CAT Armored Face Conveyor PCM-D- Drive Control System Impact roll crusher SK 1118 Majialang1 Operat

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Impact roll crusher SK 1118 Project:

"Majialang 1"

Object-No.: 55281700000000 Mach.-No.: 564

Bucyrus Europe GmbH Industriestraße 1 D-44534 Lünen

Phone: ++49 (0) 2306 / 709-0 Fax: ++49 (0) 2306 / 709-1421

Email: info@de.bucyrus.com Internet: www.bucyrus.com

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Documentation SK 1118, Project "Majialang 1" Object-No.: 55281700000000 1

Crusher plant SK 1118 Operating manual

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Spare part list 55281700000000

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P&S Tensioning nut CY M42x3/W (Impact roll) Article-No.: 55399012121000

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RINGSPANN Clamping element TLK400, 280x355 (Impact roll) Article-No.: 55399006210000

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LUKAS Hydraulic pump ZPH 1/5 (Height adjustment) Article-No.: 55395101007000

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BUCYRUS Crusher gearbox K-8B Article-No.: 369962

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BUCYRUS Crusher motor Article-No.: 774761

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REGISTER 1

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Operating manual Impact roll crusher SK 1118 Project:

"Majialang 1"

Object-No.: 55281700000000 Mach.-No.: 564

Translation of original operating manual (Übersetzung der Originalbetriebsanleitung

Bucyrus Europe GmbH Industriestraße 1 D-44534 Lünen

Phone: ++49 (0) 2306 / 709-0 Email: info@de.bucyrus.com Fax: ++49 (0) 2306 / 709-1421 Internet: www.bucyrus.com

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

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

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

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

Bucyrus Europe, GmbH, Lünen 2010

©

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Content About this manual ........................................3 Before starting work ................................................. 3 Who is this operating manual intended for?...................... 3 What is the purpose of this operating manual?................. 3 Characters and symbols used .......................................... 4

For your safety .............................................7 Personnel................................................................... 7 General safety instructions...................................... 8 Operating conditions .............................................. 11 Intended use ................................................................... 11 Unauthorized use............................................................ 11

Storage and Transport...............................15 Storage..................................................................... 15 Storing the equipment..................................................... 15

Transport ................................................................. 15 Before transport .............................................................. 16 Transport of the components .......................................... 16

Assembly ....................................................19 What to observe prior to assembly ....................... 19 Who is allowed to carry out assembly work? .................. 19 Assembly notes .............................................................. 19

Assembly ................................................................. 20 How to assemble the drive unit ....................................... 20 Drive connection assembly ............................................. 21 Installing the individual crusher components into the stageloader ..................................................................... 22 Installing the assembled crusher into the stageloader .... 23

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Dismantling.............................................................. 23

Technical data ............................................27 Technical data sheet ............................................... 27 Main components .................................................... 28 Components ............................................................ 29 Technical description ............................................. 30 Housing, substructure and pan .......................................30 Impact roll........................................................................31 Turnable impact heads....................................................32 Hydraulical height adjustment .........................................33 Central lubrication ...........................................................34

Tightening torques .................................................. 35 Screws resp. nuts with metric coarse thread DIN 13.......35

Permissible media................................................... 36 Lubricating greases .........................................................36 Hydraulic fluids ................................................................37

Operation ....................................................41 Commissioning of the crusher plant ..................... 41 Before commissioning .....................................................41 Notes for electrics............................................................42 Test run and start up .......................................................42

Operation of the crusher plant ............................... 43 General ...........................................................................43 Roll height adjustment.....................................................44

Maintenance............................................................. 46 Maintenance acc. to schedule .........................................47 Lubrication.......................................................................48 Replacing resp. turning the impact heads .......................49 Spare parts and special tools ..........................................50

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About this manual

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About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting work applicable operating manual crusher type

This operating manual is designed for the following crusher plant. It is only permitted to be used for this crusher plant (subject to change): Bucyrus crusher plant SK 1118 Object-No.: 55281700000000 Mach.-No.: 564

new operating manual

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

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the crusher plant.

It is the customer's / operator's responsibility that all persons, who work with this plant, know this operaring manual. It must be realized and accessible.

This includes persons: are in charge of transport perform assembly/disassembly work operate the crusher plant eliminate faults perform daily routine work on site perform maintenance work perform repair work Supervisory personnel who: initiate and/or supervise the activities just indicated

What is the purpose of this operating manual? cost-effectiveness

service

safety

Object-No.: 55281700000000

This operating manual is intended to help you working efficiently and safely with our product. It contains important information on all the activities releated to the crusher plant.

Pay special attention to the safety instructions.

If any details are not clearly understood, please contact our service department. Our service address is given on the title and on the first side of this operating manual.

Read the chapter "For your safety" with special attention. This chapter contains important information indicating possible hazards.

Observe the information given and follow the procedural instructions.

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Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual. Try to memorize the symbols and their meanings.

Danger!

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

Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

Caution!

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

Notice!

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

Important!

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

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For your safety

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For your safety state of the art

Original parts

further operating manuals

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

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

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

Do not make any alterations or modifications which could impair the safety of the crusher plant. All modifications and changes must be approved by Bucyrus.

Use only original spare parts from Bucyrus.

Note that the use of parts from other manufacturers will avoid the guarantee.

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

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

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

Clarify any questions before starting work.

Personnel Operation

Assembly and repair

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The crusher plant may only be operated by qualified trained personnel.

It is the customer's responsibility to guarantee this. In case of (further) training need, the customer can order training at the manufacturer.

Operate the operating field respectively the electrical control system only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective control system.

Danger!

Incorrect operation endangers yourself and others!

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

Ensure that nobody is present in the conveyor or in the danger area of the crusher plant (e.g. feeding area, discharge area) before starting the crusher plant.

Check that all protective devices (e.g. emergency-stop) have been fitted to the crusher plant and function properly Clean the control panel regularly. Ensure that the operating symbols are clearly legible so that operating errors and resultant accidents are prevented.

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

Installation and repair work on: the saftey components (pressure relief valves, extinguishers, etc.) the electrics (controls, signallin devices, etc.) the hydraulics may only be carried out by the service engineers from Bucyrus or by specially qualified personnel of the operator.

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General Safety instructions safety equipment

symbol plates EMERGENCY-STOP

lock-out

moving parts

means of attachment

replacing components

8

Familiarise yourself with your working environment.

Start the crusher plant only when it is in a good and safe condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Danger!

It is forbidden to stay in the area of possible falling material!

The operator must fix, mark and if necessary enlarge this area during test run and commissioning!

Keep the signalling and lighting systems in a proper functional condition.

Observe the acoustic and optical start-up warnings of the crusher plant.

Observe the symbol plates on the crusher plant.

Press the EMERGENCY-STOP switch immediately in the event of faults or irregularities in operation. Report any peculiarity to your superior so that the necessary measures can be taken immediately.

Secure the crusher plant against unauthorized and unintentionally restarting while performing: maintenance work inspection work repair work Attach a sign at the possible restarting point with the reference that work are proceeding and restarting is forbidden.

Never allow parts of your body to come between parts which could move, such as e.g.: rolls hydraulical height adjustments couplings and drive flanges Storage and transport Secure all moving parts.

Never stay under unsupported parts or suspended loads.

Connect the lifting equipment only to the points of attachment provided for that purpose.

Observe the different load limits of the attachment points. Also observe the instructions on the transport sheets (if any).

Only use means of attachment which are in good condition.

Never use chains or steel cables without approval.

Do not damage the machined or polished surfaces of shafts, sealings, etc.

Maintenance and repair Be sure to observe the specified maintenance and inspection intervals.

Inform the supervisory personnel and the crew about maintenance and repair work.

Sign dismantled, defect components. So you avoid the mistakenly reinstallation.

Check these components immediately and lead them to repair if possible.

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protective devices

handling of hydraulic fluids maintenance, repair

Refit protective devices removed immediately after completion of the work and check that they function properly.

Work on hydraulics (if any) Notice!

Only use hydraulic fluids given in DIN 24320 respectively 51524 parts 1 and 2.

Be sure to observe the manufacturer's instructions for use.

We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

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

You are only allowed to work on the hydraulic system if you have and can prove to have special knowledge of hydraulics.

