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Wereservetherighttointroducemodificationsasaresultoftechnical developmentswithoutpreviousnotice.
CaterpillarGlobalMiningEuropeGmbH,Lünen2012E ACaterpillarInc.Company
Aboutthismanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthecharactersandsymbolsused.
Beforestartingwork
Ifyouuseanoperatingmanualwhichhasnotbeenwrittenforyour typeofchaintensioningdevice,youwillendangeryourselfandothers.
Ensurethatthedataonthehydraulicchaintensioningdevicecorrespondtothoseintheoperatingmanual.
Thisoperatingmanualrefersto: Hydraulicchaintensioningdevice
SerialNo.:19550010000000
Theoperatingmanualistobeusedonlyforchaintensioning devicesofthistype!
AccordingtotheEuropeanDirective94/9/ECthechaintensioning devicebelongstoequipmentgroupI,categoryM2.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththechaintensioningdevice.
Anoperatingmanualforthechaintensioningdeviceshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewmanualimmediately,ifthepresentmanualisno longercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforallpersonsworkingwithoron thechaintensioningdevice. Allpersonsworkingontheface,intheintersectionbetweenface andentry,orintheentrymusthavereadthisoperatingmanual.
Thisincludespersonswho: areinchargeoftransport, preparetheriseheading, performassembly/disassemblywork, operatetheconveyor, eliminatefaults, carryoutdailyroutineworkonthefaceorintheentry, performmaintenancework, carryoutrepairs.
Supervisorypersonnelwho: initiateand/or supervise theactivitiesaboveindicated.
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtothechaintensioningdevice.
Readthisoperatingmanualcompletelyandatease.Payspecial attentiontotherespectivesafetyinstructions.Trytomemorizethe appearanceandmeaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservice department.Ourserviceaddressisgiveninthechapter7titled”For yourinformation”.
Readthechapter2”Foryoursafety”withspecialattention.This chaptercontainsimportantinformationindicatingpossiblehazards.
Observetheinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
Danger!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
Warning!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesare:veryseriousinjuryorevendeath.
Caution!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesand machinedamage.
Notice!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare: damagetothedeviceordamageintheimmediatevicinity.
Important!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.
Itemsinlistsaremarkedwithbullets.
–Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
. Pointsinthetextmarkedinthiswaydescribeindividualwork steps.Followtheseinstructionsstep-by-step. Theywillhelpyoucarryoutyourworkfasterand,moreimportantly,safer.
Yoursafety
Thischaptercontainsimportantinformationforyoursafety.Pay specialattentiontothischapter.Thesafetyinstructionsandrulesof procedurewillhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thetensioningdevicehasbeenmanufacturedinaccordancewith thestateoftheartandgenerallyrecognizedsafetystandardsand regulations.
Youandotherscanneverthelessbeexposedtodangeroussituationse.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthechaintensioningdevice.Allmodificationsandchanges mustbeapprovedbyCaterpillar.
OnlyuseoriginalCaterpillarspareparts.Pleasenotethattheguaranteewillexpireifyouinstallpartsfromothermanufacturers.
TheEuropeanDirectives/Standardsreferredtointhisoperating manualhavetobeobservedwhenusingthechaintensioning deviceinamemberstateoftheEuropeanUnion(EU).ForuseoutsideoftheEUthedirectivesandstandardsapplicableinthe respectivecountriesmustbeobserved.
Inadditiontothisoperatingmanualbesuretoalsoobservethe respectivelegalprovisionsandregulationsforaccidentprevention inyourcountry.
Observethesafetyandaccidentpreventionregulationsof: themine,
theMinesInspectorate,and theminers'accidentinsuranceassociation.
Pleasereadalsotheoperatingmanualsoftheothercomponents requiredforoperation,e.g.ofthegearboxes,electricmotors,conveyor etc.,carefullyandthoroughly.Clarifyanyquestions before starting work.
Personnel
Operation
Thehydraulicchaintensioningdevicemayonlybeoperatedbyqualifiedpersonnel.
Readingoftheoperatingmanual,especiallythechapteronsafety, shallconstituteapartofthistraining.
Youmusthavesufficientknowledgeofthe mechanics, hydraulicsand controlsystems andbeabletoprovethisknowledge.
Installationandrepair
Ingeneral,installationandrepairworkshallbeperformedonlyby personswhohavebeenadequatelytrainedforthespecialrequirements.
Installationandrepairworkon: thesafetycomponents(pressurereliefvalves,etc.), theelectricalequipment(controlunits,etc.), thehydraulicsystems
shallonlybecarriedoutbyCaterpillarserviceengineersorbyspeciallytrainedpersonneloftheminingcompany.
Organization
Coordinatetheworkonconveyorandplowinstallationswiththe workonthechainoftheconveyorandonthechainoftheplow.
Operatingconditions
Intendeduse
Thehydraulicchaintensioningdevicehasbeenexclusivelydesiged andmanufacturedforslowlymovingaconveyororplowdrive. Inconnectionwithasuitablechainlockingdeviceitisusedfortensioningaconveyororplowchainorforcouplingtheendsofan openconveyororplowchain.
Intendedusesinclude: couplingtheendsofanopenconveyororplowchain, tensioningconveyororplowchains, holdingatensionedconveyororplowchain.
Employthehydraulicchaintensioningdeviceonlyforitsintended use.
Unauthorizeduse
Applicationsnotexpresslylistedasintendeduseareunauthorized usesandare not allowedtobeperformedbymeansofthe hydraulicchaintensioningdevice.
Caterpillaracceptsnoliabilityforanydamageresultingfromany suchunauthorizeduse.
Surroundingareaconditions
Suitablemeasuresmustbetakenbytheoperatortocombatthe explosionhazardsduetofiredamportheignitionofdustwhich mightoccurinamine(seeDINEN1710).
Theseinclude:
adequateandconsistentventilation, plowtracksprayingsystem/watersprayingsystem.
Iftheminegasconcentrationinthefreecrosssectionoftheconsistentlyventilatedareasofthefaceexceedsacertainpercentage ofthelowerexplosionlimit(LEL)asdefinedintherespective nationallawstheM2equipmenthastobede-energized.
Itmayonlyberestartedbyanauthorizedperson.
Theatmosphereintheminehastobemonitoredinthehazardous locationstopermitdisconnectingthepowersupplyofallpiecesof equipmentexceptofthosewhicharerelevantforthesafetyand suitableforuseinexplosiveatmospheres.
TheM2equipmenthastobestoppedatonceandsecuredtopreventarestartiffiredampprotectionfacilitiesarefoundtobedamaged.
Operatingconditions
Prerequisitesforoperation
Puttingthechaintensioningdeviceintoserviceisprohibiteduntil themachineintowhichthischaintensioningdeviceisinstalledhas beenfoundtocomplywiththeEuropeanDirective94/9/ECandthe StandardDINEN1710.
Astheequipmentsuppliedisonlypartofanoverall systemthe operatorisresponsibleformeetingthenecessarysafetyrequirementsorinstallingtherequiredsafety systemsforthedevices/componentsnotincludedinthescopeofsupplyofthisequipmentand/ orotherdevices/componentsrequiredforoperation.Theseshallbe markedaccordingtothelegalprovisionsapplicableatthetimethey areplacedonthemarket.
TheM2equipment/chaintensioningdeviceisonlyallowedtobe operatedwhenthesafetyrequirementsaccordingtoDINEN1552 havebeenmet.Theseinclude: facilitiespreventingunauthorizedstarting, pre-startwarningsystems, watersprayingsystems, safelock-outcommandsystems, emergencystop systems, dustextractionsystems, noiseprotection, warningstatementsetc.
Allelectricalequipmentrequiredtooperatethechaintensioning deviceshallbemarkedaccordingtothelegalprovisionsapplicable atthetimewhenitisplacedonthemarket.
Safetyinstructions
Generalrules
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveclothingandequipment.This alsoincludesearprotectorsasthenoiseemittedbytheconveyor mayexceed85dB(A)attimes(e.g.whentheconveyorisemptied).
Informyourcolleaguesof yourexactlocation, theworkyouareperforming, thetimewhichyouwillprobablyrequire.
Isolateandlockoutallelectricmotorsoftheconveyororplowsystemtopreventthemrestartingbeforestartingthechaintensioning device.
Onlystartthechaintensioningdevicewhenitisinatechnically soundcondition.
Keepthesignallingandlightingsystemsinaproperfunctionalcondition.
Observethewarningsignsontheconveyor.
Cordonoffyourworkingareawithsufficientroomtobeabletowork safely.
Neverstandorreachbetweenanypartswhichcouldstarttomove, e.g.: conveyorchains, conveyorflights, spillplates, chainsprockets, lockingdevices.
