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Operating Manual Gearbox P-25/30 Doc. no.: 1946 003 000 BA 00

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

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

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008E

Contents

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

1.3

Who is this operating manual intended for? . . . . . . . . . . . .

What is the purpose of this operating manual? . . . . . . . . . .

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

1.3 1.4 1.4

2. Your safety 2.3

Installation and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

2.4

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

Unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Prerequisites for the operation of the gearbox . . . . . . . . . .

2.4 2.4 2.4 2.5

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

2.6

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

3.3

Storage of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preservation of gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3

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

3.5

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

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

Transport plan for gearbox P-25/30 . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.6

4. Installation How to install the gearbox . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Prior to installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive connection assemblies . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and pulling-off device for Voith-Turbo coupling .

Flexible coupling for use with fluid coupling . . . . . . . . . . . . .

Flexible coupling for use without fluid coupling . . . . . . . . . .

Drive connection protective cover . . . . . . . . . . . . . . . . . . . .

Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.8 4.9 4.13 4.14 4.15 4.16

How to assemble and start up the gearbox . . . . . . . . . 4.17 Before starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.17 4.18 4.18

Dismantling and removing the equipment . . . . . . . . . . 4.19 Important instructions for dismantling . . . . . . . . . . . . . . . . .

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4.19

Contents 5. Operation How to maintain the gearbox . . . . . . . . . . . . . . . . . . . . . .

5.3

Checking bolt connections . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cleaning the gearbox housing . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3 5.4 5.4 5.5 5.5

Replacement of defective components . . . . . . . . . . . .

5.6

Replacing the heat exchangers . . . . . . . . . . . . . . . . . . . . . .

5.6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Troubleshooting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

6.3

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

6.4

Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Permissible power and torque . . . . . . . . . . . . . . . . . . . .

6.8

Input speed 1480 min-1, 50 Hz . . . . . . . . . . . . . . . . . . . . . . .

Input speed 1780 min-1, 60 Hz . . . . . . . . . . . . . . . . . . . . . . .

6.8 6.9

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 Mounting and pulling-off device for Voith-Turbo coupling .

6.10

Oil levels and oil quantities . . . . . . . . . . . . . . . . . . . . . . . 6.11 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.13

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 Recommended oils for Bucyrus-gearboxes . . . . . . . . . . . .

Requirements for gear oils for Bucyrus-gearboxes . . . . . .

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

Cooling water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14 6.15 6.16 6.17

Marking of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18

7. For your information Our service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

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

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

America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

7.3 7.3 7.4 7.4 7.4 7.5

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

7.6

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

Referenced european standards and guidelines . . . . . . . .

7.6 7.6

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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

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6. Technical data

1

About this manual

Before starting work

About this manual This chapter contains important information which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used.

Before starting work applicable operating manual

gearbox type

Take care to ensure that the operating manual available to you is applicable for the type of gearbox used. Failure to do so can result in a safety hazard for yourself and others. Ensure that the data on the gearbox comply with the data given in the operating manual.

This operating manual is designed for: Gearbox P-25/30 Serial No.:

1946 003 000 00 00 1946 004 000 00 00

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

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

It should, if possible, always be available at the place of operation.

E Bucyrus DBT Europe GmbH, Lünen 2008

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

new operating manua

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 all persons working with or on the gearbox.

All persons working on the face, in the intersection between face and entry, or in the entry must read this operating manual.

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

Supervisory personnel who: J initiate and/or supervise the actvities just indicated.

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1.3

Before starting work What is the purpose of this operating manual? efficiency

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

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled ”For your information”.

safety

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.

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

Warning!

These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

Caution!

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

Notice!

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

Important!

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

J Items in lists are marked with bullets.

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

. Points in the text marked in this way describe individual work steps. Follow these instructions step-by-step.

They will help you carry out your work faster and, more importantly, safer.

1.4

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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.

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Try to memorize the symbols and their meanings.

2

Your safety

Personnel

Your safety This chapter contains important information for your safety.

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

The gearbox 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 gearbox. All modifications and changes must be approved by Bucyrus.

Only use original Bucyrus spare parts. Please note that the guarantee will expire if you install parts from other manufacturers.

Bucyrus DBT Europe GmbH, Lünen 2008

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The European Directives/Standards referred to in this operating manual have to be observed when using the gearbox in a member state of the European Union (EU). For use outside of the EU the directives and standards applicable in the respective countries must be observed.

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

Observe the safety and accident prevention regulations: J of the mine, J of the Mines Inspectorate and J of the mining supervisory authorities. further operating manuals

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

Personnel Installation and repair In general, installation and repair work shall be performed only by persons who have been adequately trained for the special requirements. Installation and repair of J the safety devices (pressure relief valves, extinguishers, etc.), J the electrical equipment (controls units, signalling devices, etc.), J the hydraulic system,

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

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2.3

Operating conditions Operating conditions Intended use The gearbox has been exclusively designed and manufactured for use as part of BSL conveyor drive units or plow drive units.

J It serves to reduce the speed and to transmit the torque of the

electric motor to the conveyor drive shaft resp. plow drive unit.

J In combination with additional devices the gearbox can also be

used for coupling or tensioning the conveyor chain assembly.

Devices permissible for this task are: – hydraulic or pneumatic chain tensioner as auxiliary drive at the drive connection assembly of the gearbox if the drive connection assembly has been prepared accordingly.

– brake tong.

Employ the gearbox only for its intended use!

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

veyor drives. resp. plow drive units.

Bucyrus accepts no liability for any damage resulting from any such unauthorised use.

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

These include: J adequate and consistent ventilation, J plough track spraying system / water spraying system.

If the mine gas concentration in the free cross section of the consistently ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL) as defined in the respective national laws the M2 equipment has to be de-energized.

It may only be restarted by an authorized person.

The atmosphere in the mine has to be monitored in the hazardous locations to permit disconnecting the power supply of all pieces of equipment except of those which are relevant for the safety and suitable for use in explosive atmospheres.

The M2 equipment has to be stopped at once and secured to prevent a restart if firedamp protection facilities are found to be damaged.

2.4

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

J coupling or tensioning the conveyor chain by means of the con-

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Such unauthorised uses include i.a.:

Operating conditions Prerequisites for the operation of the gearbox Putting the gearbox into service is prohibited until the machine into which this gearbox is installed has been found to comply with the European Directive 94/9/EC and the Standard DIN EN1710.

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

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

These include: J facilities preventing unauthorized starting, J pre-start warning systems, J water spraying systems, J safe lock-out command systems, J emergency stop systems, E

J dust extraction systems, Bucyrus DBT Europe GmbH, Lünen 2008

J noise protection, J warning statements etc.

All electrical equipment required to operate the gearbox shall be marked according to the legal provisions applicable at the time when it is placed on the market.

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2.5

Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarise yourself with your working environment.

protective equipment

Always wear your personal protective clothing and equipment. This also includes ear protectors as the noise emitted by the conveyor may exceed 85 dB(A).

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

condition

Start the conveyor or the mining machine 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.

safety equipment

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

Observe the acoustic and optical start-up warnings of the mining machine and the conveyor.

