CAT Beamed Stageloader BEVEL HELICAL PLANETARY GEARBOX EKP-15 Operation & Maintenance Manual – PDF DOWNLOAD

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CAT Beamed Stageloader BEVEL HELICAL PLANETARY GEARBOX EKP-15 Operation & Maintenance Manual – PDF DOWNLOAD

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CAT Beamed Stageloader BEVEL HELICAL PLANETARY GEARBOX EKP-15 Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :79
Downloadable : Yes
File Type : PDF
Size:2.54 MB

TABLE OF CONTENTS:

CAT Beamed Stageloader BEVEL HELICAL PLANETARY GEARBOX EKP-15 Operation & Maintenance Manual – PDF DOWNLOAD

1 Introduction ………………………………………………………………………… 4
Revision Table …………………………………………………………………….. 4
1.1 Legal Provisions ……………………………………………………………….. 4
Identification …………………………………………………………………. 4
Manufacturer …………………………………………………………………… 4
Proper Use …………………………………………………………………….. 4
Improper Use …………………………………………………………………… 4
Liability ……………………………………………………………………… 4
Warranty ………………………………………………………………………. 5
Copyright ……………………………………………………………………… 5
1.2 The Operating Manual …………………………………………………………… 6
Definition of Terms …………………………………………………………….. 6
Gearbox ……………………………………………………………………. 6
Eickhoff …………………………………………………………………… 6
User ………………………………………………………………………. 6
Operating Personnel …………………………………………………………. 6
Qualified Personnel ………………………………………………………… 7
Skilled Electrical Engineers …………………………………………………. 7
Eickhoff Antriebstechnik GmbH Personnel ……………………………………….. 7
Residual Hazards ……………………………………………………………. 7
Protective Clothing …………………………………………………………. 7
Pictorial Representations and Textual Displays ……………………………………. 8
General Hazard ……………………………………………………………… 8
High Electric Voltage ……………………………………………………….. 8
Hot Components ……………………………………………………………… 8
Ecologically Harmful Substances ………………………………………………. 8
Safety-Related Note …………………………………………………………. 8
Supplementary Information ……………………………………………………. 8
Structure and Contents of the Safety Instructions …………………………………. 9
Essential Elements of a Safety Instruction …………………………………….. 9
2 Safety Instructions …………………………………………………………………..10
2.1 General Safety Instructions ………………………………………………………10
Safety of the Gearbox ……………………………………………………………10
The Operating Manual …………………………………………………………….11
Duties of the User ……………………………………………………………..12
Active Personnel ………………………………………………………………..12
2.2 Safety Instructions for Transport and Storage ……………………………………..13
2.3 Safety Instructions for Assembly …………………………………………………15
2.4 Safety Instructions for Commissioning/Start-up …………………………………….16
2.5 Safety Instructions for Servicing and Maintenance ………………………………….17
2.6 Safety Instructions for Waste Disposal ……………………………………………19
3 Technical Description …………………………………………………………………20
3.1 Scope of Supply …………………………………………………………………20
3.2 State as Supplied ……………………………………………………………….20
3.3 Rating Plate …………………………………………………………………..21
3.4 Designated Use ………………………………………………………………….21
3.5 Design and Principle of Operation ………………………………………………..22
General ………………………………………………………………………..22
Casing …………………………………………………………………………22
Toothing ……………………………………………………………………….22
Bearings ……………………………………………………………………….22
Lubrication ……………………………………………………………………23
Cooling ………………………………………………………………………..23
Monitoring ……………………………………………………………………..23
Sealing ………………………………………………………………………..23
Bolted and Screwed Connections ……………………………………………………23
3.6 Limits of Application …………………………………………………………..24
3.7 Quality Assurance ……………………………………………………………….24
3.8 Technical Details ………………………………………………………………25
4 Transport and Storage …………………………………………………………………26
4.1 Transport of the Gearbox …………………………………………………………26
Transport Conditions …………………………………………………………….26
4.2 Storage of the Gearbox ………………………………………………………….28
Storage Conditions ………………………………………………………………28
Long-Term Preservation ………………………………………………………….29
Interim Storage / Withdrawal from Service …………………………………………30
Only for gearboxes with complete sealing by shaft seal rings ……………………..30
Inspection ……………………………………………………………………..30
5 Assembly and Commissioning/Start-up …………………………………………………….31
5.1 Assembly ……………………………………………………………………….31
Prerequisites for Assembly ……………………………………………………….31
Mounting the Gearbox …………………………………………………………….31
Converting the Gearbox to the Clockwise or Counterclockwise Direction of Rotation ……..33