Besuretoobservetheintervalsspecifiedformaintenanceand checksofthechaintensioningdevicesincehotsurfacesmight causeanignitionofexplosiveatmospheres(air)anddust.
Safetyinstructions
Storageandtransport
Maintaintheprescribedstorageperiodsandobservetheinstructionsforstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteand theanticipateddurationoftransport.
Ensurethatthetransportlocksarecorrectlyfitted.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Attachliftingequipmentonlytotheliftingpointsprovided.
Useonlyliftingequipmentwhichisingoodconditionanddesigned fortheloadstobehandled.
Assemblyandcommissioning
Oninclinedfaces,secureallindividualpartsusingchains,e.g.tothe shields.
Whenworkingwithoils,greasesandotherchemicalsubstances, observethesafetyregulationsapplicabletotheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil, greaseorotherchemicalsubstancesinanenvironmentallysafe manner.
Operation
Operatethecontrolsystemonlyifyouhaveaprof oundknowledge ofthecontrolelementsandtheirfunctions.Itisnecessarythatyou havebeentasktrainedontherespectivecontrol system.
Checkthatallprotectivedevicesareinstalledontheconveyorand functionproperly.
Ensurethattherearenopersonsintheconveyorbeforeyoustart tensioningorreleasingthechain.
Ensurethattheoperatingsymbolsarelegibleinordertoavoidany operatorerrorsandresultingaccidents.
Maintenanceandrepair
Besuretoobservetheprescribedmaintenanceandinspection intervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenanceandrepairoperations.Givetheminformationontheintended operationsandtheanticipatedduration.
Cordonoffyourworkingareawithsufficientspacesothatotherpersonsarenotendangered.
Securetheconveyortopreventanyunauthorizedoraccidental switchingon.
Youmayonlyworkintheminingareawhenyouhave supportedtherooftopreventfallingrock, supportedthecoalfacetopreventcollapsing, switchedofftheminingmachineandconveyorandsecured themtopreventrestarting.
Removedefectivepartsfromthefaceareaimmediatelyinordernot tohinderthefacecrew.Thisalsoavoidstheriskoftheseparts beinginadvertentlyinstalledagainelsewhere. Sendthesepartsforrepairimmediately.
Oninclinedfaces,securesparepartse.g.withchainsorhoists.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements.ThisisonlyensuredwithoriginalCaterpillarspareparts. Pleaserefertothesparepartslistsfortheordernumbers. Reinstallanyprotectivedevicesremovedimmediatelyafterfinishing theworkandcheckthattheyfunctioncorrectly.
Hydraulics
Avoiddirectcontactbetweentheskinandhydraulicfluids. Hydraulicfluidcanpenetratetheskinandcauseseriousinfections. Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids representaveryseriousdangertohealth.
Whenremovingprotectiveequipmentwhichincludeshydraulic componentskeepinmindthatthesecomponentsmaybepressurized.Youcouldbeseverelyinjuredbyhydraulicfluidjettingoutin anuncontrolledmanner.Thereforeitisimperativethatyoudepressurizethehydrauliccomponentsbeforeremovingtheprotective equipment.
Onlypersonswhohaveandcandemonstrateaspecialknowledge ofhydraulicsareallowedtoworkonthehydraulicsystem. Makesurethatpressurereliefvalvesarealwaysprovidedwith protectioncaps.Replacedefectivecapswithoutdelay.
Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Inparticularcheckthat: thehosesarenotpinchedortrapped, thehoseshavenobubblesorblisters, thehosesortheoutersheathesofthehosesarenotabnormallyrigidorhard, theoutersheathofthehoseisnotdamaged, theconnectorsaresecurelyinsertedintothesockets, theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamageinthewhole system!Flushoutthehydrauliclinesthoroughlybeforeconnecting. Ifhydraulichosecouplersaredifficulttodisconnectorcannotbe disconnected,thehydrauliclinemaystillbepressurised.Besureto depressurisethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththe propercouplingclamps.Alwaysfastentheclampscompletely. Neverusenails,wireorsimilarmaterialsforsecuring.
Safetyinstructions
permissablehoses
layinghydraulichoses
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressuringthesystem again.
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorworn O-rings.
Replacehydraulichosesonlywithhosesofthesameorahigher quality.
Observethedateofmanufacturestampedonthefittingsofthe hydraulichoses.Neverusehydraulichoseswhicharemorethan2 yearsold,eveniftheyhavenovisiblesignsofdamage.
Fig.1:Example:Hydraulichose,designation
Nevertrytoholdapulsinghydraulichose.Depressurisethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
Laythehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwayslayhydraulichosessothatthey: alwayshavealittleslack,
Fig.2:Layinghydraulichoses,slack
arenottwisted,
Fig.3:Layinghydraulichoses,twisting RIGHT WRONG
arenotbentdirectlybehindtheconnections (distancemin.1.5xnominaldiameter),
Fig.4:Layinghydraulichoses,bending RIGHT WRONG
cannotchafe,
Fig.5:Layinghydraulichoses,crossing RIGHT WRONG
arenotkinked, donothavetowithstandtensilestrains, areprotectedagainstthermalradiation, areaccessibleatalltimes.
Pushhydraulichosesintothesocketsonlybyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagetheconnections.
Safetyinstructions
Wheninstallingthehydraulichoses,ensurethattheycannotbe: tornout, kinked, crushed, drivenoveror twisted(Fig.:6)bythemovementoftheequipment.
Fig.6:Layinghydraulichoses,connectionsonmovingparts RIGHT WRONG
Besuretoobservethemanufacturer'sinstructionsforuse. FurtherinformationiscontainedinDIN24320.
3
Storageandtransport
Storageandtransport
Thischaptercontainsimportantinformationonthecorrectstorage andtransport.
Observanceoftheinstructionsandtipswillincreasetheservicelife andavailabilityofthehydraulicchaintensioningdevice.Youwill alsobeabletocarryoutthetransportworkquickerandmore safely.
Carefulattentiontothepointsinthischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage
Storingtheequipment
Componentscoatedwithtemporarycorrosioninhibitorareprotectedforapproximatelysixmonths.
Priortodeliverythehydraulicallyoperatedequipmentwillbeoperatedusingatestmediumwhichhastobedrainedcompletely beforeshipment.Theremainingfilmwillprotecttheinteriorparts againstcorrosionalsoforatleastsixmonths.
Protecttheequipmentagainstdirectexposuretosunlight.
Storetheelectricalequipment,electroniccomponents,spareparts ofrubberorplastic-suchassealsandhoses-andhydraulicfluids onlyinclosedroomsattemperaturesof15 Cto25 C.
Protectallpartsoftheequipmentstoredoutdoorsagainstmoisture anddirt,e.g.usingtarpaulins.
Applycorrosionprotectiontotheconnectingsurfacesofthecomponentsandclosewithblindplates.
Protectthehydraulicplugconnectorsandtheconnectorsofthe electricalcableswiththerespectivecapsandplugsprovided.
Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors,butattemperatures above freezing,electricalcomponents neednotberemoved.Suchcomponentsmustbeparticularlyprotectedagainstexcessivetemperatures,dirtandmoisture.
Duringlong-termstorage(morethan4weeks),theequipmentmust notbestoredoutdoors.Itmustbestoredinadry,wellventilated room.
Iftheequipmentistobestoredformorethan6months,the hydrauliccomponentsmustbecompletelyfilledwithapreserving fluid.Thisfluidmusthavecorrosion-protectionpropertiesand shouldbefrost-proof,e.g.CV50.
Afterastorageperiodofapprox.twoyears,aninspectionmustbe performedtodeterminewhetherthemeasurestakenandthe methodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyCaterpillar.
Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Donotusethesecomponentswhentheyhavebeenstored formorethantwoyears.
Informationonthestorageofconcentratesfortheproductionof pressurefluidsisgiveninthesection”Pressurefluidsofgroup HFA”inthismanual.
Transport
Important!
Takecaretoensurethatnewsuppliesarestoredseparately fromexistingstockandthatremovaltakesplaceonthe”first in,firstout”principle.
Transport Loadunits
Observethetransportsheetsforthevarioustransportunits. Theycontaininformationon: dimensions, weight, liftingpoints, centreofgravity,etc.
Wheretechnicallypossible,theloadunitshavesuitablelifting pointsfortransportandassembly.
Warning!
Useonlyloadhandlingdeviceswhichcomplywiththetechnicalandlegalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Beforetransport
Beforetransportingtheequipmentattemperaturesbelowfreezing, allhydrauliccomponentsoperatedwithHFAEorHFASemulsion havetobecompletelydrainedandthenfilledwithapreservingfluid (e.g.CV50).