Important!

Inspect and maintain all components of the hydraulic system such as e.g. pump stations, filter systems etc. as specified in the respective operating manuals.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause great damage to the complete hydraulic system. Flush out the hydraulic lines thoroughly before connecting.

Warning!

Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system.

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

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

Figure 1: Typical hydraulic hose

Manufacturer Date of manufacture Hose type with internal diameter

Never try to hold a jumping hose. Depressurize the respective line immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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laying hydraulic hoses

Lay the hydraulic hoses properly behind the backets and clamps provided for that purpose.

Lay hydraulic hoses such that they: always have a little slack.

Figure 2: Laying hydraulic hoses, slack

CORRECT

WRONG

are not twisted.

Figure 3: Laying hydraulic hoses, twisting

CORRECT

WRONG

are not bent directly behind the connections (distance min. 1.5 x nominal diameter) Figure 4: Laying hydraulic hoses, bending

CORRECT

WRONG

cannot chafe.

Figure 5: Laying hydraulic hoses, crossing

CORRECT

WRONG

are not kinked. are not subjected to tensile loads.

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are protected against thermal radiation. are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this may damage the connections.

When installing the hoses ensure that they cannot be: torn out, kinked, squeezed, driven over or twisted (Figure 6). by the movement of the crusher plant.

Figure 6: Laying hydraulic hoses, connection to moving parts

CORRECT

noise emissions

environmental acceptability

WRONG

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

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

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

Operating conditions Intended use The crusher plant will be used in a coal mine.

Employ the crusher plant only for its intended use!

The intended use is: Crushing coal

Unauthorized use Applications not expressly listed as intended uses are unauthorised uses and not allowed to be performed with the crusher plant.

Such unauthorized use includes i.a.: Transporting persons or objects of any kind Crushing other material Bucyrus accepts no liability for any damage resulting from any such unauthorised use.

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Storage and transport

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

Observing the notes and instructions will increase the service life and the availability of the crusher plant.

You will be able to carry out the transport work safer and faster.

Reading this chapter carefully will help you to make your day-to-day work easier.

Storage corrosion protection

Components provided with a temporary corrosion protection are protected for a period of about six months.

Before delivery, the hydraulically operated equipment is operated with a test medium which is drained to the extent possible prior to shipment.

The medium remaining in the equipment protects the internal parts against corrosion for at least six months.

Storing the equipment no direct exposure to sunlight

dirt and moisture

sample inspection

natural ageing

Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts made of rubber or plastics – such as seals and hoses – as well as hydraulic fluids only in closed rooms at temperatures between 15°C and 25°C. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.

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

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

Upon request, the inspection can be carried out by Bucyrus.

Even when properly stored, seals and hoselines are subject to natural ageing. Do not use these components if they have been stored for more than two years.

Important!

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the "first in, first out" principle.

Transport Warning!

Only use load handling devices complying with the respective technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads. Only use permissible load handling devices.

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Before transport

temperature below freezing

electrical and electronic components

Warning!

Before starting transport, remove any loose material from the crusher plant.

Disconnect the electrical supply.

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE bzw. HFAS) must be completely drained and then filled with a preserving fluid (e. g. CV 50).

Transport of equipment at temperatures as of and below -21°C is only permissible when certain measures were taken to meet these requirements already at the design and manufacturing stages.

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

During transport of this equipment at such temperatures using industrial trucks take care to ensure that parts and devices are not subjected to sudden impact loads.

Therefore, the speed of the trucks must be adapted to the prevailing conditions when transporting equipment at very low temperatures and on poor roads.

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

The electric cables remain on the equipment. They must be carefully protected against transport damage and soiling of the connections.

At temperatures below zero electric cables are only allowed to be transported on drums.

Transport of the components machine parts

It is planned to transport the impact roll crusher as a completely assembled unit.

For transporting the crusher housing with substructure is provided with lifting points. These are generally welded eyes or screwed 3D load hooks.

All lifting points have a number werlded on or engraved showing their permissible load-carring capacity ("3" or "3t" means the load-carring capacity of the lifting point is max. 3000kg).

Danger!

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

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

Warning!

Only use permissible lifting equipment!

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Assembly

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Assembly What to observe prior to assembly Who is allowed to carry out assembly work?

Assembly work is only allowed to be carried out by personnel having received adequate training to perform these tasks.

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signalling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by specially trained personnel.

A set of different tools and devices should be available at the points of assembly, including hoists with adequate lifting capacity load handling devices with adequate lifting capacity

Assembly notes Observe the valid accident prevention instructions and the special safety instructions.

Secure the working area.

Caution!

Serious damage can be caused to the crusher plant and the drive units due to incorrect assembly!

Caution!

Please take care to observe the respective separate operating manuals!

Components which were stored or transported at below freezing temperatures must not be thrown or pushed. Care must be taken that these parts are slowly exposed to the ambient temperature. They should not be put into operation before they have reached this temperature.

Sensitive components must be handled with special care.

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Assembly How to assemble the drive unit The gearbox K-8B will be installed at the crusher over the gearbox holder. Furthermore it will be connected to the drive shaft over the connecting flange at the impact roll.

Figure 7: Connecting flange for gearbox, gearbox holder

4 bores for fastening screws M24 at connecting flange; Tightening torque = 920 Nm

4 bores for fastening screws M24 at connecting flange; Tightening torque = 920 Nm

Instructions for installation of the gearbox Important!

Be sure to observe the separate operating manual for the gearbox K-8B! All flange surfaces, centerings, parallel keys and grooves must be clean and free from burr.

Before flanging on, carefully grease the gearing.

Align the gearing such that tooth and tooth gap are exactly opposite one another to ensure that they mesh smoothly. Try to avoid damage to the teeth. Take special care to ensure that the gearbox is not tilted when installing it.

The gearbox must be positioned exactly on the centering bores, plugtype connections, and parallel keys.

The bolt sizes must be selected to match the gearbox used.

Caution!

After installation of the gearbox, there must be no strain between gearbox and connecting flange / gearbox holder or between gearbox and drive shaft.

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

Figure 8: Drive connection assembly

2

7

11 3), 15

Ø780

10 2), 14

Ø85H7

1 1)

Ø100

Ø730

Ø775

Ø900

3

Motor side

Ø720H7

Gearbox side (Gearbox K-8B)

30 “W”

1 2 3 7 10 11 14 15

Coupling 650 TWVC, Turbo coupling with constant filling, medium water 1) Coupling SX301-VKR Protection cover Intermediate flange Hexagonal bolt M16x45-8.8 2) Hexagonal bolt M30x90-8.8 3) Spring washer VSK 16 Spring washer VSK 30

X = 30mm flange position "W" (Distance from motor flange to shaft collar), to be checked before motor assembly 1) Observe separate operating manual of Voith 2) Tightening torque Ma = 195Nm 3) Tightening torque Ma = 1300Nm

Flange position "W" Flange position ”W” of the electric motor means the distance between the motor flange and the shaft collar. On the drive connection it is the distance between the contact surface of the protection cover (motor side) and the contact surface of the coupling (see figure 9).

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Caution!

If the flange position ”W” at the electric motor is larger than at the drive connection, the motor shaft and gearbox drive shaft bearings will be strained. This can result in damage to the gearbox and the electric motor!

Fig. 9: Flange position "W"

Particular attention must be paid to the following instructions before installing the electric motor: The exact flange position "W" of the electric motor must be measured before installation.

If the flange position ”W” of the electric motor is larger than that of the drive connection, a component of the drive connection (e.g. hub of the flexible coupling) must be shortened accordingly.

The coupling parts have to be installed using the mounting and pulling-off device.

Caution!

Blows on the motor shaft and/or gearbox shaft will damage the roller bearings! Therefore always use a mounting and pulling-off device for installation and removal of the coupling parts!

Important!

Be sure to observe the separate operating manual for the electric motor!

The crusher can either be directly installed and mounted in the stageloader or pre-assembled next to the stageloader to be integrated later into the stageloader assembly.

To install the impact roll crusher into the stageloader, the chain in the top and bottom races is separated and afterwards, the required number of pans removed.

