PDF Operating Manual CAT Bucyrus RHH AFC PF 3822 - 755 KB
Master the functions of the CAT Bucyrus RHH AFC PF 3822 with this detailed operating manual.
It provides comprehensive instructions on the machine's controls, systems, and proper operational techniques.
This guide is essential for ensuring both safety and productivity in demanding mining environments.
Operators will find all the necessary information to run the equipment effectively.
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Operating manual
RHH-AFC PF 3/822
Doc. no.: 0010 297 000 BA 00
Bucyrus DBT Europe GmbH
Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: [email protected]
D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com
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Safety instructions
Carry out a visual inspection of all the hydraulic components at reg-
ular intervals. In particular check that:
J the hoses are not pinched,
J the hoses have no bubbles or blisters,
J the hoses or the outer sheaths of the hoses are not abnormally-
rigid or hard,
J the outer sheath of the hose is not damaged,
J the connectors are securely inserted into the sockets,
J the connections are leak-tight.
Ensure that no dirt enters the hydraulics system during repair work.
Dirt in the hydraulic system can cause serious damage to the whole
system. Flush out the hydraulic lines thoroughly before connecting.
If staples are difficult to disconnect or cannot be disconnected, the
hydraulic line may still be pressurized. Make sure the line is de-
pressurized.
Secure the connectors of the hydraulic elements with the proper
coupling clips only. Always fasten the staples completely with both
sides.
E
Never use nails, wire or similar materials to secure the connectors.
Bucyrus DBT Europe GmbH, Lünen 2008
After finishing repair work, check all connectors and connections for
leaks before pressurizing the system again.
permissible hoses Use only hydraulic hose lines approved for the prevailing pres-
sures.
Do not use any hydraulic hoses with damaged connectors or worn
O-rings.
Replace hydraulic hoses only with hoses of the same or a higher
quality.
Observe the date of manufacture stamped on the hydraulic hoses.
Never use hydraulic hoses which are more than 2 years old, even if
they have no visible signs of damage.
Fig. 1: Example: 4SP hydraulic hose, identification
3
2
1
4
5
6
1 manufacturer 4 Standard
2 hose type
5 nominal diameter
3 date of manufacture,
1st Quarter 2002 6 Flame-resistant and antistatic
Never try to hold a hydraulic hose that is thrashing about. Depres-
surize the line in question immediately.
Doc. no.: 0010 297 000 BA 00 VRVT / 01
2.11
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Bucyrus DBT Europe GmbH, Lünen 2008
E
Head Gate
Coal Block 160 m
Coal Face Conveying Direction
Doc. no.: 0010 297 000 BA 00
Fig. 11: Installation plan
VRVT / 01
Coal Block 160 m
Plow Limit / Synchronization Switch
Coal Face
Loudspeaker + Emergency Stop
Outrigger Steering Cylinder
Outrigger Steering Control Valve
Auxiliary Control panel
RHH-pans
RHH-pans w. switch
RHH special pans
Tail Gate
Outrigger steering
Overview - RHH-AFC PF 3/822
4.11
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How to install drive frames and drive units
Gearbox P 25/30 and P-30 UEL-R
Notice!
Observe the separate operating manuals for the gearboxes
used.
Important general information on installing the gearbox:
J All flange surfaces, centering bores, parallel keys and grooves
must be clean and free of burrs.
J The gearing must be well-greased before being mounted.
J The gearing must be aligned so that tooth and tooth gap are ex-
actly opposite one another to ensure that they mesh smoothly.
Try to avoid damage to the gearing. Take special care to ensure
that the gearbox is not tilted during installation.
J The gearbox must be positioned accurately on the centering
bores, connectors, and parallel keys when being installed.
J All gearbox connections must be sealed with O-rings. The vari-
ous O-ring sizes can be obtained from the spare parts docu-
mentation for the gearbox utilized.
J Ensure you use the correct screw sizes corresponding to the
E
gearboxes used.
Bucyrus DBT Europe GmbH, Lünen 2008
J The gearbox is fixed to the flange plate using hydraulic tension-
ing nuts. Pay attention to the working pressure for the tension-
ing nuts (Fig. 19, Item 3).
Notice!