EMERGENCY-STOP

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Observe the signs on the gearbox.

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

Also operate the emergency stop switch if protective devices such as for example firedamp protection devices fail.

lock-out

Lock-out the mining machine and the conveyor to prevent restarting during: J maintenance work, J inspection work, J repair work, J failure of protective devices such as

– firedamp protection. block working area moving parts

Isolate your working area over a wide range for monorails (EHB) and gallery conveying devices.

Never allow parts of your body to come between parts which could move, such as e.g.: J plow and conveyor chains, J flights, J plow, J spill plates, J chain sprockets.

ignition hazard

2.6

Be sure to observe the intervals specified for maintenance and checks of the gearbox. Make sure that the gearbox is always sufficiently cooled since hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

information signs

Safety instructions hot surfaces

During normal operation the temperature in the gearbox housing may reach up to 85 _C! When you work on the gearbox, the temperature must not exceed 60 _C. If necessary, wait until the gearbox has cooled down accordingly.

Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel route or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport.

transport safety device

Ensure that the transport locks are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Attach lifting equipment only to the lifting points provided. Pay attention to the different load limits of the lifting points. Observe the instructions on the transport sheets.

Bucyrus DBT Europe GmbH, Lünen 2008

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Use only lifting equipment which are in good condition and are designed for the loads to be handled.

For round components which are not provided with points of attachment use transport straps, only. Never use chains or steel cables.

Do not damage the treated surfaces of shafts, sealing surfaces, etc. floor mounted rail device

When transporting using a floor mounted rail system, ensure that the centre of gravity is as low as possible.

Erection and commissioning

Inclined storage

environmental acceptability

If stored at an angle, secure all individual parts using chains, e.g. to the shields.

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

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

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

Inform the supervisory personnel and the face working crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

Stop work on the gearbox before the mining machine reaches your area.

protect

Cordon off your working area with sufficient space so that other persons are not endangered.

Secure the mining machine and the conveyor to prevent any unauthorised or accidental switching on.

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2.7

Safety instructions working in the mining area

You may only work in the mining area when you have J secured the roof against rockfall, J supported the coal face to prevent collapsing, J switched off the mining machine and conveyor and secured

them to prevent restarting. replacing parts

Before replacing parts, stop the conveyor and the mining machine and secure to prevent restarting.

Remove defective parts from the face area immediately in order not to hinder the face crew. This also avoids the risk of these parts being inadvertently installed again elsewhere.

Send these parts for repair immediately.

In faces with inclines, secure spare parts e.g. with chains or hoists.

original parts

Use only spare parts which satisfy the specified technical requirements. This is only ensured with original Bucyrus spare parts.

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

lifting points

When lifting, use only the gearboxes: J lifting points provided,

Lift the conveyor only with shields which are linked to the conveyor by means of the shifting unit. Disconnected shields could tip forward. safety equipment

2.8

Install the removed protective devices again immediately on finishing the work and check that they are functioning correctly.

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

Use only the lifting points provided. On no account should brackets of cylinders be used as they are not designed to withstand tensile loads.

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J hoists with sufficient safe working load.

3

Storage and transport

Storage

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

Observance of the instructions and tips will increase the service life and availability of the gearbox. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage Storage of the equipment corrosion protection

Components coated with temporary corrosion inhibitor are protected for around six months.

no direct exposure to sunlight

Protect the equipment against direct exposure to sunlight.

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

moisture and dirt

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

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

long-therm storage

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

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

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

natural ageing

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.

Important!

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

protection against frost damage for oil cooling

Before transporting or storing gearboxes with oil cooler at ambient temperatures below freezing, the oil cooler must be flushed with antifreeze.

Preservation of gearboxes Gearboxes that have to be stored for a longer period of time require a special preservation of the inside. It is not sufficient to only apply a preserving agent to the unprotected outer areas particularly susceptible to corrosion such as shaft ends, flanges and the like.

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3.3

Storage As preserving agent should be used: J TECTYL 511-M by VALVOLINE

To preserve the inside areas of the gearbox carry out the following steps: J Completely drain off the gear oil. Take care that no oil deposits,

for those areas then will not be protected against corrosion. To ensure complete draining off, turn the gearbox as is required.

J Subsequently, fill up the gearbox with the preserving agent. The

quantity required corresponds to the inside volume of the gearbox (see chapter on technical data). Coverage of the preserving agent is 35 to 45 m2/l.

Caution!

When applying the agent, its temperature must be at least 18 oC to 20 oC. The instructions by VALVOLINE are to be observed.

J Remove the breather plug as the preserving agent might nega-

tively affect its efficiency.

J Operate the gearbox under no load for at least 15 minutes to

ensure that all areas are sufficiently wetted.

J Completely drain off the preserving agent. Take care that no

open for at least 24 hours to permit the solvent (white spirit) contained in the preserving agent to escape.

Danger!

Flash point of the solvent (white spirit) 40 oC according to DIN 51 755. Danger classification is A II according to VbF The volatile solvent is heavier than air. Therefore, the respective opening should be located at the bottom or at the side. If necessary, turn the gearbox as is required.

Storing of the gearbox under cover without additional packing is possible for a period of 9 months with the above corrosion protection having been applied.

When storing the gearbox, ensure that the venting bores and other openings are protected in a way to prevent water from penetrating into the gearbox. Care is to be taken that these measures do not negatively affect aeration of the gearbox.

Preserved gearboxes are to be identified by marking down the corrosion preventive used, the date of preservation and the storing period.

Unprotected areas on the outside such as shaft ends, flanges and the like are to be provided with a wax cover fast to handling or with wax tape.

When operating the gearbox, the preserving agent will dissolve in the gear oil. It may therefore remain in the gearbox until the next oil change is made; the lubricity of the oil will not be adversely affected.

Prior to putting the gearbox into operation check the breather plug and remove any preserving agent that may have deposited. Petrol, petroleum, diesel oil, wax solvent or alkaline cleaners may be used.

During the initial stage of operation regularly check all filters in the gear oil circuit.

3.4

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

J Thoroughly aerate the gearbox with the inspection hole cover

E

residue is formed.

Transport Transport Load units; dimensions and weights Observe the transport sheets for the various transport units. They contain information on: J dimensions, J weight, J lifting points, J centre of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and erection.

Warning!

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

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

Use only suitable load handling devices.

Before transport

Bucyrus DBT Europe GmbH, Lünen 2008

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temperatures below freezing

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

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

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

Antifreeze Measures for Oil Cooler

Before transporting or storing gearboxes with oil cooler at ambient temperatures below freezing, the oil cooler must be flushed with antifreeze.

eletrical and eletronic components

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

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

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3.5

Transport Transport plan for gearbox P-25/30 Transport plan for gearbox P-25/30 - 1946 003 000 00 xx

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 1:

S

54

25

25 shaft protection 54 lifting eye TAWGK 5 (5000 Kg) S centre of gravity Weight: 2120 kg (without oil filling)

Important!

Always use all lifting eyes for lifting the gearbox.