Transportofequipmentattemperaturesbetween-21 Cand-40 C isonlypermissiblewhencertainmeasuresweretakentomeet theseconditionsatthedesignandmanufacturingstages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnot besubjectedtosuddenimpactloadsatsuchlowtemperaturesand areonlyloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloorconveyorsatsuchlow temperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads. Atverylowtemperaturesandonpoorroads,thetransportvehicle speedmustthereforebelimitedtomax.25kphfortrucktransport.
Electricalandelectroniccomponentsmustberemovedforoverseastransportorprolongedstorageoutdoorsunlessthesecomponentsorthecompleteequipmentisprotectedagainstharmful environmentalinfluencesbysuitablepackaging. Theelectricalcablesremainintheequipment.Theymustbecarefullyprotectedagainsttransportdamageandsoilingoftheconnections.
4 Installation
Installation
Installationofthechaintensioningdevice
Thehydraulicchaintensioningdeviceisinstalledontheoutsideof theprotectivehoodusingfourhexagonheadboltsandcentered usingtwospringdowelsleeves.Dependingontheinstallationpositionoftheprotectivehood,thetensioningdevicecanbeflangedto thehoodinvariouspositions(seefigure“Possibleattachmentpositionsofthehydraulicchaintensioningdevice).
Notice!
Intheeventofachangeinthegearratioofthemaingearbox, thehydraulicbrakemotormustbereplacedasdescribedinthe section“OrderNo.”.
Installationinstructions
Installthetensioningdevicesothattheswitchgear,lockingdevice andcontrolunitareatthetop.Dependingontheavailablespace, thehydraulicbrakemotorcanbemovedbyupto90 fromthepositionshown.Theleakageoillinemustbelaidpressure-freeand separatedfromthereturnlinesothatthemotorhousingisalways filled.
Thelineportsaremarkedwiththeletters
”P”=Pressureport,
”R”=Returnport,
”L”=Leakageoilportand
”St”=Controllineporttothebrakes.
Instructionsforremoval
Thehydraulicbrakemotorwithconnectedcontrolunitmustbe removedinsuchawaythatnoemulsioncanescapefromthecomponents,asonlyadequatewettingensuresprotectionagainstcorrosion.Ports”P”,”R”and”L”mustbeclosedwiththeblindplugs provided.
Installationofthechaintensioningdevice
Provisionsforattachment
Fig.7:Possibleattachmentpositionsof thehydraulicchaintensioningdevice
spurgear
bevelspurgear splineddisc pinion
Thepossibleattachmentpositions1,2or3ofthehydraulicchaintensioningdevice aredeterminedbytheinstallationpositionoftheprotectivehood.Differentprotective hoodsareinstalled,dependingonthecoupling.
”W”=protectivehoodforshaftcoupling
”F”=protectivehoodforfluidcoupling
Provisionsforattachmentofthehydraulicchaintensioningdevice inconjunctionwithgearboxesofnominalsizes5,10,15,20,25, 30,35,45and65.
Tab.1:Possibleattachmentpositions-gearboxeswithoverloadsystem Gearboxtype Protectivehood“W” Protectivehood“F” S-5 1and2
P-30CST/P30UEL 1,2and3
KP-30CST/KP30/35UEL 1and2
P-45CST/P-45UEL 1,2and3
KP-45CST/KP-45UEL 1and2
P-65CST/P-65UEL 1,2and3
KP-65CST/KP-65UEL 1and2
Tab.2:Possibleattachmentpositions-gearboxeswithoutoverloadsystem GearboxtypeProtectivehood“W” Protectivehood“F”
S-5 1,2and3 1and3 K-5 1and2 1 S-10 1and3 1and3 K-10 1and2 1 SF-15 1,2and3 1and3 KF-15 1and2 1
1,2and3 1and3 KF-20 1and2 1 SF-25 1,2and3 1and3 KF-25 1and2 1
P-25/30 1,2and3 1and3
KP-25/30 1and2 1
KP-15 1and2 1
Caution!
Gearboxesanddriveconnectionswhichdonotformpartofthe Caterpillarscopeofsupplymayonlybeinstalledafterconsultationwithus.
Hydrauliccircuitdiagrams
Fig.8:Linestothehydraulicchaintensioningdevice
Connectiondiagram
pressurereducingstation hydraulicchaintensioningdevice
4pressurereducingstation 30filter 40hoseDN10 54fitting 55checkvalve 59fittingwithrestrictor
60blockballvalve 61glycerine-filledpressuregauge 71screwfittingR1"-R1/2" 82adapterDN25 84T-pieceDN32 88connectorDN10
Circuitdiagram
pressurereducingstation hydraulicchaintensioningdevice
onlyincontrolvariant02
5 Operation
Operation
Generalinformation
ThehydraulicchaintensioningdeviceofCaterpillarallowsthe necessaryworkonthechainsofconveyorsorplowstobecarried outquicklyandsafely.
Thehydraulicchaintensioningdevicealsoenablesthenecessary chainpretensiontobecreated.
Danger!
Conveyororplowchains underloadcouldrupturewhentheir loadlimitisexceeded.Thiscouldresultinseriousinjuryor evendeath.
Neverloadthechainsbeyondtheirlimits.Alwaysworkfrom alongsideofthechain.Thiscanhelptoavoidyoubeingstruck bythechainintheeventofachainrupture.
Mininggearboxesofsizes5,10,15,20,25,30,35,45,and65do notneedtobemodifiedfortheinstallationofthehydraulicchain tensioningdevice.
Majorbenefits:
Precise,reliableandsafetensioningofthechains.
Safeholdingofthepretensionedchainusingthechainlocking devicesandthehydraulictensioningdeviceduringinstallation. Gentlerelievingofthechaintoagivenpretensionafterconnectionofthechainends,thusprotectingthechainsandthechain sprockets.
Recognitionofreferencevaluesforthechainpretensionusing thedisplayonthepressuregauge.
Installationandstartingaids.
Overlappingoftheshearrimboresforeasyinsertionofthe shearpins.
Gradualequalizationofthestrainintopandbottomracesofthe conveyorchainorplowchainforswitchingovertheselector valveofthehydraulicbrakemotortoconveyingdirection.
Preconditionsforproperandsafetensioning:
Useofthehydraulicchaintensioningdevicewiththehydraulic brakemotor,whichisspecifiedforthegearratioandthetypeof maingearboxinchapter6,section“OrderNo.”
Thehoselinesbetweenpressurereducingstationandcontrol unitofthehydraulicbrakemotormustbeinstalledproperly.
Theoperatingpressurenecessaryfortensioningmustbe applied,dependingontheequipmentinuse.
Theoperatingpressureselectedfortensioningmustbesetat theappropriatepressurereliefvalvefortherequiredsenseof rotation(seesection”Hydraulicbrakemotorwithcontrolunit”) byaqualifiedpersonaccordingtothedisplayonthepressure gaugeinstalledforthispurposeandthepressurereliefvalve lockedtopreventalteration.
Important!
Themax.permissibleoperatingpressurefortheindividual gearboxtypesandratios,forgearboxeswithorwithoutoverloadprotection,aregiveninsection”Tensioningforceseffectiveatthechainsprocket”.Theadjustmentmustbe donewith thechaintensionerrunning.
Theelectriccontrolunitfortheelectricmotorsofthehead-end drive(drive1)andtail-enddrive(drive2)mustbedesignedso thatallrelatedelectricmotorsoftheconveyorandplowinstallationareisolatedandpreventedfrombeingstartedbeforethe hydraulictensioningdeviceisswitchedon.
Theoverloadprotectionsystemsinthepowerflows houldbe switchedoff.
Caution!
Observethesafetyregulationsgivenbytheindividualmanufacturers.
Thehydraulicchaintensioningdeviceissuitableforthefollowingapplications:
holdingandtensioningofconveyororplowchains, shorteningorlengtheningconveyorandplow systemsatthe head-enddrive(driveI), retensioningconveyororplowchains, assemblyafterachainrupture.
Fig.9:Hydraulicchaintensioningdevice
1ON/OFFswitchin“OFF”-position 2controlunit
3selectorvalvecontrolleverin “STOP”position 4hydraulicbrakemotor 5tensioninggearbox
Chaintensioning,lengtheningorshortening
Auxiliarydevicesforholdingthechains
Chainholdingdevices(retainingclaworchainlockingdevice)are availableforholdingtheplowandconveyorchainassemblies.
Achainhold-backdeviceorretainingpawlisprovidedatthedrive topreventthechainfrommovingduringthetensioningoperation.
Notice!
Forgearboxeswithoverloadsystemspleaseobservethe instructionsoftherespectivemanufacturers.
Theload-carryingcapacityoftheauxiliarydevicesismatchedto themaximumoperatingforceoftherespectivechain(valuesupon request).
Pleaseobservetheploworconveyoroperatingmanuals.