Aligning the Gearbox …………………………………………………………….33
Environmental Conditions …………………………………………………………33
Mounting the Shaft Connections …………………………………………………..34
For parallel key connections: …………………………………………………34
For flange connections: ………………………………………………………34
For frictional connections (such as shrink disks): ………………………………34
Mounting the Ancillary Units ……………………………………………………..34
For Couplings, Hubs, Flanges … : …………………………………………….34
For Backstops: ……………………………………………………………..35
For Forced Lubricating Systems: ……………………………………………….35
For Oil Heaters: …………………………………………………………….35
For Oil Coolers: …………………………………………………………….35
After Assembly ………………………………………………………………….35
5.2 Commissioning/Start-up ………………………………………………………….36
Preservation ……………………………………………………………………36
Prior to Commissioning ………………………………………………………….37
Procedure …………………………………………………………………..37
For Hydraulic Motors …………………………………………………………37
For Forced Lubricating Systems: ……………………………………………….37
For Oil Coolers: …………………………………………………………….37
For Oil Heaters: …………………………………………………………….37
Oil Filling ……………………………………………………………………38
For filling through the Oil Filling Hole or the Threaded Hole of the Breather ………38
Oil Level Check ………………………………………………………………..39
For Gearboxes with Oil Level Sight Glass ……………………………………….39
During the Running-in Period ……………………………………………………..39
Commissioning / Start up …………………………………………………………39
6 Servicing and Maintenance ……………………………………………………………..40
Hoses (if any) ……………………………………………………………………..42
Ball Cocks (if any) ……………………………………………………………..42
6.1 Maintenance / Inspection Schedule Table …………………………………………..43
6.2 Oil Analysis and Oil Changes …………………………………………………….44
Acceptable Oil Types …………………………………………………………….44
Oil Sampling ……………………………………………………………………44
Oil Analysis …………………………………………………………………..45
Oil Changes ……………………………………………………………………46
Oil Changing Procedure …………………………………………………………..47
Flushing Procedure ………………………………………………………………48
Flushing with Flushing Oil ……………………………………………………48
6.3 Application of Loctite ………………………………………………………….49
Applying the Adhesive ……………………………………………………………49
For Bolted or Screwed Connections …………………………………………………49
6.4 Changing the Rolling Bearing Grease ………………………………………………50
6.5 Table of Malfunctions …………………………………………………………..51
7 Drawings and Tables …………………………………………………………………..52
7.1 Dimensioned Drawing ……………………………………………………………..52
006923G1C……………………………………………………………………….53
7.2 Spare Parts Drawings …………………………………………………………….54
G028225XA_01…………………………………………………………………….55
G028225XA_02…………………………………………………………………….56
7.3 Spare Parts Lists and Spare Parts Sublists …………………………………………57
Spare Parts Lists ……………………………………………………………….57
G028225X ……………………………………………………………………58
Spare Parts Sublists…………………………………………………………….62
G029475ZA …………………………………………………………………..63
G038063Y ……………………………………………………………………64
7.4 Table of Lubricants …………………………………………………………….65
7.5 Assembly of the Bevel Gears ……………………………………………………..66
Klingelnberg Cyclo-Palloid-Bevel Gears …………………………………………….66
Contact Zone of Klingelnberg Cyclo-Palloid Bevel Gears ……………………………..67
Options for Correcting the Contact Zone …………………………………………..68
Height Displacement of the Contact Zone ………………………………………..68
Lateral Displacement of the Contact Zone ……………………………………….68
Guides for the Torsional Backlash Relative to the Normal Module ……………………..69
8 Annex ……………………………………………………………………………….70
8.1 Service ………………………………………………………………………..70
8.2 Company Address …………………………………………………………………70
8.3 Agencies ………………………………………………………………………71
8.4 Declaration of incorporation ……………………………………………………..72
8.5 Supplement …………………………………………………………………….73
Supplement to the Operating Manual Governing the Use of Gearboxes according to 94/9/EC ….73
Prerequisites for operation: ………………………………………………….73
Actions to be carried out before commissioning/start-up: …………………………73
Actions to be carried out during commissioning/start-up: …………………………74
…………………………………………………………………………..74
Maintenance on the gearboxes …………………………………………………75
Functional disorders of the gearbox such as: ……………………………………75
9 Accessories ………………………………………………………………………….76
9.1 CORTEC Corrosion Inhibitor ……………………………………………………….76
9.2 Anticorrosion Grease ……………………………………………………………78

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