3.6

Gearbox P-25/30

Transport Transport plan for gearbox P-25/30 - 1946 004 000 00 xx

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 2:

S

25

54

25 shaft protection 54 lifting eye TAWGK 5 (5000 Kg) S centre of gravity Weight: 2160 kg (without oil filling)

Important!

Always use all lifting eyes for lifting the gearbox.

Doc. no.: 1946 003 000 BA 00

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3.7

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Transport

3.8

Gearbox P-25/30

4

Installation

How to install the gearbox

Installation How to install the gearbox Caution!

Incorrect installation can result in serious damage to the gearbox and the drive.

Install the gearbox only under the instruction of specialists from Bucyrus.

Prior to installation attachment parts

Oil dipsticks, breather plugs and the magnetic rod are supplied separately.

They have to be fitted before the gearbox is installed according to the instructions given in the following (position of attachment parts, see chapter 6, section ”main dimensions”, fig. 22 - attachment parts). The bores for the attachment parts are closed with screw plugs.

The gearbox is unhanded.

The oil dipstick and the breather plug always have to be fitted at the top.

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The magnetic rod is fitted at the bottom of the gearbox. flange plate

The flange plate must be mounted before fitting the gearbox.

Check that all bolted connections between drive frame and flange plate are in place and check on the tightening torques.

Make sure that all bolts for securing the gearbox and the centring pins or the parallel key (torque support, see fig. 5 or fig. 6) of the flange plate have been fitted.

heat exchanger

The heat exchangers (1) are provided with a plate reading ”cooling water inlet” or ”cooling water outlet”. The heat exchanger ”cooling water inlet” is equipped with a pressure relief valve (6) to protect the cooling system.

Depending on the conditions of operation at the site, the heat exchangers can be optionally mounted either on the left side or on the right side of the gearbox.

For replacement of the heat exchangers, remove the water connections and loosen the fastening bolts. Next, pull the heat exchangers out from the outside and replace them. In order to make the assembly easier, the covers (4) can be removed and - after the assembly of the heat exchangers - be added again.

The heat exchanger ”cooling water inlet” must be mounted so that the pressure relief valve (6) is always at the top and protected against external damage.

Doc. no.: 1946 003 000 BA 00

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4.3

How to install the gearbox Fig. 3:

Cooling water connections

E

18 o-Ring 100x3 20 adapter G 3/4-DN 12 21 coupling clamp DN 12 22 ring bolt M 12-C 15 23 fitting R 3/4’’-DN 12 24 plug DN 12 25 hose line 12x800 ST/ST 30 loctite no. 270 E cooling water inlet DN 12 A cooling water outlet DN 12

*) mounted at the top **) can be mounted optionally on the right or on the left

4.4

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

1 heat exchanger **) 2 reducer M42x1,5/G1 4 cover 6 pressure relief valve *) 8 hex. head bolt M 16x40-8.8 10 screw plug G 3/4 A-5.8 11 sealing ring A 27x32 13 screw plug M 42x1,5-5.8 14 sealing ring A 42x49 15 screw plug G 1 A-5.8 16 sealing ring A 33x39

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A

How to install the gearbox Important notes for the installation of the gearboxes: J Remove the transport protection devices from the input and

output shafts.

Fig. 4:

Transport protection

27 28

25

24

24 protective cover 25 shaft protection 27 hex. head bolt M 12x25-8.8 E

28 hex. head bolt M 36x260-8.8 Bucyrus DBT Europe GmbH, Lünen 2008

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

must be clean and free from burrs.

J Before flanging on the gearbox, the gearing ( - fig. 5, 6) must be

wellgreased - grease type B3 according to paragraph “Recommended Lubricating Greases and Pastes”, see chapter 6.

J During installation, the gearbox must be positioned exactly on

the centering bores and centring pins or parallel keys.

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

exactly opposite one another in order to permit correct assembly. Damage to the gearing and tilting of the gearbox must be avoided during installation!

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

J The fastening bolts must be tightened to the torque specified.

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4.5

How to install the gearbox Fig. 5:

Gearbox P-25/30 - 1946 003 000 00 XX

2

1

:

Bucyrus DBT Europe GmbH, Lünen 2008

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Y

1 bolted connection M 36 (flange plate) 2 hole 70, 80 deep (torque support) 3 bolted connection M 20 (drive connection assembly) Y 3

4.6

bores marked such are not required for installation : internal toothing DIN 5480 N 220x10x30x20

Gearbox P-25/30

How to install the gearbox Fig. 6:

Gearbox P-25/30 - 1946 004 000 00 XX

1 Y

Y

2

Bucyrus DBT Europe GmbH, Lünen 2008

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:

1 bolted connection M 36 (flange plate) 2 parallel key groove (torque support) 3 bolted connection M 20 (drive connection assembly) Y

bores marked such are not required for installation : internal toothing DIN 5480 N 220x10x30x20

3

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4.7

How to install the gearbox Drive connection assemblies The drive connection assembly comprises all parts arranged between gearbox and electric motor.

The type of drive connection assembly to be used is determined by the assembly dimensions of both motor and gearbox, the motor power, motor speed and any additional equipment that may be used.

Fig. 7:

Drive connection Type A with fluid coupling

Gearbox side

Type B with flexible coupling Motor side

Motor side

Gearbox side

Type C with fluid coupling and toothed disk Gearbox side

Type D with flexible coupling and toothed disk Motor side

Motor side

Gearbox side

Intermediate flange

4.8

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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Intermediate flange

How to install the gearbox Mounting and pulling-off device for Voith-Turbo coupling The Voith-Turbo coupling is to be fitted on and to be removed from the input shaft of the gearbox by means of the mounting and pulling-off device provided.

The mounting device is screwed in the pulling-off device, both devices are housed in a protecting tube. The mounting and pulling-off device can also be used for fitting and removing the toothed disk necessary for the operation of a chain tensioner.

Mounting and pulling-off device

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Fig. 8:

1 protection cap 4 threaded tube 5 protection tube 11 threaded spindle M 30 12 thrust disk 13 bush 14 thrust disk

Doc. no.: 1946 003 000 BA 00

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17 hex. head bolt M 20 x 50 18 hex. head bolt M 16 x 70 19 hex. head bolt M 6 x 16 23 hexagon nut M 30 x 8 26 sI-ring 27 ball bearing

4.9

How to install the gearbox Fig. 9:

Voith-Turbo coupling

7

R 11/2

8

6

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5

5 hex. head bolt M 30 x 120 6 spring washer VSK 30

7 spring dowel sleeve 8 retaining disk

Installing the Voith-Turbo coupling Before installing the Voith-Turbo coupling, arrange intermediate flange of protective cover in a way suitable for connection to the flange of the gearbox, as this will no longer be possible once the coupling has been mounted.

To enable safe installation and removal of the coupling, coat cleaned shaft of gearbox with a solid lubricant that does not contain molybdenum disulphide (see chapter on recommended lubricating greases and lubricating pastes).

4.10

Gearbox P-25/30

How to install the gearbox Fig. 10: Mounting device 12 23 13

11

11 threaded spindle 12 thrust disk 13 bush 23 hexagon nut

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Press coupling by hand on input shaft of gearbox. Pass threaded spindle (11) with thrust disk (12) and bush (13) through coupling hub. Screw spindle into tapped hole in input shaft. Evenly tighten hexagon nut (23) to press coupling on input shaft as far as the stop.