Conveyorchainlockingdevice
Onconveyors,blocktheupperchainwiththeconveyorchainlockingdevicebyengagingthelockingdeviceinthemountingbrackets weldedtotheupperraceofthepanprofiles.Differentlocking devicesareavailableforconveyorchainswithoutboardchain strands,fortwin-centerchainassembliesorforsingle-centerchain assemblies.Themountingbracketsarelocatedontheadaptorpan oronaspecialpanatthehead-enddrive.
fortwinoutboardchainassemblyfortwin-centerchainassembly (analogousforsingle-centerchain)
Fig.10:Conveyorchainlockingdevice
Chaintensioning,lengtheningorshortening
Retainingclawforplowchain
ThechainofReisshakenhobel®,Gleithobel® andBaseplateGleithobel® plowsisfixedbymeansofaretainingclaw.Theclawis attachedtotheplowendguideinsuchawaythatitcanswivel.
Fig.11:Retainingclawforplowchain
retainingclawinrestposition
retainingclawintensioningpositionshownwithoutplowchain!
Notice!
Inordertoblocktheplowchaintheretainingclawengagesina verticalchainlinkbetweentwohorizontallinks.
Conveyorchainhold-backdevices
Fortensioningconveyorchains,thehold-backdevicemustbe installedonthedriveframeofthehead-enddrive(drive1).Ifthe driveframeisequippedwithabaffleplate,thepawlonthebaffle plateisusedtopreventtheconveyorchainrunningback.
1pawlholder
2pawl
3boltforsecuringthebrackettothedriveframe
4pawlinrestposition
5pawlintensioningposition
6baffleplate
7driveframe
Thehold-backdevicesfortwin-outboardandsinglecenterchainassembliesare designedanalogously.
Fig.12:Hold-backdevice
Ratchetpawlforplowchain
Thehold-backdevice(pawl)oftheplowchainmustbeputinplace attheplowdriveforthetensioningoperation.Dependingonthe designoftheplowframeortheplowflangeplatethepawlmustbe installedbeforehand.
Fig.13:Pawlforplowchain pawlhousing pawlintensioningposition
Chaintensioning
Danger! Alwaysworkfromalongsideofthechain,only.
Besuretoobservethefollowingsafetyinformation: Keepallpersonsnotinvolvedinthetensioningworkoutofthe dangerarea.
Isolatetheelectricmotorsontheconveyorandplowsystems. Switchonthehydraulictensioningdevicebypullingthelocking knobatthetensioninggearboxandmovingthecontrollever fromthe”OFF”tothe”ON”position.Atthesametimeelectricallyinterlocktheelectricmotorstopreventthembeingswitched onagain(seesection“Overview-maincomponents”).
Fig.14:Switchingpositions viewonX
Beforetensioningthechainitisnecessarythatyou: . emptytheconveyorordisengagetheplowfromthecoalface, . movetheadjustingchainsoftheconveyororplowchain assemblytowardsthehead-enddrive.
Chaintensioning,lengtheningorshortening
Danger!
Takecaretoensurethatthelockingelementsdescribedinthe previoussectionareinstalled(chainhold-backdevice,retainingclaw)orengaged(pawl).
ig.15:Schematicrepresentation-chaintensioning
pawl conveyorchainlockingdevice plowchainretainingclaw/lockingdevice
chainpullingdirection
senseofrotationofchaintensioner
. Opentheselectorvalvetotensionthechain. Dependingonthedirectioninwhichyouwishtotensionthe chain,youhavetomovetheselectorvalvelevertotheleftorto theright.Theleverengagesandthechainistensioned.
. After thepresetoperatingpressurehasbeenreachedandthe hydraulicbrakemotorhascometoastandstill,engagethe pawlattheconveyordriveorattheplowdrive.
Important!
Youmayhavetothrottlethehydraulicbrakemotortoallowthe pawlstoengagebehindaverticalchainlink.
. Nowopentheselectorvalveintheoppositedirectionsothat thepawlcanengageinthechainattheconveyororplowdrive.
De-couplingandcouplingconveyorandplowchains
Chaintensioning
Tensionthechainfirstasdescribedinthesection“chaintensioning”untilitissafetode-coupleit.
De-couplingthechain
. Pulltheslackchainoutoftheconveyorfromtheside.
. De-coupletheconveyororplowchainandremovetheadjustingchainsorchainlinks.
Relievingthechain
. Nowopentheselectorvalveintensioningdirection.
. Pullthepawlsoutofthechain.
. Closetheselectorvalveagainagainstthetensioningdirection tocompletelyrelievethechain.
Fig.16:Selectorvalve
Shorteningorlengtheningthechain
. Pulloffthehead-enddriveusingthedevicesprovidedfor installingandremovingthepansorplowguides.
. Pansorplowguidescannowbeinstalledorremoved.
. Next,pullthehead-enddrivebackontotheconveyor.
. Shortenorlengthentheconveyororplowchainaccordingly.
Tensioningthechain
. Opentheselectorvalvetotensionthechain. Dependingonthedirectioninwhichyouwishtotensionthe chain,youhavetomovetheselectorvalvelevertotheleftorto theright.Theleverengagesandthechainistensioned.
. After thepresetoperatingpressurehasbeenreachedandthe hydraulicbrakemotorhascometoastandstill,engagethe pawlattheconveyororplowdrive.
Important!
Youmayhavetothrottlethehydraulicbrakemotortoallowthe pawlstoengagebehindaverticalchainlink.
. Nowopentheselectorvalveintheoppositedirectionsothat thepawlcanengageinthechainattheconveyororplowdrive.
Couplingthechain
. Usetherespectivechainconnectors(e.g.block-typeconnectors)tocoupletheconveyororplowchain.
. Placetheslackchainintotheconveyorfromtheside.
Relievingthechain
. Nowopentheselectorvalveintensioningdirection.
. Pullthepawlsoutofthechain.
. Closetheselectorvalveagainagainstthetensioningdirection torelievethechaincompletely.
Removingthechainlockingdevices
Removethelockingdevicefromtheconveyorchainortheplow chain.
Conveyor:
Removethelockingdevicefromthedriveor ifthelockingdeviceismountedtothebaffleplatejustswingthe lockingdeviceintoitsrestposition.
Plowdrive:
removethehold-backdevice.
Chaintensioning,lengtheningorshortening
Puttingthehydraulicchaintensioningdeviceoutofoperation
. Movethecontrollevertothe”OFF”positiontoswitchthechain tensioneroff.Thisalsoactivatestheelectricalinterlockofthe electricmotors.
Warning!
Checkthewholeconveyororplowsystemfordamage.Only startthesystemagainafternofaultshavebeenfound.
Tensioningthechainwithsize45/65driveframes
Notice!
Forconveyorsystemswithdriveframesofsize45/65themaximumpermissibleoperatingpressuresmaypossiblynotbe sufficientifthechainistobetensionedatthehead-enddrive, only.Therefore,thechainhastobetensionedseparatelyinthe topandbottomracesorbothattheheadandatthetaildrives.
Fig.17:Schematicrepresentation-tensioningthechainwithsize45/65driveframe
1.tensioningthechaininthetoprace-tail-enddrive
pawl
lockingdevice
pullingdirectionofchain
senseofrotationofchaintensioner
2.tensioningthechaininthebottomrace-head-enddrive
holdingthepretensionwiththe chaintensioner
pawl
lockingdevice
pullingdirectionofchain
senseofrotationofchain tensioner
Theprocedureisasdescribedinthesectiontitled”tensioning,and lengtheningorshorteningchains”.
Insertthelockingdevice.
Tensionthechaininthetopraceatthetail-enddrive.
Fortherecommendedpretensionforthehead-endandtail-end drive,pleaserefertothesection“Explanationsonhowtopretensionthechain”.Takehalftheconveyorlengthtodetermine thepressureptobesetatthetensioningdevicefortheindividualconveyorandchaintypes.
Holdthepretensionbymeansofthechaintensioneratthetailenddrive.
Tensionthebottomracechainatthehead-enddrive.
Retensioningconveyororplowchains
Ifthepretensionappliedtotheconveyororplowchainisnotyet sufficientresultingintoomuchslackthechainhastoberetensionedasdescribedinsection“Chaintensioning”.
Assemblyaidafterchainrupture
Addchainlength(adustingchain)atthepointofdamage.
Tensiontheconveyororplowchainasdescribedinsection“Chain tensioning”.
Pretensioningconveyorandplowchains
Pretensioningconveyorandplowchains
Inanemptyconveyor,thechainsmustbepretensionedsuchthat onlyamoderateamountofslackiscreatedunderloadduringoperation.Experiencehasshownthatduringoperation,theconveyor chainassemblyshouldhavenomorethanroughlyonehand breadthofslackatthehead-enddrivewhenunderload.Thechain willotherwisecollidetoomuchwiththeentryedgeofthelower chainduct.Loudnoisesandexcessivewearwillbetheresult.Furthermore,climbingandjumpingofthechainsonthechainsprocketswillincreaseiftoomuchslackchaindevelops.
