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Translationofthe originaloperating manual.
Amendmentsandalterationstothispublicationarenotsubject tonotification.Bucyrusreservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws.Nopartofthispublication maybereproducedortransferredinanywayorformwithoutthe priorwrittenapprovalofBucyrus.
Bucyrusdeclinesanyliabilityfordirectorindirectconsequencesof printingerrors.
Wereservetherighttointroducemodificationsasaresultoftechnicaldevelopmentswithoutpreviousnotice.
BucyrusEuropeGmbH,Lünen2009E
5.Operation Aboutthismanual Aboutthismanual Thischaptercontainsimportantinformationmakingiteasierfor youtousethismanual.Italsoprovidesyouwithinformationon thestructureofthemanualandthesymbolsused.
Beforestartingwork Usinganoperatingmanualthatisnotwrittenforthegearboxtype athandcanresultinasafetyhazardforyourselfandothers. Ensurethatthedataonthegearboxcomplieswiththedatagivenin theoperatingmanual.
Thisoperatingmanualisdesignedfor:
Itisonlypermittedtobeusedforgearboxesofthistype.
AccordingtoEuropeanDirective94/9/EC,thegearboxbelongsto equipmentgroupI,categoryM2.
Anoperatingmanualforthegearboxshouldalwaysbeavailableat theplaceofoperation.
Sendforanewoperatingmanualimmediatelyifthepresentoperatingmanualisnolongercompleteorhasbecomeillegible.
Personsforwhomtheoperatingmanualisintended
Thisoperatingmanualisintendedforthosepersonswhoworkwith oronthegearbox.
Allpersonsworkingontheface,intheintersectionbetweenface andentry,orintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
J areinchargeoftransport
J preparetheriseheading
J performassembly/disassemblywork
J operatetheconveyor
J correctmalfunctions
J carryoutdailyroutineworkonthefaceorintheentry
J performmaintenancework
J performrepairwork.
Supervisorypersonnelwho:
J authorizeand/orsupervise.
Purposeofthisoperatingmanual Thisoperatingmanualisintendedtohelpyouworkeconomically andsafelywithourproduct.Itcontainsimportantinformationonall theactivitiesrelatedtothegearbox.
Readthisoperatingmanualcompletelyandatyourleisure. Payspecialattentiontothesafetyinstructions. Trytomemorizetheappearanceandmeaningofthesafetyand instructionsymbols.
Shouldyouhaveanyquestions,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechapter “Foryourinformation”.
Readthechapter“Yoursafety”closely.Thischaptercontains importantinformationindicatingpotentialhazards. Observethisinformationandfollowtheinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationintheoperatingmanual. Trytomemorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
Warning!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesareveryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesareminortomoderatelyseriousinjuriesand machinedamage.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare:damagetothe gearboxordamageintheimmediatevicinity.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.
J Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Pointsinthetextmarkedinthiswaydescribeindividualwork steps.Followthismanualstep-by-step.Theywillhelpyoucarry outyourworkfasterand,moreimportantly,moresafely.
Yoursafety Thischapterprovidesvitalinformationforyoursafety.
Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedureareintendedtohelpyouavoidhazardoussituationsandperformthenecessaryworkassafelyaspossible.
Thegearboxhasbeenmanufacturedinaccordancewiththestate oftheartandgenerallyrecognizedsafetystandardsandregulations.
Youandotherscanneverthelessbeexposedtodangeroussituationse.g.asaresultofenvironmentalinfluences,machinedamage oroperatorerrors.
Donotmakeanymodificationsorcarryoutconversionswhich couldimpairthesafetyofthegearbox.Allmodificationsand changesmustbeapprovedbyBucyrus.
OnlyuseoriginalBucyrusspareparts.Notetheuseofpartsfrom othermanufacturerswillvoidtheguarantee.
TheEuropeanguidelines/standardswhichappearinthisoperating manualmustbeappliedwhenthegearboxisbeingusedwithinthe memberstatesoftheEuropeanUnion.
IfthedeviceisusedoutsidetheEU,thedirectivesandstandards whichapplyinthosecountriesmustbeobserved.
