replace flights.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Fault

5.30

Rock Mover RM900

6

Technical data

Main components of the conveyor system

Technical data This chapter contains the most important technical data of the conveyor. Further information is given in the spare parts lists and in the separate operating manuals for the individual components such as 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.

Main components of the conveyor system The maximum output of the conveyor system described here is 2 x 90 kW 1).

Changes to the components listed must be checked and approved

by Caterpillar.

Technical data sheet Conveyor length: . . . . . .

Speed: . . . . . . . . . . . . . . .

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

approx. 78.6 m 0.15 m/s > 85 dB(A) 2)

drive frame

Drive frame: . . . . . . . . . .

Bearing service life: . . . .

Chain sprocket: . . . . . . .

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

MR 35-1200 10 000 h 3) DKB 42x146/107 Z = 7, KA = 1200 bevel helical gearbox KDEH550-X, i = 311.4; from KWE 4) N-Eupex clutch A180 75/55 from Siemens/Flender 4) low-voltage motor 90 kW IM B; 400 V; 50 Hz 1), from Siemens 4) return unit U-1200 10 000 h 3) DKB 42x146/107 Z = 5, KA = 1200 RM-pan with adaptor spill plate 1 RM-pan with adaptor spill plate 2 RM-pan PF 1200 super flat chain DKB 42x146/107 KA = 1200

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

general

Drive connection: . . . . . .

E-motor: . . . . . . . . . . . . . . return head

Return head: . . . . . . . . . .

Bearing service life: . . . .

Chain sprocket: . . . . . . .

RM-pans: . . . . . . . . . . . . .

Chain: . . . . . . . . . . . . . . . connecting element

Pan connection: . . . . . . .

Chain connector: . . . . . .

Tools: . . . . . . . . . . . . . . . .

block connector 42x146/107, super flat chain harness RM 900

1) The specified power ratings are continuous power ratings. They apply to E-motors with a nominal speed of 1470 rpm. A stalling torque of 2.5 must not be exceeded when starting the E-motors.

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

3) Corresponds to 90% of the calculated nominal bearing service life.

4) Further information can be found in the separate operating manuals or spare parts documentation from the respective manufacturers or suppliers.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

6.3

Identification Identification The identification of the conveyor and the individual components is specified below.

Identification of the conveyor Manufacturer: . . . . . . . . . . . Caterpillar Global Mining Europe GmbH Type: . . . . . . . . . . . . . . . . . . Rock Mover RM900 Year of manufacturing: . . . . MM/YY (e.g.: 06/12 ≙ June 2012) ID no.: . . . . . . . . . . . . . . . . . . 5445 001 000 00 00 Weight: . . . . . . . . . . . . . . . . . 161 333 kg The conveyor is labeled with the following information: Fig. 60:

Type plate and CE-marking example

06/12 5445 001 000 00 00 RM900

161 333 kg

Identification of the drive frame Manufacturer: . . . . . . . . . . . Caterpillar Global Mining Europe GmbH Type: . . . . . . . . . . . . . . . . . . drive frame MR 35-1200 Year of manufacturing: . . . . MM/YY (e.g.: 06/12 ≙ June 2012) ID no.: . . . . . . . . . . . . . . . . . . 5445 001 110 00 00 Weight: . . . . . . . . . . . . . . . . . 12 863 kg The drive frame is labeled with the following information: Fig. 61:

Example of type plate and CE-marking

Caterpillar Global Mining Europe GmbH

06/12 5445 001 110 00 00 MR 35-1200

6.4

12 863 kg

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Caterpillar Global Mining Europe GmbH

Identification Identification of the tensionable return unit U-1200 Manufacturer: . . . . . . . . . . . Caterpillar Global Mining Europe GmbH Type: . . . . . . . . . . . . . . . . . . return unit U-1200 Year of manufacturing: . . . . MM/YY (e.g.: 06/12 ≙ June 2012) ID no.: . . . . . . . . . . . . . . . . . . 5445 001 300 00 00 Weight: . . . . . . . . . . . . . . . . . 9 775 kg The drive frame is labeled with the following information: Fig. 62:

Example of type plate and CE-marking

Caterpillar Global Mining Europe GmbH

06/12 E

5445 001 300 00 00 Caterpillar Global Mining Europe GmbH, Lünen 2013

U-1200

9 775 kg

Important!

Information on the components of the conveyor subject to identification marking not included here is listed in the respective operating manuals.

Doc. No.: 5445 001 000 BA 00

VRSP / 03

6.5

Tightening torques Tightening torques Screws and bolts with ISO metric thread Tab. 9: Tightening torques at tot. = 0.14 Tightening torque 4)

Pitch P

(mm)

(mm) Coarse thread

M8

MA (Nm) 8.8

10.9

12.9

A 2-70

A 4-80

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

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

M 42

4.5

3670

5160

6190

(M 45)

4.5

4590

6450

7740

M 48

5

5540

7790

9350

Caterpillar Global Mining Europe GmbH, Lünen 2013

d

Important!

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

1) 2) 3) 4)

6.6

E

Thread 1)

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

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

Only for expansion bolts with a reduced shaft cross-section of 24.2 mm.

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

Rock Mover RM900

Permissible media Permissible media Hydraulic oil Permissible hydraulic oil Hydraulic oil: HLP 46 operating temperature

The maximum permissible temperature of the hydraulic fluid is 60C. During normal operation, however, an operating temperature of 45C should not be exceeded. Higher working temperatures reduce the service life of the sealing material.

Quality of the process water for use as spraying water

E

limit values

The water used for this purpose must not contain aggressive components or dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter of at least 100 m.