Installing the individual crusher components into the stageloader When installing the crusher into the stageloader, first the substructure including crusher pan is pulled into and connected with the stageloader assembly – observing the conveying direction! If not carried out yet the replaceable side profiles have to be screwed into the substructure.

The chains in the top and bottom races are pulled in and coupled.

The complete impact roll will be installed at the substructure - observe the conveying direction! Now the side walls can be mounted on the substructure. Fitting and sealing the hood completes the installation.

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Installing the assembled crusher into the stageloader Using lifting and pulling gear the completely assembled crusher is pulled into the stageloader and connected with the pans. The chain is guided through the rop and bottom race of the impact roll crusher and coupled.

Finally, the personnel safety and dust protection zone facilities are fitted ahead of and behind the crusher.

Dismantling Stop the crusher plant.

Disconnect the electrical supply.

Important!

Dismantling is peformed using the same tools and devices as for assembly.

When dismantling the power unit, care should be taken that all exposed shafts, hubs, labyrinth paths, and flanges are protected against corrosion, dirt, and mechanical damage.

Particular care should be used in the treatment of machine parts that can get damaged easily.

When disconnecting hose lines, the hose ends should be plugged by blind or screw plugs.

Loose parts (screws, bolts etc.) should be kept in suitable boxes, well arranged and protected against dirt and damage.

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Technical data

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Technical data This chapter contains the most important technical data on the crusher plant.

Furthermore the crusher plant will be described.

Further data can be found in the spare part lists and in the separate operating manuals for the individual components such as e.g. hydraulic pump.

At the end of this chapter you will find information on bolt tightening torques; greases, etc. Read this chapter carefully and pay attention in particular to the safety advices.

Technical data sheet General

Dimensions

Crusher

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Feeding material: Feeding grain size: Final product size: Throughput: Total weight:

Coal approx. 1800 x 650 x X mm 0 - 250 mm + oversize approx. 4250 t/h approx. 21 t

Length: Width: Height:

approx. 3000 mm approx. 3200 mm approx. 1755 mm

Impact roll diameter: Impact roll width: Pass line height roll / conveyor: R.P.M: Circumferential speed: Impact elements: Drive power:

1100 mm 1808 mm 180 - 300 mm 380 rpm 21,9 m/s 8 impact heads, turnable 400 kW

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Main components

material flow

The crusher plant SK 1118 consists of the following main components (see also figure 10): the substructure with pan the impact roll with impact heads the crusher housing the gearbox holder the roll height adjustment the central lubrication the water spray system The impact roll crusher SK 1111 is a continuous flow crusher which will be integrated into the stageloader of a coal mining installation. It is designed for breaking the coal mined to a size which allows it to be transported on a downstream belt system.

The material to be broken is taken through the crusher by means of the stageloader. Larger lumps of coal are crushed by the impact roll while smaller pieces pass underneath the roll.

Important!

The section above is a general description of the crusher plant.

Find more detailed information, descriptions and operating instructions for adjustments, maintenance work and similar on the following pages ("Technical description") and in chapter 6 "Operation"!

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Components Figure 10: Crusher plant SK 1118

180

Förderrichtung

Brechereinlauf

Brecherauslauf

Item 1 2 3 4 5 6 7 8

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Description Substructure cpl.

Impact roll cpl. (without impact heads) Crusher housing cpl.

Impact head cpl.

Gearbox holder cpl.

Roll height adjustment cpl.

Central lubrication cpl.

Spray pipe cpl.

Weight (kg) 8546,00 8482,50 3191,00 400,00 126,00 116,00 6,70 5,00

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Technical description Housing, substructure and pan

Spray system

The housing of the crusher plant and the substructure with pan are manufactured from wear resistant material and in welded construction.

The crusher housing is screwed to the substructure.

Welded guidings in the pan warrant a faultless run of the chain.

For active dust suppression the crusher housing is provided with a port for connecting the spraying system.

Screwed-in flat jet nozzles are facing into the crusher housing. The customer sided water fitting will be connected to the spray pipe. Over this pipe the water is routed into the crushing chamber via the flat jet nozzles.

Figure 11: Spray pipe

1 2 3

Spray pipe Flat jet nozzle 1/4" Coupling clamp

Flat jet nozzle

1

Spray pipe

3

2

Crusher housing

In order to prevent wear and clog of the nozzles the water should be filtered. The mesh size of the filter should be at least 500μm. The water pressure for spraying should be in the 2 to 10 bar range.

Water consumption depends on the pressure and is as follows for a spraying unit with 4 nozzles: at 2 bar per nozzle approx. 1,6 liters / minute at 5 bar per nozzle approx. 2,5 liters / minute at 10 bar per nozzle approx. 3,5 liters / minute Notice!

The maximum pressure is 50 bars. This pressure must not be exceed.

Operating without water is not permissible.

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Impact roll

Height adjustment

The impact roll is also designed in welded construction.

The roll is fastened and balanced on the crusher shaft with clamping elements.

The impact roll is shifting in bearing housings and spherical roller bearings.

The connection to the crusher housing is via threaded rods.

Spacing plates are available for adjusting the passage height between the roll and the conveyor.

The height adjustment is by means of hydraulic cylinders which are powered by a hydraulic pump (hand pump).

(Find more details on the following pages and in chapter 6 - "OperationRoll height adjustment".)

Figure 12: Impact roll

glued in glued in

glued in Transport protection

rotated for 22,5°

in Darstellungsebene gedreht

Tightening torque 520 Nm

View Y

Tightening torque 32 Nm Attention! for actual position of the drive train, please refer to the superordinated drawing Item 53 for transport only Item 46 for impact arm

just flange, item 8

1 2 3 11 12 20 22 43

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Impact arm Crusher shaft Bearing housing Spacing plate 40 thick Spherical roller bearing Cone grease nipple Clamping element Tensioning nut For parts not listed here, please refer to the spare part list supplied

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Turnable impact heads The reversible impact heads are made from wear resistant material.

They are fastened to the impact arms by means of a hexagonal neckeddown bolt (2) and a hexagonal nut (3).

The impact heads can be turned and used again after wearing down on one side.

Figure 13: Reversible impact head

Torque Ma = 7700Nm

1 2 3

Reversible impact head Hex. head necked-down bolt M48x3 Hex. nut M48x3

Important!

Details with respect to work on the impact heads (replacing, turning) are given in chapter 6 "Operation - Replacing resp. turning the impact heads"!

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Hydraulical height adjustment The final product size while crushing can be varied with the height adjustment.

The impact roll can be adjusted in its height by means of hydraulic cylinders.

The hydraulic cylinders are powered by means of a hydraulic pump (hand pump).

Pressure fluid is oil (see also "Hydraulic fluids" at the end of this chapter).

Danger!

When adjusting the height of the impact roll the crusher plant must be in standstill!

Important!

How to adjust the height of the impact roll will be described in chapter 6 "Operation - Roll height adjustment")!

Figure: 14: Hydraulical height adjustment

Roll left

1 5 10 45,47

Object-No.: 55281700000000

Roll right

Hydraulic cylinder Hydraulic pump Manometer Hose lines For parts not listed here, please refer to the spare part list supplied

33

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Central lubrication The bearings of the impact roll will be supplied with grease via the central lubrication system.

The bearings will be greased from the right hand and the left hand crusher side.

Figure 15: Central lubrication

Right

Left

optional

1 Connecting piece 6 Cone grease nipple 7,8 Hose lines For parts not listed here, please refer to the spare part list supplied

Important!

Find more details in chapter 6 "Operation - Lubrication"!

34

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Tightening torques Screws resp. nuts with metric coarse thread DIN 13 Tightening torques at µtotal = 0,14 Thread

Pitch

Tightening torque

(mm)

(mm)

d

P

8.8

10.9

12.9

M8

1,25

23

32,5

39

MA(Nm)

M10

1,5

46

65

78

M12

1,75

80

113

135

(M14)

2

127

178

215

M16

2

195

275

330

(M18)

2,5

270

380

455

M20

2,5

380

535

640

(M22)

2,5

510

720

865

M24

3

655

920

1100

(M27)

3

965

1360

1630

M30

3,5

1310

1845

2215

(M33)

3,5

1780

2500

3000

M36

4

2290

3220

3860

(M39)

4

2970

4170

5000

M42

4,5

3670

5160

6190

(M45)

4,5

4590

6450

7740

M48

5

5540

7790

9350

Important!