Slackchainmustnotbeallowedtobuildupinfrontofthetail-end drivesprocketduringoperationtosuchanextentthathorizontal chainlinkscanbestruckbythetipsoftheteeth.Jammingofthe chainisalsopossible,resultingindamagetothepansandcausing chainruptures.
Thesameappliestothepretensionofplowchainsaftercoupling. Atthedrivesprocket,wherethechainpassesfromthetoptothe bottom,theplowchainmustthereforenotbeallowedtohavemore thanoneortwohandbreadthsofslackwhenunderload.Thesame appliestothedrivesprocketoverwhichthechainpassesfromthe bottomtothetop,aslongasfreepassageispossible.Ifchain passesfromtoptobottomontoaslidingplateslackchainshould notbuildupbeforethechainsprocketsuchthathorizontallinkscan behitbythetipsoftheteethorjamsoccur.Thiscouldresultin problemsatthechainentryortochainfailures.
Excessivelytensionedchainscauseefficiencylosseswhenthe chainspassaroundthesprockets.Theseresultinincreasedwear ofchainsandsprockets,heaviernoisesandhigherdrivepower requirements.
Asthefaceadvances,thepretensionintheconveyorandplow chainscanchangeastheconveyorandpossiblyalsotheplow guideattachedtoittakeondifferentanglesinhorizontalandverticaldirections.Changescanalsobecausedbycompressionor stretchingofthepanlineandbychangesinthegradient.Inaddition,changesinloadarepossibleduetofluctuationsinthepropertiesofthematerialbeingconveyed,e.g.byfluctuationsintheplowabilityofthefaceandthenecessaryloadingwork.
Finallythechainassemblyitselfchangesduetoincreasingpermanentelongation.
Inordertoensuretrouble-freeoperationwithfavorabledrive powersandlongservicelivesofchainsandsprockets,thechains mustthereforebeconstantlymonitoredwithrespecttothecriteria slackchainandnoiselevel.Thiscangiveanearlyindicationof whenaconveyorchainassemblyorplowchainhastobe lengthenedorshortened.
Guidevaluesforthepretensionoffaceorentryconveyorchain assembliesandofplowchainscanberequestedatCaterpillar. Thesevaluesarebasedonempiricalvaluesforaverageoperating conditionsandforuniformloadingoffaceconveyors,forfullloading ofentryconveyorsandthemostfrequentlyemployedspeedsfor theindividualchainsizesforplows.Thepretensionmaytherefore havetobeadaptedaccordingtotheobservationsoftheparticular operatingsituation.
Forcouplingofconveyorchainassembliesorplowchainswith chainconnectors,i.e.withshackle-typeconnectorsorchainconnectinglinks,thechainfirsthastobepretensionedmorethan necessaryforthepretensionrequiredaftercoupling.Inordertobe abletoinsertachainconnector,thetwoendlinksmustbetouching oneanother,i.e.aminimumofapprox.onechainpitch”t”is requiredasslack.
Notealsothatachainstrandmayonlybelengthenedorshortened bytwochainlinksoramultiplethereofatatime.
Maximumpermissibleoperatingpressuresfortensioning
Themaximumoperatingpressureisthedifferenceinpressure betweenfeedandreturnpressureatthehydraulicbrakemotor.
Tab.3:Permissibleoperatingpressures Gearratioof themain gearboxi
Themaximumpermissibleoperatingpressuresinbargiveninthe tablerelateonlytothemaximumpermissibleloadonthegearbox andnottothepermissibleloadonthechains.Thelatterdepends onthechainandthecorrespondingsprocket(seetable10).
Danger!
Ifthemaximumpermissibleoperatingpressuresareexceeded, thegearsmaybedestroyed,andexcessivelyhighforcesmay betransmittedtothechains.Thiscanresultinsevereoreven fatalinjurytoyourselfortoothers.Neverexceedthemaximum permissibleoperatingpressuresindicatedinthetable!
Maximumachievabletorques
Tab.4:Maximumachievabletorques
Gearratioof themain gearboxi
Hydraulicbrake motortype
MaximumachievabletorquesattheoutputshaftinkNmGearboxsize
Pretensioningconveyorandplowchains
Tab.5:Gearboxsize5
Thetorquesshowninthetableareachievedatthemaximumpermissibleoperatingpressuresshownintable3.
Caution!
Ongearboxeswithoverloadprotectiondevices,takecarethat themaximumpermissibletorqueforactuationoftheoverload protectiondeviceisnotexceeded.
Torquesattheoutputshaft
Torquesattheoutputshaftofthegearboxesin kNm atthepreset operatingpressureofthetensioningdevice.
Tab.6:Gearboxsizes10and15
Operating pressureinbar
Tab.7:Gearboxsizes20,25and30
Operating pressureinbar
Tab.8:Gearboxsize35
Operating pressureinbar Gearratioofthegearbox
Gearratioofthegearbox
Tab.9:Gearboxsize45/65
Sizesandchainoperatingforces
Caution!
Dependingonthelength,typeandpositionoftheinstallation, thechainforcesmaydecreaseupto50%overthelengthofthe chainassemblyorthechainuptothechainlockingdevice.
Tab.10:Chainandsprocketsizes ChainSprocket toDIN22252-Class2 dxt Pitchcircle
Forchainassemblieswithtwochains,twicetheworkingforceis permissible.
Pretensioningconveyorandplowchains
Calculationofthechainpretension
Important!
TheexertedchainforcesFK candecreasebyupto50%over thelengthofthechainassemblyuptothelockingdevice, dependingonthelength,typeandpositionoftheinstallation. Thechainforcetobeexertedatthechainsprocketmustthereforebedoubledtoachievetherecommendedchainpretension overthewholechainassembly. Thechainforceappliedmustnotexceedthetestforceofthe chain!
Required:
Chainpretensionandpressuretobesetatthetensioning device.
Given:
Gearbox:Size 25/30 withoutoverloadprotection, iGear =33
Chain: DKB34x126
Numberofteethonthechainsprocket: z=7
Pitchcirclediameterofthechainsprocket: do =567mm (seetable10)
Transmissionratioofthetensioninggear iTension =62.624 (seechapter6,table11)
CorrespondingtensioningdevicewithOrderNo.: 19550010000004(variant4)
Specifictorqueofthehydraulicmotor: T=0.95Nm/bar (seechapter6)
Recommendedchainpretension: Fv =140kN
Chainforcetobeexerted: FK =2xFv =2x140kN=280kN
Pressuretobesetatthetensioningdevice:
p= FK xd0
2xiGear xiTension xT
p= 280x567 2x33x62,624x0,95 [bar]
¶ 40bar
p= 40bar isthepressuretobeset
FK =280kN d0 =567mm
iGear =33
iTension =62,624
T=0,95Nm/bar
Tensioningforceseffectiveatchainsprocket
Calculationofthechainforcefromtherespectivetorquesatthe gearboxoutputshaft
Torquesasafunctionoftheoperatingpressure(seetables5-9)
Chainandnumberofteethofthechainsprocket,pitchcircle diameter(seetable10)
Required:
Chainforceatthesprocket: FK
Given:
Gearbox: KP-45 withagearratio i=33
Chain: DMKB42x146 (twin-centerchain)
Numberofteethonthechainsprocket: z=7
Operatingpressure: p=80bar
Valuestakenfromtablesordiagrams:
Chaintensioningdevice: 1955.001.000.00.04 (fromchapter6,section“orderNo.”)
Torqueatthegearboxoutputshaft: MD =161.8kNm (fromchapter6,section“Torques-gearboxoutputshaft/main gearbox)
Chainsprocketdiameter: do =658mm (fromtable“sizesandchainoperatingforces”)
CalculationofthechainforceFK:
FK = 2xMD x1000 d0
FK = [kN] =491,8kN
2x161,8x1000 658
FK = 491.8kN istherequiredchainforce
Maintenanceandlubrication Tensioninggearbox
Theoilinthetensioninggearboxhastobechangeddependingon theload,butatleastonceperyear.Thegearoilwithaviscosityof 115to180mm2/s(cSt)at50 Ccanbepouredintothegearboxat oilfillerplug”E”uptotheoverflowplug”Ü”.Whenopeningplugs ”E”and”Ü”(seeFig.18“Tensioninggearbox”),takeparticularcare thatnoforeignmatterentersthegearbox.