In order to protect the components, the limit values listed in the table must not be exceeded.

The following table lists limit values for the main properties and components of the process water.

Caterpillar Global Mining Europe GmbH, Lünen 2013

Caution!

Using water that is not of the specified quality can cause serious damage to component surfaces and the entire system.

Only use water that complies with the specified limit values!

Tab. 10: Properties of the process water, limit values Test criterion

Limit value

Appearance, color, odor

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

Electrical conductivity

< 1800 S/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+ content

Not specified

Water hardness

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

Cl- - content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



1 mg/l

Bacteriological requirements



105 col/ml 1)

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



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1)

Doc. No.: 5445 001 000 BA 00

The specified values must be observed for the production of hydraulic fluids.

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

VRSP / 03

6.7

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

Important!

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

Greases grease A1

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

Tab. 11: Grease A1 Supplier

Make

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm)

Application temperature range: . . . . . -40 to +120C grease A2

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

Tab. 12: Grease A2 Supplier

Make

Base

NLGI class

Flashpoint in °C

Shell

Alvania E.P. grease 2

Lithium soap

2

205

Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . practically insoluble in water Application temperature range: . . . . . -15 to +120C grease A8

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

Tab. 13: Grease A8 Supplier

Make

Base

NLGI class

Flashpoint in °C

Castrol

Molub-Alloy 3036/680-1

Lithium soap

1

210

Worked penetration: . . . . . . . . . . . . . . 310 to 340 (0.1 mm) Behavior in the presence of water: . . insoluble in water at 90C Temperature of application: . . . . . . . . -20 to +120C

6.8

Rock Mover RM900

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Behavior in the presence of water: . . practically insoluble in water

Permissible media Lubricating pastes lubricating paste B1

Lubricating paste as spray with solid lubricant molybdenum disulfide and adhesive active agents. To lubricate fixed and sliding fits, heavy-duty dowel pins for facilitate installation. Reduced friction and wear.

Tab. 14: Lubricating paste B1 Lubricant carrier

Supplier

Make

Gleitmolybdän

gleitmo 100 S Spray Mineral oil

NLGI class -

Static penetration: . . . . . . . . . . . . . . . . . . 250 to 270 (0.1 mm) Behavior in the presence of water: . . . . no information Temperature range of application: . . . . -35 to +450C, when air is excluded, up to 630C lubricating paste B2

Multi-purpose and installation paste with solid lubricant. Prevents corrosion and rusting-in of tight fits, corrosion protection effect, against friction and fretting corrosion.

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Tab. 15: Lubricating paste B2 Supplier

Make

Lubricant carrier

Klüber

NB 50

Barium complex soaps

NLGI class 2/3

Worked penetration: . . . . . . . . . . . . . . . . 235 to 265 (0.1 mm) Behavior in the presence of water: . . . . insoluble in water Temperature range of application: . . . . -35 up to +150C, briefly up to 200C 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. 16: Lubricating paste B3 Supplier

Make

Lubricant carrier

NLGI class

Flashpoint in °C

Gleitmolybdän

gleitmo 805

Lithium soap

2

220

Worked penetration: . . . . . . . . . . . . . . 265 to 295 (0.1 mm) Behavior in the presence of water: . . insoluble in water Temperature of application: . . . . . . . . -20 to +120C Lubricants lubricant B6

Parting agents and lubricants with organic lubricating agent on a synthetic base material for greasing threaded areas and fitting points at props and hydraulic cylinders, pin connections and similar connecting elements.

Tab. 17: Lubricant B6 Supplier

Make

Lubricant carrier

Flashpoint in °C

Chesterton

Parting agent/lubricant 785

Paraffin base

132

Behavior in the presence of water: . . insoluble in water Application temperature range: . . . . . -34 to +120C

Doc. No.: 5445 001 000 BA 00

VRSP / 03

6.9

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Permissible media

6.10

Rock Mover RM900

7

For your information

Standards and directives

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

Standards and directives Applied standards and directives Tab. 18: Standards and directives, excerpt

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

Designation

Date of issue

Title

EC Directive of the European Parliament and Council on Directive 2006/42/EC the approximation of the laws of the Member States relat2006-05-17 ing to machinery Directive of the European Parliament and the Council on the approximation of the laws of the Member States conDirective 94/9/EC 1994-03-23 cerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 2004-04 Safety of Machinery 12100-1/A1 2009-10 DIN EN ISO 12100-2 Safety of Machinery 2004-04 Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water content - Distillation method Non-electrical devices for use in potentially explosive atDIN EN 13463-1 2009-07 mospheres - Part 1: Basic principles and requirements Electrical equipment for explosive gas atmospheres DIN EN 60079-0 2010-03 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces 2007-11 Underground mining machinery - Specification DIN EN 12321 2009-07 of the safety requirements for chain scraper conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - Safety requireDIN EN 1552 2003-09 ments for shearer loaders and plough systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic self-advancing support 2010-05 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentationDIN 2000 Quality of drinking water 2000-10 DIN 6789 Documentation system 1990-09 DIN 20043 Plug connectors for hydraulics 2003-09 DIN 24320 Fire-resistant hydraulic fluids 2006-12 DIN 24343 Maintenance and inspection list for hydraulic systems 1982-02 DIN 51558-1 Determination of the acid number 1979-07 DIN 51575 Determination of the sulfate ash 2011-01

Doc. No.: 5445 001 000 BA 00

VRSP / 03

7.3

Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA-fluids in mining

1985-02 1992-06 1985-02 2008-01

Caterpillar Global Mining Europe GmbH, Lünen 2013

E

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

1985-02

1) EWN = works standard

7.4

Rock Mover RM900