Bucyrus DBT Europe GmbH, Lünen 2008

Lock input shaft by means of the hexagon of the threaded spindle (11). Remove spindle from end of shaft. Fit retaining disk (8) and spring dowel sleeve (7). Finally, thread hexagon head bolt (5) with spring washer (6) into the input shaft to obtain a proper connection between coupling and shaft of gearbox.

Fig. 11: Voith-Turbo coupling being installed

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4.11

How to install the gearbox Removing the Voith-Turbo coupling Before removing the Voith-Turbo coupling, remove electric motor, protective cover and flexible coupling.

Loosen and remove from the end of the gearbox shaft hexagon head bolt (5) with spring washer (6) inserted into retaining disk (8).

Further, remove from the coupling hub retaining disk (8) secured by spring dowel sleeve (7).

Fig. 12: Threaded tube with thrust disk - Pulling-off device

14

4 4 threaded tube

14 thrust disk

Screw threaded tube (4) into thread of the coupling hub. Turn hexagon head of tube clockwise, using a spanner with an opening of 55 mm. The tube with its thrust disk (14) will rest against thrust disk on the end of the gearbox shaft and will, by screwing, withdraw the coupling from the shaft end.

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Fig. 13: Voith-Turbo coupling being withdrawn

4.12

Gearbox P-25/30

How to install the gearbox Flexible coupling for use with fluid coupling The flexible cam coupling shown below is fitted between the electric motor and the Voith coupling to connect these two units in a flexible manner. It corrects minor radial, angular and axial misalignments resulting from inaccurate installation.

The motor-side coupling hub is finish-drilled to suit the electric motor.

Fig. 14: Flexible coupling for use with fluid coupling 2

3

,

1

Bucyrus DBT Europe GmbH, Lünen 2008

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1 coupling hub 2 mounting flange 3 spacer

Installing and removing the flexible coupling Clean bore in coupling hub and apply a solid lubricant that does not contain molybdenum disulphide (see chapter on recommended lubricating greases and lubricating pastes). Next, bolt mounting flange to housing cover of Voith coupling after Voith coupling has been mounted and secured. Fit flexible coupling on motor shaft using a mounting device. To complete installation, insert spacer between the two coupling halves.

For removing the coupling, proceed in reverse order.

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4.13

How to install the gearbox Flexible coupling for use without fluid coupling The coupling shown below is fitted between the electric motor and the gearbox to connect these two units in a flexible manner. It corrects minor radial, angular and axial misalignments resulting from inaccurate installation.

Fig. 15: Flexible coupling for use without fluid coupling 1

2

3

Installing and removing the coupling halves Clean bores in coupling halves and apply a solid lubricant that does not contain molybdenum disulphide (see chapter on recommended lubricating greases and lubricating pastes). Fit spacer between the two halves of the coupling. Use a mounting and pulling-off device to install the coupling halves on and to remove them from the shaft ends of gearbox and motor.

4.14

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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1 coupling half 2 spacer 3 coupling half

How to install the gearbox Drive connection protective cover The protective cover houses the high-speed Voith coupling as well as the flexible coupling and connects the gearbox to the electric motor.

After removal of the cover, a chain tensioner can be attached.

Protective cover with fluid coupling It further gives protection against fluid spouting out of the Voith coupling when the fusible plug melts.

Warning!

Be careful when opening the coupling, as hot fluid may spout out.

Handholes covered with plates are provided for filling the Voith coupling with fluid and for exchanging the fusible plug. The other openings provided are to prevent an overheating of the running coupling. It is essential that these holes always be kept free.

Motor side

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 16: Protective cover with fluid coupling Gearbox side

Protective cover without fluid coupling Fig. 17: Protective cover without fluid coupling Gearbox side

Motor side

1 2

1 protective cover

2 cover

Intermediate flanges for the protective covers For adaptation of different centerings at drive unit and protective cover intermediate flanges will be fitted.

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4.15

How to install the gearbox Electric motor Flange position “W” flange position ”W”

Flange position ”W” describes for the electric motor the distance between the motor flange and the shaft collar, and for the drive connection the distance between the contact surface of the protective cover (motor side) and the contact surface of the flexible coupling.

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!

Particular attention must therefore be paid to the following instructions before installing the electric motor: J The exact flange position ”W” of the electric motor must be

measured before installation.

J 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.

J The coupling parts have to be installed using the puller.

Installation of the electric motor Clean the shaft of the electric motor and coat it with a solid lubricant not containing molybdenum disulphide (see chapter on recommended lubricating greases and lubricating pastes). Fit the motorside half of the cam coupling (coupling hub) on the shaft of the motor. Flange the motor to the protective cover by fitting the coupling hub into the rubber cams on the coupling flange. Take care to obtain a proper connection.

Caution!

Blows on the motor shaft and gearbox drive shaft will damage the roller bearings. Therefore always use the mounting and pulling-off device to install and remove the coupling components.

Caution!

Only install electric motors with performance data (torque, speed) which are permissible for the gearbox (see chapter 6, ”technical data”).

If you plan to use electric motors other than those approved by us you are required to contact our service department beforehand.

4.16

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 18: Flange position “W” of electric motor

How to assemble and start up the gearbox How to assemble and start up the gearbox The gearbox installation must be started up under the instruction of specialists from Bucyrus.

Caution!

Be sure to observe the relevant instructions on starting up in the separate operating manuals of the complete conveyor installation. Errors during start-up can result in serious machine damage and thus high repair costs.

Carefully read all the operating manuals on the conveyor installation!

Before starting up Before starting up, the following operations have to be carried out: J checking the oil level

Certain oil levels have to be maintained, depending on the angle of inclination of the gearbox. The gearbox is supplied without oil filling!

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Caution!

A plate attached to the gearbox indicates the corresponding oil level mark for the various angles of inclination (see ”Oil levels and oil capacities” in section ”Technical data”).

Remove the oil dipstick and fill oil into the respective bore. Make sure that the magnetic rod and the screw plug have been fitted and tightened.

J inspection of the gearbox

Check that every gearbox is fitted with a breather plug. braether plug

Doc. no.: 1946 003 000 BA 00

The breather plug always must be fitted at the top. Position of the breather plug, see section ”technical data – main dimensions”.

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4.17

How to assemble and start up the gearbox Start-up procedure The first start-up of the gearbox must be carried out under the instruction of specialists from Bucyrus.

Danger!

Ensure that all persons remain outside the danger area of the conveyor installation. Keep a safe distance from the conveyor, particularly during the test run and start-up. Installation errors, for example, can lead to dangers which would not occur during normal operation.

. The conveyor must be properly aligned before the start of commissioning.

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

. Check all bolted connections, in particular on the drives, for completeness and tightness.

. Check the electrical connection.

tors.

. Test the function of the signalling devices and the intercom system.

When operating the gearbox, the preserving agent will dissolve in the gear oil. It may therefore remain in the gearbox until the next oil change is made; the lubricity of the oil will not be adversely affected.

