CAT BUCYRUS FB58 Awaba Feeder Breaker Maintenance Manual M01259 - PDF DOWNLOAD Language : English P

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Technical Manual

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Awaba Feeder Breaker Maintenance Manual FB58 Manual No.M01259

BI619308

Bucyrus Australia

Awaba Feeder Breaker Operators Manual

Version 1

Release

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CONTENTS SPECIFICATION OF FEEDER/BREAKER.................................................................................................... 5 TECHNICAL DATA: MOBILE FEEDER/BREAKER FB 63 MT ........................................................ 5 OPERATING AREA....................................................................................................................................... 6 GENERAL DESCRIPTION ........................................................................................................................... 6 FEEDER/BREAKER MAIN COMPONENTS ............................................................................................. 7 LUBRICATION AREAS AND FFEQUENCY ............................................................................................. 8 SECTION 2........................................................................................................................................................... 9 BREAKER............................................................................................................................................................ 9 IMPACT ROLL SIZER................................................................................................................................... 9 SIZING ADJUSTMENT (OPTIONAL) ....................................................................................................... 10 OPERATIONAL DATA OF ROLL SIZER ................................................................................................ 11 BREAKER DRIVE........................................................................................................................................ 12 MAX. THROUGHPUT.................................................................................................................................. 14 FUNCTIONAL CHARACTERISTICS ........................................................................................................ 15 DUST SUPPRESSION ................................................................................................................................ 16 SECTION 3......................................................................................................................................................... 17 CRAWLER TRACK .......................................................................................................................................... 17 TRANSPORT ................................................................................................................................................ 18 TRACK CHAIN TENSIONING ................................................................................................................... 19 CRAWLER CHAIN....................................................................................................................................... 20 SECTION 4......................................................................................................................................................... 21 CONVEYOR....................................................................................................................................................... 21 CONVEYOR (FEEDER) .............................................................................................................................. 21 CONVEYOR DRIVE..................................................................................................................................... 21 CONVEYOR DRIVE..................................................................................................................................... 22 CONVEYOR PAN, CHAINS AND FLIGHTS ........................................................................................... 22 CONVEYOR PAN, CHAINS AND FLIGHTS ........................................................................................... 23 TAIL END AND HYDRAULIC TENSIONING DEVICE........................................................................... 24 CONVEYOR LIFTING DEVICE.................................................................................................................. 26 SECTION 5......................................................................................................................................................... 27 HYDRAULIC CIRCUIT................................................................................................................................... 27 SECTION 6......................................................................................................................................................... 28 ELECTRICAL ................................................................................................................................................... 28 OPERATION OF THE FEEDER/BREAKER............................................................................................ 28 HYDRAULIC BRAKE PRINCIPLES OF OPERATION AND DESIGN.................................................... 29

Sequence for dismantling ................................................................................................................... 29 Supply connections .............................................................................................................................. 30 SECTION 7 COMMISSIONING OF MACHINE ................................................................................................................ 31 SIZER WITH GEARBOX............................................................................................................................. 31 TRACK SYSTEM (UNDERCARRIAGE) .................................................................................................. 32 CONVEYOR AND HOPPER ...................................................................................................................... 32 SECTION 8......................................................................................................................................................... 33 MAINTENANCE AND REPAIR ..................................................................................................................... 33

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CHECK IMPACT ROLL AND BEARING ..................................................................................................33 CHECK OF GEARBOXES AND PLANETARY REDUCTION GEARS ...............................................33 GENERAL CHECKS ....................................................................................................................................33 CRAWLER TRACK ASSEMBLY ...............................................................................................................33 DISASSEMBLY OF TRACK CHAIN .........................................................................................................34 ASSEMBLY OF NEW PARTS....................................................................................................................34 CRAWLER TRACK ASSEMBLY ...............................................................................................................35 CONVEYOR CHAIN AND FLIGHT ASSEMBLY.....................................................................................36 BREAKER AND HOPPER ADJUSTMENT (LOCKING)........................................................................36 SECTION 9 .........................................................................................................................................................37 TOOLS ................................................................................................................................................................37

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SPECIFICATION OF FEEDER/BREAKER 0B

TECHNICAL DATA: 16B

MOBILE FEEDER/BREAKER FB 63 MT

Drawing No.

0404.00000.

