PDF Operation & Maintenance Manual CAT K-20B Armored Face Conveyor Gearbox - 875 KB
This manual provides essential operation and maintenance instructions for the CAT K-20B Gearbox, used in Armored Face Conveyor (AFC) systems in mining.
It covers proper operating procedures, lubrication requirements, and routine maintenance schedules to ensure maximum reliability in harsh underground environments.
Following these guidelines is crucial for preventing catastrophic failures and extending the service life of this critical powertrain component.
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EM015401-0 (EN-US)
ID-Nr. BI001716
Jul. 2010
Operation and
Maintenance
Manual
Gearbox
Doc-No.: 9145 010 000 BA 00
SAFETY.CAT.COM
SAFETY.CAT.COM
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EM015401-0 (EN-US)
2 Your safety
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EM015401-0 (EN-US)
Storage
Storage and transport
This chapter contains important information on the correct storage
and transport of the gearbox.
Following the instructions and tips will increase the life cycle and
service life of the gearbox. 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
Storing the equipment
corrosion protection Components coated with temporary anticorrosive are protected for
around six months.
avoid direct exposure Protect the equipment against direct exposure to sunlight.
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 ºC to 25 ºC.
E
moisture and dirt Protect all parts of the equipment stored outdoors against moisture
Caterpillar Global Mining Europe GmbH, Lünen 2012
and dirt, e.g. using tarpaulins.
The mounting surfaces of hydraulic components must be protected
against corrosion and sealed with blind plates. Protect the hydraulic
plug connectors and the connectors of the electrical cables with the
caps and plugs supplied.
short term storage During short-term storage (approx. 4 weeks) of equipment out-
doors, but at temperatures above freezing, electrical components
need not be removed. Such components must be particularly pro-
tected against excessive temperatures, dirt and moisture.
long term storage During long-term storage (more than 4 weeks), the equipment must
not be stored outdoors. It must be stored in a dry, well ventilated
room.
After a storage period of approx. two years, a random sample
inspection must be performed to determine whether the measures
taken and the method of storage has prevented damage.
The inspection can be carried out by DBT 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.
Important!
Ensure when storing that any new supplies are stored separ-
ately from existing stocks in such a way that on removal, old
stocks are always taken first.
frost protection for Before storing gearboxes with oil coolers at ambient temperatures
the oil cooler below the freezing point, flush out the oil cooler with antifreeze.
Doc. no.: 9145 010 000 BA 00 VTVI / 03
3.3
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EM015401-0 (EN-US)
Gearbox installation
Fig. 6: Mounting device
12
23
13 11
11 Threaded spindle 13 Bush
12 Washer 23 Hex. nut
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Caterpillar Global Mining Europe GmbH, Lünen 2012
The drive shaft is locked in place using the hex. nut on the
threaded spindle (item 11).
The retaining washer (item 8 - Fig. 5) and sprung dowel pin are
inserted into the Voith Turbo fluid coupling after the threaded
spindle has been removed from the shaft end. The hex. head screw
(item 5) is then screwed in with the spring washer (item 6) into the
gearbox drive shaft.
The gearbox shaft connection is thereby firmly secured to the
Turbo coupling hub ready for operation.
Fig. 7: Mounting the Voith Turbo fluid coupling
Doc. no.: 9145 010 000 BA 00 VTVI / 03
4.7
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EM015401-0 (EN-US)
5 Operation
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Main dimensions and connections
Fig. 15: Gearbox K-10 - toothed hub 190, main dimensions, port dimensions
M2 M1 ZN
OS
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Caterpillar Global Mining Europe GmbH, Lünen 2012
PA W MS A
O2
O1
A = Breather plug O2 = Oil drain (screw plug M 30x1.5)
M1 = Dipstick 517 lg. MS = with shearing head
M2 = Dipstick 360 lg. OS = without shearing head
with breather plug PA = Parallel key A 25x14x140
W = Water port ZN = Toothed hub N 190
O1 = Oil drain (screw plug M 30x1.5)
Doc. no.: 9145 010 000 BA 00 VTVI / 03
6.5
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EM015401-0 (EN-US)
Oil levels and oil quantities
Oil level - Oil overflow screws
If the gearbox is operated in horizontal position in a low heading,
instead of using a dipstick the oil level can be checked using the
overflow screw on the side of the gearbox.
The oil chambers of the gearbox K-10 / oil chamber of the K-10.1
must be filled with oil so that it reaches the lower edge of the
respective oil overflow bore.
Caution!
When using this measurement method the gearbox inclination
must not exceed ±10 in conveying direction and 0º in mining
direction.
Fig. 26: Checking the oil level using the overflow screw
1 2
OH
OA
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Caterpillar Global Mining Europe GmbH, Lünen 2012
3 4 5
1 Oil filling screw - Drive shaft bearings 1)
2 Oil filling screw - Main gearbox
3 Oil overflow screw - Drive shaft bearings 1)
4 Oil overflow screw - Main gearbox
5 Oil level sign
OA = Drive shaft bearing oil level 1)
OH = Main gearbox oil level
1) Only applicable to gearbox K-10 with two oil chambers
Doc. no.: 9145 010 000 BA 00 VTVI / 03
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