The tightening torques given in the spare part drawings must be observed at assembly and maintenance work.

Besides they must be treated favourable!

When using screws and nuts together but different types of strength, the lower tightening torque is valid!

Object-No.: 55281700000000

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Permissible media Lubricating greases Properties

Base: NLGI-class: Penetration: Attitiude in the presence of water: Temperature of application:

Lithium soap 2 265 to 295 (0,1 mm) practically non-soluble -25 to + 130oC

Recommended lubricating greases: Supplier

Type

ARAL

Aralub HLP 2

BP

BP Energrease LS-EP 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

SHELL

Shell Alvania EP Grease 2

BECHEM

High-Lub L474-2

FUCHS

Renolit LX 2 Renolit LEP 2 HD

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating grease is: BP Energrease LS-EP 2 Important!

The greases listed in the above mentioned table can be mixed.

Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubricating effect is not sufficient.

It may also be dangerous t ouse lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

36

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Hydraulic fluids Roll height adjustment:

approx. 5 litres mineral oil DIN 51524 (viscosity depends on the temperature of environment) (Observe operating manuals of manufacturers!)

Recommended hydraulic fluids Description acc. DIN51519 ISO-viscosity class

Company denotation

VG 46

Aral Vitam DE 46

46

30

BP Energol HLP 46

46

30

FUCHS RENOLIN B15

46

32

Mobil DTE 25

44

29

Shell Tellus Oil 46

46

30

Texaco Rando Oil HD-B 46

44

29

Viscosity in mm²/s (cSt) mm²/s (cSt) 40°C 50°C

Admissible temperature range in oil tank

from 30°C - 80°C

Minimal starting temperature

0°C

Important!

Please arrange with Bucyrus if other oil types should be used!

Object-No.: 55281700000000

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38

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6

Operation

39

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Operation Commissioning of the crusher plant The commissioning may only be executed from authorized and specially trained personnel.

Notice!

Observe the notes given in the respective operating manuals of the crusher components additional, e.g. motors, gearboxes etc.

Before commissioning Execute the following work before commissioning: Important!

Check the oil levels at the gearbox and fill up if necessary!

Clean the crusher plant and the working area from tools, all aids, etc.

Check all screw connections and fastening elements (bolts, etc.) for tight seat, especially at the impact roll and the drives.

The impact roll must be free to rotate.

At crushers with height-adjustable roll the spacing plates fitted must be of the same quantity and thickness on both sides.

The roll must not grind against the side wall of the housing. The distance to the housing wall must be the same over the whole circumference.

The minimum distance between the top surface of the conveyor and an impact head with the roll in its lowest position is approx. 40 mm at the outer edges.

Existing protecting devices must be assembled respectively fastened according to instructions.

All lubricating points must be filled with grease sufficient. Only then a faultless lubrication is possible from the beginning.

If any: Check the hydraulic fittings and hydraulic lines for leakages and damages.

Check the correct installation of the supply lines.

Check all hydraulic connections.

Danger!

Percussive hydraulic hoses can cause very serious injuries or even death!

After eliminating all founded faults the commissioning of the crusher plant can be executed.

Object-No.: 55281700000000

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Notes for electrics The crusher plant is supplied without electrical equipment. It is the responsibility of the operator to arrange for the installation and availability of all necessary functions.

Please observe the applicable regulations and guidelines for the electrical system. Additionally, follow the general requirements mentioned below and observe any special regulations which may apply for the respective application. start-up phase

operation

switch off

emergency stop switch

Actuate acoustic and optical start-up warning signals before starting the crusher. All persons who may be in the hazardous area should be given enough time to leave the respective area before the roll is allowed to start rotating.

The drive of the crusher roll must always be actuated before starting the conveyor drive.

The conveyor drive is only allowed to start when the crusher roll runs at rated speed.

When a Turbo coupling is installed, the electric motor should be switched on directly. If this is not possible, a change over from star to delta connection must take place within 3 seconds.

The conveyor drive must stop automatically when the speed of the roll has dropped to 90% of its rated speed.

The roll drive must stop when the limit temperature of the Turbo coupling is reached and/or the fusible plug actuates.

The conveyor and roll drive must stop immediately if the conveyor chain fails/breaks.

The conveyor drive must be stopped before the roll drive.

The roll has to continue running for a short while after the conveyor drive has been switched off.

All drives must stop immediately.

Test run and start up Danger!

During the test run no person may be in the danger area of the crusher plant.

There could be faults, which do not exist at standard operation, e.g. assembly faults.

Because of such faults very serious injury or even dead can be the result!

Warning!

For safety reasons there should always be at least two persons when performing the test run.

The valid safety instructions of the mechanics and electrics must be observed! e.g.: - Never operate switches, valves, control devices, etc. unauthorized Danger!

Always wear protecting helmet, goggles, hearing protection, safety shoes and safety gloves!

42

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Check the following points during the test run: Perform test run of approx. 0.5 hours at no load: Particularly check temperature of the bearings, running noises, leakages at bearing points, vibrations etc.

Perform trial run under load: Increase load gradually up to rated load. While doing so, check drives for rises in temperature, running noise, vibration, and leakages.

Check function of the safety devices.

Check for uniform and equal current consumption of the electric motors.

Check that gearboxes run smoothly.

Notice!

Immediately stop the crusher plant by operating the Emergency Stop switch in the event of faults, inexplicable noises and movements!

When no defects have been found during the trial run or all defects found have been eliminated the crusher plant can be put into operation.

Retighten screw connections

Because of setting of the screw connections respectively the components, screws can become loose.

The following mentioned screw connections of the crusher plant must be retightened after a first operating time of approx. 50 hours.

Pay attention to the respective torque.

Drive connections at the crusher plant: – Gearbox - drive – Gearbox - motor – Gearbox - gearbox holder Crusher housing - inlet side Crusher housing - outlet side Face connection pan - stageloader Attachments at the substructure with pan

Select tightening torque

Take the torque of the respective screw connection from the corresponding spare part drawing.

If the spare part drawing gives no other information, the torques of table "Tightening torques - Screws resp. nuts with metric coarse thread DIN13" in chapter 5 are valid.

Operation of the crusher plant General During normal operation please observe the following: Avoid to switch the crusher plant on and off without need.

Feed the material at a fairly constant rate, if possible.

Avoid overloading.

Take care to ensure that the plant is serviced regularly.

Object-No.: 55281700000000

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BI623043

Roll height adjustment The passage height under the roll can be adjusted in 3 different positions by means of hydralic cylinders (three times 40mm = 120mm total).

Pressure to the hydraulic cylinders will be given from the hydraulic pump (hand pump).

Pressure fluid is oil (see "Hydraulic fluids" in chapter 5 "Technical data").

Danger!

The passage height may only be adjusted when the crusher plant is in standstill!

It must be secured against unauthorized restarting!

Notice!

The impact roll is in neutral position (lowest position) when all spacing plates are located above the bearing housing (see figure 16).

The desired passage height will be achieved by uniformly raising or lowering the impact roll by means of the hydraulic cylinders attached underneath the bearing housing.

The following describes the procedure for raising the impact roll.

Lowering is analogous (see figure 16).

Notice!

The spacing plates located under respectively above the bearing housing must be of the same quantity and thickness on both sides of the impact roll!

Loosen the screw connections between crusher housing and bearing housing. For this the tensioning nut must be loosened (see operating manual from P&S in the annex). The threaded rod is equipped with a hexagon (key width 30mm) on both sides. Hold against with a key that the threaded rod does not rotate with the connection while loosing.

Remove the required spacing plates located above the bearing housing on both sides. Take care that there are two bolts (∅20mm) on the top side of each spacing plate which come approx 10mm into the above located plate.

Raising the impact roll is by means of the hydraulic cylinders located at the side of the crusher housing, under the bearing housing. The hydraulic pump (hand pump) is located in the accessories. The plugin connections are located at the crusher housing.

Notice!

Uneven raising of the bearing housings can lead to damages of the bearings and sealings. While raising the level difference on both sides must not be more than maximal 20mm!

The above removed spacing plates will be placed under the respective bearing housing.