Type of Breaker

Impact Roll Sizer SB 63 Fab.No.996

Gear

1 Gearbox KSB 63

Total Length

9000mm

Height

1820mm

Width

2724mm

Hopper Capacity

13m³

Customer Centennial Mine Awaba Seam/District Machine No.FB58 Job No. Customer Order No. Delivery Date

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OPERATING AREA 17B

The transportable Feeder/Breaker (self-propelled or tow able) is one of the key tools in coal mining.

The never ending demand for increased efficiency of the three functional operations into which work is divided: 1)

Preparation and excavation of coal to be dug.

2)

Crushing and sizing of coal gained from face.

3)

Transportation of sized coal to surface.

Means that these functions must be collectively executed with proper coordination to give the best efficiency. The transportable Feeder/Breaker is the key equipment of Phase Two (2) of the overall operation, providing a high degree of reliability with min. maintenance requirements. Being the major unit in the sequence, the efficiency of the overall operation depends on the continued functioning of this tool. The transportable Feeder/Breaker is provided with full control, well balanced in speed and power and, if properly used, is capable of high volume output at a low cost per unit of throughput.

GENERAL DESCRIPTION 18B

KLOCKNER-BECORIT mobile feeder/breakers are designed to crush coarse material of high compressive strength to a grain size that allows a smooth, steady and efficient flow.

The standard heavy duty impact roll sizer incorporated in the feeder/breaker not only crushes coal, but also hard rock, sandstone or other tough materials with ease and efficiency, which has proven in Australia, Africa, The United States and Europe in manu applications.

The material is discharged by a continuous miner or front end loaded into the hopper and fed into the sizer, which is driven by either one or two electric motors via a flexible coupling, a hydraulic coupling and a gearbox.

The impact roll, fitted with hard faced, wear resisting impact elements, rotates at high speed thus generating appreciable kinetic energy, which safeguards against excessive drop in rotation speed at peak throughputs.

Two adjustable hydraulically operated cylinders allow the height of the breaker drum to be adjusted to achieve the specified material size.

The chain conveyor, driven by either an electric or hydraulic motor, is designed for a continuous output and to meet the heavy forces applied by the sizer.

Friction between flight bars and the face conveyor pans is kept to a minimum, resulting in low drive power requirements and long life. The conveyor tail end is equipped with grease jacks to allow easy tensioning of the two endless chain strands.

The two wide heavy duty caterpillar tracks are driven independently by electric or hydraulic motors, operating directly on the gearboxes to the drive sprockets. When tramming, the feeder is held in a horizontal position by two hydraulic cylinders.

After Feeder/Breaker has been positioned to accept flow of material, the two hydraulic cylinders controlling hopper elevation can be activated by a hand pump, to elevate discharge side of Feeder/Breaker to clear boot of outgoing conveyor.

Usually this means that the Feeder/Breaker hopper end will be resting on the ground providing a stable crushing unit. The hand operated hydraulic system is controlled by two four-directional valves, one for the breaker and one for the hopper circuit.

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FEEDER/BREAKER MAIN COMPONENTS Tramming Position 19B

Item 1:- Breaker (Impact Roller Sizer).

Item 2:- Conveyor.

Item 3:- Crawler Tracks.

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LUBRICATION AREAS AND FFEQUENCY 20B

C

Fluid Coupling

SFR-D 46

D E F

Gearbox Breaker Planetary Drive Track Gearbox Conveyor Tail End Shaft Bearings

Omala 220 Omala 220 MP-Grease

11 ltr-horiz 20 ltr. 15º

X

X

X

X

X

X

6 lt.each Side Pump till outrun witness

Every 4000 hrs

SFR-D 46

Every 2000 hrs

Fluid Coupling

X

Monthly

B

Lower Plug Only 13 1

Weekly

Omala 220

OILCHANGE AND LUBRICATE

Daily

Gearbox Conveyor

TO BE CHECKED & OIL ADDED IF NECESSARY Monthly

A

VOLUME

Weekly

TYPE OF LUBRICANT

Daily

APPLICATION

X X

X

X

X

F1 Pump till outrun witness

Breaker Shaft Bearings Conveyor Chian Tensioning Cylinder Conveyor Drive Shaft Bearing

MP-Grease

As Req’d

X

MP-Grease

Pump till outrun witness

X

K

Track Tension Cylinder

MP-Grease

As req’d

L

Track Rollers, Upper & Lower

MP-Grease

Packed Only

M

Gearbox Conveyor

MP-Grease

Plug near E-Motor Only 500 g

N

Electric Motor Bearings

MP-Grease

As Req’d

O

Hydraulic System

Tellus 46

Sight Glass

P

Coating of FlameProof Faces

Molicoat* 3 (Appr.Lube)