For this, follow the separate operating manual of the hydraulic
tensioning nuts of the respective manufacturer.
J After installing the gearboxes, there must be no strain between
gearbox and drive frame or between the drive shafts.
Drive connection
The drive connection comprises all components arranged between
the E-motor and the gearbox. It mainly consists of a protection
cover and a coupling.
Flange position “W” Flange position “W” of the E-motor means the distance between the
motor flange and the shaft collar. On the drive connection the
flange position is the distance between the contact surface of the
protection cover (motor side) and the contact surface of the coup-
ling (see Fig. 22).
Caution!
If flange position “W”on the E-motor is larger than on the drive
unit connection assembly, the motor shaft and gearbox drive
shaft bearings can become strained This can result in damage
to the gearbox and the E-motor!
Doc. no.: 0010 297 000 BA 00 VRVT / 01
4.21
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How to install drive frames and drive units
Rerailer
Rerailers are installed in the bottom race on both sides of the ad-
aptor pans on the head and tail gate.They are used to guide flights,
that are below the bottom race, into the bottom race again before
they enter the drive frame. The flight flips the rerailing flap (2) up
and the flight moves onto the inlet supports (c).
Prior to start-up the spring (4) must be tensioned sufficiently so that
the rerailing flap is level with the lower profile.
Fill the rerailer with grease before start-up via the lubricating nipple
(9). Lubricate once a month during operation.
Fig. 32: Rerailer in the adaptor pan
8 a
2
c
E
Bucyrus DBT Europe GmbH, Lünen 2008
b
Detail rerailer
(diagram without rerailing flap)
5, 7 3
9
4 10
6, 7
2 rerailing flap 8 spring dowel pin
3 shaft 9 lubricating nipple
4 flexible spring for rerailers 10 end ring
5 hex. head screw M 20x60-10.9 a stop plate
6 hex. head screw M 20x90-10.9 b adaptor pan
7 hex. nut V M 20-10 c inlet supports
Doc. no.: 0010 297 000 BA 00 VRVT / 01
4.31
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How to install the conveyor pans
Fig. 45: Dogbone connection - face side
b
c
2 a 3 5
2 filler piece for dogbone a dogbone pocket
3 lock for dogbone
b dogbone
5 centering bolt
M 20x45-10.9 c dogbone retainer at the pan
. Place the filler piece (1) on the centering bolt (5) and screw the
E
Bucyrus DBT Europe GmbH, Lünen 2008
centering screws with the nut (4) tight.
Fig. 46: Dogbone connection - face side
2 3 5 1 4
1 filler piece 4 collar nut M 20
2 filler piece for dogbone with securing element,
SW 30
3 lock for dogbone 5 centering bolt
M 20x45-10.9
a dogbone
The connection is now completed and secured.
Doc. no.: 0010 297 000 BA 00 VRVT / 01
4.41
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How to restrain and tension the chain
Danger!
A ratchet pawl apparatus that has not been fastened properly
or sufficiently might come loose during the tightening opera-
tion. As a result, you or others can be seriously injured or even
killed!
Only use the connecting and securing elements provided. Each
time before installation always check the connecting elements
for damage.
Warning!
If the ratchet pawl is able to engage in the chain during opera-
tion you or others can be severely injured and can cause seri-
ous damage to the drives. After work on the chain has been
completed, the support with ratchet pawl and all nuts and se-
curing devices must be removed.
Chain-ratchet pawl on baffle plate
The pivot-mounted ratchet pawl for blocking the chain is loaded
after the flap (5) is opened so that its dead-weight will cause it to lie
against the chain strands. If the chain is retracted (head gate), then
the vertical chain links will lift the ratchet pawl. The ratchet pawl en-
gages in the openings of the subsequent horizontal chain links and
blocks the chain.
E
Bucyrus DBT Europe GmbH, Lünen 2008
Caution!
Once the chain has been tensioned, the ratchet pawl must be
folded away to the outside and the flap closed again, so that
the ratchet pawl will be prevented from engaging in the chain
during operation!
Fig. 59: Chain ratchet pawl on baffle plate - tail gate
5
7
5 flap 7 ratchet pawl
Doc. no.: 0010 297 000 BA 00 VRVT / 01
4.51
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How to start up the conveyor system
Test run of the conveyor
Danger!