The flow of hydraulic oil to the cylinders can be controlled over the stop valves. So, the uneven weight distribution can be compensated.

Lower the impact roll slowly.

For this open the safety relief valve at the hydraulic pump slowly.

Take care that the impact roll does not cant while lowering. If necessary regulate with the stop valves.

44

Object-No.: 55281700000000

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Fasten the bearing housing. For tightening the tension nut see operating manual from P&S in the annex.

Necessary torque = 32Nm. The roll must be free to rotate. The distance between impact roll and side wall of housing must be equal allover the circumference.

Press grease at both nipples on the front side of the bearing housing.

This protects the threaded rods against corrosion and the disassembly will become easier.

The position of the gearbox must be fitted / adapted adequately. For this the hydraulic pump (hand pump) can be used also.

Perform a test run.

Figure 16: Roll height adjustment 2,3

1

4 1 2 3 4

Spacing plates (40mm thick) Threaded rod Tensioning nut Rod for fastening the hydraulic cylinder with the hydraulic pump

Danger!

The entrance to the annulus of the cylinder must never be blocked, because the movements of the cylinder can build up pressure extremely. Serious injuries or even death can be the result when pressure passes out off defect lines!

Warning!

No overpressure must be build up when the piston rod extends!

Object-No.: 55281700000000

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Maintenance Warning!

Lock and secure the roll when performing any work on the roll or in the danger area!

For this the roll can either be wedged with the crusher housing or the conveyor (e.g. with wooden wedges).

Notice Maintenance at regular intervals increases the operating safety and service life of the crusher plant.

Insufficient or improper maintenance may cause damage to the crusher plant resulting in considerable cost. Additionally, it may void the guarantee.

Important!

Any work required for maintenance shall only be carried out by authorized and specially trained personnel with due regard to the applicable regulations on safety and accident prevention.

When replacing any components only use original spare parts provided

by Bucyrus.

Important!

Be sure to also observe the operating manuals for components such as gearboxes, electric motors, hydraulic components etc.

Danger!

When working on the electrical system first disconnect power, make sure it cannot be connected again, check that power is off, connect to ground and short-out!

Please be sure to observe the applicable safety requirements!

Informations on the maintenance work required, the respective intervals, and whether work has to be performed with the plant "in operation" or "in standstill" are given in the following maintenance table.

46

Object-No.: 55281700000000

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Substructure with General visual inspection, report any deformations pan, crusher and external damage, also check welds housing

Impact roll

in operation

in standstill

Check existing protective devices for damage and completeness and replace, if required

every 8 hours resp. daily

every 50 hours

Maintenance work

every 200 hours.

Assembly

every 500 hours

Maintenance acc. to schedule

X

X

X

X

X

Check that all fastening bolts and screws are correctly tightened, retighten any loose and replace any missing bolts or screws

X

X

General visual inspection, report any deformations and external damage, also check welds

X

X

Check that all fastening bolts and screws are correctly tightened, retighten any loose and replace any missing bolts or screws

X

X

Check bearing temperature, if ≥ 60°C + ambient temperature: determine cause and eliminate problem (if required, contact manufacturer)

X

X

X

X

X

X

Lubricating service see "Lubrication" (next page) Spray system

Functional and visual inspection

Turnable impact Check impact heads for tight fit, completeness head and wear.

Turn or replace impact head if wear limit of 10mm has been reached (see "Turning or reversing the impact heads" in this chapter).

Check tightening torques of screws and bolts during the first days of operation after assembly and retighten, if required.

After the first week, tighten fastening bolts and screws to the required torque.

Roll drive

Height adjustment and lubrication

Lubrication

X

General visual inspection, report any deformations and external damage, also check welds

X

X

Check that all fastening bolts and screws are correctly tightened, retighten any loose and replace any missing bolts or screws Visual inspection of all hydraulic components: Hoses should not be pinched or trapped, or have any bubbles or blisters, or be conspicuously rigid or damaged, connectors should be securely inserted in the sockets, connections should be leak-tight.

Check function; visual check; screw off the hoses from the lubricating points, perform lubricating service and check if grease comes out off the hose ends

X

X

Object-No.: 55281700000000

X

X

X

X

X

47

BI623043

Lubrication Component

Quantity of lubricating points

Lubricating quantity

Bearings, impact roll

2

200 g per day (approx. every 10 operating hours)

Connection gearbox-shaft

1

200 g per week

Figure: 17: Lubricating points

X

View X Grease nipple

Grease nipple

The following grease points are not connected to the central lubrication system and have to be lubricated separately.

Gearbox (see operating manual of supplier) Bearing of the electric motor (see operating manual of supplier) Threaded rod of the bearing housing (depending on frequency of use) Important!

For lubricating the above mentioned lubricating points, only use lubricating greases of water hazard class 0, as the lubrication system is a total loss system.

It is absolutely necessary to observe the relevant environmental protection regulations.

48

Object-No.: 55281700000000

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Replacing resp. turning the impact heads Notice!

The impact heads must be reversed or replaced at the latest when the wear limit of 10mm has been reached (s. Fig. 18)!

Danger!

When replacing/turning the impact heads the impact roll crusher must be locked-out and secured to prevent restarting!

Warning!

The impact roll must be locked (wedging the crusher housing or the conveyor with e.g. wooden wedges)!

Warning!

The impact roll continues to turn for a few minutes after being stopped!

Observe the following when replacing the turnable impact heads: The impact heads must be replaced completety including all connecting elements.

Seating surfaces of the impact heads at the impact arm must be checked for damage before installing a new impact head. The contact surfaces must be level.

Notice!

Unlock the locking device before (re) commissioning.

The roll must be free to rotate!

Warning!

Never operate the impact roll crusher when the turnable impact heads are worn or incomplete!

Fig. 18: Reversible impact head, wear limit

Wear limit approx. 10mm Tightening torque Ma = 7700Nm

Object-No.: 55281700000000

49

BI623043

Spare parts and special tools In order to minimize production losses (caused by necessary repairs) we recommend to always having a minimum stock of the following spare parts and the tools required for repair available.

Returnable impact head cpl. (item No. 55382001790000, at least one set = 8 off) Lubricant Tools (above all torque wrenches)

50

Object-No.: 55281700000000

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REGISTER 2

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REGISTER 3

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REGISTER 4

5,1*63$11 *PE+

Date: 09.05.2007

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,03257$17 Please read these instructions carefully before installing and operating the product. Your particular attention is drawn to the notes on safety.

These installation and operating instructions are valid on condition that the product meets the selection criteria for its proper use. Selection and design of the product is not the subject of these installation and operating instructions.

Disregarding or misinterpreting these installation and operating instructions invalidates any product liability or guarantee by RINGSPANN; the same applies if the product is taken apart or changed.

These installation and operating instructions should be kept in a safe place and should accompany the product if it is passed on to others -either on its own or as part of a machine- to make it accessible to the user.

6$)(7< 127,&( •

Installation and operation of this product should only be carried out by skilled personnel.

•

Repairs may only be carried out by the manufacturer or accredited RINGSPANN agents.

•

If a malfunction is indicated, the product or the machine into which it is installed, should be stopped immediately and either RINGSPANN or an accredited RINGSPANN agent should be informed.

•

Switch off the power supply before commencing work on electrical components.

•

Rotating machine elements must be protected by the purchaser to prevent accidental contact.

•

Supplies abroad are subject to the safety laws prevailing in those countries.

5,1*63$11 *PE+ Schaberweg 30-34

Telefon +49 6172 275-0

D-61348 Bad Homburg Telefax +49 6172 275-275

internet: http://www.ringspann.com e-mail: mailbox@ringspann.com

5,1*63$11 *PE+

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*HQHUDO LQIRUPDWLRQ

1.1 Function: The RLK 400 cone clamping elements are used to connect machine components fastening without play to shafts for the transmission of torques, axial forces and longitudinal forces.

The RLK 401 clamping device is designed specifically for use under conditions which prevail during the installation of conveyor drums.