Sealing Coat Against Moisture

G H J

MP-Grease

X

X

X

J1

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X PREPACKED FOR LIFETIME, ONLY REQUIRED WHEN SEALS ARE CHANGE X

X

PRE-LUBRICATED MOTORS – REPACK AFTER 20,000 HRS. GREASABLE MOTORS – EVERY 10,000 HRS. x

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Section 1B

2

Breaker 2B

IMPACT ROLL SIZER 21B

Item 4:- Impact Roller and Shaft Item 5:- Breaker Drive Item 6:- Breaker Lifting Device Item 7:- Dust Suppression Item 8:- Breaker Housing

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SIZING ADJUSTMENT (OPTIONAL) 2B

The passage height through the crusher can be adjusted by means of two hydraulic cylinders, which are operated by a hand pump.

Adjustment can be achieved in steps of 40 mm from 150 mm up to 310 mm. Locking pins hold the breaker at the selected operating height.

11) Hydraulic Lifting Cylinder.

12) Locking Pin.

Hydraulic Lifting Cylinder

Locking Pin

Crusher/Sizer lever

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OPERATIONAL DATA OF ROLL SIZER 23B

TYPE

SB 63 U COMPACT ROLL

SB 63 U COMPACT ROLL

SB 63 U COMPACT ROLL

Drive power (kW)

75

90

110

Speed (Rev/min) (min-1)

470

470

470

Peripheral speed (m/s)

22,4

22,4

22,4

Throat area below roll (m²)

0,230,34

0,260,36

0,260,36

Rotational energy (Nm)

196.000

196.000

196.000

Volume flow up to approx (m³/h)

750

1100

1500

at constant speed of m/sec

0,65

1,0

1,5

at a sizing of (mm)

-200

-200

-200

Volume flow and energy requirements depend on universal crushing conditions and conveying speed.

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BREAKER DRIVE 24B

To fit the drive unit, the protective cover for the sizer shaft end is removed, the rubber gasket inserted, and the gearbox type KSB 63 fitted to the toothed shaft end by means of the hydraulic mounting device. The shaft end has to be cleaned and greased before assembly. The gearbox case is bolted to the bearing cover of the impact roll bearing. Whilst pushing the gearbox onto the breaker shaft, it has to be ensured during the last 30 mm that the bottom shaft of the gearbox slides smoothly onto the breaker shaft. The location of the venting plug is to be on the upper side of the gearbox. The fluid coupling together with one half of the flexible coupling SV 230 has already been mounted to the drive shaft of the gearbox.

Connecting flange of Breaker Fluid coupling

Breaker shaft

Gearbox KSB 63

Bell housing Flexible cam coupling

Using these types of couplings, attention must be paid prior to mounting of the electric motor that a spacer is placed between the electric motor and the bell housing. Also the dimensions specifically marked on the enclosed drawing have to be checked. These dimensions have to be maintained to avoid axial loads on the motor bearings.

Prior to mounting the electric motor, the support bracket between bell housing and breaker housing, has to be fitted. This support bracket is not only supporting the breaker drive but acts as an antirotation device.

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ELAOL OIL NON-FLAMMABLE

MINERAL OIL COUPLING TYPES FOR BREAKER & CONV. DRIVES / 4 POLE E/M

CONTENTS IN LTR.

NO. OF BOLTS FROM 12,00

CONTENTS IN LTR.

NO. OF BOLTS FROM 12,00

TUVA 422 – 75 kW

10,5

8

8,5

9

TUVA 487 – 90 kW

12,5

12

10,0

13,5

TUVA 487 – 100 kW

13,5

10

12,0

12

TUVA 487 – 75 kW

11,5

12,5

10,5

13

TUVA 366 – 22 kW

6,0

7

5,0

8

TUVA 366 – 37 kW

7,0

6

6,0

7

SPECIFIC DENSITY:

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SFR – D 46 = 1.35 / dm³ MINERAL OIL = 0.84 / dm³

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MAX. THROUGHPUT 25B

The valves indicated in the diagram are to be considered approx. since the throughput is influenced by the following factors: Shape of roll and sizing tools, adjusting height of the roll, conveying speed and number of flight bars, type and composition of material to be crushed, height of loaded material before the sizer and drive power.