Oilvolume:approx.2.5l
Oilgrade:seesection”OilrecommendationsforCaterpillar gearboxes”
Fig.18:Tensioninggearbox
Besuretoobservetheintervalsspecifiedformaintenanceand checksofthechaintensioningdevicesincehotsurfacesmight causeanignitionofexplosiveatmospheres(air)anddust.
Hydraulicbrakemotor
Thehydraulicbrakemotorismaintenance-freeandislubricatedby thehydraulicfluid.Itmustbestartedbrieflyatleasttwiceperweek togetherwiththetensioningdevice.
Notice!
Inordertoavoiddamagebycorrosion,thehydraulicbrake motormustbefilledwithemulsionatalltimes.Ensurethatthe emulsioncannotflowoffviatheleakage-oilline.(Installthe leakage-oillineintheformofasyphon).
Controlunit
Thecontrolunitismaintenance-free.
Pressurereliefvalves
Thefunctionofthepressurereliefvalvesmustbecheckedevery sixmonths.
6 Technicaldata
Technicaldata
Thischaptercontainsthemaintechnicaldataofthechaintensioningdevice.Attheendofthischapteryouwillfindfurtherinformationwithrespecttotighteningtorques,oilgrades,HFAfluids,etc. Pleasereadthischaptercarefullyandatease.Particularlyobserve thesafetymessagesincluded.
Technicaldatasheet
Tab.11:Maindimensionsandweight
Length: .................L=767mm
Width:..................B=335mm
Height:.................H=400mm
Weight(withoutoilfilling):.M=150kg
Gearratios
Thegearratiosinthetensioninggearboxincludingthesplineddisc onthedriveshaftofthemaingearboxcanbefoundinthefollowing table.
Tab.12:Gearboxsizesandtensioninggearratios
Gearboxsizetensioninggearratioi 5 41,12:1 10and15 50,17:1 20,25and30 62,62:1 35,45and65 71,68:1
Permissibleoperatingpressures
Aninformationsignonthetensioninggearboxshowsthemaximum permissibleoperatingpressureduringtensioning.
Fig.19:Informationsign“Maximumpermissibleoperatingpressure”
1informationsign ratio i brakesmotor type
Max.operatingpressure duringtensioningoperation whenusinggearboxessize: Pressureinbar
Strictlyobserveoperatinginstructions andinformationplatefittedtothemotor
Maincomponents
Thetensioningdeviceconsistsoftheelements: tensioninggearbox, hydraulicbrakemotor, controlunit, controlgearunitwithelectricalinterlock.
Fig.20:Tensioningdevicewithhydraulicbrakemotor(sectionA-B)
1hydraulicbrakemotor
2controlunit
3pressurereliefvalves
4controllever
5selectorvalve
6tensioninggearbox
7electricalinterlock
Powerflow
Theengagementofthepinion(item10)inthesplineddisc(item8) ofthegearboxdriveshaftsimultaneouslylocksoutalltherelated electricmotorsontheconveyorand/orplowinstallationfrom restarting.Thehydraulicbrakemotorcanthenbestarted. Thepowerflowcomesfromthehydraulicbrakemotor,whichis linkedtothedriveshaft(item11)ofthetensioninggearbox,tothe gearstage(item12).Thisgearstagetransmitsthetorquetothe pinionshaft(item13)andthroughtothepinion(item10).Thispinionislinkedtothesplineddisc(item8)onthegearboxdriveshaft. Thepowerflowisthentransmittedviathisdiscandthroughthe gearstagesofthemaingearboxtotheoutputshaftandtothe sprocketoftheconveyororplowsystem.
Fig.21:Tensioninggearbox
Hydraulicbrakemotorwithcontrolunit
Hydraulicbrakemotorwithcontrolunit
Hydraulicbrakemotorsofthistypecomprisearadialpistonmotor withdownstreamhydraulicallyreleasedspring-loadedmultipledisc brake.
Intheeventofachangeinthegearratioofthemaingearboxthe hydraulicbrakemotormustbereplacedasdescribedinthesection ”Ordernumbers”.
Technicaldata
HydraulicbrakemotortypeKM63ZAD-KMB2AN geometricabsorbedvolume:V=66cm3/U specifictorque: T=0.95Nm/bar max.speed: n=1,200rpm brakereleasepressure:p=30bar
HydraulicbrakemotortypeKM110ZAD-KMB2AN geometricabsorbedvolume:V=110cm3/U specifictorque:T=1.59Nm/bar .............. max.speed:n=750rpm brakereleasepressure:p=30bar
Descriptionoffunctions
Thecontrolofthehydraulicbrakemotor(item1)forclockwiseoranticlockwiserotationiseffectedwiththeselectorvalvelever(item5). Thesign(item14)onthemountingbracketshowsthesenseofrotationofthehydraulicbrakemotor(item1)withthecorrespondingpositionoftheselectorvalvelever(item5).
Thepressuresupplycomesfromapressurereducingstation(see section”Pressurereducingstation”)ofthehydraulicfacesupportor fromaseparatepressurepump.Thepossiblecontrolrangefortensioningliesbetween30and100bar.
Thehydraulicfluidflowsthroughapressurefilterof25 mmesh widthtoport”P”ofthecontrolunit(item2).Theportforthereturn lineismarked”R”.Themultiplediscbrakeishydraulicallyreleased viathecontrolline”St”.
Theleakageoillineofthehydraulicbrakemotor(item1)must not beconnectedtothereturnline.Theleakageoilhastobedrained pressure-free viaasiphon-likehoseorpipearrangementorseparatelytothetank.Theleakageoillinemustbelaidsothatthemotor housingisalwaysfilledwithhydraulicfluid.
Thebrakeleakageoilmustbecheckedaftereachtensioningprocessanddrainedviaadrainplug”A”onthebrakehousing,if necessary.Theportfortheleakageoillineonthehydraulicbrake motor(item1)ismarked”L”.Allthecomponentsaresuitablefor operationwitha2to5%oil-in-wateremulsion.
seefig.25
Fig.22:Hydraulicbrakemotor view“X”
topview
Left/Right
PandR ratingplate
St=controlline
P=pumpport
R=returnport
L=leakageoilline
A=drainplugforbrakeleakageoil
Selectorvalve Stop
LeftRight
Notice! Beforeswitchingonthehydraulicbrakemotor,checkleakage oilline”L”forfreeflow.
Hydraulicbrakemotorwithcontrolunit
Pressurecontrol
Thesettingforthepressurerangefrom30barto100barismade atthepressurereliefvalveswiththetensioningdeviceunderload. Oneofthepressurereliefvalvesisresponsiblefortheclockwise rotationofthehydraulicmotor,theotherfortheanti-clockwiserotation.
Caution!
Themaximumpermissiblepressureis100bar. Athigherpressures,thesealingelementsonthehydraulic motorwillbedamaged!
Inordertosetthenecessarypressure,loosengrubscrew(item1). Byturningthehandsleeve(item2),youcannowchangethepresettingofthepermissibleoperatingpressurefortensioning.The pressurecanbeincreasedordecreased,dependingonthedirectionofrotation.
Fig.23:Pressurereliefvalve(pressuresettingvalve)
Pressurereducingunit
PressurereducerD500/30
ThepressurereducerD500/30issuitableforpressurereductions betweenapprox.500and30barandlargeflowrates(120l/min). Theinletpressureofthehigh-pressurefluidcanbeasmuchas 500bar.Adiaphragm-typeaccumulator(p)with0.1lcapacityacts asspringelement.
Thepressurereducercanbefitteddirectlytothehighpressure sideofthepump.Oneormorepressurereducerscanalsobe installedatanypointinthehigh-pressureline.
Thediaphragm-typeaccumulator(p)isprechargedwithnitrogen (prechargepressure:normally30bar).Theaccumulatorcanbe rechargedbyconnectingourchargingdevice,TypeFPK,tothe chargingvalve(n)andusingacommerciallyavailablenitrogengas bottleorwithourhandbottle(2lcapacity).
Fig.24:Maincomponentsof pressurereducer
1protectivehood
2pipe10x2
3pressurereducerD500/30
4straightfitting
5hexagonheadboltM12 pressurereducingvalve inletpressuremax.600bar controlrange30to500bar
”II”
Pressurereducingunit
Descriptionoffunctions
ThepressurereducerD500allowsreducedpressuresofbetween 30and450bartobeproducedfromprimaryinletpressuresofupto 500bar.Adiaphragm-typeaccumulatorwhichisnormallyprechargedwithnitrogento30baractsasspringelement.Thedesired reducedpressurecanbesetbyadmittinghydraulicfluidviathe inletvalve.Subsequentregulationispossiblebyallowinghydraulic fluidtodrainviaoutletvalvem.Thespringpressurefromthediaphragm-typeaccumulatoractsonthesurfacef1ofthecontrolspool (a).Thepressurecausesthecontrolspool(a)tomovedowntothe stopandthustoholdbutterflyvalve(b)downandopen(asshown).