1.2 General safety instructions:

&DXWLRQ 'DQJHU RI LQMXU\ %RG\ SDUWV KDLU LWHPV RI FORWKLQJ DQG REMHFWV RI RWKHU NLQGV DUH NHSW ZHOO DZD\ IURP WKH URWDWLQJ VFUHZ KHDGV ZKLOH WKH FODPS FRQQHFWLRQ LV WXUQLQJ

&RQILJXUDWLRQ DQG IXQFWLRQ

The RLK 400 and RLK 401 cone clamping devices consist of two double-tapered clamping rings 4 + 5, each with a slotted inner and outer conical sleeve 1 + 2 and a corresponding number of clamping screws 6. The conical sleeves are aligned with a centring ring 3 in fixed axial position.

When the clamping screws 6 are tightened, the clamping rings exert clamping tension. Once fitting play is overcome, this connection exerts strong radial pressing force between the clamping device and the hub or the clamping device and the shaft, effecting the friction-tight connection between the shaft and the hub. &URVV VHFWLRQDO GUDZLQJ DQG SDUWV OLVW 4

1

3

5

2

6

Pos. 1 2 3 4 5 6

Nomenclature Outer conical sleeve Inner conical sleeeve Centering ring Front clamping ring Rear clamping ring Clamping screw

3URSHU XVH The RLK 400 and RLK 401 cone clamping elements are designed for installation between the shaft and the hub bore. They are intended solely for the friction-tight mounting of hubs or conveyor belt drums to shafts in order to transmit torque and axial forces. All other uses are prohibited. RINGSPANN shall not be liable for damages caused by improper use. The user bears all resulting risks.

5,1*63$11 *PE+

Date: 09.05.2007

BI623043

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Page: 3

,PSURSHU XVH The RLK 400 and RLK 401 cone clamping elements are not suitable for: • for the direct mounting of hollow shafts to solid shafts • as torque-limiting safety devices. &RQGLWLRQ RQ GHOLYHU\ The clamping elements are delivered in tension-free condition, i.e. the front clamping ring 4 is released by the two clamping screws 6 in the threaded press-off bores.

The clamping elements are packed in special paper to protect against corrosion.

7HFKQLFDO UHTXLUHPHQWV IRU VDIH UHOLDEOH RSHUDWLRQ In order to ensure full transmission of torque and axial forces, fitting tolerances on the contact surfaces may not exceed • tolerance class h8 for shafts • and tolerance class H8 for hub bores.

In addition, the contact surfaces between the shaft and the hub must have a mean peak-to-valley height of Rz 16 µm. ,QVWDOODWLRQ 8.1 8.2 8.3

Loosen all clamping screws – except for the two screws in the threaded press-off bores – for a couple of turns.

Press the heads of the clamping screws against the front clamping ring 4 by exerting pressure on the screw heads. This loosens the rear clamping ring 5.

Lightly oil the clamping element 'R QRW XVH RLO ZKLFK FRQWDLQV PRO\EGHQXP GLVXOSKLGH RU KLJK SUHVVXUH DGGLWLYHV DQG GR QRW XVH JUHDVH

8.4 8.5 8.6

Insert the clamping element in the hub of the part to be clamped and push it onto the shaft.

Apply pressure only to the clamping screw heads on the front clamping ring.

Turn the two screws out from the release threads and screw back into the adjacent clamping holes.

Tighten the clamping screws diagonally across by hand while aligning the hub.

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8.7

With a torque wrench tighten the clamping screws diagonally across with half the tightening torque Ms. Continue diagonally across with full tightening torque Ms.

8.8

Tighten the clamping screws one after the other one in a clockwise to the full tightening torque.

5,1*63$11 *PE+

Date: 09.05.2007

BI623043

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7KH WLJKWHQLQJ SURFHVV LV RQO\ FRPSOHWHG ZKHQ QRQH RI WKH VFUHZV FDQ EH WXUQHG DW WKH IXOO VSHFLILHG WRUTXH 0V DQ\ IXUWKHU 5HSODFH PLVVLQJ RU GDPDJHG FODPSLQJ VFUHZV ZLWK LGHQWLFDO VFUHZV RI VWUHQJWK FODVV RQO\

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9.1 9.2

9.3

9.4

Install the clamping element as described in Section 8 up to No. 8.6.

Align the front clamping ring 4 and – if visible – the rear clamping ring 5 parallel to the faces of the inner and outer rings, until the two conical rings are installed parallel and without wobble. To check the gap between the shaft and the hub, check for equal circumference at several different points.

1RWH ,I HFFHQWULFLW\ LV GHWHFWHG WLJKWHQ WKH VFUHZ QHDUHVW WR WKH VPDOOHVW JDS XQWLO WKH JDS LV HTXDO RYHU WKH HQWLUH FLUFXPIHUHQFH ,W PD\ EH QHFHVVDU\ WR ORRVHQ WKH VFUHZV QHDUHVW WKH ODUJHVW JDS VOLJKWO\ Tighten each of the clamping screws with a torque wrench to the specified torque Ms uniformly by ¼ turns in several successive steps in order to achieve parallel alignment of the conical rings. Check for equal gap between the hub and the shaft along the circumference continually while tightening and adjust as needed in accordance with the instructions above.

The tightening process is only completed when none of the screws can be turned at the full specified torque Ms any further. &DXWLRQ ,I WKH VKDIW DQG RU KXE GR QRW KDYH IUHH UDGLDO PRELOLW\ VHYHUH WHQVLRQV EXLOG XS DV WKH FODPSLQJ HOHPHQW HIIHFWV FHQWULQJ DJDLQVW RXWVLGH UHVLVWDQFH 'DPDJH WR WKH VKDIW KXE DQG FODPSLQJ GHYLFH PD\ UHVXOW

'HLQVWDOODWLRQ 10.1 Loosen the clamping screws diagonally across for a couple of turns.

10.2 Remove all of the screws in the front clamping ring 4 and insert them into the release holes, turning until they abut with centring ring 3.

Note: To facilitate the installation process, grind and grease the faces of the thread ends of the press-off screws. This reduces friction loss.

10.3 Tighten the screws in the release holes crosswise in multiple steps until the front clamping ring 4 is loosened. Remove the ring.

5,1*63$11 *PE+

Date: 09.05.2007

BI623043

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Page: 5

10.4 Remove the clamping screws from the front clamping ring 4 and turn them by hand into the threaded bores of centring ring 3 until they abut with the rear clamping ring 5.

10.5 Tighten the screws in the released holes of centring ring 3 uniformly in a crosswise sequence in multiple steps until the rear clamping ring 5 is loosened. Remove the clamping devices together with the machine component from the shaft.

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The RLK 400 and RLK 401 clamping elements are maintenance-free. However, signs of loosening may appear in connections during operation. We therefore recommend checking the tightness of the clamping screws during each time maintenance is performed on the machine

5,1*63$11 *PE+

Date: 09.05.2007

BI623043

Version : 04

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Signed: Su

dxD [mm]

Clamping screws

Tightening torque Ms [Nm]

45 x 75 48 x 80 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 170 x 225 180 x 235 190 x 250 200 x 260 220 x 285 240 x 305 260 x 325 280 x 355 300 x 375 320 x 405 340 x 425 360 x 455 380 x 475 400 x 495

M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 14 M 14 M 14 M 16 M 16 M 16 M 16 M 16 M 16 M 16 M 20 M 20 M 20 M 20 M 22 M 22 M 22

35 35 35 35 35 35 71 71 71 71 71 71 121 121 121 195 195 195 195 300 300 300 300 300 300 300 580 580 580 580 780 780 780

6HULHV 5/.

dxD [mm]

70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 170 x 225 180 x 235 190 x 250 200 x 260 220 x 285 240 x 305 260 x 325 280 x 355 300 x 375 320 x 405 340 x 425

Reviewed: Co

Pages 6

Page: 6

Clamping screws

Tightening torque Ms [Nm]

M 10 M 10 M 10 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 12 M 12 M 12 M 12 M 14 M 14 M 14 M 16 M 16 M 16 M 16

45 45 45 45 45 45 45 45 45 87 87 87 87 87 87 87 87 158 158 158 207 207 207 207

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REGISTER 5

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Operating Instructions Hydraulic Tools

Hand pump ZPH 1A/.; ZPH 2A/.; Hand pump ZPH 3 /

1 2 3 4 5 6 7 8 9

drain valve Connection P G 1/4 Return connection T G 1/4 Venting- / filling cap Clamp Pressure limiting valve possible accessories pressure gauge connector MA1 pressure gauge connector MA2 Pressure gauge

1

84120/0000-85 GB Issue 10.2005 replaces 9.98

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1

Basic operation and designated use of the machine

1.1 The machine has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property.

1.2 The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine/plant, should therefore be rectified immediately!

1.3 The machine is exclusively designed for the use described in the operating manual. Using the machine for purposes other than those mentioned in the manual, such as driving and controlling other pneumatic systems, is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

Operating the machine within the limits of its designated use also involves observing the instructions set out in the operating manual and complying with the inspection and maintenance directives.