Variations resulting from different conveyor widths are negligible.

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FUNCTIONAL CHARACTERISTICS 26B

The breaker operates on the continuous principle. The material to be crushed is continuously fed through the breaker by the chain conveyor, seized and crushed by the impact roll which rotates at high speed. The impact roll fitted with sizing tools releases part of the stored rotational energy. This amount of energy is sufficient that the speed of the impact roll is hardly reduced in case or temporary peaks.

Impact Roller

Impact Hammer or Sizing Tool.

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DUST SUPPRESSION 27B

The breaker is mounted in a dustproof enclosure. Inlet and outlet sections of the breaker housing are each fitted with three special water jets.

Water feed is controlled by a paddle-valve which is activated by the outgoing hinged door of the Breaker.

A gate valve and strainer are part of the water feed assembly.

Section A-B

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Section 3 3B

CRAWLER TRACK 4B

The Feeder/Breaker tramming system consists of the following: 14) Undercarriage and tracks.

15) Drive unit.

16) Track chain 17) Support rollers.

18) Front idler and track tensioning device.

Two heavy duty cat track systems are joined by two cross beams, which also support the feeder (conveyor) and the breaker.

The machine is powered by two 11 kW electric motors which are directly mounted onto the intermediate spur gear and the planetary gear boxes. The reduction of the gearbox is 215 : 1 which will give a torque of 1590 mKp on each track.

The track chains are supported by lifetime lubricated bottom and top rollers.

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Since tensioning of the track chain is track is equipped with a hydraulic chain tensioning device.

The machine can be trammed forwards and backwards and can be spot turned by means of a pendant control system, which is described elsewhere in this manual.

TRANSPORT 28B

As a self-propelled steer able machine, the Feeder/Breaker can be trammed into position under its own power, where suitable power supply points are available along the route. Where this is not the case, it can be towed to its operating area, the removal of two easily accessible gear parts (4 & 15) in the tramming drive permitting the tracks to free wheel (Opt.)

Transport on flat-tops is also possible provided sufficient head room exists along the entry road. In the case of low head room, the overall height of the Feeder/Breaker can be reduced by removing the top cover and rotating the drum until the hammer sections are horizontal.

A further option in reduced height sections is to transport the machine on bogies which can be attached at the front and rear of the Feeder/Breaker. (This option can only be used is provision has been made at the time of ordering).

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TRACK CHAIN TENSIONING 29B

1) 2) 3) 4) 5)

Front Idler.

Compression Spring.

Idler Arm. Hydraulic Cylinder.

Grease Nipple

To absorb extreme stress loads on the crawler track, a pretensioned set of coil springs absorbs impact loads from the sliding track idler assembly. When fitting the track chain, initial stress should not be greater than relaxed dimension of coil springs. It must be observed that the track chain always remain slightly in the sag position on either side of the top roller. Should the track chain be too tight, relief of the track tension is effected by releasing some of the grease in the grease jack. A screwdriver (Size 27) permits the turning of the filler nipple which is mounted at the rear of cylinder.

The complete idler assembly consisting of coil springs, the idler stirrup and the sliding parts are pushed into the box section of the crawler side frame which is provided with matching slide ways.

When tensioning the track chain, the idler assembly is moved longitudinally by adding grease to the cylinder with a grease gun. The hydraulic tensioner is mounted at a transverse plate in the crawler side frame.

The idler and full disc wheel assembly is induction hardened at the running surfaces to reduce wear.

Idler shaft bearings are oil lubricated and the filling plug is located in the hub of the idler wheel.

The slide ring seals which are installed between the hub of the front idler and the sliding piece, prevent leakage of oil and the external penetration of dirt.

The slide ring seals have an exceptionally long working life. Re-lubrication is not necessary as the oil cavity is hermetically sealed.

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CRAWLER CHAIN 30B

tightening of the track chains

the chain is tensioned by means of a grease gun o

via the hydraulic cylinder

The chain may only be tensioned so tightly that it sags between 1.5 – 3.5 cm per 1 metre of length.

Note: Sag must be checked on either side of top.

Chains which are tensioned too slack, do not lie correctly on the idlers and are therefore slipping.

Because of this, the chain links are worn out where the idler is contacting.

Chains which are tensioned too tightly increase the wear of the front idler bearing, of the drive bearing and accelerate the wear of the track pins and bushes.