Inadditiontothisoperatingmanualbesuretoalsoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulations:
J oftheminingcompany,
J oftheminesinspectorateand
J oftheminingsupervisoryauthorities.
Pleasealsoreadtheoperatingmanualsofcomponentsrequiredfor operation,e.g.conveyor,E-motoretc.carefullyandthoroughly. Clarifyanyquestions before startingwork.
Personnel Installationandrepairs Asafundamentalrule,installationandrepairworkmayonlybecarriedoutbypersonnelwhohavebeenadequatelytrainedforthese particularrequirements.
Installationandrepairworkon: J safetycomponents(pressurereliefvalves,extinguishers,etc.)
J theelectricalsystems(controls,signalingdevices,etc.)
J hydraulics
shallonlybecarriedoutbyBucyrusserviceengineersorbyspeciallytrainedpersonnelofthemine.
Operatingconditions Intendeduse Thegearboxisexclusivelydesignedandmanufacturedtobeused aspartofadriveunittodriveaconveyororplow.
J Itreducesthespeedandtransmitsthetorqueofafixedelectric motortothedriveshaftoftheconveyororoftheplowdrive.
J Whencombinedwithadditionalequipment,thegearboxcanbe usedtocoupleorclamptheconveyorchain. Permissibleequipmentforthisare:
–Hydraulicorpneumaticchaintensionerasatail-enddriveon thegearboxconnectionassembly,ifthedriveconnection assemblyhasbeenpreparedforthis.
–Fixingbrake(arrestingbrake)
Usethegearboxonlyasintended.
Unauthorizeduse Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththegearbox.
Unauthorizeduseincludes:
J couplingortensioningtheconveyorchainusingtheconveyor drivesortheplowdrives.
Bucyrusdoesnotacceptanyliabilityforanydamageresultingfrom anysuchunauthorizeduse.
Ambientconditions Suitablemeasuresmustbetakenbytheoperatortocombat explosionhazardsduetofiredamportheignitionofdustwhich mightoccurinamine(seeprEN1710).
Theseinclude:
J adequateandconsistentventilation
J furrowsprayingsystem/watersprayingsystem
Iftheminegasconcentrationinthefreecrosssectionofthe consistentlyventilatedareasofthefaceexceedsacertainpercentageofthelowerexplosionlimit(LEL)asdefinedintherespective nationallaws,theM2equipmenthastobeswitchedoff.
Itmaybeswitchedonagainbyauthorizedpersonsonly.
Theatmosphereinthemineshouldbemonitoredathazardous pointstoallowthepowersupplyofalldevicestobeswitchedoff, exceptthosewhicharerelevantforsafetyandsuitableforusein explosiveatmospheres.
TheM2equipmenthastobestoppedatonceandsecuredagainst beingswitchedonagainiffiredampprotectionfacilitiesarefoundto bedamaged.
Prerequisitesforoperation Puttingthegearboxintoserviceisprohibiteduntilthemachineinto whichthisgearboxisinstalledhasbeenfoundtocomplywiththe EuropeanDirective94/9/ECandtheStandardprEN1710.
Astheequipmentsuppliedisonlypartofanoverall system,the operatorisresponsibleformeetingthenecessarysafetyrequirementsorinstallingtherequiredsafety systemsforthedevices/ componentsnotincludedinthescopeofsupplyofthisequipment and/orotherdevices/componentsrequiredforoperation.These shallbemarkedaccordingtothelegalprovisionsapplicableatthe timetheyareplacedonthemarket.
TheM2equipment/gearboxisonlyallowedtobeoperatedwhen thesafetyrequirementsaccordingtoprEN1552havebeenmet. Theseinclude,amongotherthings:
J systemsthatprevent unauthorizedstarting
J pre-startwarningsystems
J watersprayingsystems
J safelock-outcommandsystems
J emergencystop systems
J dustextractionsystems
J noiseprotection
J warningmessages,etc.
Allelectricalequipmentrequiredtooperatethegearboxmustbe markedaccordingtothelegalprovisionsapplicableatthetime whenitisplacedonthemarket.
Safetyinstructions Safetyinstructions Basicprinciples
Alwaysworkwithutmostconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveclothingandequipment. Thisalsoincludeswearingearprotectorsasthenoiseemittedby theconveyormayexceed85dB(A).