2

Organizational measures

2.1 The operating manual must always be at hand at the place of use of the machine!

2.2 In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

This also applies for wearing protective clothing, helmet with visor or goggles and protective gloves.

2.3 In order to avoid innjuries, the machine must only be operated by a specially trained operator who has undergone a safety training.

2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety instructions and warnings attached to the machine are always complete and perfectly legible.

2.5 Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves.

2.6 Spare parts must comply with the technical requirements specified by the manufacturer.

Spare parts from original equipment manufacturers can be relied to do so. It is only allowed to use original LUKAS spare parts of LUKAS system components.

2.7 Replace hydraulic hoses at the specified or adequate intervals, even if no defects are detected which might affect safety. This must be done after 10 years, at the latest!

2.8 Adhere to prescribed intervals or those specified in the operating manual for routine checks and inspections.

2.9 Make sure to dispose properly of packing material and dismounted parts!

2

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3

General safety instructions

3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified immediately.

3.2 Before starting up or setting the machine in motion and during operation of the machine make sure that nobody is at risk.

3.3 Before transporting the machine always check that the accessories have been safely stowed away.

3.4 Make sure that there is enough lighting during work.

3.5 Avoid any operation that might be a risk to machine stability.

3.6 Check the machine at least after every operation for obvious damage and defects. Report any changes (incl. changes in the machine’s working behaviour) to the competent organization /person immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwed connections have to be checked for leaks and obvious damage. Repair damage immediately.

Splashed oil may cause injury and fire.

3.7 All safety equipment has to be checked for completeness and flawless condition: -

instruction markings and warning signs (safety instructions) check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if they are in good condition.

3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work is indispensable sufficient mechanical supports are needed additionally.

3.9 Do not stress hoses mechanically (pulling, buckling etc.).

4

Instructions for maintenance and service

4.1 For the execution of maintenance and service work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

Work on the hydraulic system must be carried out only by personnel having special knowledge and experience with hydraulic equipment.

4.2 Before putting into operation clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lint-free cleaning rags and pay attention that the components are meticulously clean during reassembling after repair.

4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquids completely, so that they cannot reach the ground. They have to be disposed properly accord-ing to the instructions.

4.4 Always tighten any screwed and thread connections that have been loosened during maintenance and repair. Observe the stipulated torques.

4.5 Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electri- cian and in accordance with the applicable electrical engineering rules.

4.6 The electrical equipment of machines is to be inspected and checked at regular intervals.

Defects such as loose connections or scorched cables must be rectified immediately.

3

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4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary to clean the whole machine if it must be exceptionally operated under such conditions or gets into touch with these materials. Additionally, the machine must be checked as described under 3.6.

5

Safety Instructions for Hydraulic hoses

All instructions as to safe use of hydraulic hoses can be found in the booklet 84150/8056-85 deliverd with the hoses.

6

Intended use

The hand pump models ZPH 1A, ZPH 2A and ZPH 3 are meant for operation of LUKAS cylinders.

The pumps must be used only in connection with components out of the LUKAS Hydraulic Tools system 50 MPa, resp. 70 MPa. An operation of cylinders other than LUKAS is possible, but it must be approved by LUKAS in each individual case.

Warning The system operating pressure must not exceed the pressure rating of the lowest rated component in the system.

Warning NEVER set the relief valve to a higher pressure than the maximum rated pressure of the pump.

Higher settings may result in equipment damage and/or personal injury.

7

Function

7.1 Basis pump All ZPH/ series hand pumps have the two-stage design, i. e. they are working with two different speeds: a high speed in the low-pressure range (LP) for fast extension of a cylinder without load and a low speed in the high-pressure range (HP) for controlled extension of a cylinder with a load resting on it.

Switch-over from low to high pressure mode is done automatically by a factory-preset switch-over valve (see also technical data).

4

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7.2

Conversion sets

With valve kits (to be ordered separately as per following table) the basic pump can be upgraded with additional functions: Conversion set

Order no.

Weight

Application / Operation

kg Foot pump NFP (only

84120/2-0001

0.8

Conversion set from hand to foot operation

4/2-way-valve N4/2W

84111/9848

1.5

Control valve for extension and retraction of double-

2-way-distributor valve

84148/9903

2.1

ZPH 1A and ZPH 2A) acting cylinders N2W

Distributor valve used to devide a flow of oil into two part flows. By closing or opening the valve screws the flows can be regulated and matched to one another

Oil distributor with

84148/9905

1.4

With the oil distributor oil flow can be devided in four

pressure gauge

flows. 4 connectors G 1/4 (3 locked) + 1 pressure

connectors N4M

gauge connector G 1/4

Each upgrading kit (except pressure gauge connector) is delivered with fixing and sealing material.

8

Putting into Operation

8.1 Preparing the pump The pump is, normally, connected to a hydraulic cylinder by means of suitable pressure hoses or, for stationary applications via pipes. The hose connection nipple is to be mounted at outlet „P“ on the pump head and to be tightened with a torque of 45 +5 Nm.

8.2 Mounting of couplers at the hydraulic hose Mount screw-type or quick-disconnect coupler at the retaining nut on the hose end and tighten it with a torque of 45 +5 Nm.

8.3 Venting the cylinder Connect the cylinder with the pump. Extend the piston by half its stroke and turn the cylinder so that the piston is facing downwards. The highest point of the cylinder must be on a lower level than the pump. Fully extend the piston and retract again so that eventual air bubbles can escape into the oil container of the pump.

Remark: The oil filler cap of the pump must be open during bleeding.

5

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9

Operation of two single-acting cylinders

9.1

Connection of a single-acting hydraulic cylinder system 50 MPa

9.2 -

-

-

-

Operation of two single-acting cylinders

fully close the hand wheel (1) on the pump head (turn it clockwise) open hand wheels on the two-way distributor valve and extend the cylinder(s) by operating the hand lever of the pump. Observe safety remarks as per para 10.1 ! the return speed of both connected cylinders can be adjusted by slowly opening the hand wheels on the two-waydistributor valve. The hand wheel (1) on the pump head must be opened, otherwise the load cannot be lowered.

9.5 -

Connection of two single-acting hydraulic cylinder System 50/70 MPa

mount valve kit N2W (two-way distributor valve) at the basic pump as per separate mounting instruction (comes with the valve kit).

Fix the hand pump in vertical position to prevent oil spill and remove locking screws from outlets A and B on N2W valve kit. mount hydraulic hoses at outlets A and B and tighten them with a torque of 45 +5 Nm. mount couplers as per para 8.2.

9.4 -

Operation of a single-acting cylinder

fully close the hand wheel (1) on the pump head (turn it clockwise) extend the cylinder by operating the hand lever of the pump. Observe safety remarks as per para 10.1 !

9.3 -

system 70 MPa

Connection of a double-acting cylinder

mount valve kit N4/2W (4/2-way valve) at the basic pump as per separate mounting instruction (comes with the valve kit). fix the hand pump in vertical position to prevent oil spill and remove locking screws from outlets A and B on N4/2W valve kit. mount hydraulic hoses at outlets A and B and tighten them with a torque of 45 +5 Nm. mount couplers as per para 8.2.

6

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9.6

Connection of a double-acting cylinder system 50 MPa

system 70 MPa

Safety advise: Within the 50 MPa quick coupling system at least one hydraulic hose must be equipped with the quick-connect socket StMu61-O (colour black). This hose must always be connected to the return connector on the head area of the cylinder (see picture above). By no means the return connection must be coupled with a quick-connect socket StMu 61-M (colour silver), as this combination could cause a pressure boosting beyond the permissible pressure.

