DOWNLOAD PDF : Cat Bucyrus Plow drive unit HK 30-3 Operating Manual

Operating Manual Plow drive unit HK 30-3 Doc. no.: 6052 015 000 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

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

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

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

1.3 1.4 1.4

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

2.3

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

2.3

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

2.4

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

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

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

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

2.4 2.4 2.4 2.4

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

2.6

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

3.3

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

3.3

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

3.4

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

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

Transport of the components . . . . . . . . . . . . . . . . . . . . . . . .

3.4 3.4 3.5

4. Installation Points to observe prior to installation . . . . . . . . . . . . . .

4.3

Who is allowed to carry out installation? . . . . . . . . . . . . . . .

4.3

How to install the plow drive unit . . . . . . . . . . . . . . . . . .

4.3

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to install the plow drive unit . . . . . . . . . . . . . . . . . . . . . .

Mounting assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flanging the plow drive unit on to the drive frame . . . . . . . .

Flanging on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the drive connection assembly and the E-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.5 4.5 4.7 4.8 4.10

Locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 How to lock the plow chain . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11

Tensioning the plow chain . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Test run and start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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4.12 4.13

Contents How to dismantle the plow drive unit . . . . . . . . . . . . . . 4.13 Important instructions for dismantling . . . . . . . . . . . . . . . . .

Disassembling the plow drive unit from the drive frame . . .

4.13 4.14

5.3

Who is allowed to operate the plow drive unit? . . . . . . . . . .

5.3

How to maintain the plow drive unit . . . . . . . . . . . . . . .

5.3

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

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening the bolted connections . . . . . . . . . . . . . . . . . . . .

Lubricating the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.4 5.4 5.5 5.5

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

5.7

Plow chain wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling the wheel-bearing set . . . . . . . . . . . . . . . . .

Chain stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exchanging the plow chain wheel . . . . . . . . . . . . . . . . . . . . .

5.7 5.12 5.13 5.14

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

6.3

Permissible power ratings . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Screws with ISO metric thread . . . . . . . . . . . . . . . . . . . . . . .

6.4

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

6.5

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

6.5

Plow drive unit identification . . . . . . . . . . . . . . . . . . . . .

6.7

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 directives . . . . . . . . .

7.6 7.6

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

How to operate the plow drive unit . . . . . . . . . . . . . . . .

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5. Operation

1

About this manual

Before starting work

About this manual This chapter contains important information making it easier for you to use this manual. It provides you with information on the structure of the manual and the symbols used.

Before starting work applicable operating manual

type of plow drive unit

Take care to ensure that the operating manual available to you is applicable for the corresponding type of plow drive unit . Failure to do so can result in a safety hazard for yourself and others.

Ensure that the data on the plow drive unit comply with the data given in the operating manual.

This operating manual is designed for: Plow drive unit HK 30-3 ID no.: 6052 015 000 BA 00 It is only permitted to be used for plow drive units of this type.

Bucyrus DBT Europe GmbH, Lünen 2008

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category acc.

Atex directive

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

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

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

new operating manual

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

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with or on the plow drive unit.

All persons working on the face, at the edge of the face or at the entry must have 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 correct malfunctions, J carry out daily routine work on the face or in the entry, J perform maintenance work, J perform repair work.

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

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1.3

Before starting work Purpose of this operating manual efficiency

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

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions.

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our service department. Our service address is given in the chapter “For your information”.

safety

Read the chapter “Your safety” closely. This chapter contains important information indicating potential hazards.

Observe this information and follow the instructions.

Characters and symbols used

Danger!

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

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

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

Notice!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the plow drive unit 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 this manual step-by-step. They will help you carry out your work faster and, more importantly, more safely.

1.4

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

Try to memorize the symbols and their meanings.

E

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

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

The plow drive unit 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 modifications or carry out conversions which could impair the safety of the plow drive unit. All modifications and changes must be approved by Bucyrus.

Use only original spare parts from Bucyrus. Note that the use of parts from other manufacturers will void the guarantee.

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The European guidelines/standards which appear in this operating manual must be applied when the plow drive unit is being used within the member states of the European Union.

If the device is used outside the EU, the directives and standards which apply in those 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 mining company, J of the mines inspectorate, and J of the mining supervisory authorities. additional operating manuals

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

Personnel Installation and repairs As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements. Installation and repair of J safety components (pressure relief valves, extinguishers, etc.), J electrical system (controls, signaling devices, etc.), J hydraulics,

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

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2.3

Operating conditions Operating conditions Intended use The tensionable plow drive unit has been exclusively designed and manufactured to transmit the drive torque of the fixed plow drive unit to the plow chain.

Intended uses are: J Transmitting the drive torque of the drive unit to the plow chain.

J Tensioning the plow chain.

Use the plow drive unit only as intended.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses are not allowed to be performed with the plow drive unit.

Bucyrus does not accept any liability for any damage resulting from any such unauthorized use.

These include: J adequate and consistent ventilation, J plow water curtains/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 switched off.

It may only be switched on again by authorized persons.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except those which are relevant for safety and suitable for use in explosive atmospheres.

The M2 equipment is to be stopped immediately and secured against being switched on again if firedamp protection facilities are found to be damaged.

Prerequisites for operation Putting the plow drive unit into service is prohibited until the machine into which this plow drive unit is installed has been found to comply with the European Directive 94/9/EC and the Standard DIN EN 1710.

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.

2.4

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

Ambient conditions

Operating conditions The M2 equipment/plow drive unit may only be operated when the safety requirements according to DIN EN 1552 have been met.