Informyourcolleaguesof:
J yourexactlocation
J theworkyouarecarryingout
J thetimewhichyouwillprobablyrequire.
Starttheconveyororminingequipmentonlywhentheyarein agoodandsafeconditionandallsafetyequipment,e.g. EMERGENCYSTOPdevices,coverplates,etc.arecorrectly installed.
Keepthesignalingandlightingsystemsinworkingorder.
Payspecialattentiontotheacousticandvisualstartwarningsof theconveyorandfortheminingmachine.
Observethesymbolplatesonthegearbox.
PresstheEMERGENCYSTOPswitchimmediatelyintheeventof faultsorirregularitiesinoperation.Notifyyoursupervisorabout anythingstrangetoallowanynecessaryactiontobetakenimmediately.
AlsopresstheEMERGENCYSTOPSWITCHwhensafetyequipmentsuchasfiredampprotection systemsbreakdown.
Lockouttheminingequipmentandtheconveyorduring:
J maintenancework
J inspectionwork
J repairwork
J failureofsafetyequipment,e.g.: –firedampprotection
Cordonoffyourworkingareawidelytokeepoutmonorailandfloor conveyingdevices.
Neverallowpartsofyourbodytocomebetweenmachine componentswhichcouldmove,suchas:
J Plowandconveyorchains
J Flights
J Plow
J Spillplates
J Chainsprockets
Complywiththemaintenanceandinspectionintervalsforthe gearbox.Besurethatthegearboxisadequatelycooled,sincehot surfacesmightcausepotentiallyexplosiveatmospheres(air)and dusttoignite.
Thegearboxcasingcanheatupto85ºCduringnormaloperation. Ifyouhavetoworkonthegearbox,thetemperatureisnotpermittedtobehigherthan60ºC.Waituntilthegearboxhascooled downifrequired.
Storageandtransport Observethespecifiedstoragetimelimitsandthestorageinstructions.
Donotstoreanymaterialsorcomponentsinthetravelwayorin yourworkingarea.
Informthepersonsconcernedabouttheintendedtransportroute andtheprobabledurationofthetransport.
Ensurethatthetransportsecuringdeviceshavebeencorrectly installed.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsecuredcomponentsorsuspendedloads. Connecttheliftingequipmentonlytotheliftingpointsprovidedfor thatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheets.
Onlyusemeansofattachmentwhichareinagoodconditionand havebeendesignedfortheloadsconcerned.
Onlyusetransportstrapstoattachroundpartsthatdonothave anyliftingpoints.Neverusechainsorsteelcablesforthispurpose.
Donotdamagethefinishedorpolishedsurfacesofshafts,sealing surfaces,etc.
Whenusingfloorconveyingdevicesfortransportmakesurethat thecenterofgravityisaslowaspossible.
Installationandinitialstart-up Usechainsorstrapstosecureallindividualpartsoninclinedfaces, e.g.ontheextensions.
Whenhandlingoil,greaseorotherchemicalsubstances,observe thesafetyinstructionsapplicablefortheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,greaseorotherchemicalsubstancesinanenvironmentallysafe manner.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspection intervals.
Informthesupervisorypersonnelandotherpersonconcerned aboutmaintenanceandrepairwork.Providethemwithinformation ontheintendedworkanditsprobableduration.
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Safetyinstructions Secureyourworkingareaextensivelytoavoidendangeringother persons.
Beforeallwork,lockouttheminingequipmentandtheconveyorto preventunauthorizedorunintentionalrestarting.
Youmayonlycarryoutworkintheminingareaif J theroofhasbeensecuredagainstrockfall, J thecoalfacehasbeensecuredagainstslopingdown,and
J theminingequipmentandconveyorhavebeenshutdownand lockedout.
Beforereplacingdefectiveparts,shutdowntheconveyorand miningequipmentandlockitout.
Defectivecomponentsshouldimmediatelybetransportedaway fromtheworkingarea,inordertoavoidhinderingotherpersons. Moreover,thismeasurepreventsinadvertentreinstallationofthese componentselsewhere. Passonthesecomponentsforservicingwithoutdelay.