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SECTION 4 5B

CONVEYOR 6B

CONVEYOR (FEEDER) 31B

24) 25) 26) 27) 28)

Drive Head.

Drive Unit.

Conveyor Pan, Flight and Chain.

Hopper.

Tailend with Chain Tensioning Device.

29) Lifting Device.

Conveyor Chain and Flights

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CONVEYOR DRIVE 32B

The conveyor is powered by a 37 kW electric motor via a fluid coupling and speed reducing bevel gear box. With the gear reduction of 29:1, we achieve a theoretical torque on the chain sprocket of 6000Nm, at a chain speed of 0.65 m/sec. This will result in a discharge rate of approx. 550 to/hr. at a flight bar distance of 1000 mm.

The drive head with the attached drive unit is bolted onto the outlet or discharge side of the breaker.

El. motor, fluid coupling, gearbox, chain sprocket, bearings and drive shaft form one unit and can be dismantled from the drive frame without removing the drive frame from the breaker.

Due to the spline shaft connection between gearbox and conveyor drive shaft, misalignment between gearbox and shaft is avoided.

Heavy duty roller bearings (grease lubricated) guarantee long service of the drive head.

Parts such as chain and flight guides, which are prone to wear, can be easily removed.

Terminal J Box

Conveyor Drive Motor Conveyor Drive Gearbox

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CONVEYOR PAN, CHAINS AND FLIGHTS 3B

As conveyors pans, longwall face conveyor sections with 20 mm deckplates are used. The chain is a 19 x 64.5 mm endless round link chain, which is joined with a master link.

The master link must be positioned in the upright position to have access to the lock pin.

The flights are held between two chain links. The roll pin is only necessary for assembly reasons. No load is transmitted through the pin.

The flight bars can only be removed or fitted on the drive head of the conveyor and slots cut into the deckplates of the drive frame give access for assembly and dis-assembly.

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TAIL END AND HYDRAULIC TENSIONING DEVICE 34B

Return sprockets, the shaft and the bearing can be removed from the tail end after disconnecting of the conveyor chain and removing of bumper and skid loader. As sprockets, shaft and bearing form one unit, no misalignment can occur. All wearing parts in the tail end can be easily removed and replaced.

31) Grease Jack For trouble-free operation, proper chain tensioning is very important. This is achieved by two grease operated jacks. If the conveyor chain is too tight, it will increase the power consumption. If it is too loose, it could result in jamming of flights and chain in the drive head and tail end.

Tail roller grease line

Tail roller Nipple and Bleed off Screw

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Extend Grease Nipple and Bleed off Screw

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32) Filler Plug The grease jacks are operated by an ordinary grease gun.

Releasing of over-tensioned chain will be achieved by loosening the filler plug and locking plates have to be taken out. If the chain is too loose, the grease jack has to be operated and locking plates have to be added.

Tail roller Nipple and Bleed off Screw

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Extend Grease Nipple and Bleed off Screw

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CONVEYOR LIFTING DEVICE 35B

Whilst being transported or trammed, the Feeder/Breaker is held in the horizontal position by a locking device.

If the Feeder/Breaker is in position close to the boot end, it will be lifted up by hydraulic cylinders to accommodate the boot end underneath the drive head or discharge of the conveyor. A locking device secures the conveyor in the chosen height.

Lockout bar

Conveyor lift cylinder

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Section 7B

5

Hydraulic Circuit 8B

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Section

6

Electrical OPERATION OF THE FEEDER/BREAKER 36B

Control E/L test

Control E/L Reset

Machine Start

Machine Stop

Sequence Defeat

Conveyor Inch Reverse

Overload Reset

Conveyor Inch Reverse Interlock

Power pack start

12 Volt lights Tram Sequence

Forward

Reverse

Power pack Stop

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HYDRAULIC BRAKE PRINCIPLES OF OPERATION AND DESIGN 9B

To suit 160 motor frame flange/flange mounting.

Maximum shaft speed 3500 rpm Wet dynamic torque 260 Nm Wet static torque 370 Nm Brake release pressure 15-18 Bar 218-263 PSI Pressure inlet thread M12x1.5 Brake cavity drain thread M12x1.5 Pressure relief valve 20 Bar 290 PSI

Sequence for dismantling 49B

1) 2) 3) 4)

Remove electric motor from outer flange item (3).

Undo the 12 brake assembly screws item (7).

Remove the outer flange from the brake assembly.

Using a bearing puller withdraw the exposed “press fitted” bearing item (6) from the inner shaft item (4).