Prior to putting the gearbox into operation check the breather plug and remove any preserving agent that may have deposited. Petrol, petroleum, diesel oil, wax solvent or alkaline cleaners may be used.

Test run Observe and check the following points: J Each gearbox is to be carefully checked for any leakage. Prior

to carrying out the test, the gearbox is to be thoroughly cleaned from any oil. Only thus it will be possible to detect any leakage.

J The inside temperature of the gearbox is to be measured. After

a test run of two hours the temperature must not exceed 85 ºC. J The noise level of the gearbox is to be checked towards the

end of the load test.

4.18

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

. Check the cooling water supply for gearbox and electric mo-

E

. Check the direction of rotation of the electric motors.

Dismantling and removing the equipment Dismantling and removing the equipment Dismantling is performed in the most favourable order permitted by the local conditions, normally in the reverse order of installation.

Important instructions for dismantling Dismantling and removal operations may only be carried out by persons who have sufficient knowledge of the work to be performed and who have been adequately trained. handling of delicate components

J When dismantling the drive assembly, all exposed shafts, hubs,

labyrinths and flanges must be protected against corrosion, soiling and damage.

J When disconnecting lines, the connection points must be sea-

led with protective caps or plugs.

J Loose parts, bolts, screws and similar items must be neatly ar-

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ranged and stored in suitable containers and protected against contamination and damage.

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4.19

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Dismantling and removing the equipment

4.20

Gearbox P-25/30

5

Operation

How to maintain the gearbox

Operation Warning!

The temperature of the gearbox housing can rise to 85 °C. You may be badly burned when touching hot surfaces or the components inserted into these surfaces (oil dipstick, breather plug, gearbox sensors, heat exchanger etc.) or you may scald yourself with hot oil escaping (oil change).

Check the gearbox temperature and wait until the temperature has dropped to at least 60 °C, if required. Observe the information given on the labels attached to the gearbox.

How to maintain the gearbox Maintenance at regular intervals increases the operational safety and service life of the gearboxes. ignition hazard

Be sure to observe the intervals specified for maintenance and checks of the gearbox. Make sure that the gearbox is always sufficiently cooled since hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Maintenance includes:

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J checking for proper functions, Bucyrus DBT Europe GmbH, Lünen 2008

J checking bolt connections, J checking oil levels, J changing oil, J maintaining filters and breather plug, J check gearbox bearings, J clean gearbox housing.

Only suitable tools may be used for maintenance work.

Important!

A container with the necessary tools and the most frequently needed spare parts should be set up in the vicinity of the working point. Ensure sufficient protection of the contents against soiling and moisture.

Checking bolt connections retighten bolts

The bolts listed below must be retightened 60 hours after commissioning and then every 500 hours!

J drive connection (motor and gearbox side), J gearbox (connection to the drive frame).

tightening torque

Required tightening torques please see chapter ”technical data”.

Checking oil levels Check the oil level every week, taking care that no foreign matter is allowed to enter the gearbox.

Too little oil is a threat to the proper lubrication of the gears and roller bearings. Too much oil results in large splash losses, oil foam and increased heat generation.

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5.3

How to maintain the gearbox Changing oil The first oil change of a new or completely overhauled gearbox must be made after 250 operating hours. Thereafter the gearbox must be thoroughly cleaned and filled with fresh oil every 2000 operating hours, but at least every 6 months.

Important!

The oil change should be carried out with the gearbox at operating temperature as the warm thin oil can flush out the oil sludge more easily.

Oil is drained via the bore of the oil drain plug. See chapter 6, section ”main dimensions” for the position of the magnetic rod.

After removal, clean the magnetic rod. Refit and tighten the magnetic rod before filling in new oil.

An oil change at shorter intervals is necessary if: J the degree of soiling has reached 0,1% foreign particles, J the water content has exceeded the value of 0,1%, J with mineral oils the ageing resistance has decreased such that

the increase in the neutralisation number NZused - NZfresh = ∆NZ has exceeded the value ∆NZ = 2.0 mg KOH / g oil.

J determination of the neutralisation number in accordance with

DIN 51 558, J determination of the water content in accordance with

DIN 51 582, J determination of the foreign matter content in accordance with

DIN 51 592, J determination of the sulphate ash content in accordance with

DIN 51 575.

Maintaining filters Checking breather plug Check the breather plug for proper functioning every week and replace, if necessary.

Remove the breather filter with the gearbox at working temperature.

If air escapes when the filter is removed, the filter is defective and has to be replaced.

Notice!

Replace a defective breather plug by a new plug, only. Never try to clean the old plug. Used breather plugs are not allowed to be re-used. Please dispose of them in an environmentally safe manner.

5.4

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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Note:

How to maintain the gearbox Checking the gearbox bearings Listen for strange noises of the gearbox as these often indicate bearing damage. Defective bearings can cause serious damage to the gearbox and may lead to an overheating of the gearbox As soon as the bearings have reached their maximum service life they must be replaced. Forward the gearbox to the repair and maintenance shop.

Important!

If the bearings reach their maximum service life while a panel section is worked they should be exchanged as a precaution.

The bearing running times are given in chapter 6 ”technical data”. structure-born noise monitoring

In order to detect bearing damage at an early stage a continuous structure-born noise monitoring system can be used.

Cleaning the gearbox housing

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Excessive dust deposits cause a heat build-up which may cause the gearbox housing to get very hot. In the extreme, this may lead to a spontaneous ignition of the coal dust.

Therefore, clean the gearbox housing every day to remove dust deposits or the like.

Doc. no.: 1946 003 000 BA 00

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5.5

Replacement of defective components Replacement of defective components Replacing the heat exchangers The cooling system comprises one top mounted and one bottom mounted heat exchanger. Both heat exchangers are interconnected by an external hose line.

If the cooling system is damaged the heat exchangers can be replaced; this can even be done underground.

Fig. 19: Cooling water connections

A

1 heat exchanger **) 2 reducer M42x1,5/G1 4 cover 6 pressure relief valve *) 8 hex. head bolt M 16x40-8.8 10 screw plug G 3/4 A-5.8 11 sealing ring A 27x32 13 screw plug M 42x1,5-5.8 14 sealing ring A 42x49 15 screw plug G 1 A-5.8 16 sealing ring A 33x39

18 o-Ring 100x3 20 adapter G 3/4-DN 12 21 coupling clamp DN 12 22 ring bolt M 12-C 15 23 fitting R 3/4’’-DN 12 24 plug DN 12 25 hose line 12x800 ST/ST 30 loctite no. 270 E cooling water inlet DN 12 A cooling water outlet DN 12

J drain gear oil, J remove water supply and connection lines, J loosen fastening bolts and pull defective heat exchanger out of

the housing, J remove cover (4) before installing the new heat exchanger (in

order to make the assembly easier), J install new heat exchanger, tighten with bolts and reconnect

connection and water supply lines. Pay attention to the flow direction! The pressure relief valve must always be mounted into the heat exchanger “cooling water inlet”,

5.6

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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Replacement of defective components J the heat exchanger “cooling water inlet” must be mounted so

that the pressure relief valve (6) is always at the top and protected against external damage, J fill up gear oil.