Securethecomponentstobereplacedagainstslippingoninclined facesbyusingchainsorliftinggear,forexample.
Onlyusesparepartswhichsatisfythespecifiedtechnicalrequirements.ThisisonlyensuredwithoriginalBucyrusspareparts. Pleaserefertothereplacementpartslistsfortheordernumbers.
Forliftingthegearbox,onlyuse:
J thefasteningpointsprovidedforthepurpose
J liftinggearwithadequateload-carryingcapacity.
Onlyuseonlythepointsofattachmentintendedforthatpurpose. Onnoaccountshouldcylinderliftingpointsbeusedastheyarenot designedtowithstandtensileloads.
Onlyattachliftinggeartoshieldsthathavebeenset.Shieldsthat havebeenretractedcouldtiltforward.
Refitanysafetyequipmentremovedimmediatelyaftercompletion ofworkandcheckthattheyfunctionproperly.
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Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorage andtransportofthegearbox.
Followingtheinstructionsandtipswillincreasethelifecycleand servicelifeofthegearbox.Youwillalsobeabletocarryoutthe transportworkquickerandmoresafely.
Payingcarefulattentiontothepointsinthischapterwillalsohelp youtosimplifyyourday-to-daywork.
Storage Storingtheequipment Componentscoatedwithtemporaryanticorrosiveareprotectedfor aroundsixmonths.
Protecttheequipmentagainstdirectexposuretosunlight. Onlystoretheelectricalequipment,electroniccomponents, replacementpartsmadeoutofrubberorplasticsuchassealsand hosesaswellashydraulicfluidsinclosedroomsat15ºCto25ºC.
Protectallpartsoftheequipmentstoredoutdoorsagainstmoisture anddirt,e.g.usingtarpaulins.
Themountingsurfacesofhydrauliccomponentsmustbeprotected againstcorrosionandsealedwithblindplates.Protectthehydraulic plugconnectorsandtheconnectorsoftheelectricalcableswiththe capsandplugssupplied.
Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors,butattemperatures above freezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularly protectedagainstexcessivetemperatures,dirtandmoisture.
Duringlong-termstorage(morethan4weeks),theequipmentmust notbestoredoutdoors.Itmustbestoredinadry,wellventilated room.
Afterastorageperiodofapprox.twoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. TheinspectioncanbecarriedoutbyDBTonrequest.
Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Astorageperiodofapprox.twoyearsisthereforequoted asanindicativevaluefortheseparts.
Important! Ensurewhenstoringthatanynewsuppliesarestoredseparatelyfromexistingstocksinsuchawaythatonremoval,old stocksarealwaystakenfirst.
Beforestoringgearboxeswithoilcoolersatambienttemperatures belowthefreezingpoint,flushouttheoilcoolerwithantifreeze.
Storage Gearboxpreservation Whenthegearboxistobestoredforalongperiod,itsinteriormust bespeciallypreserved.Preservingonlyespeciallycorrosion-sensitive,brightexteriorsurfacessuchasshaftextensions,flanges,etc. isinsufficient.
Werecommendthefollowingpreservative:
J TECTYL511-MbyVALVOLINE
Thefollowingstepsmustbecarriedouttopreservetheinteriorof thegearbox:
J Thegearoilmustbecompletelydrained,evensmallpoolsand dropsofoilresiduemustbeavoidedbecausetheyhinderanticorrosives.Thegearboxmayneedtobeswivelledorturnedto theside.
J Thencompletelyfillthegearboxwithpreservative.Therequired quantityequalsthevolumeoftheinteriorofthegearbox(see section“Generaltechnicaldata”).Theyield35to45m2/l.
Caution!
Theoperatingtemperatureofthepreservativemustbeatleast 18 ºCto20ºC.ObserveVALVOLINE'sinstructions
J Removethebreatherplugsothatitisnotadverselyaffectedby thepreservative.
J Allowthegearboxtorunforatleast15minwithoutloadsothat itbecomesthoroughlycoated.
J Drainthepreservativeasthoroughlyaspossible.Donotallow smallpoolsofliquidtoformintheprocess.