These include, among other things: J systems that prevent unauthorized start-up, J pre-start warning systems, J water spraying systems, J safe lock-out command systems, J emergency stop systems, J dust extraction systems, J noise protection, J warning messages, etc.

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Electrical equipment required to operate the plow drive unit shall be marked according to legal provisions applicable at the time it is placed on the market.

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2.5

Safety instructions Safety instructions Basic principles general

Always work with utmost concentration.

Familiarize yourself with your working environment.

Always wear your personal protective clothing and equipment. This also includes ear protectors as the noise emitted by the plow drive unit may at times exceed 85 dB(A), (e.g. when the conveyor is being emptied).

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

protective device

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

symbol plates EMERGENCY STOP

Observe the symbol plates on the plow system.

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Notify your supervisor about anything strange to allow any necessary action to be taken immediately.

Also press the EMERGENCY STOP switch if safety equipment such as firedamp protection systems break down.

cordon off working area

Press the support lock-out switch when performing: J maintenance work, J inspection work, J repair work, J or when safety equipment fails such as:

– firedamp protection. moving parts

Never allow parts of your body to come between machine components which could move, such as: J mining equipment, J plow chain, J conveyor chains, J flights, J spill plates, J chain sprockets, J shifting units.

danger of explosion

2.6

Be sure to observe the intervals specified maintenance and checks of the plow drive unit as hot surfaces may ignite explosive atmospheres and dust.

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

Pay attention to the acoustic and visual start warnings of the conveyor and the mining equipment.

E

Maintain the signaling and lighting systems in a functional order.

Safety instructions Storage and transport Observe the specified storage periods and the storage instructions.

Do not store any materials or components in the travel way or in your working area.

Inform the persons concerned about the intended transport route and the probable duration of the transport. transport securing devices

Ensure that the transport securing devices have been correctly installed.

Fix all moving parts with transport locks.

Never stand under unsecured components or suspended loads.

means of attachment

Connect the lifting equipment only to the lifting points provided for that purpose. Observe the different load limits of the lifting points.

Also observe the instructions on the transport sheets.

Only use means of attachment which are in a good condition and have been designed for the loads concerned.

Bucyrus DBT Europe GmbH, Lünen 2008

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For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the finished or polished surfaces of shafts, sealing surfaces, guide surfaces, etc. floor conveying devices

When using floor conveying devices for transport make sure that the center of gravity is as low as possible.

Installation and start-up

inclined faces

environmental acceptability

On an inclined face secure all individual parts using chains, e.g. on 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 crew about maintenance and repair work. Provide them with information on the intended work and its probable duration.

securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Secure the plow drive before all work against unauthorized and unintentional restarting.

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2.7

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Safety instructions

2.8

Plow drive unit HK 30-3

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and transport of the plow drive unit.

Following the instructions and tips will increase the life cycle and service life of the plow drive unit. You will also be able to carry out the transport work quicker and more safely.

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

Storage corrosion protection

Components coated with temporary anticorrosive are protected for about six months.

The hydraulically actuated equipment is run with a test medium before delivery and is emptied as thoroughly as possible before shipping. The internal parts are also protected against corrosion by the residual film for at least six months.

Storing the equipment Protect the equipment against direct exposure to sunlight.

Only store the electrical equipment, electronic components, replacement parts made out of rubber or plastic such as seals and hoses as well as hydraulic fluids in closed rooms at 15 °C to 25 °C.

moisture and dirt

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

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avoid direct exposure to sunlight

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

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

long term storage

If storage exceeds a period of six months, the hydraulic components must be filled completely with a corrosion inhibitor. This fluid must have anti-corrosive and frost-proof properties, such as CV 50.

Fill the empty cavities of the hydraulic components (e.g. the piston and ring spaces of the cylinders) in a horizontal position (connections facing upwards) until the fluid overflows.

The ports must then be sealed with plastic or steel plugs.

The equipment should never be stored outdoors. It must be stored in a dry, well ventilated room.

plastic deformation

To prevent deformation of the sealing elements, cylinders must be stored in a vertical position. Some cylinders have to be dismantled so that they can be stored in a vertical position.

random sample inspection

Random sample inspections must be carried out after a storage period of approximately two years. This will make it possible to determine whether the measures carried out and the type of storage used have prevented any damage.

Inspection can be carried out by Bucyrus on request.

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.

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3.3

Transport HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in the section “Hydraulic fluids of the HFA group” of this operating manual.

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.

Transport Load units; dimensions and weights Observe the separate transport sheets for the respective transport units. They include information on: J dimensions, J weights, J points of attachment,

Warning!

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

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

Use only suitable load handling devices.

Before transport temperatures below freezing

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

Transporting equipment at temperatures from -21 ºC to -40 ºC is only permissible if certain measures were already 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 may only be loaded statically or quasi-statically.

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

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

3.4

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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

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J center of gravity, etc.

Transport electrical and electronic components

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

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

Transport of the components machine parts

The plow drive unit is equipped with lifting eyes for transport.

In some cases you have to screw the lifting eyes into the bores provided before transport and to remove them again immediately after transport.

Danger!

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

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

Plow drive unit - Points of attachment

900

1248

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Fig. 1:

1600

679

1 1

1

1

1 Lifting eye TAWGK 3 (load capacity 3000 kg)

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Weight: 3375 kg

3.5

Transport Important!

The transport covering must be removed before installing the plow drive unit.