Ontheprimaryside,thehydraulicfluidentersat(c)viaafilter(k) andisdischargedonthesecondarysideat(d).Aslongasthe hydraulicpressureinthesystemislowerthanthespringpressure inthediaphragm-typeaccumulator,thebutterflyvalve(b)remains open.Whenthebutterflyvalveisopen,theliquidpressureactson surfacef2ofthecontrolspool(a)andviacontrolduct(g)alsoon theringsurfacef3.Asf1=f2-f3,twoequallylargesurfacesare actingagainstoneanother.
Fig.25:Pressurereducer
Whenthepresetreducedpressure(springpressure)isreachedor exceeded,controlspool(a)movesuptogetherwithbutterflyvalve (b)untiltheconicalsurfaceofthebutterflyvalvecontactstheconicalsurfaceofvalvebushing(h),closingthereducingvalve.When thevalveisclosed,theprimarypressurealsoactsonthevalvesurface(i)forcingitupwards.Inorderforthevalvetofunctionindependentlyoftheprimarypressure(pilotpressure),thedifferential surfacef3isjustaslargeasthevalvesurface(i).Thesurfacef3is forceddownbytheprimarypressurecomingviathecontrolduct (g).Ifthesecondarypressuredropsbelowthesetreducedpressure,thevalveopensslightlysothatthepressureonthesecondarysideincreasesonceagain.Thisrepeatedopeningandclosing withthrottlingeffectmaintainsaconstantpressureonthesecondarysideevenwithvaryingliquiddischarges.Intheeventofleaks duetoimpurities,etc.whichmayoccuratthemainvalveseat(i), thepressurecanstillincreasewhenthetwoconicalsurfacesarein contact.Thecontrolspool(a)thenmovesuptoanupperstopand ifthepressurecontinuestoincrease,thepressurereliefvalve(s)in themaincontrolspoolopens.Theexcessfluidcanbedischarged viatheleakageoilbore(l).Thepressurereliefvalve(s)shouldnormallyonlydischargethevolumeofhydraulicfluidoccurringdueto leaksatthevalveseat.Pressureincreasescomingfromthesecondarysideshould,whereverpossible,bedischargedviaaseparatevalveinthesecondaryline.
Settingareducedpressure
Slowlyopeningtheinletvalve(e)admitshigh-pressurefluidviathe line(g)intodiaphragm-typeaccumulator(p),causingtheminimum pressurecausedbythenitrogenchargetobefurtherincreased. Forlowerpressuresettings,drainvalve(m)isslowlyopenedand hydraulicfluidisdischargedviabore(l).Theinletandoutletvalves canbeactuatedwitha5mmAllenkey(DIN 911).Pressurerelief valve(s)preventsanincreaseinthereducedpressureif,e.g.the valveseat(i)isnotcompletelytightduetocontaminationofthe hydraulicfluid.
Fig.26:Pressurereducer
Pressurereducingunit
Thepressurereliefvalvecanonlydischargethesmallamountsof leak-offoilcausedbyleaksatthereductionvalveseat(i).Itcannot takeonthefunctionofasafetyvalveforthereducedpressureline (2ndpressurerange).Ifpressureincreasesaretobeexpected fromtheconsumerside(e.gduringplowingviatheadvancingcylinder),werecommendtheinstallationofasufficientlylargesafety valve.
Forproperfunctioningofthepressurereducer,thefluidsusedsuch asoilemulsionorwatermustbefreefromforeignparticles.The filter(k)onthevalveinletsideprovidesprotectionagainstany minorsoiling.
Blockballvalve
Theblockballvalvespermitahydraulicfluidsupplytobeshutoff andareavailablewithawiderangeofnominalsizesandconnectiontypes.
Fordetailsoftheblockballvalvesrequiredfortheparticularapplicationpleaserefertothesparepartslist.
Fig.27:Blockballvalve
Controlgearwithelectricinterlock
Important!
Theelectriccontrolofthedrivesmustbedesignedsuchthat allrelatedelectricmotorsontheconveyorandplowinstallationareisolatedandpreventedfrombeingswitchedonbefore thetensioningdeviceisswitchedon.
Descriptionoffunctions
Thepulseswitch(item16)connectedintothecircuitisactuated whenthetensioningdeviceisswitchedoff.Movingcontrollever (item4)withthepermanentmagnet(item17)inthedirectionofthe arrowpressurizesaleafspring(item18)oftheinertgascontact withapole(northorsouthpole)ofthecross-magnetizedpermanentmagnet(item17).Thecontact(item18)inthecircuitofthecontrolcontactor(item15)isthusclosed.
Withtheswitchinthisposition,thedrivemotorscanbestarted. Thecontact(item18)opensagainwhenthepermanentmagnet (item17)movesawayandtheactuatedcontacttab(item19)isno longermagnetized.Theelectricmotorsontheconveyorand/or plowaresimultaneouslylockedouttopreventrestartingwhenthe tensioningdeviceisswitchedon.
Fig.28:Electricalinterlock functiondiagram
Controlgearwithelectricinterlock
Switchpositions
Thepinionisengagedordisengagedbyoperatingtheleveronthe gearboxofthechaintensioningdevice.Theknobispulledupand thelevermovedintothedesiredposition.
Switchposition”ON” (leverposition”I”).Thepinionofthetensioningdeviceisengagedinthesplineddiscofthegearboxdrive shaft(seesection”Descriptionoffunctionsofthetensioning device”):Theelectricmotorsontheconveyorand/orploware lockedouttopreventrestarting.
Switchposition”OFF” (leverposition”II”).Thepinionofthetensioningdeviceisdisengagedfromthesplineddisc:Thecontact (Fig.28,item18)inthecircuitofthecontrolcontactorisclosed again.Conveyorand/orplowcanberestarted.
Fig.29:controllever
1knob 2controllever 3gearbox 4lockingknob
Technicaldata
Tab.13:Connectiondataandapprovals
Pulseswitch
Ex-design
Aswitchingposition-ONBswitchingposition-OFF-
Pulseswitch intrinsicallysafedesign Type esHKPT1 IK167K114 Contact 1505(normallyopen) (normallyopen)
Typeofprotection P43(Sch)es(Ex)esG5 EExiaI Approvalnumber. T4688/NI+Z1bisZ3 88B1100
Actuatingmagnet cross-polarizedpermanentmagnet
Ordernumbers
Tab.14:Ordernumbersofthecompletehydraulictensioningdevice-electrical interlockinintrinsicallysafedesign
MaingearboxratioOrderNo. Tensioningdevice Hydraulicbrakemotor
Caution!
Intheeventofachangeinthegearratioofthemaingearbox takecaretoensurethatthecorrecthydraulicbrakemotoras listedinthetablesisused.
Theordernumbersforthehydraulicbrakemotorsaregiveninthe sparepartslists 19550011300000 and 19550011400000
Inaddition,thesettingvalueofthepressurereliefvalveforthe requiredsenseofrotationmustbechecked.Themaximumpermissibleoperatingpressuremustnotbeexceeded(seesection ”Maximumpermissibleoperatingpressurefortensioning”).
*Onlyforgearboxofsize45and65
changeof gearoiltypes
retableof gearoils
Permissiblemedia
OilrecommendationsforCaterpillargearboxes
Onlyusethegearoilsrecommendedorsuchproductsthathave provedtobeequivalent.
Ifgearoilsofothercompaniesareused,gearoilsonmineraloil basewithappropriateadditivesmaybeused.
Shouldsyntheticoilsotherthanthoselistedintherightcolumnbe usednowarrantycanbeacceptedastothedurabilityoftheinterior gearboxcoating.
OnlysyntheticoilswithEPcharacteristicareallowedtobeused.In theFZGspecialtestA/16.6/140theremustbenoincreasedwear onthegearsinanyofthe12loadranges.
Whenchangingfromoneoiltoanotherwerecommendtofirstclean thegearboxortohavethecompatibilityofthedifferentoilsconfirmedbytherespectivesuppliers.
Thedifferenttypesofgearoilsinthetwocolumnsofthetableare equivalent.Thesequenceinwhichtheoiltypesarelistedgivesno indicationastothequalityoftheoil.Werecommendnottomixdifferentoiltypesorproductsfromdifferentcompanies.
Tab.15:RecommendedoiltypesforCaterpillargearboxes
Manufacturer
RequirementsforgearoilsforCaterpillargearboxes
Thecorrectchoiceofgearoilsandclosemonitoringofthelubricationaremajorprerequisitesfortrouble-freeoperationandcontributetoalongerservicelifeofthegearbox.