J Ventthegearboxthoroughlyforatleast24hourswiththe inspectionholecoveropenasthepreservativecontainsasolvent(petroleumspirit)thatmustbeallowedtoevaporate.
Danger!
Solventflashpoint(petroleumspirit)40ºC accordingto DIN51755.HazardclassAIIaccordingtoVbF(Ordinancefor flammableliquids)
Theflammablesolventisheavierthanair.Theopeningshouldbeif possibleatthebottomonthelowersidesothatthesolventevaporateoutofthebottom.Thegearboxmayneedtobeswivelledor turnedtotheside.
Afterreceivingtheanticorrosiontreatmentmentionedabove,the gearboxcanbestoredunderneatharoofwithoutadditionalpackagingforninemonths. Itshouldbestoredsothatventsandotheropeningsarecoveredto preventwaterfrompenetratingtheinteriorofthegearbox. Themeasurestopreventthewaterfrompenetratingshouldnot adverselyaffecttheinnerventilationofthegearbox. Preservedgearboxesmustbemarkedwithinformationontheanticorrosive,dateofpreservationandstorageperiod.
Brightexteriorflangessuchasshaftextensions,flanges,etc. shouldbecoatedwithanon-slipperywaxfilmorwaxtape. Whenthegearboxisstartedup,thepreservativeinthegearoildissolve.Itcanremaininthegearboxuntilthenextoilchangewithout adverselyaffectingtheabilityoftheoiltolubricate.
Preservativesmustberemovedfromthebreatherplugbeforestart upifrequired.Gasoline,paraffin,dieseloil,waxremoverorbasic mediacanbeusedtodothis.
Filtersthatarepartofthegearoilcircuitmustbemonitoredregularlyforthefirstmonthsaftercommissioning.
Transport Loadunits;dimensionsandweights Itisimperativethatyouobservethetransportsheets.Theyinclude informationon:
J Dimensions
J Weight
J Liftingpointsand
J Centersofgravity.
Wheretechnicallypossible,theloadunitshavesuitablelifting pointsfortransportanderection.
Warning!
Useonlyloadhandlingdevicescomplyingwiththetechnical andlegalregulationsfortransportingloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Beforetransport Transportofequipmentattemperaturesbetween-21ºCand-40ºC isonlypermissiblewhencertainmeasuresweretakentomeet theseconditionsatthedesignandmanufacturingstages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnot besubjectedtosuddenimpactloadsatsuchlowtemperaturesand mayonlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloorconveyingdevicesat suchlowtemperatures,measuresmustalsobetakentoensure thatthepartsanddevicesarenotsubjectedtosuddenimpact loads.
Atverylowtemperaturesandonpoorroads,thetransportvehicle speedmustthereforebelimitedtomax.25km/hfortrucktransport.
Beforetransportinggearboxeswithoilcoolersatambienttemperaturesbelowthefreezingpoint,flushouttheoilcoolerwithantifreeze.
Electricalandelectroniccomponentsmustberemovedforoverseastransportorprolongedstorageoutdoors,unlessthese componentsorthecompleteequipmentisprotectedagainstharmfulenvironmentalinfluencesbysuitablepackaging. Theelectricalcablesremainintheequipment.Theymustbecarefullyprotectedagainsttransportdamageandsoilingoftheconnections.
TransportplanforgearboxK-10andK-10.1
Fig.1:TransportplangearboxK-10andK-10.1
1ThreadboreM24-45deep
(withoutoil) Withshearing head
(withoutoil)
ThegearboxisequippedwiththreadboresM24-45deepinorder toscrewonliftingpoints(loadcapacity3000kg). Alwaysuseallfourliftingpointswhenliftingthegearbox.
4 Installation Installation Gearboxinstallation Caution!
Seriousdamagecanbecausedtothegearboxanddriveasa resultofincorrectinstallation.
Installthegearboxonlyaccordingtotheinstructionsof Bucyrustechnicians.
Beforeinstallation Thedipstickandbreatherplugaresuppliedloose. Beforeinstallingthegearboxtheymustbefittedaccordingtothe followinginformation(seeChapter6,section“Maindimensions”for thelocationoftheinstallationparts).Theboresfortheinstallation partsaresealedwithscrewplugs.