5) The brake assembly item (8) can now be withdrawn from the inner shaft item (4) and inside flange.

6) The shaft with the “press fitted” bearing item (5) can readily be withdrawn from the inside flange item (2) and out of the gearbox arrangement.

7) Unbolt the inside flange from the gearbox.

Sequence for assembly A reversal of the above procedure is sufficient.

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Brake size KMB 2 5 12 32 50 80

Screws for manual emergency release M6x20 M6x20 M8x20 M8x25 M8x25 M10x20

Brake size KMB 125 225 550 800 1250 2500

Screws for manual emergency release M12x35 M12x35 M12x40 M12x55 M16x60 M16x60

Supply connections 50B

The brakes are provided with pressure oil and a leakage oil pipe. The pressure oil pipe for the pressure oil conduct is made as per DIN 3852 shown on page 37. The nominal diameters are stated on the dimensional drawing.

The pressure oil conduct for brake opening is connected to the pressure oil pipe. The pressure oil conducts must be short and free from sharp bends or cross section contractions. To protect the brake against inadmissible oil peaks a pressure relief valve has to be provided. Place the manometer as close as possible to the brake.

The stated brake torque is only achieved with unpressurized feed lines.

When provides an oil leakage pipe, it must be arranged vertically to bottom allowing the leakage oil to drain unpressurized to the oil tank.

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SECTION 10B

7

Commissioning of Machine 1B

Having established the electrical connection and connected the monitoring equipment, proceed as follows prior to first trial run.

SIZER WITH GEARBOX 37B

a.)

Lubricate the roll bearing (see lube-chart)

b.) rams

Adjust impact roll to the required passage height by activating power pack operated hydraulic

c.)

Check gear lubricated oil level and top-up if required. 11 litres in horizontal position and 20 litres at 15 degree inclined position (see lube-chart) d.)

Fill fluid coupling with heat resistant oil (see lube chart) and check thermal safety plugs.

Maximum oil level at 15 degree filler plugs position from top. e.)

Start E-motor for a short time to establish correct rotation of roll. Impact roll must rotate in the direction of conveyor run. f.)

Connect water system and check operation.

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TRACK SYSTEM (UNDERCARRIAGE) 38B

a.)

Check oil level in planetary gear reductions and top-up if required with specified gear oil.

b.)

Check track tension and correct it.

c.)

Start E-motors for a short time to establish correct rotation and function of planetary.

d.)

Operate both forward and reverse tramming and negotiate spot turns in both directions.

e.)

Fasten main power cable before relocating machine and secure towing attachment.

CONVEYOR AND HOPPER 39B

a.)

Check oil level in reduction gear box by removing lower plug. Top-up if necessary with specified gear oil. b.)

Check grease fill in pinion shaft bearing by removing upper plug. Top-up if necessary with specified grease. c.)

Check oil level of fluid coupling by removing filler plug. Maximum fill at 15 degree from top position. Top-up with specified fluid. d.)

Check conveyor flight chain tension and correct it by either adding or releasing grease to/from grease jacks. e.)

Clear trough and remove any obstruction to allow flights to travel freely.

f.)

Start E-motor for a short time to establish correct direction of conveyor movement.

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Section 12B

8

Maintenance and Repair 13B

CHECK IMPACT ROLL AND BEARING 40B

The sizing tools have to be checked for wear at least once a week. Excessive wear results in imbalance of the roll and in an uneven run of the sizer. The sizing tools have to be replaced before the cemented-carbide bars or the armour plating are worn. Appropriate welding templates are available. If imbalance of the roll is discovered too late, serious problems can arise, repairs may become necessary on the bearings and on the drive. During this check, attention has to be paid to proper attachment of the sizing tools, if necessary the attachment screws have to be retightened.

Proper tightening of the screws of the roll bearing has to be checked at the same interval. The shaft bearing must be lubricated daily with roller bearing grease (see lube chart).

CHECK OF GEARBOXES AND PLANETARY REDUCTION GEARS 41B

Gearboxes and planetary gears have to be checked once a week. Special attention has to be paid to oil levels; if necessary top up gear oil. The fluid level of the hydraulic couplings has to be checked and topped up when necessary. The venting plug has to be checked weekly, if necessary clean it with compressed air. The normal gearbox temperature is about 70ºC. During this weekly check, attention has to be paid to proper tightening of the screws at the flange and the gearbox bracket (to prevent the gearbox dislocating).