Transport covering

1 2

1 Transport covering

3.6

2 Hex. head screw M 16x30-8.8

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 2:

4

Installation

Points to observe prior to installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

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

Work on: J safety components (pressure relief valves, extinguishers, etc.), J the electrics (controls, signalling devices, etc.), J the hydraulics (cylinders, directional control valves, hoses etc.),

shall only be carried out by service engineers from Bucyrus or by specially trained personnel.

How to install the plow drive unit E

Before installation Bucyrus DBT Europe GmbH, Lünen 2008

Depending on the local conditions it may be necessary to pre-assemble the plow drive unit along with the other drive components to form a drive train. The complete drive train can then be installed on the drive frame.

Important!

Please observe the conveyor operating manual.

Important!

Note that after installing the plow drive unit, screws are no longer or may only be partly accessible. working pressure

Pump pressure acts upon the tensioning nuts of the mounting assembly. Observe the maximum applicable working pressure for each of the tensioning nuts.

tightening torque

Please refer to the corresponding spare parts list for tightening torques not listed in this manual.

rust protection

Before installation rust protection must be removed from flange surfaces, parallel keys and parallel key grooves. The locations concerned must cleaned with a solvent until they are grease-free and should then be treated with a solid lubricant which does not contain molybdenum disulfide (see “Recommendations for lubricating greases and pastes”).

A left and right handed plow drive unit is required in order to operate a plow system.

The left or right handedness of symmetrical plow drive units is defined by the position of the locking device (ratchet pawl), covering plate and lifting. These components must always be installed at the top. The mounting assembly also differs on the gearbox side.

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4.3

How to install the plow drive unit Fig. 3:

Plow drive unit HK 30-3, illustration of the gearbox (direct gearbox flange connection) a 1

900

1248

X

2

1600

Bucyrus DBT Europe GmbH, Lünen 2008

665

539

E

2

4 1 Plow drive unit HK30-3 2 Mounting assembly HK30-3 plow drive unit - drive frame 4 Mounting assembly HK30-3 plow drive unit - Gearbox

a Cover plate X Marking

You can either assemble the individual components of the drive train - plow drive unit, gearbox, drive connection assembly, E-motor - one after the other or install the completely pre-assembled drive train on the plow flange plate.

The installation of the individual components is described in the following. For information on installing the pre-assembled drive train refer to Chapter 5, section “How to replace wear parts”.

Important!

Be aware that the following instructions for the “individual assembly” of the components also applies to the pre-assembly of the drive train.

4.4

Plow drive unit HK 30-3

How to install the plow drive unit How to install the plow drive unit The HK30-3 plow drive unit is installed on the head-end and the tail-end drive.

It can be flanged either directly to the gearbox or to an intermediate gearbox (optional). The length and arrangement of the mounting assembly differs accordingly.

The mounting assembly of the HK30-3 is fastened to the drive frame or gearbox using hydraulic tensioning nuts.

Notice!

For hydraulic tensioning nuts it is also imperative that you observe the separate operating manual of the respective manufacturer.

Mounting assembly Fig. 4:

HK30-3 mounting assembly, plow drive unit - drive frame 6 3

Bucyrus DBT Europe GmbH, Lünen 2008

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** ** **

2

**

**

** 4 3

1

* 5 ** ** 1 Hydr. tensioning nut M 30x3.5 KU 1) 2 Hydr. tensioning nut M 30x3.5 KO 2) 3 Expansion screw M 30x248 4 Expansion screw M 30x538 5 Expansion screw M 30x426

1) 2)

Doc. no.: 6052 015 000 BA 00

6 Hex. head screw M 30x110-10.9 * Working pressure 1850 bar ** Working pressure 2275 bar

KU = Lower lock ring KO = Upper lock ring

VLVT / 03

4.5

How to install the plow drive unit Fig. 5:

HK30-3 mounting assembly, plow drive unit - gearbox ** **

**

**

2

1

3

**

**

Fig. 6:

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3 Hex nut M 36x10 ** Working pressure 1850 bar

HK30-3 mounting assembly, plow drive unit - intermediate gearbox *** ***

***

***

***

*** 2 1 3

***

***

1 Hydr. tensioning nut M 36x4 KU 1) 2 Screw bolt M 36x328

1) 2)

4.6

3 Hex nut M 36x10 *** Working pressure 1900 bar

KU = Lower lock ring KO = Upper lock ring

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

1 Hydr. tensioning nut M 36x4 KU 1) 2 Screw bolt M 36x480

How to install the plow drive unit Flanging the plow drive unit on to the drive frame Before installation remove the mounting assembly expansion screws from the plow drive unit (see Fig.4).

. Using lifting equipment position the plow drive unit on the driveframe. When flanging on be sure to observe the correct hole patterns of the machine parts.

. Insert the expansion screws into the bores. . Handtighten the tensioning nut on the expansion screws.

Caution!

The tensioning nuts are tightened using pump pressure. Observe the working pressure required for tightening each individual tensioning nut. The working pressure must not exceed 2275 bar under any circumstances.

Bucyrus DBT Europe GmbH, Lünen 2008

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Notice!

For hydraulic tensioning nuts it is also imperative that you observe the separate operating manual of the respective manufacturer.

Fig. 7:

Installing the plow drive unit 1 2

4

3 1 Plow drive unit HK30-3

3 Mounting assembly HK30-3 plow drive unit - drive frame

2 Drive frame

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4 Mounting assembly HK30-3 plow drive unit - intermediate gearbox

4.7

How to install the plow drive unit Flanging on the gearbox Before installation insert the mounting bolts in the corresponding bores. Ensure that the expansion screws have been inserted correctly.