Thetwooildipsticks-gearboxK-10-alwayshavetobefittedat thetop.Theoildipstickof517mmlengthisscrewedintothemain gearboxchamber,theoildipstickof360mmlength,withbreather plug,intothegearboxchamberoftheinputshaftbearingassembly. ThegearboxK-10.1isequippedwithoneoildipstickwhichhasto befittedatthetop.
ThebreatherplugofthegearboxK-10isalsomountedatthetop. ThebreatherplugofthegearboxK-10.1mustbefittedsuchthatit willnotcomeintocontactwiththegearoil.
Theflangeplatemustbeinstalledbeforethegearboxcanbe attached.
Checkwhetherallboltedconnectionsbetweenthedriveframeand theflangeplateareathandandcheckthetighteningtorque. Makesurethatallscrewsforfasteningthegearboxandtheparallel key(torquearm)areinsertedontheflangeplate.
Notesoninstallation J Thetransportsecuringdevices(protectivecaps)ofthedrive andoutputshaftaretoberemoved.
J Allflangesurfaces,centeringbores,parallelkeysandgrooves mustbecleanandfreefromburr.
J Beforemountingtheflange,thegearingmustbewellgreasedlubricatingpasteB3asindicatedinChapter6,section“Recommendationsforlubricatinggreasesandpastes”.
J Thegearboxmustbealignedtoslideoverthecenteringbores andtheparallelkeyswithouttilting.
J Avoiddamagingthegearingandcantingthegearboxduring assembly.
J Observethetighteningtorqueoftheconnectionscrews.
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Gearboxinstallation Fig.2:GearboxK-10 / K-10.1-mounting
connectingthecooling waterports
1BoltedconnectionM30 2Parallelkey(32P9-10deep) 33 33M30-50deep
Thecoolingwaterportsarelabeledwitha“coolingwaterinlet”or “coolingwateroutlet”sign. The“coolingwaterinlet”isequippedwithapressurereliefvalvein ordertoprotectthecoolingsystem.
Fig.3:GearboxK-10 / K-10.1-Coolingwaterports
1CoolingwaterinletG3/4
2CoolingwateroutletG3/4
3Pressurereliefvalve
Driveconnectionassembly Thedriveconnectionassemblycomprisesallcomponentsarranged betweenthegearboxandtheelectricmotor.
Themotorandgearboxconnectiondimensions,motoroutput, motorspeedandadditionalequipmentifanydeterminewhichdrive connectionassemblyisrequired(seeChapter,section“Drive connectionassembly”).
Mountingandpulling-offdevicefortheVoith-Turbo fluidcoupling
TheVoith-Turbofluidcouplingistobefittedonthegearboxdrive shaftusingthemountingandpulling-offdevice.
Bothdevicesarehousedinaprotectivetube.Theprotectivetube alsoactsasamountingandpulling-offdevice.
Fig.4:Mountingandpulling-off device
1Protectivecap
4Threadedtube
17Hex.headscrewM20x50
18Hex.headscrew16x70
19Hex.headscrewM6x16
20Hex.headscrewM12x220
23Hex.nutM30x8
26Circlip
27Ballbearing
1/2
5Hex.headscrewM30x120
6SpringwasherVSK30
7Sprungdowelpin
8Retainingwasherforcoupling
MountingtheVoith-Turbofluidcoupling BeforemountingtheVoith-Turbofluidcouplingalwayspositionthe protectioncoverintermediateflangeonthegearboxflange,asitis nolongerpossibleafterwards(seeFig.12).
Inordertoensuresafemountingandpulling-off,thecleaned gearboxshaftshouldbelubricatedwithmolybdenumdisulfideor anotherlubricantofthesametypeandquality.
TheVoith-Turbofluidcouplingisthenmanuallypushedontothe gearboxdriveshaft.
Thenscrewinthethreadedspindle(item11-Fig.6)withwasher (item12)andbush(item13)throughthecouplinghubintothe threadboredofthegearboxdriveshaft.TheVoithTurbofluid couplingispushedasfarasitwillgoonthegearboxdriveshaft bysteadilytighteningthehex.nut(item23).