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Perform pressure test at approx. 30 bar (observe pressure gauge reading and pressure relief valve (6)).

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5.7

Troubleshooting Troubleshooting Troubleshooting gearbox If the gearbox temperature is too high, you should ... ... check the oil cooling.

Check cooling water supply; required cooling water volume: approx. 10 - 15 litres per minute.

Important!

The cooling water temperature on entering the system must not be warmer than 25 °C. ... allow enough heat to dissipate Fine coal on the gearbox housing acts like an insulating layer preventing the dissipation of heat.

Remove fine coal, also from the side walls and bottom side. ... check the oil level

... check for possible overloads Constantly overloading the gearbox results in high gearbox temperatures. Measure the loads using an ampmeter.

If the gearbox leaks oil, you should ... ... check for leaking connection surfaces and covers Retighten the housing bolts, cover bolts and oil drain plugs.

Important!

Clean the gearbox thoroughly of any previously leaked oil. So you can better see, if oil is leaking out or the connection is leakproof. ... check for oil leaks at the breather plug Check the installation position of the breather filter!

The breather filter must always be fitted on top. ... check the oil level See chapter 6 “ Oil level and oil quantities” ... check the breather plug Remove the breather plug with the gearbox at operating temperature. If air escapes when removing the plug, the plug is defective.

A wet breather filter clogs due to adhering dust.

Notice!

If in doubt, always install a new breather filter. Do not try to clean the breather filter.

5.8

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

An excessive oil level results in heat-generating splash losses and to foaming of the gear oil. Foam prevents the dissipation of heat.

E

An insufficient oil level endangers the lubrication of the roller bearings and gear wheels and can contribute to an excessive build-up of heat (see chapter 6 “ Oil level and oil quantities”).

6

Technical data

Technical data sheet

Technical data This chapter contains the most important technical data of the gearbox. Further data can be found in the spare parts lists.

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

Technical data sheet permissible rated input power 1) max. at n1 = 1500 rpm . . . . . . . . . . . . . . . . . . . . permissible rated input power 1) max. at n1 = 1800 rpm . . . . . . . . . . . . . . . . . . . . max. permissible continuous torque at the output shaft till i = 45 . . . . . . . . . . . . . . . . . . . . . max. permissible continuous torque at the output shaft at i = 50 . . . . . . . . . . . . . . . . . . . . . . max. permissible torque at the output shaft . . max. permissible drive speed . . . . . . . . . . . . . .

PAN

= 500 kW

PAN

= 600 kW

T1

= 110.000 Nm

= 130.000 Nm T1 T2 max = 300.000 Nm n1 max = 1.800 rpm = 16/21/24,4/28/ 33/39/45/50

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ratios of reduction . . . . . . . . . . . . . . . . . . . . . . . . Iges

length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . width . . . . . . . . . . . . . . . . . 1946 003 000 00 xx 1946 004 000 00 xx height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L = 1185 mm B = 820 mm B = 1260 mm H = 820 mm shaft diameter 100 mm with parallel key output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . internal toothing 220x10x30x20 DIN 5480 weight (without oil filling) 2120 kg 1946 003 000 00 xx . . . . . . . . . . . . . . . . . . . . . .

M = 1946 004 000 00 xx . . . . . . . . . . . . . . . . . . . . . .

2160 kg volume of gearbox casing . . . . . . . . . . . . . . . . . Q = 150 l lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oil splash lubrication oil temperature at rated power . . . . . . . . . . . . . t = 60 - 65 _C life of the bearings (continuous operation at Q = 13500 h 2) rated power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug-type heat exchangers, can be fitted from the outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection for water, inlet and outlet . . . . . . . required cooling water quantity . . . . . . . . . . . . . pressure relief valve set at . . . . . . . . . . . . . . . . recommended cooling water pressure . . . . . . max. cooling water inlet temperature . . . . . . . . max. dirt particle size in cooling water . . . . . . . required pH value of the cooling water . . . . . .

1) 2)

Doc. no.: 1946 003 000 BA 00

2x Q Pü Pümax tmax max PH

~ = = = = ~

602 mm long DN 12 10 -15 l/min 30 bar 25 bar 25 _C 0,25 mm 7

applies to ratios of reduction i = 16; 21; 24,4; 28 und 33 corresponds to 90% of the calculated nominal bearing life

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6.3

Main dimensions Main dimensions Fig. 20: Connection dimensions - 1946 003 000 00 xx

1) 40 deep 2) 80 deep Internal toothing DIN 5480 N 220x10x30x20

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:

6.4

Gearbox P-25/30

Main dimensions Fig. 21: Connection dimensions - 1946 004 000 00 xx

1) 40 deep

Bucyrus DBT Europe GmbH, Lünen 2008

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:

Doc. no.: 1946 003 000 BA 00

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Internal toothing DIN 5480 N 220x10x30x20

6.5

Main dimensions Fig. 22: Attachment parts a) *)

E **)

A **) 20, 30

Bucyrus DBT Europe GmbH, Lünen 2008

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22, 30 *)

23, 30 *)

2 heat exchanger . 20 oil drain plug 21 magnetic rod 22 breather plug *) 23 oil dipstick 685 lg. *) 30 sealing ring A 30x36 35 plate - oil level

41 plate - reduction ratio 54 lifting eye TAWGK 5 a) pressure relief valve *) A cooling water outlet DN 12 **) E cooling water inlet DN 12 **) XX marking

*) must be mounted at the top **) can be mounted optionally on the right or on the left

6.6

Gearbox P-25/30

Technical Description Technical Description design

The two-speed planetary gearbox P-25/30 is designed for use underground. It can be fitted to drive frames and plow drives with separate shaft bearing assembly.

The P-25/30 dimensions and transmission accuracies correspond to those of gearbox size 25 acc. to RAG N 330 000. The gearbox is designed for higher continuous duties and higher peak torques, though (corresponding to size 30).

The following ratios of reduction are available: Iges 16/21/24.4/28/33/39/45 and 50:1 The gearbox 1946 004 000 00 xx can be used as R.H. and L.H. design by merely relocating oil dipstick, breather plug, and magnetic rod.

Torque support with respect to the drive frame or plow frame is via centring pins (gearbox 1946 003 000 00 xx) or a parallel key (gearbox 1946 004 000 00 xx).

Bucyrus DBT Europe GmbH, Lünen 2008

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The output stage has maintenance-free face seals installed. When the internal toothing N 220x10x30x20 DIN 5480 is worn, the planet carrier at the output can be reworked and overhauled by installing a replaceable coupling sleeve system. ratings and torques

The permissible continuous rating depends on the ratio of reduction and is 500 kW at an input speed of 1480 rpm (50 Hz motor) and 600 kW at an input speed of 1780 rpm (60 Hz motor).

The max. permissible output torque of short duration is 300,000 Nm.

lubrication

Gears, rolling contact bearings and seals are oil splash lubricated.

The compact construction of the gearbox allows inclinations in working and conveying direction. Specified oil levels must be maintained for certain inclinations.