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

must be clean and free from burr.

J Before flanging on, grease the shaft gearing well and align it

such so that the teeth and tooth gaps are opposite one another to ensure that they mesh smoothly.

J During installation move the gearbox horizontally and parallely

to the plow drive unit. Then position on the centering bores, plug connections and parallel keys.

J Avoid damaging the gearing and canting the gearbox during

assembly.

J After installing the gearbox, there must be no strain between

gearbox and plow drive unit or between the drive shaft.

J Observe the working pressure of the tensioning nuts.

. Insert the expansion screws into the bores. . Handtighten the tensioning nut on the expansion screws.

Caution!

The tensioning nuts are tightened using pump pressure. Observe the working pressure required for tightening each individual tensioning nut. The working pressure must not exceed 2275 bar under any circumstances.

Notice!

For hydraulic tensioning nuts it is also imperative that you observe the separate operating manual of the respective manufacturer.

Caution!

Observe the separate gearbox operating manual.

4.8

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

unit. When flanging on be sure to observe the correct hole patterns of the machine parts.

E

. Using lifting equipment position the gearbox on the plow drive

How to install the plow drive unit Fig. 8:

Installing the plow drive unit directly to the gearbox 4

1

Bucyrus DBT Europe GmbH, Lünen 2008

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2 1 Plow drive unit HK30-3

4 Mounting assembly HK30-3 plow drive unit - gearbox

2 Gearbox

Fig. 9:

Installing the plow drive unit to an intermediate gearbox

4

1 2 3 1 Plow drive unit HK30-3

4 Mounting assembly HK30-3 plow drive unit - intermediate gearbox

2 Intermediate gearbox 3 Gearbox

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4.9

How to install the plow drive unit Installing the drive connection assembly and the E-motor Notice!

It is imperative you observe the separate operating manuals of the E-motors used and the manufacturer’s instructions regarding installation of the drive connection assembly.

Bucyrus DBT Europe GmbH, Lünen 2008

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Caution!

Only install electric motors with performance specifications (torque, speed) permissible for the plow drive unit (see Chapter 6 “Technical data”).

If you prefer to install electric motors other than those approved by us, please contact our service department in advance.

4.10

Plow drive unit HK 30-3

Locking device Locking device When coupling a plow chain a locking device must be used to safely clamp the open plow chain. Please refer to the face conveyor operating manual for detailed information on coupling and tensioning the plow chain.

Danger!

Working on chains which are under tension requires particular care.

You or others could be seriously injured or even killed by the recoiling plow chain!

During the tensioning procedure, you must thus ensure that all persons are kept out of the danger area and that the danger area is cordoned off over a wide range.

Always work from alongside of the plow chain.

How to lock the plow chain

E

The plow drive unit is equipped with a pivot-mounted locking device (ratchet pawl). The locking device prevents the chain from moving forward or backward into the plow drive unit when the plow chain is opened.

Bucyrus DBT Europe GmbH, Lünen 2008

Danger!

The plow drives generate forces in the chain which could irreparably damage the claw or the ratchet pawl.

As a result, you or others can be seriously injured or even killed!

When the claw or the ratchet pawl are engaged, only use the hydraulic or pneumatic chain tensioner to move the plow chain.

Note the separate operating manual.

. Undo the screw connection item 4 and push the ratchet-type lock item 1 to one side.

. Pivot the locking device (ratchet pawl) onto the chain sprocket.

Fig. 10: Locking device

4

2

1 3

1 Ratchet-type lock 2 Locking device 3 Plow chain wheel

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4 Hex. nut M24-10 Hex. head screw M 24x75-10.9

4.11

Tensioning the plow chain Danger!

The locking device can only lock the plow chain if it engages in a chain link which is lying flat.

Note that the plow chain must also be blocked in the area of the end guide before you open it (see the conveyor operating manual).

Caution!

After connecting the plow chain, the locking device must be disengaged and secured against reengaging using the ratchettype lock.

Tensioning the plow chain In order the tension the plow chain during operation chain links are removed from the plow chain.

Further information about tensioning the plow chain can be found in the plow operating manual.

Test run and start-up Danger!

Make sure that all personnel has left the hazardous area of the plow system. Make sure you keep a safe distance from the plow system, particularly during test runs. In these phases for example, installation errors may cause hazards that would not arise during normal operation.

Caution!

It is imperative you observe the following instructions, the corresponding special instructions contained in the plow system operating manual and in the operating manuals of the plow system components, e.g.: plow, E-motors, gearbox.

Before start-up The following points need to be checked on the plow drive unit before beginning with the start-up of the plow system: J The cover plate must be closed.

J The ratchet pawl must be in idle position.

J The bearing must be sufficiently greased.

J Check the bolted connections for secure fit.

J Check the chain pretension of the plow chain (retension if nece-

ssary).

4.12

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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The plow chain is correctly pretensioned when approx. 1 to 2 links of chain are slack in the upper race of the drive that pulls the lower chain, when the plow is mining.

How to dismantle the plow drive unit Test run The chain should be coated with oil in order to avoid dry rubbing between plow chain and chain wheel.

Notice!

Make sure that you observe environmental protection regulations under all circumstances. Use bio-degradable vegetable oils, water pollution class 0, due to total-loss lubrication Check and inspect the following points during the test run: J Steady motor current consumption.

J Level motor current consumption.