Load-bearingcapacity
DuringthemechanicaltestofgearoilsinaccordancewithDIN 51354,theremustbenoincreaseinwearonthegearsinanyof the12loadranges,eitherintheFZGstandardtestA/8,3/90orin theFZGspecialtestA/16.6/120,i.e.theloadrangecausingdamagemustbehigherthan12.
Furthermore,the”specificchangeinweight”ofthetestgearsms (specificwear)mustnotexceed0.27mg/kWh.
Ageingresistance
Thegearoilsshouldhaveexcellent”thermostability”and”ageing resistance”attheprescribedoilchangeintervals,i.e.after2000 operatinghours.
Fig.30:Curveoftheneutralizationnumber
pointofinflection
1000 2000 hoursofoperation
NZ=neutralizationnumber
Duringnormaloperation,thecurveoftheneutralisationnumber(NZ number)ofmineraloilsmustonnoaccountreachthepointof inflectionafter2000hoursofoperationandatthepermanenttemperaturesstated(seefigure).
Kinematicviscosity
Thegearoilsshouldliewithintheviscosityrangeof210to320 mm2/sat40 _Cwithahighviscosityindex.
Additives
againstwearEP, againstcorrosion, againstfoaming.
Suitability
compatibilitywithcommerciallyavailablesealingelements.
HydraulicfluidsofgroupHFA
Notice!
UseonlyhydraulicfluidsapprovedbyCaterpillar! ThesefluidshavebeentestedatCaterpillarandguaranteea reliableoperationofthehydraulicsystem.
Hydraulicfluidconcentrates
Listofapprovedwater-misciblehydraulicfluidconcentratesforthe productionoffire-resistanthydraulicfluidsofGroupHFA.
Tab.16:Approvallist(Part1)
ManufacturerProduct designation Recommendedconcentration forusewithprocesswateraccordingto thechemicalcomposition
ARAL
Lubricants P87AF nottested 1.5% 3%
CarlBechem FimitolP87AF nottested 1.5% 3%
Castrol AnvolC18 nottested 5% nottested AnvolC19 nottested 5% nottested
AnvolSF2000 nottested 2.5% nottested
Fuchs/Century Solcenic2 nottested 5% nottested
Solcenic2BW Code443250AA nottested 5% nottested
Solcenic2000M nottested nottested 2%
Solcenic2011 nottested 5% nottested
Solcenic2012 nottested 5% 5%
Solcenic2020 4% nottested nottested
Solcenic3002 nottested 2% 3%
Solcenic Ecosyn3050 nottested 1.5% nottested
Solcenic Ecosyn3060 nottested nottested 2%
Renolin EcubsolBOA|| nottested 1.5% 2%
MobilOil MobilmetS-122 nottested 5% nottested
QuakerLTD
Quintolubric812-01 nottested 3% nottested
Quintolubric814-01 nottested 5% nottested
Quintolubric N807Al nottested 3% nottested
ShellTellinaQ nottested 5% nottested
Tab.17:Approvallist(Part2)
ManufacturerProduct designation
Recommendedconcentration forusewithprocesswateraccordingto thechemicalcomposition
Theunissen
Important!
Weexpresslypointoutthattheapprovalofthelistedpr oducts relatesonlytothepuretechnicaluseinourhydraulicsystems. Theresponsibilityfortheconstituentsusedinthehydraulic concentratesliessolelywiththerespectivemanufacturer.
Storageofthehydraulicfluidconcentrate
Donotstorethehydraulicfluidattemperaturesbelow5 C. Avoidexcessiveheatingofthefluids.Protecttheconcentrate againstdirectexposuretosunlight.
Important!
Besuretoobservethemanufacturer'sinstructionsforuse.
Preconditionsforuseunderground
TheapprovaloftheresponsibleMinesInspectorateisrequiredfor useunderground.
Foruseininternationalmining,therelevantnationalregulations mustbeobserved.Approvalbytheresponsibleauthoritiesmaybe necessary.Responsibilityfortheapprovalsprocedurelieswiththe equipmentoperator.
Suitabilityofthehydraulicfluid
Thesuitabilityofthehydraulicfluidforuseinminingequipment mustbedemonstratedbypositiveexperienceinpractice.Shoulda productexhibitanynegativecharacteristicsduringoperation,we reservetherighttodeletetheproductfromourapprovallist.
Workingconcentrationofthehydraulicfluid
Therecommendedworkingconcentrationoftheproductsessentiallycorrespondstotheconcentrationatwhichtheproductpassed thecrevicecorrosiontestinaccordancewiththeWorksStandard orRAGStandard.
1)Willbedistributedas“AnvolJD2000”byCastrol.
2)OnlypermissibleisthevariantmanufacturedinGermany.Thevariantof IsosynthVX110BF,manufacturedanddistributedinUSA,isnotpermissible becauseofdifferentingredients.
Qualityoftheprocesswater
Thequalityoftheprocesswaterisacriticalfactorforthefunctional reliabilityoftheemulsion.Thewatermustnotcontainanysolidor liquidimpuritiesandmustsatisfythebacteriologicalrequirements fordrinkingwater(DIN2000).
Thefiguresquotedfortheconcentrationofthehydraulicfluidswere obtainedfromtrialswithtestwatersamples. Thechemicalcompositionofthetestwatersamplesusedare showninthetablebelowforyourorientation.
Tab.18:Chemicalcompositionofthetestwatersamplesused typeXtestwater (NCB18to Luxembourg Report) typeYtestwater (DIN24320resp. Luxembourg Report)
typeZtestwater (NCB19to Luxembourg Report)
Iftheprocesswateravailabledoesnothavethedemandedquality, thespecialapprovalofCaterpillarmustbeobtainedbeforeuse.
Emulsionvalues
pHvalue:7.5-9.5
Permissiblebacteriaintheemulsion: ≤ 105 Kol/ml
Themaximumpermissibletemperatureis55 C;normally45 C, shouldnotbeexceeded.Ahigherworkingtemperaturewillreduce theconsistencyoftheemulsionandshortentheservicelifeofthe sealmaterial.
Checkingoftheemulsionvalues
Atleastonceperweek,check: thepHvalue, theconcentration testmethod:byagreementwiththeconcentratemanufacturer, themicrobialload testmethod:dipslides.
Important!
FurtherinformationiscontainedinDIN24320.
*ThesevaluesdeviatefromthequotedstandardorfromtheLuxembourgReport. **°d=degreeGermanhardness(isnolongerpermissibleinaccordancewiththe applicablelegalregulations.Theinformationgivenisintendedonlyfororientation.)
Markingofthechaintensioningdevice
Manufacturer: CaterpillarGlobalMiningEurope GmbH
Type: EK-hydr.
Yearofconstruction:MM/YY(e.g.03/09 ≙ March/09) .....
Identificationnumber.:195500100000XX*)
Weight: 150kg(withoutoilfilling)
Thechaintensioningunitismarkedwiththefollowingdata.The positionofthemarkingsisshowninfigure22.
Fig.31:Markingofthechaintensioningdevice
Chaintensioningdevicedata
1type 2ident.no.
3itemno./yearofconst. 4weight
CE-marking
19550010000000
No.xxx/xx
G=150KG
Thechaintensioningdevicehasbeendesignedandmanufactured inaccordancewiththeEuropeanDirective94/9/EGandDINEN 1710andissuitableforuseinpotentiallyexplosiveatmospheres.
*)X=wildcardforvariantidentificationnumber
7
Foryourinformation
Foryourinformation
Ifyoushouldrequiresparepartsoriftechnicalproblemsoccur, pleasecontactourafter-salesservicepersonnelorcontactus directly(homepage: www.mining.cat.com).
Tab.19:Standardsandguidelines,extract
DesignationTitle
Directive2006/42/EC
Directive94/9/EC
DirectiveoftheEuropeanParliamentandtheCouncilon theapproximationofthelawsoftheMemberStatesrelatingtomachinery
DirectiveoftheEuropeanParliamentandtheCouncilon thelawsoftheMemberStatesconcerningequipmentand protectivesystemsintendedforuseinpotentiallyexplosive atmospheres
DINEN1710 Equipmentandcomponentsintendedforuseinpotentially explosiveatmospheresinundergroundmines
DINEN1552 Mobileextractingmachinesattheface-safetyrequirementsforshearloadersandplough systems- 2003-09
Standardsandguidelines
Designation Dateof issue
Title
EWN6003 1) Tensioningforce,tighteningtorquesandsurfacepressure forbolts 1985-02
EWN6110 1) Hammerheadbolts 1985-02
EWN7068 1) Lubricatinggreases&solidlubricants 1992-06
EWN7069 1) Non-metallic(coating)surfaceprotection 1985-02
EWN8350-1 1) Approvalprocedureforfire-resistantHFA-fluidsinmining 2008-01