Necessary retightening must be done. Replacement of oil will be first necessary after approximately.

800 working hours. Any further oil change has to take place at intervals of approximately. 2000 working hours. Note: Oils may be used for no longer than six (6) calendar months

GENERAL CHECKS 42B

These checks will be necessary once a month and the following has to be observed: a)

Loosened screws at the sizer

b)

Existence of rubber aprons and scalping bar or chain

c)

Existence of baffle plates

d)

Existence of swinging flap doors

e)

Functioning of water spraying system

f)

Functioning of safety equipment.

Tighten al loosened screws and replace missing screws, nuts and bolts. Proceed likewise with the rubber apron, baffle plate, swinging flap, etc.

Check electric cables for damage due to chaffing on moving path, holding clamps etc.

CRAWLER TRACK ASSEMBLY 43B

Replacing broken chain link Delivery of parts required: 1 chain link right side, pressed 1 chain link left side, pressed 1 end bush 2 track chain bolts 4 end bush rings 4 bottom plate screws and nuts (track pad)

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Awaba Feeder Breaker Operators Manual

DISASSEMBLY OF TRACK CHAIN 4B

Cut off track chain at the torn section and layout the track chain on the ground Flame-cut through the chain links, the bush and the track bolts at the damaged section Remove debris Burn the remaining track bolt in the centre and drive remnant out of link Burn off the bush at the front side and grind it smooth

ASSEMBLY OF NEW PARTS 45B

Join the pressed chain segment and two end bush rings with a track bolt to the chain.

Drive in the track bolt with sledge hammer.

Fit the chain and connect both ends with tracks bolts and tow end bush rings Assemble the bottom plate (track pad)

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Awaba Feeder Breaker Operators Manual

CRAWLER TRACK ASSEMBLY 46B

Assembly and disassembly of knurled track bolt:

Assembly.

Insert end rings into end links and join chain.

Position knurled end bush and drive it in until knurled head is mated into chain link.

Join the guide tube to chain link bolt eye and drive in the knurled track bolt with mandrel, until knurled bolt has the same protrusion on both sides.

Disassembly.

Locate cylinder bore.

Join the guide tube to chain link bolt eye.

Insert driving mandrel into guide tube and drive track chain bolt through.

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Awaba Feeder Breaker Operators Manual

CONVEYOR CHAIN AND FLIGHT ASSEMBLY 47B

Tension of conveyor chain strands determines the correct movement and sprocket arrangement.

Elongated chain requires tensioning and if adjustment is not possible, tow chian links must be removed from each strand, shortening overall length and allowing tensioning. The removal of two links will ensure that the chain strands remain straight since a turned chain will jam and damage assembly.

Flight bars are mounted at equal chain link intervals and replacement of broken or damaged flight bars must be retain such given interval.

Removal and mounting of flightbars is best accomplished at the discharge end of the hopper. Slots are provided in the conveyor plate to allow the removal of roll pins which secure the flight bar to the chain strand.

Check the free running of flight bars daily and tighten the drive and return sprocket shaft assemblies when required.

Check fluid coupling and gearbox for oil leaks daily and tighten loose bolts on drive assembly.

BREAKER AND HOPPER ADJUSTMENT (LOCKING) 48B

a) Select valve position on hydraulic hand pump circuit to ‘up’ and pump until locking pins (two) can be removed from existing hole position. b) Pump up or release down to required sizing height of breaker roll, height of hopper or drive head (loading or discharge height). Insert locking pins (two) into selected hole position and secure with clips. c) With the locking pins secured and the hopper (breaker) at the desired height, release the hydraulic pressure by slightly moving valve form the ‘up’ into ‘neutral’ position. d) If valve lever cannot be moved (hydraulic lock-up) release line pressure by moving check valve stem anti-clockwise. Re-tighten stem of check valve before commencing with pump.

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Awaba Feeder Breaker Operators Manual

Section 14B

9

Tools 15B

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Awaba Feeder Breaker Operators Manual

Manual No.:M01259

Item

Quantity

1

1

Push Plate

2

2

Stud

3

1

Yoke

4

1

Yoke

5

1

Draw Bar

6

1

Hexagon. Nut

7

1

Washer

8

2

Hexagon. Nut

9

1

Hydraulic. Cylinder

10

1

H.P. Hose

11

1

Fitting

12

1

Manual Operating Hydraulic Pump

Object

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