J Rolling behavior of the chain at the chain wheels.

J Slack chain formation.

J Heating and quiet running of the gearboxes.

Remedy any faults discovered during the test run.

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How to dismantle the plow drive unit Bucyrus DBT Europe GmbH, Lünen 2008

Dismantling should be carried out in the most practical sequence according to the prevailing conditions, generally in reverse assembly order.

Important instructions for dismantling Dismantling and withdrawing operations may only be carried out by persons with adequate knowledge of the work to be performed and who have been adequately trained for these particular requirements.

Important instructions for dismantling handling of delicate components

. Protect all exposed shafts, hubs, labyrinth channels and flanges against corrosion, contamination and damage.

. Close off all open lines and separation points with protective caps or screw plugs.

. Pack loose parts, screws, etc. in suitable containers in order to protect the components against soiling, damage and/or loss.

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4.13

How to dismantle the plow drive unit Disassembling the plow drive unit from the drive frame In order to make it easier to disassemble the plow drive unit, the two mounting assembly expansion screws are used as jack screws.

The expansion screws must be removed and repositioned in the corresponding bores (see Fig.7). Tightening the expansion screws pushes the plow drive unit away from the drive frame making disassembly easier.

Notice!

For hydraulic tensioning nuts it is also imperative that you observe the separate operating manual of the respective manufacturer.

. Prior to disassembly attach the plow drive unit to suitable lifting equipment.

. Disassemble the mounting assembly “HK 30-3, Plow drive unit - drive frame”. See chapter 4, figs. 4 and 7.

. Remove the expansion screw (4) from bore (a) and place it in

. Tighten the expansion screws in turn until the plow casing is pushed away from the drive frame.

. To prevent damage to the expansion screws (4, 5)

during disassembly remove them before detaching the plow drive unit.

Fig. 11: Disassembly of the plow drive unit

a d

b c

5

4 4 expansion screw M 30x538 5 expansion screw M 30x426

4.14

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

. Remove the expansion screw (5) from bore (c) to bore (d).

E

bore (b).

5

Operation

How to operate the plow drive unit

Operation This chapter contains important information on the operation and maintenance of the plow drive unit.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in Chapter 2 “Your safety”.

How to operate the plow drive unit Danger!

Incorrect operation endangers yourself and others!

Incorrect operation of the plow drive unit is often the cause of very serious accidents.

Operate the plow drive unit only when you have sufficient knowledge of the plow drive unit and have read and understood all the operating manuals on the conveyor system.

Should anything be unclear, please contact your supervisor!

Who is allowed to operate the plow drive unit?

Bucyrus DBT Europe GmbH, Lünen 2008

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The plow drive unit may only be operated by persons with an adequate knowledge of the whole conveyor system.

This also entails knowing: J Which safety systems are installed on the system.

J Where these safety systems are located.

J How these safety systems are to be operated.

How to maintain the plow drive unit Maintenance at regular intervals increases the operational safety and prolongs the service life of the plow drive unit. danger of explosion

Be sure to observe the intervals specified maintenance and checks of the plow drive unit as hot surfaces may ignite explosive atmospheres and dust.

Temperature and acoustic emission monitoring Three measuring points are provided in the plow drive unit for temperature and acoustic emission monitoring (see Fig. 12).

The operator can use a continuous monitoring system to switch off the drive if: J impermissible temperatures are reached, J impermissible structure-borne noise characteristics are indi-

cated.

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5.3

How to maintain the plow drive unit Important notes Please observe the following instructions: J in order to avoid individual components not being serviced or

being only inadequately serviced during maintenance work on the conveyor system as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operating manual and the manuals of the other components.

J Inadequately performed maintenance can cause machine dam-

age which can result in considerable costs.

Be sure to observe the specified maintenance intervals.

J Use only suitable and approved tools for maintenance work!

J Use only original DBT spare parts when replacing components.

Maintenance includes: J Checking the bolted connections for secure fit, J Lubricating the bearings, J Scheduled maintenance,

J Inspecting wear parts, J Replacing bearings.

Use proper tools only for maintenance work.

Important!

You should place a container with the tools required and the most useful spare parts in the vicinity of the point of operation.

Adequately protect the contents from dirt, dust and moisture.

Tightening the bolted connections tightening torque

tightening bolts

For bolted connections, the tightening torques of which are not listed in this operating manual or replacement parts list, the tightening torques according to EWN 6003 apply (list in Chapter 6 “Technical data”).

The bolted connections listed in the following must be tightened 60 hours after initial start up and then once every 500 hours.

J Gearbox mounting bolts

Notice!

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

Caution!

Damaged and missing parts must be exchanged or replaced immediately.

5.4

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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J Maintenance of the hydraulic system,

How to maintain the plow drive unit Lubricating the bearings Caution!

During operation, the relubrication intervals must not exceed 100 hours. Lubrication of the plow drive must take place when it is running.

The lubrication points are located outside on the end face of the plow drive unit. The plow drive unit is lubricated via the grease inlet (lubricating nipple) (Grease A2, see Chapter 6, section “Lubricating greases and pastes”). The lubricating nipple has been marked red at the factory.

Grease the lubrication point with the plow drive running until fresh grease is visible at the grease outlet.

Important!

Leaking lubricant must be disposed of according to the manufactuer’s instructions.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 12: Lubrication point

X 1 2

1 Grease inlet (lubricating nipple) 2 Grease outlet

X Thread bores M 8 for bearing monitoring

Scheduled maintenance daily

Check the function and condition of the safety systems.