The gearbox is supplied without oil filling.

cooling system

The gearbox is equipped with amply dimensioned oil coolers.

The oil coolers are protected against overload by a pressure relief valve set at 30 bar. The cooling water quantity required is about 10 - 15 l/min.

The cooling water must be filtered before entering the cooler (max. dirt particle size 0.25 mm).

The max. permissible cooling water inlet temperature is 25 °C. The connections at the inlet and outlet sides of the cooler are of size DN 12.

The oil coolers are pushed into the gearbox from the outside and fastened (plug-type). They can be replaced underground.

Doc. no.: 1946 003 000 BA 00

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6.7

Permissible power and torque Permissible power and torque Input speed 1480 min-1, 50 Hz

E Bucyrus DBT Europe GmbH, Lünen 2008

permissible rated input torque T1 [Nm]

permissible rated input power at n1 = 1480 min-1 P [kW]

Fig. 23: Permissible rated input power and rated input torque Input speed 1480 min-1, 50 Hz

ratio of reduction permissible rated output torque: 110000 Nm till i = 45 resp. 130000 Nm at i = 50 water cooled only!

Tab. 1: Performance data - Input speed 1480 min-1, 50 Hz ratio of reduction

permissible rated input power

permissible input torque

output speed

i Nenn

P [KW]

T1 [Nm]

n2 [min-1]

16

92,2

21 24,4

6.8

70,6 500

3220

61,0

28

52,6

33

44,3

39

435

2800

37,6

45

370

2400

33,0

50

400

2600

29,7

Gearbox P-25/30

Permissible power and torque Input speed 1780 min-1, 60 Hz

Bucyrus DBT Europe GmbH, Lünen 2008

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permissible rated input torque T1 [Nm]

permissible rated input power at n1 = 1780 min-1 P [kW]

Fig. 24: Permissible rated input power and rated input torque Input speed 1780 min-1, 60 Hz

ratio of reduction permissible rated output torque: 110000 Nm till i = 45 resp. 130000 Nm at i = 50 water cooled only!

Tab. 2: Performance data - Input speed 1780 min-1, 60 Hz ratio of reduction i Nenn

permissible rated input power P [KW]

P [HP]

permissible input torque T1 [Nm]

T1 [ft.lbs]

16

Doc. no.: 1946 003 000 BA 00

n2 [min-1] 110,9

21 24,4

output speed

85,0 600

800

3220

2360

73,3

28

63,2

33

53,3

39

525

700

2800

2065

45,2

45

450

600

2400

1770

39,6

50

480

650

2600

1900

35,7

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6.9

Accessories

Accessories Mounting and pulling-off device for Voith-Turbo coupling Fig. 25: Mounting and pulling-off device

Bucyrus DBT Europe GmbH, Lünen 2008

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1 mounting and pulling-off device order no.. 9951 090 400 00 00

6.10

Gearbox P-25/30

Oil levels and oil quantities Oil levels and oil quantities The oil level to be maintained depends on the inclination of the gearbox. The oil level marking applicable to the respective inclination is shown on a plate attached to the gearbox or can be taken from the table ”oil levels marks”.

Oil dipstick Fig. 26: Oil dipstick Reference edge 100

The oil dipstick is provided with graduated markings spaced 1 centimeter apart, starting at reference edge 100 (sealing surface of the oil dipstick). Every second marking has a number, from 100 down to 0 (see fig. 26).

Insert the oil dipstick vertically into the dipstick bore and bolt tight.

The minimum oil level must not be more than one graduation mark below the required oil level marking (Position of the oil dipstick, see ”Technical data, main dimensions”).

Oil level marks

1cm

Fig. 27: Oil level marks P-25/30 (values in cm) inclined in conveying direction

Bucyrus DBT Europe GmbH, Lünen 2008

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view of the drive shaft

inclined in working direction

output shaft raised

output shaft lowered

oil dipstick lowered

oil dipstick raised

Important!

The values apply with the dipstick screwed in!

Permissible deviation ±1 graduation mark.

Example: If the gearbox is inclined in conveying direction by 20o (oil dipstick high) and in working direction by 10o (output shaft lowered), the dipstick must show an oil level reading of ”57”.

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6.11

Oil levels and oil quantities Oil quantities Fig. 28: Oil quantities P-25/30 (values in liters) inclined in conveying direction

view of the drive shaft

inclined in working direction

output shaft raised

output shaft lowered

oil dipstick lowered

Important!

The oil quantities are approximate only. The oil level values, however, must be observed.

6.12

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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oil dipstick raised

Tightening torques Tightening torques Screws with ISO metric thread Tab. 3: Recommended tightening torques at µges. = 0.14 Thread 1) (mm)

(mm)

E

MA (Nm) 8.8

10.9

12.9

1,25

23

32,5

39

M 10

1,5

46

65

78

M 12

1,75

80

113

135

(M 14)

2

127

178

215

M 16

2

195

275

330

(M 18)

2,5

270

380

455

M 20

2,5

380

535

640

(M 22)

2,5

510

720

865

M 24

3

655

920

1100

-

1100

-

d

coarse thread

M8

M 24

Bucyrus DBT Europe GmbH, Lünen 2008

Tightening torque 4)

Pitch P

fine thread

2

DM 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(M 27)

2

(DM 27 2))

3

580

-

-

M 30

3,5

1310

1845

2215

-

1450

-

M 30 3)

2

(M 33)

3,5

1780

2500

3000

M 36

4

2290

3220

3860

(M 39)

4

2970

4170

5000

M 42

4,5

3670

5160

6190

(M 45)

4,5

4590

6450

7740

M 48

5

5540

7790

9350

Important!

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

1) dimensions in brackets in exceptional cases only 2) according to works standard (EWN 6110), February 1985 edition 3) only for expansion screws having a reduced shaft cross-section of 24.2 mm 4) the tightening torques comply with EWN 6003 works standard.

Doc. no.: 1946 003 000 BA 00

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6.13

Permissible media Permissible media Recommended oils for Bucyrus-gearboxes Only use the gear oils recommended or such products that have proved to be equivalent. gear oils on mineral oil base

If gear oils of other companies are used, gear oils on mineral oil base with appropriate additives may be used.

gear oils on synthetic base

Should synthetic oils other than those listed in the right column be used no warranty can be accepted as to the durability of the interior gearbox coating.

Only synthetic oils with EP characteristic are allowed to be used. In the FZG special test A/16.6/140 there must be no increased wear on the gears in any of the 12 load ranges.

change to other oil types

When changing from one oil to another we recommend to first clean the gearbox or to have the compatibility of the different oils confirmed by the respective suppliers.

re table of gear oils

The sequenc in which the oil types are listed gives no indication as to the quality of the oil. We recommend not to mix different oil types or products from different companies.