Fig.5: Voith-Turbofluidcoupling
11Threadedspindle 12Washer 13Bush 23Hex.nut
Thedriveshaftislockedinplaceusingthehex.nutonthe threadedspindle(item11).
Theretainingwasher(item8-Fig.5)andsprungdowelpinare insertedintotheVoithTurbofluidcouplingafterthethreaded spindlehasbeenremovedfromtheshaftend.Thehex.headscrew (item5)isthenscrewedinwiththespringwasher(item6)intothe gearboxdriveshaft.
Thegearboxshaftconnectionistherebyfirmlysecuredtothe Turbocouplinghubreadyforoperation.
Fig.7:MountingtheVoithTurbofluidcoupling
Fig.6:Mountingdevice
Gearboxinstallation PullingofftheVoith-Turbofluidcoupling RemovetheE-Motor,theprotectioncoverandtheTschancoupling beforepullingofftheVoith-Turbofluidcoupling.
Undoandremovethehex.headscrew(item5)andspringwasher (item6)fromtheretainingwasher(item8-Fig.5)onthegearbox shaftend.Alsoremovetheretainingwasher(item8)whichisheld inplacebyasprungdowelpin(item7)fromthecouplinghub.
Thenscrewthemountingandpulling-offdevice'sthreadedspindle (item4-Fig.8)intothecouplinghubthread.Steadilyturnthehex. headthreadedspindle(item4)usingawrench.Indoingthisthe threadedspindlebracesitselfagainstthegearboxshaftendand thescrewingactionpullstheVoith-Turbofluidcouplingoffthe gearboxshaftend.
Fig.8:Threadedtubewiththrustwasher-pulling-off device
Fig.9:Pulling-off the Voith-Turbofluidcoupling
Flexiblecouplingforoperationwithafluidcoupling ThecouplingillustratedbelowisfittedbetweentheE-motorandthe Voithcouplingandactsasaflexibleconnectingelement.Itcompensatesforminorradial,angularandlongitudinalpositioning errorswhichmayarisefromerrorsduringinstallation.
Installationandremovaloftheflexibleplug-incoupling Cleantheboreonthecouplinghubandlubricateusinggreasefree frommolybdenum.AftermountingandsecuringtheVoithcoupling bolttheconnectingflangeonthecouplinghousing.
Mountthecouplingonthemotorshaftendsusingamounting device.Theintermediateringisfittedbetweenbothcouplinghalves.
Disassemblyiscarriedoutinreverseorder.
Fig.10:Flexiblecoupling
Gearboxinstallation Flexiblecouplingforoperationwithoutfluidcoupling
ThecouplingillustratedbelowisfittedbetweentheE-motorandthe gearboxandactsasaflexibleconnectingelement.Itcompensates forminorradial,angularandlongitudinalpositioningerrorswhich mayarisefromerrorsduringinstallation.
Fig.11:Flexiblecoupling
1Couplinghalves
2Intermediatering
Installationandremovalofthecouplinghalves
Cleanthecouplingboresandlubricateusinggreasefreefrom molybdenum.Theintermediateringisfittedbetweenbothcoupling halves.
Thecouplinghalvesaremountedontoandpulledoffthegearbox andmotorshaftendsusingamountingandpulling-offdevice.
Driveconnectionassemblyprotectioncovers Theprotectioncovershousethehigh-speedVoithcouplingand/or theflexiblecouplingandconnectthegearboxtotheE-motor.
Protectioncoverforusewithfluidcoupling
Inadditiontotheabovementionedfunction,thecoveralsoserves toshieldagainstjettingoilwhenthefusiblesafetyplugisopened.
Warning! Becarefulwhenopeningthecouplingatoperatingtemperature ashotoilcanjetout.
TheinspectionholesareusedtofilltheVoithcouplingwithoiland tochangethefusiblesafetyplug,thelateralopeningscooland ventilatethecouplingwhenitisrunningandmustalwaysbekept freefromdirt.
Allcoverplatesmustbefittedbeforestart-up.
Intermediateflangesarefittedtobridgethegapbetweendiffering centeringboresonthedrivegearandtheprotectioncover.