Perform a visual check to monitor the free-flow of the chain on the chain sprocket.

Check the general condition of the plow drive unit. Pay particular attention to over heating. The plow drive unit must also must be cleaned. Abnormal discoloring on the housing and abnormal noises during operation are signs of over heating.

Check the plow chain pretension and retension it if necessary. For this see Chapter 4 in the conveyor operating manual.

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5.5

How to maintain the plow drive unit weekly

Visual check of the fastening elements.

monthly

Check the screw fittings on the plow drive unit and the conveyor as well as the plow drive unit and gearbox for secure fit.

Check the chain pretension of the plow chain and retension if necessary.

replacing bearings

Replace the bearings after the maximum bearing service life has elapsed.

In order to replace the bearings the complete plow drive unit must be dismantled and passed on for servicing. It is not possible to exchange the bearings underground.

Bearing service life data is listed in Chapter 6 “Technical data.”

Bucyrus DBT Europe GmbH, Lünen 2008

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After completion of a removal phase and a move to a new removal phase the remaining service life of the bearings must be sufficient for the runtime in the removal phase. Should this not be the case the bearings must be replaced.

5.6

Plow drive unit HK 30-3

How to replace wear parts How to replace wear parts Plow chain wheel The chain sprocket transmits the torque from the gearbox to the chain. The chain sprocket is subject to increased wear due to drive forces and must be replaced periodically.

The degree of wear can be measured at anytime with a depth gauge. The height H is measured with the depth gauge diagonally over the chain link to the bottom of the groove. The chain sprocket must be exchanged or replaced if the height H is less than 77 mm (87 mm - 10 mm wear).

Fig. 13: Wear measurement on the chain sprocket

Bucyrus DBT Europe GmbH, Lünen 2008

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H

Caution!

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

When the wear on the chain sprocket is greater than 10 mm it must be replaced.

Forward the wheel-bearing set to servicing.

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5.7

How to replace wear parts Caution!

When the wheel-bearing set needs repairing the complete plow drive unit must be removed and sent for servicing. assembly unit

The low chain wheel is a component of an assembly unit (wheelbearing set). The complete assembly unit is removed from the plow drive unit in order to replace the plow chain.

The main components of the assembly unit are: J the bearing housings with bearings, J the shaft, J the chain stripper (deflector plate), J the plow chain wheel.

Fig. 14: Wheel-bearing set (assembly unit) 26 2 X

Bucyrus DBT Europe GmbH, Lünen 2008

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1

3

13 4, 12 5 8

22 20 9

11

10

1 Plow chain wheel HK30-3 2 Bearing housing fixed bearing side (FT) 3 Shaft W 220x10x20 4 Bush movable bearing side 5 End plate

5.8

8 Shear pin

20 Hex. head screw M 30x60 - 10.9

9 Centering piece

22 Expansion screw M 24x150 - 10.9

10 Retaining bolt for chain stripper

26 -Hex. head screw M 24x90 - 10.9

11 Deflector plate

x Fitted wheel-bearing set

12 Spherical bearings

Plow drive unit HK 30-3

How to replace wear parts The following figure (Fig. 15) shows the schematic arrangement of the drive line components. You can either dismantle the individual components of the drive line - plow drive unit, intermediate gearbox (optional), gearbox, drive connection assembly, and motor - one after the other or dismantle the whole drive line on the drive frame.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 15: Drive line - Plow (schematic diagram)

1

2

3

1 E-motor 2 Drive connection assembly 3 Gearbox dismantling the drive line

4

5

6

4 Intermediate gearbox 5 Plow drive unit 6 Drive frame

The complete drive line or the individual components are removed from the plow drive unit in order to exchange the assembly unit (wheel-bearing set) along with the plow chain wheel.

. Suspend the complete drive line using a suitable chain hoist.

Note that the drive line has to be swung out after it has been dismantled from the drive frame.

. Observe the plow drive unit assembly/disassembly instructions (see Chapter 4, section “How to install the plow drive unit”).

. Swing the drive line so far away from machine so that you sufficient space to dismantle the plow drive unit (5) (See Fig. 17 for the depth of the assembly unit).

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5.9

How to replace wear parts Danger!

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

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

Fig. 16: Dismantling the drive line

1

3

3 Drive frame Bucyrus DBT Europe GmbH, Lünen 2008

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1 Drive line 2 Plow drive unit

2

Fig. 17: Depth of the plow drive unit

3

2

665 2 Wheel-bearing set 3 Plow drive unit

5.10

Plow drive unit HK 30-3

How to replace wear parts Caution!

When the wheel-bearing set needs repairing the complete plow drive unit must be removed and sent for servicing. exchanging the assembly unit

The wheel-bearing set (assembly unit) is pushed out of the plow drive unit to exchange the chain sprocket and the chain stripper.

. Remove the hex. head screws M24 (item 4). . Push the assembly unit out of the plow drive unit using back-off thread M 24 (item 1).

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 18: Plow drive unit with wheel-bearing set (assembly unit)

2

4

1 3 1 Back-off thread M 24 2 Wheel-bearing set

3 Plow drive unit 4 Hex. head screw M 24x90 - 10.9

. Send the wheel-bearing set to servicing to have the chain sprocket and the chain stripper replaced.

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5.11

How to replace wear parts Disassembling the wheel-bearing set Caution!

When the wheel-bearing set needs repairing the complete plow drive unit must be removed and sent for servicing. exchanging the plow chain wheel and the strippers

In order to replace the chain sprocket and the chain stripper the wheel-bearing set (assembly unit) is dismantled during servicing (see Fig. 19).