9.6.1 Operation of a double-acting cylinder - fully close the hand wheel (1) by turning it clockwise - switch the hand lever on the 4/2-way valve to position A or B (extension or retraction).

- activate the cylinder by operating the pump lever. Observe safety remarks as per para 10.1 !

9.6.2 Load holding function The 4/2-way valve (N4/2W) itself does not have such a function.

Load can be sustained when the hand wheel (1) is fully closed. The lever of the N4/2W valve must thereby stay in position „extending“.

9.7

Connection of hose coupling to cylinder

9.7.1 Quick couplers (system 50 Mpa)

Before coupling, remove the dust protection covers and unlock the connect socket with adjusting ring by turning it. Withdraw the sleeve and connect plug and socket while holding the sleeve in this position. Release the sleeve and set the showglass to „red“ with the adjusting ring. Now the parts are connected and locked. Decoupling is done in the reverse order.

Note regarding the modified release mechanism as of June 2004 When connecting the hoses, be aware of the following basic functions of the quick couplers:

X

Y 7

BI623043

Before coupling unlock the connect socket by turning the sleeve into position X. Retract sleeve and connect plug and socket. Release sleeve and turn it into position Y. Now the connection has been made and locked. Uncoupling is done in the reverse order.

Connection of the hoses is possible only, when they are depressurized.

In order to prevent contamination of the tool lines protect the couplings with delivered dust caps.

9.7.2 Screw couplers (system 70 Mpa) - remove dust caps - connect nipple SKN 2 on the hose with its female counterpart SKM 1 on the cylinder - turn the threaded sleeve of SKM 1 by hand until it is tightened.

10 Lifting a load 10.1 Safety remarks as to safe use of the hand pump Caution!

NEVER add extensions to pump handle. Extensions cause unstable pump operation.

Warning!

In certain situations the pump handle can "kick back". Always keep your body to the side of the pump, away from the line of force of the handle.

Note To reduce handle effort at high pressure, take short strokes. Maximum leverage is obtained in the last 5 degrees of stroke.

10.2 Observe „Safety measures prior to and during lifting“ as per separate operating manual of your LUKAS cylinder.

11 Lowering a load (pressure release) 11.1 Open the oil filler cap (4) on the reservoir a few turns 11.1.1To retract the piston of the cylinder, open the drain valve of the pump carefully (rotation to the left). Closing the drain valve (rotation to the right) will interrupt the drain process. By means of fine adjustment of the drain valve, an extremely precise retraction of the piston of the cylinder is facilitated.

11.2 Special function „quick stop“ If you open the drain valve rapidly (rotation to the left), an existent quickstop only for 50 MPa cylinders StMu61-M (silver) is activated, i.e. a non-return valve, incorporated in the quick-connect coupling, will prevent the oil from flowing back. While the hose is at zero pressure, the cylinder remains under pressure. Pump and cylinder can now be separated and the pump can be used elsewhere.

The "quickstop" also serves as a safety valve if for some reason the hose is damaged. The quickstop will in this case prevent the load from falling.

In order to release the quickstop, the pressure in the cylinder must be increased with a few pump slaps. This will re-open the non-return valve in the quick-connect plug StNi 6. The draining can now be continued.

8

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11.3 Uncoupling pump and cylinder Before uncoupling the pump from the cylinder, make sure (by opening the drain valve) that there is no pressure and that the piston is completely retracted.

Remount the protection caps after uncoupling in order to avoid pollution of the coupling parts.

Close the oil reservoir filler cap, so that no oil is spilled during transport.

11.4 Adjustment of the maximum pressure (pressure range 50 - 70 MPa) Check adjusted pressure with closed drain valve.

Adjust pressure limiting valve (item 6, see cover page) as follows: - Unscrew the screw plug 6.1 (SW5), with the hexagonal socket-head wrench (SW4) adjust the nut 6.2 to the intended pressure.

Note: Rotation to the right = pressure increase; Rotation to the left = pressure relief Caution: Observe para 6 of this operating manual!

12

Servicing and Maintenance

Oil should be changed once a year. In case of frequent use or operation in particularly dusty environment, oil should be changed every six months.

12.1 Adding Oil to the Pump Warning: Always add oil with cylinders fully retracted (extended if pull cylinders) or the system will contain more oil than the reservoir can hold.

-

Remove vent/fill cap from reservoir.

Fill reservoir only to level mark shown on pump.

Remove air from system if necessary. See 8.3. Recheck oil level after removing air.

Return vent/fill cap to proper position.

-

Make sure no dirt gets into the oil reservoir or into the pump, as this will cause malfunction.

-

To extend pump life and improve performance, lubricate the beam pin A, cross pin B and piston head C regulary, using roller bearing grease. See cover page

13

Troubleshooting

Problem Cylinder does not advance, advances slowly or advances in spurts

Possible cause Oil level in pump reservoir is low Release valve open Loose hydraulic coupler Load is too heavy Air trapped in system

Solution Add oil according to the maintenance instructions on 12.1 Close the release valve Check that all couplers are fully tightened Do not attempt to lift more than rated tonnage Remove air according to the instructions on point 8.3 Check for damage to cylinder: have cylinder by a authorized dealer or LUKAS themselves

Cylinder plunger binding

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Cylinder advances, but does not hold pressure

Leaking connection Leaking seals Internal leakage in pump

Cylinder does not retract, retracts part way or retracts more slowly than normal

Drain valve closed Pump reservoir is over-filled Loose hydraulic coupler Air trapped in system Hose dia. too narrow Cylinder retraction spring broken or other cylinder damage

Check that all connections are tight and leak free Lokate leak(s) and have equipment serviced by authorized dealer or LUKAS themselves Have pump serviced by authorized dealer or LUKAS themselves Open drain valve Drain oil level to full mark. See 12.1 instructions for adding oil Check that all couplers are fully tightened Remove air according to the instructions on point 8.3 Use larger diameter hydraulic hose Have cylinder serviced by an authorized dealer or LUKAS themselves

If the defects cannot be repaired, contact an authorised LUKAS dealer or the LUKAS service department. The address: LUKAS Hydraulik GmbH, Weinstraße 39, D-91058 Erlangen, Pf 2560, D-91013 Erlangen, service phone 09131/698 348; fax 09131/698 353

14

Technical data

Type

ZPH 1A/1

Order no.

84120/

Working pressure (MPa)*

50

Oil capacity / usable oil capacity (l) Oil delivery LP / HP (cm3)

70

50

1.3 / 1.1

ZPH 2A/5

70

50

ZPH 3/4

ZPH 3/8

50

70

20 / 1.6 per

13.1

18 760x130x203 760x230x203 11

15.4

*10bar = 1 MPa

14.1

Oil recommendations

For LUKAS hydraulic devices, use mineral oil in accordance with DIN 51 524 and others

A B C D E

Range of oil temperature - 24 ... + 30 °C - 18 ... + 50 °C - 8 ... + 75 °C + 5 ... + 80 °C - 8 ... + 70 °C

Viscosity rating HL 5 HLP 10 HLP 22 HLP 32 HF - E 15

Remarks

biodegradable

Recommended viscosity range: 10 ... 200 mm²/s, delivered with HLP 10 to DIN 51 524

10

70

10.5 / 8

10.8 / 4.2 per piston stroke

5 628 x 160 x 190

7.7

50

5.25 / 4

piston stroke

10 608x120x190

Weight including Öl (kg)

70

5.0 / 4.5

10 / 1.6 per piston stroke

Automatic switch-over (MPa)* Dimensions l x w x h (mm)

ZPH 1A/5

/0120 /0179 /0122 /0180 /0322 /0380 /0410 /0415 /0420 /0425

© Copyright 1998 LUKAS Hydraulik GmbH

BI623043

LUKAS Hydraulik GmbH A Unit of IDEX Corporation Weinstrasse 39, 91058 Erlangen • Germany Postfach 2560, 91013 Erlangen • Germany Telefon +49(0)9131/698-0 • Telefax (+49(0)9131/698-394 E-mail: info@lukas.de

ZPH1A_2A_3A_84120_0000_Ag1005_e.P65

11

Subject to revision

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REGISTER 6

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REGISTER 7