Fig.12:Protectioncover-Fluidcoupling
Electricmotors
Flangeposition“W”
Fore-motors,flangeposition“W”describesthedistancefromthe motorflangetotheshaftcollar.Forthedriveconnectionassembly, itisthedistancefromthecontactsurfaceoftheprotectioncover (motorside)tothecontactsurfaceoftheelasticcoupling.
Caution!
Iftheflangeposition“W”attheelectricmotorislargerthan atthedriveconnection,themotorshaftandgearboxdrive shaftbearingswillbestrained.Thiscanresultindamageto thegearboxandtheelectricmotor!
Fig.13:Flangeposition“W”one-motor
Payparticularattentiontothefollowinginstructions before installing thee-motor:
J Theexactflangeposition“W”oftheelectricmotormustbe measured beforeinstallation
J Iftheflangeposition“W”oftheelectricmotoris larger thanthat ofthedriveconnectionassembly,onecomponentofthedrive connectionassembly(e.g.huboftheflexiblecoupling)mustbe shortenedaccordingly.
J Theconnectingpieceshavetobeinstalledusingthemounting andpulling-offdevice.
Installingtheelectricmotor
CleantheshaftoftheE-motorandapplymolybdenumdisulfide. Pullthemotorsidecouplinghalfoftheplug-incoupling(coupling hub)ontothemotorshaft.Flangethee-motorontotheprotection coverandguidethecouplinghubintotherubbertappetofthe couplingflange.Makesurethattheflangeconnectionfitsfirmly andiscenteredperfectly.
Caution!
Blowstothemotorshaftandgearboxshaftwilldamagethe shaftbearings.Thereforealwaysuseamountingandpullingoffdeviceforinstallationandremovaloftheconnectingpieces.
PleasemakesureyouobservetheinstructionsintheE-motor's separateoperatingmanual.
Caution!
Onlyinstallelectricmotorswithperformancespecifications (torque,speed)permissibleforthegearbox(seeChapter6 “Technicaldata”).
Ifyouprefertoinstallelectricmotorsotherthanthoseapprovedbyus,pleasecontactourservicedepartmentinadvance.
Starting-upthegearbox Thegearboxmustbestartedupundertheinstructionoftechnicians fromBucyrus.
Caution!
Besuretoobservetherelevantinstructionsonstartingupin theseparateoperatingmanualsofthecompleteconveyor installation. Errorsduringstart-upcanresultinseriousmachine damageandthushighrepaircosts. Carefullyreadalltheoperatingmanualsontheconveyor installation!
Beforestart-up Thefollowingworkhastobeperformedonthegearboxbefore beginningwiththeactualstart-up:
J checkingtheoillevel
Inanycase,beforestartingupthegearboxyouhavetocontrolthe oillevelofthegearbox!Thegearboxissuppliedwithoutoilfilling!
TheK-10gearboxhastwooilchambers.Theoilchambers”main gearbox”and”inputshaftbearingassembly”mustbefilledwithoil separately.
TheK-10.1gearboxhasoneoilchamber.
Removetheoildipstickandfilloilintotherespectivebore.Make surethatthemagneticrodandthescrewplughavebeenfittedand tightened.
Caution!
Theoillevelsrequireddependontheinclinationofthe gearbox.Aplateattachedtothegearboxindicatesthecorrespondingoillevelmarkforthevariousanglesofinclination (see ”Oillevelsandoilcapacities”insection”Technicaldata”). Filloilintotherespectiveoilchamberuntiltheoildipstickreadinggivestheapplicableoillevel.
Toolittleoilisdetrimentaltothelubricationofthegearsandrolling contactbearings.Toomuchoilresultsinlargelossesduetosplashing,tooilfoamformationandincreasedheatgeneration.
J inspectionofthegearbox ChecktomakesurethattheK-10gearboxhasthetwobreather plugsfitted(”maingearbox”and”inputshaftbearingassembly”oil chambers).TheK-10.1gearboxhasonebreatherplug.
Thebreatherplugalwaysmustbefittedatthetop.Positionofthe breatherplug,seesection”Technicaldata–maindimensions”.
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