Caution!

The wheel-bearing set is sensitive to contamination when it has been dismantled and removed. It may not be dismantled on site. Always send the wheel-bearing set to servicing!

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 19: Wheel-bearing set

2

9

11

10, 18

3

1 Plow chain wheel HK30-3 2 Bearing housing fixed bearing side (FT) 3 Shaft W 220x10x20 4 Bush movable bearing side 5 End plate 9 Centering piece

5.12

1

13

4, 5, 12

22

10 Retaining bolt for chain stripper 11 Deflector plate 12 Spherical bearing 13 Face seal 22 Expansion screw M 24x150 - 10.9

Plow drive unit HK 30-3

How to replace wear parts Chain stripper Caution!

When the wheel-bearing set needs repairing the complete plow drive unit must be removed and sent for servicing.

Chain stripper

The plow drive unit is equipped with chain stripper to release the circulating plow chain from the plow chain wheel at the right moment.

Fig. 20: Chain stripper

9

9 Centering piece 10 Retaining bolt for chain stripper

E Bucyrus DBT Europe GmbH, Lünen 2008

11

disassembly / assembly

10 11 Chain stripper (deflector plate)

The chain stripper is mounted on the bearing housing - fixed bearing of the bearing set (assembly unit). It should always be exchanged together with the chain sprocket.

. Pull the retaining bolts (10) out of the deflector plate (11) and the centering piece (9).

. Remove the deflector plate that is now exposed.

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5.13

How to replace wear parts Exchanging the plow chain wheel Caution!

When the wheel-bearing set needs repairing the complete plow drive unit must be removed and sent for servicing.

. Unscrew the three expansion screws (22). . Remove the bush (4) along with the end plate (5), spherical

bearing (12) and face seal (13) from the shaft (3) (see Fig. 19).

. Now you can pull the plow chain wheel (1) off the shaft. . Install the new plow chain wheel and the new deflector plate in reverse order.

Fig. 21: Wheel-bearing set with installed chain stripper

22

9 2 11 10 1 Plow chain wheel 2 Bearing housing fixed bearing side (FT) 9 Centering piece 10 Retaining bolt for chain stripper

1 11 Deflector plate 22 Expansion screw M 24x150 - 10.9 26 Hex. head screw M 24x90 - 10.9

. Tighten the screw connections (22) (expansion screw M24 - 10.9) with the specified tightening torque.

. Transport the repaired wheel-bearing set from servicing to the plow drive unit.

. Push the wheel-bearing set into the plow drive unit. . Tighten the nuts on the bolted connection with the specified tightening torque (bolted connection M 24 - 10.9).

5.14

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

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26

6

Technical data

Technical data sheet

Technical data This chapter contains the main technical data for the plow drive unit. Further information is given in the spare parts lists and in the separate operating manuals for the individual components such as e.g. the gearboxes and the electric motors. Information about tightening torques, greases etc. is given at the end of this chapter.

Please read this chapter carefully and at your leisure. Pay particular attention to the safety instructions.

Technical data sheet Length: . . . . . . . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . . . . . . . .

1600 mm 665 mm 1248 mm 3380 kg

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Symmetrical type Conversion to left or right hand opeof construction: . . . . . . . . . . . . ration can be achieved by switching round the locking device (ratchet pawl), protective flap and lifting eyes Bucyrus DBT Europe GmbH, Lünen 2008

Permissible power ratings: . . . see table 1 Gear variable: . . . . . . . . . . . . . . 45 Gearing: . . . . . . . . . . . . . . . . . . . W 260 x 10 x 24; DIN 5480 Service life of bearing: . . . . . . . 10 000 h 1) Preparation . . . . . . . . . . . . . . . . Thread bores for bearing monitoring 2)

Permissible power ratings Tab. 1: Max. permissible power ratings on the HK 30-3 with 2 drives and a 42x137-6Z plow chain Chain sprocket 42x137-6Z Ratio

16

21

25

28

33

Chain speed (m/s)

2.52

1.92

1.61

1.44

1.22

Motor stall coefficient Total of transferable powers at the headend and tail-end drive (KW)

1.6

2.5

1.6

2.5

1.6

2.5

1.6

2.5

1.6

2.5

2 x 500 =

2 x 500 =

2 x 500 =

2 x 500 =

2 x 455 =

1000

1000

1000

1000

910

The following parameters were applied when calculating the power ratings: J Gearbox coefficient: . . . . . . . 0.96 J Chain wheel coefficient: . . . 0.85 J Upper race coefficient: . . . . 0.24 J Face length: . . . . . . . . . . . . . 300 m 1) Corresponds to 90% of the calculated modified bearing service life.

2) Preparation for bearing monitoring. The operator can use a continuous bearing monitoring system.

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6.3

Tightening torques Permissible power ratings The power ratings given in table 1 are continuous ratings. They apply to E-motors with a nominal rpm of 1470 min-1. The stalling torque must not exceed the stall coefficient of 2.5 when starting up the E-motors.