ARAL

BP

ESSO

KLÜBER

MOBIL

SHELL

TEXACO

WINTERSHALL

6.14

Gear oils on mineral oil base

Kinematic viscosity mm2/s (cSt)

Flash point

at 40_C

_C

Aral Degol BG 220

220

265

Aral Degol TU 220

220

255

BP Energol GR-XP 220

218

240

BP Energol GR-XP 320

315

245

SPARTAN EP 220

210

236

SPARTAN EP 320

300

237

Klüberoil GEM 1-220

220

>200

Klüberoil GEM 1-320

320

>200

Mobilgear 630

206

>232

Mobilgear 632

302

>232

Shell Omala 220

220

240

Shell Omala 320

320

245

Universal gear lubrican EP SAE 85 W/90

195

225

Meropa 220

220

245

Ersolan 220 Ersolan 320

220 320

240 245

Gear oils on synthetic base

Kinematic viscosity mm2/s (cSt)

Flash point

at 40_C

_C

Aral Degol GS 220

230

215

BP Energol SG-XP 220

240

250

Klübersynth GH 6-220

220

>300

MOBIL SHC 632

300

250

Shell Tivela Öl WB

234

320

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

Manufacturer

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Tab. 4: Recommened oil types for Bucyrus-gearboxes

Permissible media Requirements for gear oils for Bucyrus-gearboxes The correct choice of transmission oils and close monitoring of the lubrication are major prerequisites for trouble-free operation and contribute to a longer service life of the gearbox.

Load-bearing capacity During the mechanical test of transmission oils in accordance with DIN 51354, there must be no increase in wear on the gears in any of the 12 load ranges, either in the FZG standard test A/8, 3/90 or in the FZG special test A/16.6/120, i.e. the load range causing damage must be higher than 12.

Furthermore, the ”specific change in weight” of the test gears ms (specific wear) must not exceed 0.27 mg/kWh. Ageing resistance The transmission oils must exhibit an excellent ”thermostability” and ”ageing resistance” at the prescribed oil change intervals, i.e. after 2000 operating hours.

Fig. 29: Curve of the neutralisation number

Bucyrus DBT Europe GmbH, Lünen 2008

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Oil change

NZ

∆NZ

Used oil Point of inflection

Fresh oil

1000 NZ = Neutralisations number

2000

Hours of operation

During normal operation, the curve of the neutralisation number (NZ number) of mineral oils must on no account reach the point of inflection after 2000 hours of operation and at the permanent temperatures stated (see figure).

Kinematic viscosity The transmission oils should lie within the viscosity range 210 to 320 mm2/s at 40 _C with a high viscosity index.

Additives J against wear (EP grade), J against corrosion, J against foaming.

Suitability J Compatibility with commercially available sealing elements.

Doc. no.: 1946 003 000 BA 00

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6.15

Permissible media Lubricating greases and pastes Important!

The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

Lubricating greases general properties

lubricating greases A1

base:

lithium soap

NLGI class:

2

worked penetration:

265 to 295 (0.1 mm)

behavior in the presence of water:

practically non-soluble in water

temperature of application:

-20 to +120 °C

flash point:

≧ 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN *) 7068 Tab. 5: Lubricating greases for general application Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

lubricating greases A2

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 6: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Flash point in °C

Important!

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

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

*) EWN = standard

6.16

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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Flash point in °C

Permissible media Lubricating pastes lubricating pastes B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Tab. 7: Lubricating pastes free from molybdenum disulfide Supplier

Type

gleitmolybdän

gleitmo 805 *)

Base Li

NLGI class

Flash point °C

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the Bucyrus works standard EWN 7068 is: gleitmolybdän ”gleitmo 805” lubricating pastes B6

Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water:non-soluble in water Temperature of application:

-34 to +120° C

Bucyrus DBT Europe GmbH, Lünen 2008

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When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the works standard EWN 7068 is : Chesterton separating agent & lubricant 785 (flash point 132 °C) Important!

The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

Cooling water quality The cooling water must be chemically neutral and not aggressive to avoid damage to the heat exchangers. The pH value should lie in the range of 7.

The maximum size for dirt particles in the cooling water is 0.25 mm.

Install filters upstream as required.

The temperature of the cooling water on entry must not exceed 25 ºC. Higher entry temperatures for the cooling water reduce the effect of the heat exchanger.

*) The products listed in table 5 are suitable lubricating greases for filling of adjacent cavities.

Doc. no.: 1946 003 000 BA 00

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6.17

Marking of the gearbox Marking of the gearbox Manufacturer: . . . . . . . . . . . . . . . Bucyrus DBT Europe GmbH Type: . . . . . . . . . . . . . . . . . . . . . . . P-25/30 Year of construction: . . . . . . . . . mm/yy (e. g. 03/05 ≙ March 2005) Ident. No.: . . . . . . . . . . . . . . . . . . 1946 003 000 00 xx or . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1946 004 000 00 xx *) Weight: . . . . . . . . . . . . . . . . . . . . . 2 120 kg or 2 160 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . (without oil filling) The gearbox is marked as follows.

Fig. 30: Markings on the gearbox Gearbox data

1 type 2 ident. no.

3 item no. / year

E

5

P-25/30 1946 003 000 00 xx Nr xxx / xx I = xx G = 2120 KG 4 transmission ratio 5 weight

CE-marking

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

*) X = wild card for variant identification number

6.18

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

1 2 3 4

7

For your information

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.bucyrus.com).

Service addresses Europe Germany

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

Great Britain

Bucyrus UK Ltd.

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Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: info@gb.bucyrus.com Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

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

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

Russia

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

Bucyrus DBT Europe GmbH Office Moskau Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com

Doc. no.: 1946 003 000 BA 00

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7.3

Our service OOO Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

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

America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 +1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889 Bucyrus DBT Europe GmbH, Lünen 2008

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Tel: Fax:

Australia Australia

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

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

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

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

Africa South Africa

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

7.4

Gearbox P-25/30

Our service Asia China

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

Bucyrus DBT Europe GmbH, Lünen 2008

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

Doc. no.: 1946 003 000 BA 00

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7.5

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 8: Referenced national standards and guidelines, extract

Designation

Title

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

Quality of drinking water Documentation System Plug Connectors for Hydraulics Fire-resistant hydraulic fluids Maintenance- and Inspections list for Hydraulic Systems Hydraulic Systems - DesignPrinciples Determination of the acid number Determination of sulphate ash Tensioning force, tightening torques and surface pressure for bolts T-head-bolts Lubricating greases and solid lubricants Non metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

EWN 6003 1)

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

Referenced european standards and guidelines Tab. 9: Referenced european standards and guidelines, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council Directive 98/37/EWG on the approximation of the laws of the member states relating to machinery Directive of the European Parliament and the Council on the approximation of the laws of the member states Directive 94/9/EG concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of Machinery DIN EN ISO 12100-2 Safety of Machinery Nonelectrical equipment for potentially explosive atmosDIN EN 13463-1 pheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface Preparation of instructions DIN EN 62079 - Structuring, content and presentation Petroleum product and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Underground mining machines - Equipment and compoDIN EN 1710 nents intended for use in potentiallyexplosive atmospheres in mines Mobile extraction machines on the face - Safety requireDIN EN 1552 ments for shearer loaders and plough systems -

1998-06-22

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

1) EWN = standard

7.6

Gearbox P-25/30

Bucyrus DBT Europe GmbH, Lünen 2008

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

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