Make sure that nobody is present in the hazardous area of the
conveyor system during the test run.
In this phase, a safe distance should be kept to the conveyor
as e.g. due to installation errors hazards may occur which
would not occur during normal operation.
These hazards could cause severe injuries or even death!
Make sure that you keep sufficient distance between you and
the conveyor system especially during the test operation.
test run of the When you have checked the conveyor and remedied any faults dis-
empty conveyor covered, the proper interaction of the individual components of the
complete system must be checked. For this purpose, carry out a
test run with the empty conveyor (appoximately ½ hour).
. As the conveyor is running empty, you have to lubricate the
chain at the chain sprockets, in order to avoid excessive wear
of the chain sprockets.
Notice!
Use biodegradable vegetable oils, Water Pollution Class 0, to
lubricate the chain sprockets due to total-loss lubrication.
E
Ensure you observe the applicable environmental regulations.
Bucyrus DBT Europe GmbH, Lünen 2008
. lubricate the overall installation at the lubrication points.
. Check and inspect the following points:
J Uniform and equal power consumption of the E-motors.
J Sufficient cooling of the E-motors.
J Sufficient cooling and proper oil filling of the gearboxes.
J Steady and quiet running of the gearboxes.
J Steady rolling behavior of the chain at the chain drums.
J Uniform entry of the chain to the drive frame
J Check that the flights enter the chain guides properly.
J Check conveyor flight spacing.
J Correct number and installation position of flights.
J Check that chain connectors are fitted correctly and in the right
installation position.
J Optimum chain pretension.
J Function of the sequencing control of the conveyor drive units.
J Function of the safety devices such as the signaling devices,
EMERGENCY STOP circuit, etc.
Only when tensionable tail gate drive frames are being utilized:
J Apply full working pressure to the cylinders of the tensionable
drive frame several times for approximately one minute each
during the test run. Correct the length of the chain as soon as
the required chain pretension is not achieved by tensioning the
tensionable drive frame.
Doc. no.: 0010 297 000 BA 00 VRVT / 01
4.61
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How to perform maintenance on the conveyor
Lubrication of the system in accordance with the lubrication
schedule
Tab. 6: Lubrication according to runtime
Component 1) Medium Runtime in hours
1. 2. 3. ...
Drive frame - head gate
- drive bearing Grease 2) 8 100 100 ...
Drive frame - tail gate
- drive bearing
Gearbox
E-motors
3)
Chain tensioners
(pneumatic or hydraulic)
Plow, plow drive unit, etc.
. Pump grease into the central lubrication points with the con-
veyor running until fresh grease emerges.
Notice!
During operation, the relubrication intervals must not exceed
100 hours. Lubrication must be carried out with the conveyor
E
running, as only then will the grease be distributed uniformly.
Bucyrus DBT Europe GmbH, Lünen 2008
Lubrication points
The bearings on the head gate and tail gate are each supplied with
grease via a central lubrication system.
Grease the bearings until fresh grease is visible at the grease out-
let.
Fig. 63: Bracket for central lubrication
9
9 lubricating nipples
1) The listing is general and does not relate to a particular conveyor system.
2) Grease A2, see Chapter 6, Section entitled “Lubricating greases and pastes”
3) See information in the corresponding operating manual.
Doc. no.: 0010 297 000 BA 00 VRVT / 01
5.5
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How to replace wear parts
Chain stripper
The drive frames are provided with chain strippers which assist in
releasing the circulating chain from the chain pockets of the chain
sprocket in time.
replacement When replacing a worn chain sprocket always replace the chain
strippers as well.
disassembly After opening the chain and removing the stripper plate (1), the
chain stripper (5) can be pulled out toward the top when the chain
sprocket is installed. The baffle plate must first be removed before
the chain stripper on the tail gate can be replaced (see chapter 4,
section “Chain stripper”, Fig. 26).
fastening The chain strippers are fastened on the support receptacles on the
right and the left side. The chain strippers are secured in position in
their recesses by means of a round steel bar welded to the stripper
plate.
Caution!
Should the strippers come loose during operation, the chain