Tightening torques Screws with ISO metric thread Pitch P

Tightening torque 4)

(mm)

(mm)

MA (Nm)

d

Coarse thread

Fine thread

8.8

10.9

12.9

A 2-70

A 4-80

M8

1.25

23

32.5

39

17

23

M 10

1.5

46

65

78

34

45

M 12

1.75

80

113

135

59

78

(M 14)

2

127

178

215

94

125

M 16

2

195

275

330

146

195

(M 18)

2.5

270

380

455

202

270

M 20

2.5

380

535

640

285

380

(M 22)

2.5

510

720

865

384

512

M 24

3

655

920

1100

490

654

-

1100

-

M 24

2

Dm 24 2)

3

535

-

-

(M 27)

3

965

1360

1630

-

1600

-

(Dm 27 2))

(M 27) 3

2

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 must be followed for installation and maintenance work!

1) 2) 3) 4)

6.4

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

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

Only for expansion screws having a reduced shaft cross-section of 24.2 mm.

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

Plow drive unit HK 30-3

Bucyrus DBT Europe GmbH, Lünen 2008

Thread 1)

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Tab. 2: Tightening torques at µtotal = 0.14

Permissible media Permissible media Lubricating greases and pastes Important!

The lubricants to be used are specified in the respective chapters, e.g. installation, maintenance.

Lubricating greases properties

Bucyrus DBT Europe GmbH, Lünen 2008

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lubricating grease 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 range of application:

-20 to +120 °C

Flashpoint:

>= 200 °C

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for installation (according to EWN *) 7068).

Tab. 3: Lubricating greases for general application

lubricating grease A2

Flashpoint in °C

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Lubricating greases containing additives for high pressure applications e.g. for roller bearings and bearing locations subject to extreme load Tab. 4: Lubricating greases with additives Flashpoint in °C

Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

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. Lubricating greases with different compositions must not be mixed, as this may change the consistency, i.e. the mixture might become thinner so that the lubrication effect is not sufficient.

It may also be dangerous to use lubricating greases that have the same saponification base but different origins. When in doubt, the manufacturer of the lubricating grease to be used should be contacted to confirm the compatibility of the grease in question.

Lubricating pastes lubricating paste B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering bores and connections of splined shafts of sprocket drums and chain sprockets during installation. *) EWN = works standard

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Permissible media Tab. 5: Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

Gleitmolybdän

Gleitmo 805 *)

Li

NLGI class

Flashpoint in °C

2

220

When the equipment is lubricated at our works for the first time, the lubricating paste B 3 according to the works standard EWN 7068 is used: Gleitmolybdän “gleitmo 805”

Behavior in the presence of water:

non-soluble in water

Temperature of application:

-34 to +120 °C

When the equipment is treated at our works for the first time, the lubricant type used as lubricating paste B 6 in accordance with the works standard EWN 7068 is: Chesterton parting and lubricating material 785 (flashpoint 132 °C) Important!

The instructions for mixing lubricating greases also basically apply to the lubricating pastes.

*) The products listed in table 3 are suitable lubricating greases for filling of adjacent cavities.

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Separating agents and lubricants with organic lubricating media on a synthetic base material for greasing threaded areas and fitting points on props and hydraulic cylinders, of pin connections and similar connection elements at the shield support

Bucyrus DBT Europe GmbH, Lünen 2008

lubricating paste B6

Plow drive unit identification Plow drive unit identification Manufacturer: . . . . . . . . . . . . . . . Bucyrus DBT Europe GmbH Type: . . . . . . . . . . . . . . . . . . . . . . . Plow drive unit HK 30-3 Year of construction: . . . . . . . . . MM/YY (e.g.: 05/07 ≙ May 2007) ID no.: . . . . . . . . . . . . . . . . . . . . . . 6052 015 000 00 0X *) Weight: . . . . . . . . . . . . . . . . . . . . . 3 380 kg The markings on the plow drive unit provide the following information. The location of the identifcation markings are illustrated in Fig. 3.

Fig. 22: Type plate and CE-marking, example

Bucyrus DBT Europe GmbH

05/07 Bucyrus DBT Europe GmbH, Lünen 2008

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6052 015 000 00 0X HK 30-3

3 380 kg

The design of the plow drive unit meets the requirements of the European Directive 94/9/EC and of DIN EN 1710. It is suitable for use in potentially explosive atmospheres.

*) X = Place holder for variant ID number

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Bucyrus DBT Europe GmbH, Lünen 2008

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Plow drive unit identification

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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.

Bucyrus DBT Europe GmbH, Lünen 2008

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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

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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.

+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

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4041 Wurno Road Pulaski, VA 24301

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

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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.: 6052 015 000 BA 00

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Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 6: National standards and directives, extract

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

Quality of drinking water Documentation system Hydraulic system plug connections Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulphate ash Tensioning force, tightening torques and surface pressure for bolts T-head bolts Lubricating greases & solid lubricants Non metallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) 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 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 7: European standards and directives, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 DIN EN 1710 DIN EN 1552

Date of issue

Title

Directive of the European Parliament and the Council on the approximation of the laws of the Member States relating 1998-06-22 to machinery Directive of the European Parliament and the Council on the laws of the member states concerning equipment 1994-03-23 and protective systems intended for use in potentially explosive atmospheres Safety of machinery 2004-04 Safety of machinery 2004-04 Non-electrical equipment for use in potentially explosive 2002-04 atmospheres - Part 1: Basic methods and requirements Electrical apparatus for explosive gas atmospheres 2004-12 - Part 0: General requirements Basic and safety principles for human - machine 2000-08 interface Creating manuals 2001-11 - Structure, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water - Distillation method Device and components for use 2006-01 in firedamp-endangered areas of underground mines Mobile extraction machines on the face - safety 2003-09 requirements for shearers and plane systems 1) EWN = works standard

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Title

Bucyrus DBT Europe GmbH, Lünen 2008

Designation